DRDO-CEMILAC-TCR-004-2014

Compendium of Indigenous Aircraft

Wires, Cables & Connectors

DRDO
Directorate of Aeronautics
Centre for Military Airworthiness & Certification (CEMILAC)
Regional Center for Military Airworthiness (Helicopters)
Ministry of Defence (R & D), Government of India
P.B. No. 1704 Vimanapura Post
Bangalore - 560 017

2015
 DOCUMENTATION PAGE
1 Security Classification : Unclassified 2 Distribution: Un Restricted
3 Report status: New 4 Report type: Technical
5 Report No.: 6 Part or volume No
DRDO-CEMILAC-TCR-004 -2014

7 Title and subtitle : Compendium of 8 Contact No : 080-2512 1222

Indigenous Aircraft Wires, Cables &
Connectors

9 No. of pages : - 10 Project no. -

11 Period covered (if progress report) - NA
12 Personal authors: Anantha Padmanabha, Sc.’E’
13 Affiliation of authors : Systems Group, CEMILAC, DRDO

14 Corporate author: CEMILAC, DRDO

15 Originating unit: Systems Group, CEMILAC, DRDO
16 Sponsor(s) name : - Nil
17 Date of submission : April 2015 18 Publication/issue/date: April 2015
19 Publisher/distributer: CEMILAC
20 Form of distribution Hard Copy: Yes Digital: Yes
21 No. of references: Nil
22 Abstract: 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. This compendium is intended to provide
comprehensive information on methodology of certification, acceptance of
electrical cables and to assist cable manufacturers to adhere to standard
practices and users to select the appropriate cables for a particular application.
The applicable airworthiness approval will depend on the type of aircraft in
which the cable is to be installed. Accordingly cables shall qualify to prevailing
governing specifications & standards. Cable manufacturers seeking approval of
their products need to comply with the requirements.

23 Keyword/description: Wires, Cables, Connectors, PTFE, MIL-STD-22759,

Airworthiness Certification, GOST standard

24 Supplementary elements: Nil

 TABLE OF CONTENTS

Part -1: AIRCRAFT WIRES AND CABLES

Definitions and Abbreviations 3

Chapter-1 1.1 Introduction 16

1.2 Classification of Wires and Cables 16
1.3 Classification of Cables 19
1.4 Cables Specification and Identification 21
1.5 Construction of Cables 21
1.6 Cable Performance Parameters 24
1.7 Aircraft Wiring aging and deterioration

Chapter-2 Standards and specifications for aircraft wires and cables

2.1 Introduction 28
2.2 British Standard Specifications 28
2.3 UK Military Specifications 28
2.4 US Military Specifications 28
2.5 Manufacturers Specifications 29
2.6 International Standards 29
2.7 Russian Specifications and standards 29
2.8 Specification: TU-16-505.437-73 32
2.9 Specification: TU-16-505.020-74 34
2.10 Specification: TU-16-505.911-76 35
2.11Specification: TU-16-505.941-76 35
2.12 Specification: TU-16-505.945-76 36
2.13 Specification:TU-16-705.014-77 37
2.14Specification:TU-16-505.184-78 38
2.15Specification:TU-16-505.083-78 39
2.16Specification:TU-16-505.554-81 40
2.17 Specification:TU-16-505.324 41
2.18 Standard: GOST 24335-80 42
2.19 Specification:TU-16-505.280-79 42
2.20 Comparison of MIL-Standard and Russian Specifications 45
2.21 De-rating criteria for Wires and Cables 50

Chapter -3 Failure analysis and testing requirements for aircraft wires and
Cables
3.1 Introduction 52
3.2 Cable Failure analysis 52
3.3 Arc Tracking 53
3.4 Abrasion 54
3.5 Conductor “Knuckling Through” 54
3.6 Red Plague 54
3.7 Glycol Fires 54
3.8 Poor Solderability 54
3.9 Case Studies of Electrical cable failures 55
3.10 Qualification Test 56
3.11 Qualification test details 57

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Appendix-A List of Type Approvals 73

Appendix-B List of Provisional Clearance 166

Appendix-C List of Manufacturers 171

Appendix-D Conversion table for Cables 173

Part -2: CONNECTORS

Chapter -1 1.0 Construction of Connector 184

1.1 Nomenclature: Cylindrical connectors 184
1.2 Nomenclature: Cylindrical Connectors and contacts 186
1.3 Types of Connectors 188
1.4 MIL-STD-Connectors 207

Chapter-2 2.1 Performance Requirements for connectors 221

2.2 Marking 224
2.3 Verification 224
2.4 Conformance Inspection 224

Appendix-E List of Type Approvals 228

Appendix- F List of Connector Manufacturers 239

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 DEFINITIONS & ABBREVIATIONS

Abrasion Resistance: Ability of material or cable to resist surface wear.

Alternating Current: The flow of electric charge periodically in reverse direction. Electrical
AC (alternating current) occurs when charge carriers in a conductor or semiconductor
periodically reverse their direction of movement.

Alternating Current Resistance: The resistance offered by any circuit to the flow of
alternating current.

American Wire Gauge (AWG): The standard system used for designating wire diameter.
Also referred to as the Brown and Sharpe (B&S) wire gauge.

Ampacity: (See current-carrying capacity).

Anneal: To subject (glass or metal) to a process of heating and slow cooling in order to
toughen/ strengthen/ harden and reduce brittleness.

Anti-Oxidant: An antioxidant is a molecule that inhibits the oxidation of other molecules.

Oxidation is a chemical reaction that transfers electrons or hydrogen from a substance to
an oxidizing agent.

Armored Cable: A cable provided with a wrapping of metal, usually steel wires, flat tapes,
or interlocked tapes, primarily for the purpose of mechanical protection.

ASTM: American Society for Testing and Materials.

AWG: American wire gauge (AWG), also known as the Brown & Sharpe wire gauge, is a
standardized wire gauge system used since 1857 predominantly in the United States and
Canada for the diameters of round, solid, nonferrous, electrically conducting wires. The
cross-sectional area of each gauge is an important factor for determining its current
carrying capacity.

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The gauge can be calculated from the diameter using

[3]

and the cross-section area is

Binder: A helically applied tape or thread used for holding assembled cable components in
place until additional manufacturing operations are performed.

Boot: A protective covering over any portion of a cable or conductor in addition to its jacket
or insulation.

Braid: A fibrous or metallic group of filaments interwoven in cylindrical form to form a

covering over one or more wires.

Breakdown (Puncture): A disruptive discharge through insulation due to failure under

electrostatic stress.

Breakdown Voltage: The voltage at which the insulation between two conductors, or a
conductor and ground will break down.

BS: British Standards

BSI: British Standard Institution

Bunch Stranding: A method of stranding where a single conductor is formed from any
number of wires twisted together in the same direction, such that all strands have the same
lay length, but no specific geometric arrangement.

Butt Joint: A splice or connection formed by placing the ends of two conductors together
and joining them by welding, brazing or soldering.

Butt Wrap: Tape wrapped in an edge-to-edge manner with no over-lapping between

adjacent turns.

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Cable Core: A cable core is the portion of an insulated cable lying under the protective
covering or coverings.

Cable Filler: The material used in multiple conductor cables to occupy the spaces formed
by the assembly of components, thus forming a core of the desired shape.

Capacitance: The property of a system of conductors and dielectrics which permits the
storage of electricity when potential difference exists between the conductors.

Capacitive Coupling: Electrical interaction between two conductors caused by the

capacitance between them.

Charging Current: The current produced when a DC voltage is first applied to conductors
of a non terminated cable. It is caused by the capacitive reactance of the cable and
decreases exponentially with time.

Chlorinated Polyethylene (CPE): A synthetic rubber jacketing compound.

Circular Mil: A unit of area equals to the area of a circle whose diameter is 1 mil (0.001
inch). Used chiefly in specifying cross-sectional areas of round conductors.

Coating: A material applied to the surface of a conductor to prevent environmental

deterioration, facilitate soldering or improve electrical performance.

Cold Joint: A soldered joint made with insufficient heat.

Cold Test: Any test to determine the performance of cables during or after subjection to a
specified low temperature for a specified time.

Cold Work: Altering the shape or size of a metal structure by plastic deformation.
Processes includes rolling, drawing, pressing, spinning, extruding and heading, it is carried
out below the re-crystallization point usually at room temperature. Hardness and tensile
strength are increased with the degree of cold work whilst ductility and impact values are
lowered. The cold rolling and cold drawing of steel significantly improve surface finish.

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Colour Code: A colour system for circuit identification by use of solid colour tracers,
surface printing etc.

Compact Stranded Conductor: A concentric stranded conductor where each layer is

passed through a closing die to reduce the diameter of the stranded conductor
approximately by 10%.

Concentricity: In a wire or cable, the measurement of the location of the center of the
conductor with respect to the geometric center of the circular insulation.

Concentric-lay Conductor: Conductor constructed with a central core surrounded by one

or more layers of helically laid wires.

Concentric Stranding: (A method of stranding, wherein a single conductor is formed from

a central wire surrounded by one or more layers of helically laid wires. Each layer is applied
with an opposite direction of lay. The first layer has six wires, and each additional layer has
six more wires than does the previous one. Thus the second layer has twelve wires; the
third layer has eighteen wires, etc.). These conductors shall be constructed with a central
core surrounded by one or more layers of helically laid wires.

Conductivity: A term used in describing the capability of a material to carry an electrical

charge. Conductivity is expressed for any standard configuration of a conductor.

Conductor: A wire or combination of wires not insulated from one another, suitable for
carrying an electric current.

Conductor Core: The center strand or member about which one or more layers of wires or
members are laid helically to form a concentric-lay or rope-lay conductor.

Contra-helical: A term meaning the application of two or more layers of spirally twisted,
served, or wrapped materials where each successive layer is wrapped in the opposite
direction to the preceding layer.

Core: Any portion of a cable over which some other cable component, such as a shield,
jacket, sheath or armor, is applied.

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Corona: A luminous discharge due to ionization of the gas surrounding a conductor around
which a voltage gradient exists exceeding a certain critical value.

Creep: The dimensional change with time of a material under load. At room temperature,
sometimes it is called cold flow.

Creep age: Electrical leakage on a solid dielectric surface.

Crimp Termination: A wire termination that is applied by physical pressure of terminal to

wire.

Cross Linking: The establishment of chemical bonds between polymer molecule chains. It
may be accomplished by heat, vulcanization, irradiation or the addition of a suitable
chemical agent.

Cross Sectional Area of a Conductor: The sum of cross sectional areas of all the
individual wires composing the conductor. It is generally expressed in circular mils.

Crush Resistance Test: A test to determine the ability of a cable to resist damage from
radial compression, such as might be encountered in service.

Cut-through Resistance: The ability of a given material to withstand penetration by a solid

object of specified dimensions and weight, which is permitted to free fall onto this material
from a specified height.

De-rating Factor: A factor used to reduce a current carrying capacity of a wire when used
in other environments from that for which the value was established.

Dielectric Breakdown: The voltage at which a dielectric material is punctured; which is

divisible by thickness to give dielectric strength.

Dielectric Constant: That property of an insulating material which is the ratio of the parallel
capacitance of a given configuration of electrodes with the material as the dielectric, to the
capacitance of the same electrode configuration with a vacuum as the dielectric.

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Dielectric Strength: The voltage which an insulating material can withstand before
breakdown occurs, usually expressed as a voltage gradient (such as volts per mil).

Dielectric Tests: Tests which consist of the application of a voltage higher than the rated
voltage for a specified time for the purpose of determining the adequacy against breakdown
of insulating materials and spacing under normal conditions.

Direction of Lay: The lateral direction, designated as left-hand or right-hand, in which the
wires of a member or units of a conductor run over the top of the member or conductor as
they recede from an observer looking along the axis of the member or conductor.

Eccentricity: A measure of the lack of coincidence of longitudinal axes of a circular cross-

sectional wire and its surrounding circular cross-sectional insulation. It is expressed as the
percentage ratio of the distance between wires and insulation centers to the difference
between wire and insulation radii.

Elastic Deformation: A change in a substance, whereby it reverts to its original

dimensions on release of an applied stress.

Elongation: The fractional increase in length of a material stressed in tension.

Embossing: A means of marker identification by means of thermal indentation leaving

raised lettering on the sheath material of cable.

Extrusion: The process of continuously forcing either a plastic or elastomer and a

conductor or core through a die, thereby applying an insulation or jacket to the conductor or
core.

Fault Current: The maximum electrical current that will flow in a short-circuited system
prior to the actuation of any current-limiting device. It is far in excess of normal current flow
and is limited only by a system's generating capacity and a cable's impedance.

Fibrous Filler: A material used to fill interstices in cables made from fibers, such as jute,
polypropylene, cotton, glass etc.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Filler: Any material used in multi-conductor cables to occupy interstices between insulated
conductors or form a core into a desired shape (usually circular).

Film: Thin sheet of plastic having nominal thickness usually not greater than 0.010 inch.

Flame Resistance: The ability of a burning material to extinguish its own flame, once its
flame-initiating heat source is removed.

Flame Retardance: Ability of a material to prevent the spread of combustion by a low rate
of travel so the flame will not be conveyed.

Flexing Test: Any test to determine the ability of a cable to withstand repeated bending
and twisting.

Flex Life: The number of bends or twists, of specified type, that a cable will withstand
before failure.

Ground: A conducting connection, intentional or accidental, between an electric circuit or

equipment and the earth or some conducting body serving in place of the earth.

Ground Potential: Zero potential with respect to the ground or earth.

Grounded Neutral: A circuit operates with grounded neutral when the neutral is
metallically connected to ground and there is a provision for immediate removal of a faulted
element.

Grounding Conductor: A conductor used to connect equipment or the grounded circuit of

a wiring system to a grounding electrode or electrodes; usually coloured green.

Hard-drawn Wire: As applied to aluminum and copper, wire that has been cold drawn to
final size so as to approach the maximum strength obtainable.

Heat Endurance: The time of heat aging that a material can withstand before failing a
specific physical or electrical test.

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Heat Resistance: Ability of a substance to maintain physical and chemical identity and
electrical integrity under specified temperature conditions.

Heat Shock: A test to determine stability of a material by sudden exposure to a high

temperature for a short period of time.

High Voltage Time Test: It is an accelerated life test on a cable sample in which voltage
is the factor increased.

Hygroscopic: Attracting or absorbing moisture from the ambient atmosphere.

ICEA: Insulated Cable Engineers Association. An Association of Engineers of most cable

manufacturers.

Irradiation: The exposure of a material to high energy emissions.

Jacket: A material covering over wire insulation or an assembly of components, usually an

extruded plastic or elastomer.

JAR: Joint Airworthiness Requirements

Jumper: A short length of conductor used to make a connection between terminals, around
a break in a circuit, or around an instrument.

Lap Splice: A permanent joint formed in a short overlapping region of two parallel
conductors or tapes. Also called parallel splice.

Lay: The distance along a cable occupied by one complete helix of a strand or conductor.

Marker Tape: A narrow strip of fabric, paper or plastic lay longitudinally within a cable; it
bears printed information such as the specification to which the cable was made and the
name of the cable's manufacturer.

Marker Threads: Coloured strings laid parallel and adjacent to the strands of an
insulated conductor to reveal information such as the conductor's manufacturer, the
specification to which it was made, or its thermal capability.
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Mil: Unit of measure equal to 1/1000 of an inch.

Moisture Absorption: The amount of water that an insulation or jacket, which is initially
dry, will absorb under specified conditions. It is expressed as the percentage ratio of the
absorbed water's weight to the weight of the jacket or insulation alone.

NEMA Standards: Property values adopted as standard by the National Electrical

Manufacturers Association.

Nominal: Name or identifying value of a measurable property by which a conductor or

component or property of a conductor is identified, and to which tolerances are applied.

NTSB: National Transportation Safety Board.

Oxygen Bomb Test: A test to determine the ability of conductors and insulations to
withstand physical and electrical change when immersed in pure oxygen gas of specified
temperature and pressure for a specified time.

Plating: Any thin metallic coating applied over a metallic substratum.

Polychloroprene: Chemical name for neoprene. A rubber-like compound used for

jacketing where wire and cable will be subject to rough usage, moisture, oil, greases,
solvents and chemicals.

Polyester: A resin generally used as a thin film in tape form.

Polyethylene: A thermoplastic material composed of polymers of ethylene.

Polypropylene: A thermoplastic polymer of propylene.

Polyvinyl Chloride (PVC): A thermoplastic material composed of polymers of vinyl

chloride, which may be rigid or elastomeric, depending on specific formulation.

Potting: Applying a hydrostatic seal and mechanical reinforcement by means of a

thermosetting liquid, this cures either at room temperature or at a slightly elevated
temperature.
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
PTFE: Poly Tetra Fluro Ethylene commonly known as Teflon®.

Quad: A structural unit employed in cables, consisting of four separately insulated

conductors twisted together.

Resistance: Property of a conductor that opposed the current flow produced by a given
potential difference. Ohm (Ω) is the practical unit of resistance.

Rupture: In the breaking strength or tensile strength tests, the point at which a material
physically comes apart as opposed to yield strength, elongation, etc.

Secondary Insulation: Any extremely high resistance material which is placed over
primary insulation to protect it from abrasion.

Serve: Any helical wrapping applied over a wire or cable core. It may consist of wires,
fibers, yarns or tapes.

Served Wire Shield: A barrier to the passage of interference formed by a helical wrapping
of wires over a cable core. It is also called spiral shield.

Sheath: The material usually an extruded plastic or elastomer, applied outermost to a wire
or cable. Very often referred as a jacket.

Shield: Any barrier to the passage of interference - causing electrostatic or electromagnetic

fields, formed by a conductive layer surrounding a cable core. It is usually fabricated from a
metallic braid, foil or wire serving.

Shield Coverage: The amount of cable core surface area which is covered by a shield. It
is expressed as a percentage of the cable core's total surface area. It is also called braid
coverage when applied to a braided shield.

Shielding: The practice of confining the electrical field around a conductor to the primary
insulation of the cable by putting a conducting layer over and/or under the insulation.
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
(External shielding is a conducting layer on the outside of the insulation. Strand or internal
shielding is a conducting layer over the conductor itself).

Skeleton Braid: A braid of widely separated wires or fibers, used to reinforce a jacket, bind
a cable core, or prevent the passage of electrostatic or electromagnetic fields.

Soft Wire: Wire that has been drawn or rolled to final size and then heated to remove the
effects of cold working.

Spark Test: A test designed to locate pin-holes in an insulated wire by application of an

electrical potential across the material for a very short period of time while the wire is drawn
through an electrode field.

Specific Inductance/Capacitance: That property of a dielectric material which determines

how much electrostatic energy can be stored per unit volume when unit voltage is applied.

Specific Resistance: The resistance of a unit conductor having a length of one foot and
across-sectional area of one circular mil.

Spiral Wrap: A term given to describe the helical wrap of a tape or thread over a core.

Splice: A joint used for connecting two lengths of conductor or cable with good mechanical
strength as well as good conductivity.

Stranded Conductor: A conductor composed of a group of wires, usually twisted, or of any

combination of such groups of wires.

Strand Lay: The distance of advance of one strand of a spirally stranded conductor, in one
turn, measured axially.

Stress Cone: A conical section built up of insulating tapes or a pennant to relieve the
stress at the terminal end of the cable

Tank Test: A voltage dielectric test where the specimen to be tested is submerged into a
liquid (usually water) and a voltage potential applied between the conductor and the liquid
as ground.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Tape Wrap: A term denoting a spirally or longitudinally applied tape material wrapped
around the wire, insulated or un-insulated, used as an insulation or mechanical barrier.

Tear Strength: The force required to initiate or continue a rip in a jacket or other insulation
under specified conditions.

Temperature Rating: The maximum temperature at which a given insulation or jacket may
be safely maintained during continuous use, without incurring any thermally-induced
deterioration.

Tensile Strength: The longitudinal stress required to break a specimen of prescribed

dimension divided by the original cross-sectional area at the point of rupture.

Termination: The load connected to the output end of a transmission line. The provisions
for ending a transmission line and connecting to a bus bar or other terminating device.

Thermal Conductivity: Ability of material to conduct heat.

Thermal Endurance: The time in hours at a selected temperature for an insulating material
to deteriorate to some predetermined level of electrical, mechanical, or chemical
performance under prescribed conditions of test.

Thermal Expansion (Coefficient of): The fractional change in length (sometimes volume)
of a material for a unit change in temperature.

Thermal Rating: The maximum and/or minimum temperature at which a material will
perform its function without undue degradation.

Tinned Wire: Copper wire that has been coated during manufacture with a layer of tin or
solder to prevent corrosion or facilitate soldering.

Triad: Any grouping of three conductors or three assemblages of conductors, generally

twisted together and found within a cable.

Triplex: Three single conductors twisted together, usually three single conductor cables
twisted without over-all covering.
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Ultra Violet Degradation: The degradation caused by long time exposure of a material to
sunlight or other ultraviolet rays containing radiation.

Voltage Drop: The voltage developed between the terminals of a circuit component by the
flow of current through the resistance or impedance of that part.

Voltage Rating: The maximum voltage at which a given cable or insulated conductor may
be safely maintained during continuous use in a normal manner. It is also called working
voltage.
.
Water Absorption: The ratio of the weight of water absorbed by a given material under
specified conditions, to the weight of that material when dry. It is generally expressed as a
percentage.

Wicking: The longitudinal flow of a liquid in a wire or cable construction due to capillary
action.

Wire Gauge: Any of several standard systems for designating wire sizes. As an example,
see American Wire Gauge.

Work Hardening: The increased stiffness and brittleness accompanying plastic

deformation of metal.

Yield Strength: The lowest stress at which a material undergoes plastic deformation.
Below this stress, the material is elastic; above it, viscous.

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 CHAPTER I

AIRCRAFT WIRES AND CABLES

1.1 Introduction

Modern commercial and military aircraft wiring not only distributes electrical power
but provides control and information links between multiple systems and sub-systems. The
components that make-up the wiring system include power and control conductors, signal
and instrumentation conductors, fiber optic cables, connectors, circuit breakers, relays,
power distribution and control panels. Failure of any of these components can disable an
aircraft or compromise an aircrew’s ability to control the aircraft. It is for these reasons
aircraft wiring is to be considered as a critical and vital component on aircraft.

Historically, aircraft wiring was treated as a “fit and forget” commodity rather than as
an indispensable system. While there is a tendency to ignore wire systems, there is a need
to manage wire systems so that they continue to function safely. It is for these reasons the
aviation industry and government have developed regulations, codes, standards and
operational practices that focus on maintaining the integrity of the aircraft wiring system for
aircraft safety.

1.2 Classification of Wires & Cables

Unfortunately, there is little International Standardization of terminology is available

on aircraft wires and cables. It should be noted that the term 'wire' is used in the USA
whereas most other countries talk of 'cable'.

Wire is a single conductor and cable is a group of two or more insulated conductors.
If there is no insulation on the two conductors then it would not be a cable, it would still be a
single conductor which would classify as a wire.

There are two types of wire. These are solid wire and stranded wire. Both types have
different uses depending on the level of resistance and flexibility required. Solid wire is a
single solid conductor that may be bare or insulated. This type of wire offers considerably a
lower resistance. Solid conductors are the key to better performance at higher frequencies.

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Stranded wire is made up of several strands of bare conductor to form a single conductor
when all strands are put together. This type of wire has more flexibility and a longer flex life
before becoming unusable.

There are five basic cable types as follows:

Twisted pair cable
(a) Multi-conductor cable
(b) Coaxial cable
(c) Fiber optics cable
(d) Shielded cables

(a) Twisted pair cable: It consists of pair of conductors that are twisted together.
This cable is specifically intended for signal carrying. This type of cable was
invented in the 1880's for the specific intent of wiring up early telephone systems.
Twisting the pair of conductors gives the cable some immunity to interference. It
is considered as balanced line configurations if two conductors are kept very
close together, normally by twisting them. Conductors must be the same length,
size, and have a constant distance between them.

(b) Multi-conductor cable: It is the cable that is made up of many insulated

conductors. This type of cable is common in control applications but is almost
never used in signal applications.

(c) Coaxial cable: Coaxial cable does not have the immunity to interference that
twisted pair cable does, but the performance may be more stable with coaxial
cable than with twisted pair cable because of the fact that various parts of the
cable are “knitted” together.

(d) Fiber optics cable: This cable is divided into three types viz. Plastic Fiber, Multi
Mode Fiber, and Single Mode Fiber. Plastic fiber is used in high end audio
signals. Multi mode fiber is made of glass with different diameters, and is used in
the data world. Single mode fiber is considered the king, or the best, because the
fiber is too small to see without a microscope. This fiber gives the best
performance but is very difficult to connectorise because of fiber size and
hardness.

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 (e) Shielded cables: Unshielded cable may be used where there is no crosstalk or
noise present. This configuration can also be used if noise is not important or will
not substantially affect the signal. Shields are added to cables to prevent noise
interference and radiation. There are five configurations of shields involved in
cable. These are Braid Shields, Serve/Spiral shields, French Braid Shields, Foil
Shields, and Combination Shields.

i. Braid Shields are manufactured by spinning conductors or groups of wires

around a center core. The braiding process is very labor intensive, which
makes it the most expensive step of the cable making process. The braiding
can be single or double braid, with double braiding being more effective.
Since there are always holes where the wires cross, braiding is never 100%
effective. The higher the frequency the less effective a Braid Shield is.

ii. Serve/Spiral Shields are manufactured to be extremely flexible. Serve Shield

effectiveness is compromised by the fact that every time the Serve Shield is
flexed it opens up. A Spiral Shield has an effect on the inductance of the
shield and so these shield configurations are normally used for audio not for
video.

iii. French Braid Shields are a combination of a Serve Shield and a Braid
Shield. This shield consists of two Serve Shields braided along a single axis.
This shield gives excellent flexibility and RF performance. The French Braid
Shield takes the same effort and material as a Braid Shield so the
manufacturing process costs roughly the same for both.

iv. Foil Shields are the cheapest and easiest shield to apply. They consist of two
different layers. One layer is metal and the other layer is a polyester
substrate. This shield can be applied just as quick as the cable can be run.
These shields show performance for low-frequency to be poor but
performance for high-frequency to be excellent. Since Foil Shields are made
with foil that has no holes, they can be 100% effective.

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 v. Combination Shields are shields that use a combination of braiding and foil.
Sometimes there are multiple layers of each. Combination Shields are the
most expensive of all shields. These shields give the best broadband
coverage because the foil works for high frequencies and the braiding works
for low frequencies.

1.3 Classifications of Cables

1.3.1 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 Power plants. 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.

1.3.2 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

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
commonly used in the USA to designate cables of this general type, and the designation
'Light Weight-Interconnect' may also be applied.

1.3.3 Equipment Wire

This 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
organizations 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 organizations who provide 'CAA Release' to
British Standard G210 or an equivalent specification. The term 'Module Wire' is sometimes
used for this class of cable in the USA.

1.3.4 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.

1.3.5 Fire proof 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.

1.3.6 Multi core Screened and Jacketed Cables

Airframe and interconnect cables may be supplied in a multi core form of generally
up to four cores, the cores being twisted together. The multi core 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

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
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.

1.3.7 Data Bus cable

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).

1.4 Cable specifications and identification

Because of the large number of specifications exist for aircraft cables, it is

impractical to list all those in this compendium. Significant differences can occur between
cables complying with the same basic requirements. It is also difficult to offer guidance on
interchangeability between products. The details of cable specification and standards are
covered in chapter ‘2’ of this compendium.

1.5 Construction of cables

1.5.1 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 aluminum.

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1.5.2 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. Tin plated copper maximum
continuous temperature is 135°C. Silver plated copper maximum continuous temperature is
200°C. Nickel plated copper maximum continuous temperature is 260°C. Nickel Clad plated
copper maximum continuous temperature is 260°C. Nickel clad copper is used instead of
nickel plate on fire resistant cables 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 150°C for tin plating, are
sometimes quoted but performance at such temperatures, especially in regard to stable
crimp resistance and solderability is the subject of debate. It should be noted that the
plating used on crimped terminal ends must be compatible with the conductor plating of the
cable.

1.5.3 Dielectric Materials and Cable Types

It is not practicable to review in this compendium the performance of all of the many
types of cable designs available except in general terms. Extensive studies have been
made in an attempt to determine an optimum cable type. `It may be noted 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 organizations which have a keen commercial interest in the decisions
of an intending purchaser.

Insulation material is applied to conductors by one of two basic methods called

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 is not always of 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

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
eliminates melting, increases strength and allows for thinner wall thickness. Cables
employing such design perform well on wet arc tracking.

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 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. Use of cables complying
to MIL-W-81381/11 have been discontinued in some environments. This would not reflect
the general rejection of cables containing Kapton. Most designs provide good overall
performance including excellent mechanical strength especially the 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. These are employed throughout the airframe of
some recently certified aircraft. The CAA has not granted an Accessory Approval as
'Airframe' types to such cables, these having been accepted on a 'Component' basis.
However, all PVC cables are now classed as ’Obsolescent - unsuitable for new designs’.

1.5.4 Wire Insulation

Wire insulation should be selected based on flame resistance, smoke emission

requirements and the environmental characteristics of the wire routing areas. Insulating
materials should be selected for the best combination of the following characteristics:

a) Abrasion resistance
b) Corrosion resistance
c) Dielectric strength
d) Flame resistance
e) Mechanical strength
f) Resistance to fluids
g) Smoke emission
h) Arc resistance
i) Heat distortion temperature
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 The four most common types of insulating materials used in aircraft today are shown in
Table below

Table 1

Comparative Properties of Wire Insulation Systems

Polymer Mil Desirable Properties Limitations

Specs

PTFE 22759/12 260°C thermal rating, low Cut-through

(Teflon) smoke/non-flame, high resistance, “creep”
flexibility at temperature

ETFE 22759/16 Chemical resistance, High temperature,

(Tefzel) abrasion resistance, ease cut-through, thermal
of use rating (150°C)

Aromatic 81381 Abrasion/cut-through, low Arc-track resistance

Polyamide smoke/non-flame, flexibility
(Kapton) weight/space

Composite 22759/80- High temperature rating Outer layer scuffing

(TKT) 92 (260°C), cut-through
resistance, arc-track
resistance

When choosing wire insulation it is imperative to not only to seek the best balance of
electrical, mechanical, chemical, and thermal properties but also inherent flame and/or
smoke resistance.

1.6 Cable Performance parameters

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 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 use.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Wiring integrity and safety issues have surfaced as a major aviation crisis associated
with the loss of Swissair flight 111 in 1998 and TWA flight 800 in 1996. Aircraft wiring is the
vital electrical and optical network that transmits the data, signals and power to and from
systems. Wiring problems cause loss of signals, system shutdowns, smoke, fires, and
explosions. In addition, wiring problems costs a lot in troubleshooting and maintenance.
Ensuring flight safety entails more immediate detection of electrical malfunctions and better
fire suppression methods. However, avoiding flight tragedies involves improving wire
inspection techniques. Therefore aircraft wiring is required to be visually inspected. But a
large portion of electrical wiring on aircraft is not readily visible because it is bundled with
dozens of other wires or blocked from view by other structures or components. In general
performances of cables are governed by the following parameters.

1.6.1 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 40°C rise by electrical heating as the operating
temperature and cable life are directly related. The temperature rating of an airframe cable
is determined by its construction and will be classified at one of the following temperatures:
105°C (obsolescent cable types), 135°C, 150°C, 210°C and 260°C. Clearly this
temperature rating has to be known when evaluating any design application.

1.6.2 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 in Russian GOST specification. The size of cable is the primary determinate of
the electrical protection level set by the circuit breaker or fuses and should never be
reduced below the level established by proper co-ordination data. Manufacturers usually
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

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
protection can be determined. Current rating data usually relates to a temperature rise of
40°C 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
Kilometer at 20°C 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.

1.6.3 Voltage Rating

All cables have a rated voltage. Particular reference should be made to the specified
voltage of any cable where higher than normal potentials may be used, in places such as
discharge lamp circuits and windscreen heating circuits.

1.6.4 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 exist
general requirements relating to the hazards of smoke and toxicity. In recent years, greater
emphasis has been placed upon these characteristics.

1.6.5 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 lot of failures noticed in the recent
past. Tracking can also occur under dry conditions and this failure mode reinforces the
need for good cable installation and good maintenance practices.

1.6.6 Mechanical Properties

The assessment of cable insulations includes the ability to withstand the pressure of
a sharp edge 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
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
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 be assumed that this apparent strength is translated into the ability to
withstand physical abuse.

1.6.7 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. 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.

Aircraft Wiring Ageing and Deterioration

All aircraft electrical wiring systems are liable to ageing during their normal service
life. Ageing results in the progressive deterioration of physical properties and performance
of wiring systems with the passage of time. Wiring is susceptible to more rapid deterioration
with age in areas of high contamination, vibration, temperature variation, and corrosion and
where it is attached to movable or removable parts. The aging process can be significantly
accelerated by frequent handling or maintenance actions on or near the wiring systems. As
aircraft continue to fly for long periods of time, the occurrence of wire degradation gets
higher consequently, increasing the number of wire failures. FAR 25 states: "that insulation
material can’t be used that is hazardous, unreliable, or contributes smoke/fire."

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 CHAPTER II

STANDARDS AND SPECIFICATIONS

FOR AIRCRAFT WIRES & CABLES

2.1 Introduction

A very large number of specifications exist for aircraft wires and cables. Thus it is
impractical to list all those in this compendium. Significant differences can occur between
cables complying with the same basic requirements. It is also difficult to offer guidance on
interchangeability between products. The following information has been compiled to assist
in the recognition of the specifications and wire/cable selection.
The following different specifications & standards are available for development of aircraft
wires and cable for both civilian & military aircraft applications.

2.2 British Standards Specifications (BSS)

The majority of cables used on British built aircraft now in service have been
produced to 'G' specifications e.g. BS G221 for Minyvin. Aircraft cable specifications are
issued in the Aerospace G Series of British Standards and are referenced in the BSI Year
Book. Newer Standards are based upon general requirements given in BS G230. A series
of 'Detailed Standards' numbered sequentially from G232 has 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.

2.3 UK Military Specifications

Military aircraft produced by a European consortium will have their own cable
specifications and a typical example is the Panavia project which has produced PAN
specifications. These military specifications are for referential purposes and CAA does not
validate such specifications.

2.4 US Military Specifications

The designation of US Military Specifications for cable is usually MIL-W-XXXX. Each

MIL Specification has a number of 'slash sheets' and the requirements of such individual
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
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 with equivalent cables.

2.5 Manufacturers Specifications

Aircraft manufacturers may publish specifications and some of the most frequently
seen are Boeing - BMS, Douglas - BXS, Airbus Industries - AR or ASNE,, BAC (Concorde)
– BAS. 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.

2.6 International Standards ((including European standard)

The official body for the standardization of aircraft equipment, including cable, is the
ISO (International Organization for standardization). The BSI contributes to the work of the
ISO but a few ISO cable standards are employed by industry. Within Europe, the SBAC
works in association with other manufacturers in the organization known as AECMA
(Association Europeanne Des Constructeurs De Materiel Aerospatiale). AECMA seeks to
promote their own standards and they publish European 'Normes' as EN specifications.
These have not yet been widely adopted, but preliminary specifications published are
known as prEN Standards. ISO and EN Standards may be recognised for installation
purposes except that it is not usually within the boundaries of the CAA to grant product
approval against a specification not controlled by BSI.

2.7 Russian specifications & standards

2.7.1 GOST certification (Gosstandard)

GOST is the valid quality certification system in Russian Federation. It is called

GOST-R Certification. GOST is very important for Russian companies and exporters in
Russia and carries the same meaning of ISO 9000 series certificates for the western
companies. GOST is the approved quality indicator for Russia.

GOST Certification is not only engaged with the quality management of any
company, but also focused on the products of it. To obtain this certificate the tests of
samples are necessary. These tests are carried out at accredited laboratories by

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
GOSSTANDARD. (Russian Governmental Standards Organization). Based on the results
of these tests the certificates are given to the prospective company.

For obtaining these certificates, the production system analysis and the products of
related company shall be checked and investigated for the conformity of Russian norms by
the authorized auditors. Product will be tested according to Russian Federation standards
of quality. The Certificate Organs are under strict control of GOSSTANDARD. These
Organs are situated mainly in Moscow. Each Organ has its own area. The Certification
Organs are entitled to issue certificates only for the products belonging to their accredited
area. GOST certification is based on analysis of production similar to the ISO 9000
Certification.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 2.7.2 Russian Specification
Materials, used for manufacturing of wires cables should correspond to the following: -

Table 2

Tinned copper wire - TU 16-505.850-75

Tin-and-lead solder - GOST 21930-76

- GOST 21931-76

lavsan silk cloth - OST 6-06-03-75

Triacetate silk cloth - TU 6-06-483-75

Polyethylene terephthalate film - GOST 24234-80

Polyvinyl chloride (PVC) plastic

Grade I40-14 or I40-13A for

Insulation & for casing - GOST 5960-72

Copper wire - GOST 2112-79

Ultrathene grades 11306-075, - TU 16-05-1636-78

Dust milled quartz - GOST 9077-82

Colophony cable - TU 81-05-25-77

Colophony pine - GOST 19113-73

Low-molecular polyethylene

(for compound) - TU 6-05-1837-77

High pressure polyethylene

Grade 107-61 k (for insulation) - GOST 16336-77

Painted polyvinyl chloride plastic

Concentrated paint - TU 6-01-747-77

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.7.3 Decoding of Part Number of Russian wires & Cables
Each Alphanumeric symbol of part number has a specific meaning. The details are
as follows.
(a) B: External
(b) P: Wire
(c) V: Vinyl chloride Insulation
(d) L: Varnished
(e) E: Shielded
(f) D: Two layer insulation
(g) 0: Irradiated/sheathed
(h) U: Strengthened Core
(G) M: Interior/Small size
(k) S: Glass
(I) A: Asbestos
(m) T: Heat Resistant
(n) F: Fluoroplastic Insulation
(0) I: Wear resistant
(P) Z: Protection of shield surface
(q) N: Heat resistant/Nickel plated
(r) R: Rubber insulation
(s) G: Flexible
(t) Sh: Silk braiding

Aircraft wires & cables that are manufactured complying to various Technical Specifications
are listed below for reference. Characteristics, Applications & different cable variants are
also indicated wherever information is available.

2.8 Specification: TU 16-505.437-73

Applications: These cables have two layers of impregnate natural silk. These are used in
internal control circuits.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.8.1 MLTP

M L T P

Interior/ Vamished Heat resistant Wire

MLTP : Temperature resistant wire with insulation made of polyethylene and lavsan with
copper core.
Variants
MLTPG: Same as MLTP , with flexible core.
MLTPE: Same as MLTP, with shielding.

2.8.2 BPVL

BPVL

External Wire Vinyl chloride Insulation

BPVL-Wire with tinned copper core having PVC insulation in braiding made
from cotton yarn varnished and shielded for airborne mains.
Variants
BPVLE- same as BPVL, with shielding.
BPVLM- Wire with tinned copper core having PVC insulation, in combined braiding made
from glass and caperone threads varnished, small sized.

BPVLME- same as BPVLM, with shielding.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Characteristics

Classification : External Non-Heat Resistant

Voltage Rating : 500 Volts
Temperature Range :-60 to +700 C
Operating Frequency : Up to 2000 Hz
Conductor : Copper Tinned
Insulation : Vinyl chloride

2.9 Specification: TU 16-505.020- 74

Applications: This cable is meant for fixed installation and used for aircraft wiring in the
fuselage. These cables are resistant to wear and tear and heat. They are durable to oil and
fuel.

2.9.1 BIF

B I F

External Wear Resistant Fluoro Plastic

BIF: These wires are used in Airborne systems and not effected by Oil AMG-IO mark-8,
Gasoline B-70 paraffin T-l,T-2 and fluid 7-505-3.These wires evolve toxic gases when
heated up over + 200°C.

Variants:
BIFE : Same as EIF, but shielding.
BIFEZ : Same as BIFE, but protected.
BIF-N : Strand made of Nickel-plated wire.
BIFE-N : Same as BIF-N, but shielded.
BIFEZ-N : Same as BIFE-N, but protected.

Characteristics
Classification : External Heat Resistant
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Voltage Rating : 250 Volts
Temperature Range :-60 to 200° C
Operating Frequency : 2000 Hz
Conductor : Copper Silver Nickel Plated
Insulation : Polyamide Fluoroplastic

2.10 Specification TU 16-505.911-76

Applications. Different grades of these wires are used in different Aircraft systems such as
internal lighting, fuel and power systems. BPVLM cables are combustible but durable to oil
petrol mixture.

2.10.1 BPGRL

BPGRL

External Cable Flexible Rubber Insulation Varnished

BPGRL - Flexible, with insulation of silicon rubber with lavson coating and lacquered. These
strands of it’s ~ore are made of annealed silver-plated copper.

Variants : Nil
Classification : External Heat Resistant
Voltage Rating : 250 Volts
Temperature Range : -60 to 1250 C
Operating Frequency : 1000 Hz
Conductor : Copper Silver-plated
Insulation : Rubber

2.11 Specification: TU 16-505.941-76

Applications: These wires find their applications in power, Starting and Propeller
feathering circuits. The screened versions of these wires are used in Radio, Fuel and Air
Conditioning systems of aircraft.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.11.1 MGSHV

M GSHV

INTERIOR Flexible SilK BRAIDING VINYLCHLORIDE

MGSHV: Current carrying core is made of tin plated copper having film or fibrous
polychlorovinyl insulation.

Variants
MGSHVE : Same as MGSHV, with shielding.
MGSHVEV : Same as MGSHVE, with polychlorovinylimaJlation.
MSHV : Same as MGSHV
Note: Cables are manufactured in green, red, pink, blue, sky blue, black, purple, yellow,
orange, brown ,white and natural colors.

Characteristics
Classification : Internal Non Heat Resistant Flexible
Voltage Rating : 250 Volts
Temperature Range : -50 to +70°C
Operational Frequency : 5000 Hz
Conductor : Tinned Copper
Insulation : Polychlorovinyl, Electrical Insulation Fibers

2.12 Specification: TU 16-505.945-76

Applications: These wires are used for aircraft harness, and are heat and wear resistant.

2.12.1 BFS.

B F S

External Fluoroplastic Glass Polymide

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
BFS: Core is made of strands of nickel plated wire with glass polyamide fluroplastic
insulators.

Variants:
BFSE: Same as BFS~with shielding.
BFSEZ: Same as BFSE, with a sheath over the shield.

Characteristics

Classification : External Heat Resistant

Voltage Rating : 250 Volts
Temperature Range :-60 to +250° C
Operating Frequency : 2000 Hz
Conductor : Copper Nickel Plated
Insulation : Glass Polyamide Fluoroplastic

2.13 Specification TU16-705.014-77

Applications: These cables are heat resistant and do not spread combustion. They are
used in aircraft harness.

2.13.1 MS

M S
Interior Sintering Insulation

MS: Core is made of strands of copper silver plated wires and insulation material is caking
film, can be used upto 100V.

Variants
MSE -16-13 : Same as MS-16-13 With Shielding.
MSEO-16-13 : Same as MSE-16-13, with another additional sheath.
MS-26-13 : Same as MS-16-13, 250 V.
MSE-26-13 : Same as MS-16-13, with shielding.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
MSEO-26-13 : Same as MSE-26-13 with another additional sheath.
MS-36-13 : Same as MS-16-13 but for voltages up to 500 V.
MSE-36-13 : Same as MS-36-13, but with shielding.
MSEO-36-13 : Same as MSE-36-13 but with another additional shield.
Depending on the number of strands required the cable can be designated as follows:
MS-16-13 1 x 0.5 has one strand of 0.5 mm cross section
MS-16-13 2 x 0.5 has two strands of 0.5 mm cross section.

Characteristics
Classification : Internal Heat Resistant Wire
Voltage Rating : MSl.Series 100 Volts
: MS2. Series 250 Volts
: MS3.Series 500 Volts
Temperature Range :-60 to +200° C
Operating Frequency : 10000 Hz
Conductor : Copper Silver-Plated
Insulation : Caking Fluoroplastic Film

2.14 Specification TU 16- 505.184-78

Applications: These wires are flexible with Rubber Insulation and used in controls and
landing gear systems where the moving parts are subjected to bending.

2.14.1 BIN

B I N

External Wear Resistant Heat Resistant

BIN: Silver coated copper wire core with glass fluoroplastic insulation.

Variants:

BINE : Same as BIN, with shielding.

BINEZ : Same as BI1E, with protected cover.
BlN-N : Nickel coated copper wire core with glass fluroplastic insulation.
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
BIN-N-E : Same as BH'IJ"-N, with shielding.
BIN-N-E-3 : Same as BIN-N-E, with protective cover.

Characteristics:

Classification : External Heat Resistant

Voltage rating : 250 Volts
Temperature Range :-60 to +250° C
Operational Frequency : 2000 Hz
Conductor : BIN Copper Silver Plated /BIN-N Copper Nickel plated
Insulation : Glass Fluoro Plastic

2.15 Specification TU16-505.083-78

Applications: These wires do not spread combustion. They are durable to the effect of oil,
grease and petrol. These are used in aircraft starting system, fuel system and aircraft
missile launchers.

2.15.1 BPDO.

B PD0

External CABLE DOUBLE IRRADIATED

INSULA TION

BPDO: Current carrying strands are made of tin plated copper wires with two layers of
insulations.

Variants

BPDOU: Same as BPDO with reinforced strands made of alloy/BrKhTsrK wire.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
BPDOUE: Same as BPDO with reinforced strands made of alloy/BrKhTsrK wire, with
shielding.

Characteristics
Classification : External Non Heat Resistant
Voltage Rating : 750 Volts
Temperature Range :-60 to +105°C
Operational Frequency : 2000 Hz
Conductor : Copper Alloy Mandolin
Insulation :Flouro Plastic, Polyethylene

2.16 Specification: TU 16-505.554-81

Applications: This cable is heat resistant and used in fire control Radar of MIG-29 aircraft.

2.16.1 MPO

M P O

INTERIOR WIRE IRRADIATED

MPO: These are designated earlier as MGTFL and MGTFLE grades are flexible heat-proof
wires insulated by fluroplastic-4 films and braid of lavsan silk coated with varnish. Current
conducting core and shielding braid are made of copper annealed wires.

Variants

MPOE - Same as MPO, with shield.

Characteristics

Classification : Internal Heat Resistant Wire

Voltage Rating : 500 Volts
Temperature Range : 60 to + 120°C

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Operating Freq : 10000 Hz
Conductor : Copper Wire
Insulation : Fluoroplastic

Physical Characteristics : MPO and MPOE wires were earlier designated as MGTFL &
MGTFLE grades. Respectively they are 'flexible and heatproof. When these wires are
heated up over 250°C, they evolve toxic gases.

2.17 Specification: TU 16-505.324-80

Applications: These wires are flexible and heat proof and are used in the fire control radar
of MIG-29 aircraft and infra red of MIG-29 aircraft.

P F K D E - NM – MT

WIRE FLUORO HEAT DOUBLE SCREENED NICKEL-COPPER COPPER

PLASTIC RESI- LAYER (ALLOY) TITANIUM

2.17.1 PFKE-NM-MT:
It is a thermo electrode with one strands of nickel copper and another of Copper titanium
placed in one sheath.

Variants

PFKE-NM-MT: Same as PFK-NM-MT with shielding

PFKDE-NM-MT: Same as PFKE-NM-MT with double shielding.
PTF - NM - MT & PFK-NM-MT: Are same construction wire

Characteristics

Classification : Thermo Electrode Wire

Temperature Range : - 60 to + 250°C
Insulation : Fluoroplastic

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.18 Standard: GOST 24335-80

Application: These wires are used where thermocouples are employed as sensors.
20.

P T L 200

CABLE HEAT RESISTANT VARNISHED MAX. OPERATING

TEMPERA TURE

2.18.1 PTL 200

Wires are of tin plated copper conductor, with insulating material polytetra fluroethylene and
glass thread operating temperature is between -60°C to +200°C.

Variants

PTLE-200 : Same as PTL-200, with shielding.

PTL-250 : Same as PTL-200 .Operating temp is between -60°C to +250°C
PTLE-250 : Same as PTL-200 .Operating temp is between -60°C to +2500ºC, with
shielding.

Characteristics

Classification : External Heat Resistant

Voltage rating : 250 Volts
Temperature range : - 60 to + 200°C
Operational frequency : 5000 Hz
Conductor : Tinned Copper
Insulation : Flouro Plastic, Varnished Fibre Glass Sheath

2.19 Specification TU 16-505.280-79

Applications: This is a heat-resistant cable used in Engine harness, fire protection circuits
in engine zone and also in the electrical power circuits.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.19.1 RK

RK - 50 (75)

Radio Frequency Characteristics Impedance

Co-axial Cable 50 or 75 Ohms

Radio Frequency Co-axial Cable:

These are co-axial cable used for high frequency applications. Characteristic
impedance of these cables is either 50 or 75 Ohms. Constructional details o RF cable is as
follows:

(a) Inner Conducto: It is made up of seven copper silver plated wires of nominal diameter
of 0.15mm.
(b)Insulation: Teflon tape continuously wound over inner conductor.
(c) Outer Conductor: It is a braiding of copper silver plated wires.
(d) Sheathing: It is of fluoroplastic material. The outer diameter of the cable is 3.2 mm.
Decoding of Part Number: Decoding of part number of RF cables is as follows:

I II III IV V
RK- 50 – 4 - 1 1

Radio Characteristic Value of nominal Indicates insulation Ordinal number

Frequency Impedance insulated diameter rounded category of of design development
off to nearest smaller integer heat resistant

First Place: The first two letters represent type of cable (RK - Radio frequency cable)
Second Place: There are two digits which indicate characteristic impedance in Ohms.
50 - Characteristic impedance 50 Ohms.
75 - Characteristic impedance 75 Ohms.

Third Place: There is a 'number which indicate nominal insulated diameter, rounded off to
the nearest smaller integral (whole) number.
Fourth Place: It consists one single digit that indicates insulation group and category of
heat resistance. The meaning of the digit is as follows:

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1- Normally heat-resistant cables with continuous insulation.
2- Cables of increased heat stability with continuous insulation.
3- Cables of normal heat with semi-air insulation.
4- cables of increased heat stability with semi-air insulation.
5- Cables of normal heat stability with air insulation.
6- Cables of increased heat stability with air insulation.
7- Cables of high heat stability.

Fifth Place: There can be one or two digits which indicate ordinal number of the design
development.

Thus RK-50-4-11 designates radio frequency coaxial cable with the rated
characteristic impedance equal to 50 ohms; with continuous insulation of nonna! heat
stability; nominal insulated diameter is equal to 4.6 mm; the ordinal number of the
development is 1.

Standard: For RK-50-7-11 - GOST-11326.4-67

For RK-75-4-22 - GOST-l1326.43-67

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.20 Comparison of MIL Standard & Russian specifications

Note: This comparison illustration is for a particular cable type only. The TU
specifications differ for different type of cable under consideration.
Table 2
Comparison of Properties of TU16-505.083-78 and MIL-DTL-22759/86A, 88A
Sl. Examination TU16-505.083-78
No. or Test MIL-DTL-22759/86A,
MIL-DTL-22759/88A

1. Temperature 100oC, 155 oC & 200 oC 200oC for MIL-DTL-22759/86A

Rating Table 1 of Specification 150oC for MIL-DTL-22759/88A
Refer Specification Sheet

2. Voltage Rating 600 V

100V for MS 16-13, 250V Refer Specification Sheet
for MS 26-13 & 500V for
MS 36-13
Table 1 of Specification

3. Conductor As per ‘Annexure-A’

Stranding 0.75 Sq. mm & 35-95 Sq. Refer Table II and 3.5.1.1 of MIL-W-
mm- Class 3 22759E
0.2-0.5, 1.25 Sq. mm
Class 4
GOST 22483-77
Table 2, 3 and 4 of
Specification

4. Insulation Min. 1524 MΩ-Km at room

Resistance 2.3.3 of Specification temperature
2000 MΩ-Km Refer Specification Sheet
At 200ºC- 100 MΩ-Km
for period of operation and
storage – 10 MΩ-Km
In normal climatic
conditions

Sl. Examination TU16-505.083-78 MIL-DTL-22759/86A,

No. or Test MIL-DTL-22759/88A

5. Wet Arc N.A MIL-STD-2223 Method 3006

Propagation Refer Specification Sheet
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Resistance
6. Dry Arc N.A MIL-STD-2223 Method 3007
Propagation Refer Specification Sheet
Resistance
7. Blocking N.A 200oC+2 oC
As per 3.6.6 of MIL-W-22759E
8. Color striping or N.A 125 Cycles (250 Strokes)
banding As per 3.6.4 of MIL-W-22759E
durability
9. Conductor N.A Min. 13 unbounded strands 3.5.1.1.3
Strand of MIL-W-22759E
adhesion
10. Dynamic Cut- N.A ASTM D 3032, Section 22
through Refer Specification Sheet
Wire 23+ 150+ 200+
o o
Size 5C 5C 5oC
26 10 8 lbs 6 lbs
lbs
20 25 20 lbs 15 lbs
lbs
16 25 20 lbs 15 lbs
lbs
11. Flammability N.A MIL-STD-2223 Method 1006,
Test Procedure A
Table III of MIL-W-22759E
a. Duration of 3 Seconds (max)
after-flame
b. Flame travel 3.0 inches (max)
c. Faming of No Flaming
Tissue
12. Forced N.A SAE AS4373
Hydrolysis 2000 hrs at 70oC
Refer Specification Sheet

13. High Frequency N.A MIL-STD-2223 Method 3008

Spark Test 5.7 Kilovolts (rms.)
Refer Specification Sheet
14. Immersion Test N.A MIL-STD-2223 Method 1001
Table III of MIL-W-22759E
15. Life Cycle Test N.A 500 Hrs at 230oC+2oC
Dielectric test, 2500V (rms), 60Hz
Table III of MIL-W-22759E
16. Removability of N.A Insulation shall be readily removable
Insulation without damage to the conductor

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
17. Identification of N.A RADIANT M-22759/86-16/2009
product 3.6.5 of MIL-W-22759E

18. Durability of N.A Min. 250 strokes

identification 3.6.5.2 of MIL-W-22759E
19. Mandrel Wrap N.A No cracks, No dielectric
breakdown at 2500 Volts for 5 minutes
3.6.3 of MIL-W-22759E

20. Shrinkage N.A Test at 230oC+2 oC 2.31mm for 26-

10AWG and 3.17mm for
8-04 AWG
Refer Specification Sheet

21. Low N.A No cracks, No dielectric breakdown at

Temperature 2500 Volts for 5 minutes
(Cold bend) at - Refer Specification Sheet
65+2oC
22. Smoke Test N.A 200oC+2 oC
Refer Specification Sheet

23. Solderability N.A Not Required. Primarily intended for

crimp terminations
3.6.8 of MIL-W-22759E

24. Thermal Shock 200oC+2oC

Resistance N.A Max. Change in measurement
2.31mm for 26-10 AWG and 3.17mm
for 8-04 AWG. No cracking
Refer Specification Sheet

25.
Insulation
26. Strippability ASTM D 3032 Sec.27
N.A Min. 2 N
Max. 32 N
Refer Specification Sheet
27. Thermal Index 200oC min. For MIL-22759/86A
10,000 Hrs at 155 oC / 50oC for MIL-22759/88A for 10,000
200 oC Hrs, M D3032, Section 14
Table 7 of Specification Refer Specification Sheet
28. Impulse 8.0 KV peak
Dielectric N.A 3.6.2 of MIL-W-22759E

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
29. Bending Radius 5D
5D
2.6.3 of Specification
30. Sinusoidal Range of frequency- 1 to N.A
Vibration 5000Hz

Amplitude of speed, m/s2 (g)

- 392 (40)

2.5.1 of Specification
31. Acoustic Noise Range of Frequency- 50 to N.A
10000Hz at

Level of sound pressure

160dB
2.5.1 of Specification
32. Mechanical Shock acceleration peak N.A
Impact of single value,m/s2 (g) - 1471(150)
action Duration of action, ms 1 -3
2.5.1 of Specification
33. Mechanical N.A
Impact of Shock acceleration peak
multiple action value, m/s2 (g) 9810(1000)
Duration of action, ms 0.2-1
2.5.1 of Specification
34. Linear N.A
Acceleration 4905 (500) m/s2 (g)
2.5.1 of Specification
35. Reduced N.A
Atmospheric 33x10-4 Pa (5mm Hg
Working Column)
Pressure 2.6.4 of Specification
36. Increased N.A
Atmospheric 295 kPa (3 Kf/cm2)
Working 2.6.7 of Specification
Pressure
37. Breaking N.A
strength of high 2.4 to 2.8 times more than
strength strands f normal strength strands
Point No.3 of Appendix 1
of the Specification
38. Maximum temp 250oC N.A
(short duration 2.6.2 of Specification
for 3 Hrs)

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
39. Increased Relative humidity at 35oC- N.A
Humidity 98%
2.6.9 of Specification
40. Salt Fog For non shielded wires (+) N.A
2.6.6 of Specification
41. Ultra Violet Stable, as per GOST N.A
Total Solar 16962-71
Radiation 2.6.10 of Specification
42. Mould Fungus Max. 2 Marks N.A
2.6.5 of Specification

43. Service Life 15 years Min. 25 years Min.

Period 2.8.2 of Specification

44. Operating 100000 Hrs at 100oC, 10000 Hrs at 200oC

Period 10000 Hrs at
155oC/200oC,
2.8.3 of Specification

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
2.21 De-rating Criteria for wires & cables

Table 3
Wire and Cable De-rating criteria as per MIL-STD-975

De-rated Current
(Amperes)
Wire Size Single Bundled Wire
(AWG) Wire or Cable
30 1.3 0.7
28 1.8 1.0
26 2.5 1.4
24 3.3 2.0
22 4.5 2.5
20 6.5 3.7
18 9.2 5.0
16 13.0 6.5
14 19.0 8.5
12 25.0 11.5
10 33.0 16.5
8 44.0 23.0
6 60.0 30.0
4 81.0 40.0
2 108.0 50.0
0 147.0 75.0
00 169.0 87.5

Note:
1. De-rated current ratings are based on an ambient temperature of 70°C or less
2. The de-rated current ratings are for 200°C rated wire, such as Teflon insulated (Type
PTFE) wire in a hard vacuum of 10-6 torr.
a. For 150°C wire, use 80% of value shown in Table 16.
b. For 135°C wire, use 70% of value shown in Table 16.
c. For 105°C wire, use 50% of value shown in Table 16.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
3. The current rating for bundles or cables is based on bundles of 15 or more wires. For
smaller bundles, the allowable current shall be determined by IBW = ISW x (29-N)/28 where
N = number of wires, IBW = current, bundled wire and ISW = current, single wire.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 CHAPTER III

FAILURE ANALYSIS AND TESTING REQUIREMENTS

FOR AIRCRAFT WIRES AND CABLES

3.1 Introduction

It is important to recognize the certification requirements for Aircraft electrical wires &
cables and the design standards achieved by aircraft manufacturers 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.

3.2 Cable Failure analysis

3.2.1 Polyimide insulation can be recognized by its bright translucent copper color. This is
often misinterpreted as the conductor being exposed when the topcoat cosmetic layer has
been removed due to damage. Although this has not degraded the cable insulating
properties, this mottling of the cable does lead to actual chafes being harder to detect
amongst flaking lacquer. Complacency can also creep in with tradesmen assuming it is
actually flaking lacquer. A considerable amount of flaking is now being exhibited on many
aircraft and many man-hours are being expended by electrical tradesmen re-evaluating
damage that has already been examined on a previous occasion.

3.2.2 Cracking and splitting of the polyimide insulation is normally found where cable bend
radii have been exceeded or excessive flexing of the wires allowed. This form of damage
has been found on numerous occasions within weapons pylons. This damage has been
accelerated by hydrolysis action within the Severe Wind And Moisture-Prone areas
(SWAMP) areas. Once this type of damage has occurred and the conductors are exposed,
the looms are in a primed condition for a wet or dry carbon arc track event. There are
already occurrences of inadvertent weapons release from the Tornado due to this type of
damage.

3.2.3 Polyimide is a tape-wrapped insulation. During manufacture these tapes are sintered
together to seal them in place. Experience has shown that flexing and damp conditions
allow these tapes to unwrap and exposing the conductors.

Polyimide insulated wires are stiffer than other types of wire and this has proved to be
its weakness in fighter aircraft. It is reluctant to move with areas of vibration and so chafe
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
damage is inflicted on the insulation. Due to the volume of wiring on current fighter aircraft,
where space is at a premium, cable is susceptible to inadvertent damage by tradesmen
removing or fitting equipments. If this minor scuffing is ignored then catastrophic
consequences could result.

3.2.3 The problem of fitting more wire into less space now appeared to be solved until the
US Navy reported that they were experiencing excessive chafing, cracking and damage to
the cable looms, especially in SWAMP area. As these problems appeared to be attributable
to a breakdown of the insulation material the US Navy conducted preliminary tests which
revealed three potential problems which appeared to be unique to polyimide wire types.

a. Hydrolysis: It is a phenomenon characterized by cracking and breakdown of the

insulation material through exposure to moisture; the speed of breakdown depending
on both temperature and stress.

b. Wet Arc Tracking: Carbon arc tracking occurs when contaminating moisture or
aircraft fluids create a short circuit between an exposed conductor and the aircraft
structure or an adjacent exposed conductor at a different potential.

c. Dry Arc Tracking: Carbon arc tracking occurs in dry conditions when one or more
conductors are shorted as a result of abrasion from the aircraft structure, wire to wire
abrasion, and installation error or battle damage.

The Kapton insulated wire still made this day and flies in over a third of the world’s
commercial planes. Kapton is best when young. It is feather weight. The salient feature of
this insulation is that its thickness of only about three human hairs is flame resistant &
tough. But the bad thing is that the Kapton insulation can explode like a firework if it’s
chafed and rubs against metal. That’s called ‘dry arcing’. Worse still, salt water or solvent
can penetrate the insulation and cause the same problem. That’s called ‘wet arcing’. Most
wires, when they short-circuit, simply spark and blow a fuse. But with Kapton insulation the
spark explodes. Inside the confines of the plane, and with alarming speed, this can quickly
spread into a lethal weapon of toxic fumes and flames. The following types of failures and
quality faults are amongst those seen in recent years.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
3.3 Arc Tracking
Airworthiness certification authorities have drawn the attention of Industry to the
problem of wet arc tracking of damaged cables subjected to fluid contamination. Wire
manufacturers should ensure that hot stamp printing is properly controlled. Therefore,
‘Interconnect' and 'Equipment Wires' should not be hot stamp printed.

3.4 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.

3.5 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.

3.6 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.

3.7 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.

3.8 Poor Solderability

It should be recognized that the quantity of free tin on plated conductors rapidly
reduces with time. The replacement of soldered connections during aircraft maintenance

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
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 hence prolonged storage should be
avoided. This indicates the importance of specifying electrical cable of an appropriate type
and quality. It is the design intent that the present generation of CEMILAC 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.

The data from the visual inspections, nondestructive testing, and laboratory analysis
were analyzed to accomplish two objectives:

a. To evaluate the adequacy of visual inspection for detecting deteriorating wire

installations.
b. To determine the condition of wire in aged aircraft

The intrusive inspection focused on six significant categories of wire degradation. They are
as follows.
i. Degraded wire repairs or splices
ii. Heat damaged or burnt wire
iii. Vibration damage or chafing
iv. Cracked insulation
v. Arcing
vi. Insulation de-lamination

3.9 Case studies of electrical cable failures

Case-1
Swiss Air Flight 111 and TWA Flight 800 are examples of two high profile fatal
nd
crashes that resulted from faulty electrical wiring. On September 2 1998, Swiss Air Flight
111, an MD-11 aircraft crashed off the coast of Nova Scotia in Canada. The aircraft en
route from John F. Kennedy (JFK) International Airport, New York to Geneva, Switzerland,
crashed into the North Atlantic killing all 215 passengers and 14 crew members. According
to the Canadian Transportation Safety Board (TSB): final accident report number
th
A98H0003 dated March 27 2003, the in flight fire “most likely started from an electrical
arcing event that occurred above the ceiling on the right side of the cockpit near the cockpit
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
rear wall. The arcing of one or more wires in turn ignited the inflammable cover material on
nearby thermal acoustic insulation blankets and quickly spread. A segment of electrical
cable from the in- flight entertainment network is believed to be associated with one or more
of the arcing events.

Case-2
th
On July 17 1996, Trans World Airlines (TWA) Flight 800, a Boeing 747-131 crashed
in the Atlantic Ocean near East Moriches, New York. The flight was operating as a
scheduled international passenger flight from John F. Kennedy (JFK) International Airport
New York to Paris, France. All 212 passengers and 18 crew members were killed and the
airplane was destroyed. According to the National Transportation Board (NTSB): final
rd
accident report number NTSB/AAR-00/03 dated August 23 2000, it was determined that
the probable cause of this accident was an explosion of the center wing fuel tank (CWT)
resulting from ignition of the inflammable fuel/air mixture in the tank. The source of the
ignition energy for the explosion could not be determined with certainty, but, of the sources
evaluated by the investigation, the most likely source was a short circuit outside of the
center fuel tank that allowed excessive voltage to enter it through electrical wiring
associated with the fuel quantity indication system.

3.10 Qualification Tests

The following qualification tests are conducted for aircraft wires/cables: -

1. Visual & Physical Conductor Tests

1.1. Conductor Inspection
1.2. Conductor Elongation
1.3. Conductor Resistance (Conductor Continuity)

2. Visual & Physical Finished Wire Tests

2.1. Finished Wire inspection
2.2. Insulation wall thickness and Concentricity

3. Environmental Tests
3.1. Fluid immersion
3.2. Acid resistance
3.3. Humidity resistance
3.4. Flammability
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 3.5. Fire resistance

4. Mechanical Tests
4.1. Tensile strength and elongation of insulation
4.2. Wrap Test
4.3. Cold Bend
4.4. Wrinkle

5. Electrical Tests
5.1. Spark test of primary insulation /voltage withstand test
5.2. Impulse dielectric
5.3. Insulation resistance

6. Thermal Tests
6.1. Life cycle test
6.2. High temp Endurance
6.3. Thermal Shock
6.4. Insulation shrinkage/expansion
6.5. Lamination sealing
6.6. Blocking
6.7. Smoke

3.11 Qualification Test Details

1.0 Visual & Physical Conductor Tests

1.1. Conductor Inspection
• Method : 5001, 5004, 5005, 5006 of MIL STD 2223
• Purpose : These tests determine the diameter of the conductor
after the Insulation has been removed.
• Execution : Determine the conductor diameter by measuring the
outer diameter in at least three locations along the length of the stripped
conductor. Each measurement shall consist of two micrometer readings taken 90
degrees from each other.
• Specific Apparatus : Micrometer or equivalent device capable of measuring
to the nearest 0.0001 inch.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1.2. Conductor Elongation:
• Method : 5002 of MIL STD 2223
• Purpose : This test is used as process control test on the
conductors either before application of insulation or after insulation with the
insulation removed. The insulation process may affect the elongation and break
strength of the conductor.
• Execution : The elongation of the specimen shall be calculated as
follows:

Where:
L = the distance between the bench marks on the specimen immediately after
rupture (inches).

• Specific Apparatus : Power driven tensile test machine , Strip chart recorder,
Tensile machine grips
1.3. Conductor Resistance (Conductor Continuity)
• Method : 5003 of MIL STD 2223
• Purpose : This test determines the direct current (DC) resistance
of the conductor of a wire at a specified reference temperature which is usually
200C (680F).
• Execution : Kelvin bridge method or Wheatstone bridge method.

• Specific Apparatus : Resistance measuring device.

Temperature measuring device

2.0 Visual & Physical Finished Wire Tests

2.1 Finished Wire inspection
Method : 6001,6002,6004,6005
Purpose: This test determines the diameter of the finished insulated wire.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 2.2 Insulation wall thickness and Concentricity
o Method : 6003 of MIL STD 2223
o Purpose : This test determines the wal 1 thickness and
insulation concentricity of a finished wire. Concentricity measurements are
generally only applied to the insulation of extruded wires.
o Execution : Al1 wall thickness measurements shall be made
on cross-sections of the wire specimens using the optical measuring
device set at a suitable magnification.

o Specific Apparatus : Optical measuring device capable of reading to

the nearest 0.0005 inch, Single-edged razor blade or equivalent cutting
tool, Insulation stripping tool with precision-sized blades (if needed).

3.0 Environmental Tests

3.1 Fluid immersion

o Method : 1001 MIL STD 2223
o Purpose : This test determines the ability of a wire to resist
degradation when exposed to common fluids the wire may come into
contact with during its service 1ife.
o Execution :
a) Fluid preparation: Each fluid shal1 be heated to the temperature specified.
Adequate ventilation shal1 be provided for al1 fluid fumes.
b) Pre-immersion test: Each wire specimen shal1 have the diameter measured
to the nearest 0.0001 inch within the center 12-inch portion according to
Finished wire diameter Test
c) Immersion test: Each specimen, for each test fluid listed, shall be immersed to
within 6 inches of each end for the time and temperature specified. During
immersion the radius of bend of the wire shal1 not be less than 14 nor more
than 35 times the specified maximum diameter of the wire under test. Upon
removal from the test fluid, the specimen shall be wiped dry and then remain
for 1 hour in free air at room temperature. The diameter shall be measured
within the same 12-inch section as in Pre-immersion test and compared to the
initial diameter. The insulation shall be removed for a distance .5 inch from

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 each end .of the specimen. The specimen shal1 then be subjected to the
bend test of method 2206 and the wet dielectric test of method 3005 of MIL
STD 2223.

Table -3 Test fluids and immersion time

Test Fluid Test Temperature Immersion
Time
MIL-L-23699, Lubricating 48° to 50”C (118° to 20 hours
Oil , Aircraft Turbine 122°F)
Engine,
Synthetic Base, NATO
Code
Number 0-156

MIL-H-5606, Hydraulic 48° to 50”C (118° to 20 hours

Fluid, 122°F)
Petroleum Base; Aircraft,
Missile and Ordinance

TT-I-735, Isopropyl Alcohol 20° to 25°C (68°to77°F) 168 hours

MIL-T-5624, Turbine Fuel, 20° to 25°C (68°to77°F) 168 hours

Aviation, Grades JP-4, JP-
5,
and JP-5/JP-8ST.

• Specific Apparatus : Immersion thermometer, an air circulating oven,

Micrometer to measure wire diameters within 0.0001 inch.

3.2 Acid resistance

• Method : 1002 of MIL STD 2223
• Purpose : This test determines the ability of a wire to resist
degradation when exposed to a strong acid.
• Execution : The test specimens shal1 be immersed to within 1.50
inches of each end in red fuming nitric acid (specific gravity 1.52) at room
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 temperature for 8 hours. Adequate ventilation shall be provided for all fumes.
Following this acid immersion, the specimens shall be removed and immersed,
except for 1.50 inches at each end, for 1 hour in water at room temperature
containing 0.5 percent of aerosol or equivalent wetting agent. The specimens in
the water solution shal1 then be subjected to the wet dielectric test of method
3005.

• Specific Apparatus : One Pyrex, stainless steel, or similar inert vessel and
sufficient quantity of red fuming nitric acid with a specific gravity of 1.52.

3.3 Humidity resistance

• Method : 1004 of MIL STD 2223
• Purpose : The purpose of this test is to permit evaluation of the
properties of materials used in wire as they are influenced or deteriorated by the
effects of high humidity and heat.
• Execution : The specimen shall be placed in the test chamber and
the temperature and relative humidity raised over a 2-hour period to 70°± 2°C
and 95% ± 5% and maintained at such for a period of 6 hours. At the end of the
6-hour period, the heat shal1 be shut off. During the following 16-hour period, the
temperature shall drop to 38°C or lower. This shal1 constitute a cycle (2 hours
heating, 6 hours at high temperature, 16 hours cooling). A total of 15 consecutive
cycles shall be performed for total test time of 360 hours. No more than 2 hours
after the end of the fifteenth cycle, the center 50 feet of the sample shall be
subjected to the Insulation Resistance Test of Method 3003 with one foot at each
end above the test solution.
• Specific Apparatus : A test chamber capable of maintaining an internal
temperature of 70 + 2°C and an internal relative humidity of 95 + 5 percent shal1
Fe used.
• Failure Criteria : a loss of insulation resistance of the sample

3.4 Flammability
• Method : 1006 of MIL STD 2223

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Purpose : The test determines the resistance of burning when exposed to a
flame. Burning resistance is a wire insulation measured as the amount of time combustion
continues or the distance the insulation burns during or after flame application. This test
also evaluates secondary ignition due to burning droplets.
Significance : This test provides a standard laboratory test for evaluating the
burning resistance of a wire, but does not simulate most actual service applications.

Execution :
a) Procedure A (60 flame test): The 24 inch specimen of wire shall be marked at a
distance of inches from its lower end to indicate the point for flame application and
shall be placed in the specified 60-degree position in the test chamber. The lower
end of the specimen shall be clamped in position In the specimen holder and the
upper end shal1 be passed over the pulley of the holder and loaded with sufficient
weight to keep the wire taut. With the burner held perpendicular to the specimen and
at an angle of 30° from the vertical plane of the specimen, the hottest portion of the
flame shal1 be applied to the lower side of the wire at the test mark. The flame shal1
be adjusted to provide an al1 blue conical flame approximately 2 inches high with a
temperature of 955° ± 30°C (1751° ± F) at its hottest point as measured by a
thermocouple pyrometer or equivalent device. A sheet of the facial tissue shall be
suspended taut and horizontal 9.50 inches below the point of application of the flame
to the wire specimen and at least 0.51 inch from the chamber floor, so that any
material dripping from the wire specimen shall fall upon the tissue. The flame shall
be applied for 30 seconds and then withdrawn at the end of the 30 seconds.

b) Procedure B (60 flame test with dielectric test). Perform the same 60 degree flame
test as procedure A then subject the tested specimen to the wet dielectric test of
method 3005, ‘except the time of immersion shall be 5 minutes and the time of
exposure to ful1 voltage shal1 be only 1 minute.

4.0 Mechanical Tests

4.1 Tensile strength and elongation of insulation
Method : 2001 of MIL STD 2223
Purpose : This test provides tensile property data on extruded electrical insulation
removed from the wire and is used as a process control test for the extrusion test.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Significance : Tensile properties are useful to determine the ability of the insulation to
withstand mechanical stresses it may experience in use. Comparison of tensile
Properties before and after environmental or thermal exposure is useful to determine the
extent of insulation degradation due to the exposure.

Execution :
Pretest measurements: The length between the bench marks shall be measured to the
nearest 0.01 inch. The inner and outer diameters of the straight tube samples or the
width and thickness of the dumbbell samples at the reduced area section shall be
measured. The cross-sectional area shall be calculated from these measurements.

The specimen shall be placed in the grips of the calibrated tensile test machine and
adjusted such that the tension will be distributed uniformly over the cross-section of the
specimen. The force shall be applied at a uniform rate of 20 ± 1 inch per minute. After
rupture of the specimen, the breaking force and the distance the bench marks were
apart at the time of rupture shall be recorded. Repeat the procedure on the other
specimens.

F = Breaking Force (pounds)

C = Cross-sectional area of the unstretched specimen in square inches

D = the distance between the bench marks at the moment of rupture (inches)
G = the distance between the bench marks on the unstretched specimens (inches)
Acceptance Criteria : Average tensile strength & elongation should be within
permissible limits.
Specific Apparatus :
a) Power driven tensile test machine with sample grips attached to a force indicator.
b) Extensometer, calipers, scale, or other device for accurately measuring the length
c) Micrometer or equivalent device to determine sample cross-sectional area.

4.2 Wrap Test

Method : 2001 of MIL STD 2223
Purpose : This test determines if a wire is susceptible to cracking when
wrapped around a mandrel.
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Significance : This test has been applied to many wire types especially over braided or
tape wrapped wires. This test or the wrap back test is usually required in the individual
wire specification.

Execution : Each specimen of finished wire, with a length of 12 inches plus the
additional length required for winding on the mandrel , as specified in individual
specification, shall be wound tightly for two close turns around a mandrel of the
specified diameter. The winding may be accomplished manually or automatically and
shal1 be in the middle portion of the specimen so that at least six inches of each end
shall remain straight. The specimen shal1 then be removed from the mandrel,
examined visually for cracks, and subjected to the wet dielectric test, method 3005.

Acceptance Criteria : No cracks should be observed and acceptance criteria of the

wet dielectric test
Specific Apparatus :

4.3 Cold Bend

Method : 2004 of MIL STD 2223
Purpose : This test determines the resistance of a wire to cracking or dielectric
breakdown at low temperature while being wrapped around a mandrel.

5.0 Electrical Tests

5.1 Spark test of primary insulation /voltage withstand test
Method : 3001 of MIL STD 2223

Purpose : This method is used as a process control test to determine and remove
defects in the primary insulation of insulated wires.
Significance : Presence of a weak spot in the insulation results in a
breakdown at that spot. When breakdown occurs, the spark test equipment is designed
to stop the wire spooling equipment allowing the operator to remove the defective area
of the wire.

Execution : The conductor shall be earth-grounded during the spark test. An earth-
ground connection shall be made at both ends of the pay-off and take-up reels, except
that, if the wire is tested for continuity and the conductor is one of integral length, the

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 earth-ground connection need only be made at one end. In any case, the conductor on
a reel at which a earth-ground connection is made shall be bonded directly to the earth-
ground on the transformer of the spark tester. The entire length of the wire shall be
passed through the electrode of the spark tester at the specified voltage and frequency.
Electrode length and speed of wire movement shall be such that each length of the
insulation is subjected to the test voltage for a minimum of 0.2 seconds. Any portion of
the wire showing insulation breakdown shall be cut out of the wire including at least two
inches on each side of the fault. The frequency and voltage of the spark shall be
specified in the individual specification.

Acceptance Criteria : Report if 100 percent of the wire has been subjected to the in-
process spark test and certify that al1 faults detected were removed as required before
application of any outer insulation, jacket, or other material.

Specific Apparatus : a) Spark tester capable of providing an essentially sinusoidal

voltage with a transformer of sufficient capacity to maintain the test voltage specified in
the individual specification.
b) The electrode shall be a bead chain or fine wire mesh construction capable of
providing contact with practically the entire wire insulation surface.
c) A fault signaling device or system shall include a visible signal, a fault recording
device, and/or an automatic stop device.

5.2 Impulse dielectric

Method : 3002 of MIL STD 2223
Purpose : This method detects and removes insulation defects in finished wires.
Significance : The test is primarily used as a 100 percent screening test at final
packaging, but may be used as an in-process test or as an incoming inspection test by
the user.

Execution: The finished wire shall be threaded through the electrode head and the
conductor shall be grounded at one or both ends. The electrode shall be energized to
the specified peak potential and after final adjustment of the voltage with wire in the
electrode head, the wire shall be passed from the pay-off spool through the electrode
and onto the take-up spool. The speed of passage of the wire through the electrode
shall be such that the wire is subjected to neither less than 3 nor more than 100 pulses

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 at any given point. Any dielectric failures which occur shall be cut out or marked for
later removal along with at least 2 inches of wire on each side of the failure. During all
parts of the test, including string-up of new lengths, every effort shall be made to test
the entire length, including ends of the wire, in accordance with this procedure. All ends
or other portions of the wire not so tested shall be removed subsequent to the test.
When specified, dielectric failures, untested portions of wire, or portions which have
been exposed to fewer or more than the specified number of pulses may be marked by
stripping the insulation or by other suitable method of marking as specified in the
contract in lieu of being cut out of the wire.

Acceptance Criteria : Report if 100 percent of the wire has been subjected to the
impulse dielectric test and certify that all faults detected were removed or marked as
required.

Specific Apparatus :
a) Test impulse - The waveform of the voltage supplied to the electrode head shall
consist of a negative pulse, the peak magnitude of which shall be as specified for the
wire under test, followed by a damped oscillation.
b) Instrument voltmeter - Connected to the electrode head, there shall be a peak
reading voltmeter indicating continually the potential of the electrode.
c) Failure detection circuit

5.3 Insulation resistance

Method : 3003 of MIL STD 2223
Purpose : This test determines the insulation resistance of a finished
wire sample.
Significance : Insulation resistance is of interest in high impedance circuits
and as a measure of quality control of the insulation process.
Changes in insulation resistance may indicate deterioration in
other properties of the wire

Execution : The test specimen shall be immersed within approximately six

inches of each end in a water bath containing 0.5 to 1.0 % of an anionic wetting agent
of 5 % by weight sodium chloride at room temperature. After a 4-hour minimum
immersion time, the specimen shall be subjected to a potential of 500 volts ± 10

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 percent applied between the conductors tied together and the water bath, which serves
as the second electrode. The insulation resistance of the specimen shal1 be measured
after one minute of electrification and shal1 be converted to mega ohms for 1000 feet
as follows:

Failure Criteria : Insulation Resistance value below the specified limit

Specific Apparatus : a) Megaohm Bridge, megaohm meter, insulation resistance
test set, or other suitable equipment.
b) Tub, jar, or other insulated vessel large enough to hold
sufficient water to immerse the specimen length.
c) Anionic wetting agent or quantity of 5 percent by weight
sodium chloride in water.
d) Test sample shall consist of a wire at least 26 feet in length
with the insulation removed for 1 inch at each end. The stripped
ends shal1 be twisted together.

6.0 Thermal Tests

6.1 Life cycle test
Method : Method 4001 of MIL STD 2223

Purpose : This test determines if the wire insulation can withstand a

temperature aging test for a time period at a temperature greater than the temperature
rating of the insulation. To pass this test, the wire must withstand the bend and wet
dielectric tests after the thermal exposure.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Execution : The test oven shall be set and thermally stabilized at the
specified temperature of the individual specification. The test oven shall be shut off and
allowed to return to room temperature. Each end of the conductor shall be loaded with
the test weight required in the individual specification and the central portion of each
weighted specimen shall then be bent in a “U” shape over a horizontally placed
mandrel of the diameter required. The portion of the insulation between the conductor
and the mandrel will be under compression and the conductor will be under tension.
The mandrel with the weighted samples shall then be placed in the oven and the oven
turned on again. The specimens shall be maintained for the time and at the
temperature required. The start of the time period shall be determined as the point in
time the test oven re-stabilizes at the specified test temperature. After completion of the
air oven thermal exposure, the oven shall be shut off, the door opened, and the
specimens allowed to cool to room temperature, in the oven, for at least 1 hour. When
cooled, the wire shall be immediately freed from tension, removed from the mandrel
and straightened. Each specimen shall then be subjected to the bend test of method
2006 followed by the wet dielectric test of method 3005.

Acceptance Criteria : same as that of the bend and wet dielectric test.

Specific Apparatus :
a. Air circulating test oven
b. Test mandrels which may be coated with PTFE to prevent sticking of the wire
specimens.
c. Thermocouple recorder or strip chart recorder to accurately and continuously monitor
the chamber temperature.

6.2 High temp Endurance

Method : Method 4002 of MIL STD 2223
Purpose : This test determines the ability of the insulation of a fire zone or
similar wire to resist degradation due to exposure to a high temperature.
Significance : The test is generally applied to fire resistant or similar wire
types in lieu of the elevated temperature aging (life cycle) test.

Execution : The wire sample shall be placed in the oven which shall be
maintained at 343°C + 3°C (650°F + 5°F). The ends of the specimen shall be run

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 through the ports of the oven and connected to the current source which may be either
AC or DC. The current through the conductor shall be adjusted to stabilize at the certain
values for the applicable wire size. When the stabilized oven test temperature and the
stabilized conductor current are reached, the initial voltage and current measurements
shall be recorded. The current loaded wire shall remain in the air oven at an oven
temperature of 343°C + 3°C (650°F + 5°F) for a period of 100, +1, -O hours. The current
through the conductor shall be checked periodically and maintained at the required test
value. At the end of the 100-hour period, while still at the stabilized temperature and
conductor current, final voltage and current measurements shal1 be recorded. Change
in resistance during the conditioning period shall be calculated from the voltage and
current measurements. The wire shall then be cooled to room temperature and
examined for visual defects. Change in color of the finished wire or printed identification
shall not be considered a defect. The ends of the wire sample that were outside the
oven during conditioning shall be discarded. From the wire which was inside the oven
during conditioning, the following 3 foot specimens shall be cut for further testing: viz.
bend test followed by wet dielectric test and fluid immersion test followed by bend test
and wet dielectric test

Acceptance Criteria : Same as that of conductor resistance bend and wet dielectric
tests, fluid immersion tests, and any visual defects observed.

Specific Apparatus :
1. Air oven capable of maintaining a temperature of 343°C + 3°C (650°F + 5°F).
The oven shall have test ports to allow the sample leads to be connected to a
power supply.
2. AC or DC constant current power supply
3. Voltmeter.
4. Ammeter.
5. Fluids as specified in the individual specification.
6. Test mandrels as required.
7. Load weights as required.

6.3 Thermal Shock

Method : Method 4004 of MIL STD 2223

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Purpose : This test determines the ability of wire insulation to resist
shrinkage or expansion due to a brief exposure to temperature extremes.
Significance : This test helps to measure inherent stresses in the insulation
which affect longitudinal changes in the insulation.

Execution : The specimen shall be placed in the oven or hot chamber preheated to the
specified temperature for 30 minutes. The specimen shall be removed from the oven or
hot chamber and within two minutes placed in the cold chamber precooled to -55° ±2°C
(-67°F ± 3.6°F) for 30 minutes unless otherwise specified. After 30 minutes the cycle –
(hot, room, then cold temperatures) shall be repeated. A total of 4 full cycles shall be
performed.

At the conclusion of the 4th cycle, the distance from the end of each layer of the
insulation to the end of the conductor shall be measured to the nearest 0.001 inch on
each end of each specimen. The difference in the length of exposed conductor before
and after the test shall be calculated. The insulation shall also be checked for flaring of
any layer.

Acceptance Criteria : No change in length of exposed conductor on each end of each

specimen and flaring of any layer of the insulation.

Specific Apparatus :
1. Suitable thermal shock chamber or combination of an air oven and cold chamber
capable of maintaining the specified temperatures and tolerance.
2. Timers to measure cycle times.
3. Scale to measure shrinkage/expansion to the nearest 0.001 inch.
4. Razor blade or equivalent sharp cutting tool.

6.4 Insulation shrinkage/expansion

Method : 4005
Purpose : This test determines the ability of wire insulation to resist
shrinkage or expansion due to a brief exposure to a high temperature.
Significance : This test helps to measure inherent stresses in the insulation
which affect longitudinal changes in the insulation.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Execution : The oven shal1 be thermally stabilized then the specimen shall
be placed in the oven at the specified temperature for 6 hours. After 6 hours, remove the
specimens from the oven and allow the specimens to return to room temperature. The
distance from the end of each layer of the insulation to the end of the conductor shall be
measured to the nearest 0.001 inch on each end of each specimen. The difference in
the length of exposed conductor before and after the test shall be calculated.
Acceptance Criteria : the change in 1ength of exposed conductor on each end of
each specimen should be within the permissible limits.
Specific Apparatus :
a. Suitable air oven capable of maintaining the specified temperatures and tolerance.
b. Timer to measure exposure.
c. Scale to measure shrinkage/expansion to the nearest 0.001 inch.
d. Razor blade or equivalent sharp cutting tool.

6.5 Lamination sealing

Method : 4006 of MIL STD 2223
Purpose : This test determines if tape wrapped insulations have been properly
processed.
Significance : Failure of this test indicates the layers of tape are properly sealed and
have too 1ittle adhesion between their layers.
Execution : The specimens shall be maintained at the temperature specified for 48
hours in an air oven. At the end of this period, the specimen shal1 be removed from the
oven and allowed to return to room temperature. The specimen shall then be visually
examined for de-lamination. De-lamination is defined as separation of layers or 1ifting of
tapes along the insulation or at the ends.

Acceptance Criteria : no de-lamination noticed

Specific Apparatus : Air circulating oven capable of maintaining the
temperature and tolerance specified.

6.6 Blocking
Method : 4007
Purpose : This test determines if a wire will block (stick to itself) after
exposure to a short time thermal exposure.
Significance :

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Execution : One end of the specimen shal1 be affixed to a metal spool or
mandrel of the specified diameter. The wire shall then be wound helically at the tension
shown for the wire size for at least three turns, with the succeeding turns in close
contact with one another. The winding shall be continued until there are at least three
closely-wound layers of such helical turns on the spool. The free end of the wire shall
then be affixed to the spool or mandrel to prevent unwinding or loosening of the turns.
The spool or mandrel with the attached wire specimen shal1 be placed for 24 hours in
an air oven at the temperature specified. At the end of 24 hours the spooled wire shal1
be removed from the oven and al1owed to come to room temperature. The wire shal1
be unwound from and examined for adhesion (blocking) of adjacent turns.

Acceptance Criteria : No adhesion (blocking) of adjacent turns noticed

Specific Apparatus :
a. Metal spool or mandrel of the specified diameter.
b. Clamps or other means to secure the wire to the spool or mandrel.
c. Air oven to maintain the temperature and tolerances specified.

6.7 Smoke
Purpose : This test determines if the insulation of a wire will produce smoke when the
conductor is subjected to an overload current which raises the conductor temperature to
the rated temperature of the insulation.
Execution : This test shall be conducted at room ambient temperature in still air. The
specimen shal1 be suspended so that at least the central 10-foot section is horizontal
and unsupported. One end of the wire shall be suitably weighted so that no sagging will
occur. The resistance of the central 10-foot section shall be measured in accordance
with Method 5003 (Conductor Resistance). During the test, while passing direct current
through the wire to raise its temperature, the voltage drop shall be measured over the
10-foot section. The voltage-to-current ratio (resistance) needed to provide the required
smoke test temperature specified in the individual specification

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 9

2. Approval Title : High Temperature Electrical Cables

3. Validity of Approval : 28 May 1971

4. Developer of the Item : M/s Garg Associates Pvt. Ltd.,

Ghaziabad, U.P
5. Governing Specification : MIL-W-16878D (Navy)

6. End Use of the Item : Aircraft use

7. Other Details : a) Wire electrical type EE 200oC 18 AWG (7/26) Red -

1000 V
b) Wire electrical type EE 200oC 28 AWG (7/36) Violet -
1000 V
c) Wire electrical type E 200oC 20 AWG (19/32) Black -
600 V
d) Wire electrical type ET 200oC 24 AWG (7/32) Green -
250 V

1. Type Approval No. : 10

2. Approval Title : Tinned Copper Flexible Cable Braids

3. Validity of Approval : 28 May 1971

4. Developer of the Item : M/s Metal Cloth Products

Bangalore
5. Governing Specification : QQ-B-575

6. End Use of the Item : Aircraft use

7. Other Details : a) Type 12/5/.0048 (IND)

b) Type 24/10 /.005 (IND)
c) Type 2X24X16/0.01 (IND)

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 12

2. Approval Title : Nyvin Type Electrical Cables- 16,18,20 & 22

3. Validity of Approval : 24 Jul 1971

4. Developer of the Item : M/s. Henley Cables India Ltd.,

Poona-1
5. Governing Specification : BS: G-177/MAR 1961

6. Characteristics of Wire

a) Voltage Proof Test : 2000 V AC RMS

b) Insulation Resistance : ≥ 200 MΩ
c) Temperature Range : -400 C to +550 C

7. End Use of the Item : Aircraft use

1. Type Approval No. : 14

2. Approval Title : Flexible Nylon Strapping CATNO.SC-1 &

Moulded Studs CATNO.SS3
3. Validity of Approval : 31 Dec 1980

4. Developer of the Item : M/s Mayfair Electricals

Calcutta - 7
5. Governing Specification : -

6. End Use of the Item : Aircraft use

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 15

2. Approval Title :
Unipren Type Electrical Cables

3. Validity of Approval : 31 Dec 1980

4. Developer of the Item : M/s Henley Cables India Ltd.,

Poona - 1
5. Governing Specification : BS 2E-21/1957

6. End Use of the Item : Aircraft Use

7. Other Details : − Unitpren 4,6,9 & 12

− Unipren 18,24, 35, 50, 70 & 100

1. Type Approval No. : 23

2. Approval Title : Flexible Nylon Cable Strapping 12.5mm CAT No.SC-2 and
Moulded Stud CAT No. SS4

3. Validity of Approval : 25 May 1972

4. Developer of the Item : M/s Mayfair Electricals
Calcutta - 7
5. Governing Specification : -
:
6. Characteristics of Strap

7. End Use of the Item : Aircraft use

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 48
2. Approval Title : Tinned Copper Flexible Cable
Bra
ids
3. Validity of Approval : 30 Jun 2014
4. Developer of the Item : M/s Metal Cloth Products Pvt Ltd.,
Bangalore – 560 025

5. Governing Specification : QQ-B-575

6. End Use of the Item : Aircraft use

7. Other Details : a) Type 12/5/0.0048” (IND)

b) Type 24/10 /0.005” (IND)
c) Type 2 X 24 X 16/0.01” (IND)
d) Type 24/4 /0.006” = p3 X 6
e) Type 24/8 /0.006” = p6 X 12
f) Type 24/8 /0.0076” = p12 X 16
g) Type 24/8 /0.0116” = p16 X 24
h) Type 24/8 /0.0116” = p24 X 30
8.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 49

2. Approval Title : Unipren & Uninyvin Cable & Uniflexpren-6

3. Validity of Approval : 28 Oct 1974

4. Developer of the Item : M/s Western Insulated Cables Ltd.,

Poona-1

5. Governing Specification : i) 2E, 21- Dec 1957 (PREN) - British Standard

Specifications
i) G-177, Mar 1961 (Nyvin) - British Standard

6. End Use of the Item : Aircraft use

:
7. Other Details

1. Type Approval No. : 72

2. Approval Title : Uninyvinmet Cables14. 12, 10 & 8

3. Validity of Approval : 30 Dec 1980

4. Developer of the Item : M/s Western Insulated Cables Ltd.,

Poona-1
5. Governing Specification : BSG 177: 1961

6. End Use of the Item : Aircraft use

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 81

2. Approval Title : Uninyvin Type Electrical Cables 22, 20, 18 & 16

3. Validity of Approval : 17 Dec 1975

4. Developer of the Item : M/s Western Insulated Cables Ltd.,

Poona-1
5. Governing Specification : BSG 177: 1961

6. Characteristics of Wire

a) Conductor : Annealed Tinned Copper Wires

b) Insulation : White, High Temperature PVC
7. End Use of the Item : Aircraft use

1. Type Approval No. : 140

2. Approval Title : Braided Wire for Electrical

Bonding
3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s Metal Cloth Products Pvt.

Ltd., , Bangalore – 560 025

5. Governing Specification : Technical Specification QQB-575

ETS No.1, Issue-1
dated 18 July 1974
6. Characteristics of Wire

a) Conductor : Tin coated Copper braid

b) Temperature Range : ?
7. End Use of the Item : Artouste IIIB Engines
8. Other Details : Part Nos.
a) 9.554.81.415.2 / H
b) 9.554.81.424.2 / H
c) 9.552.11.200.2 / H
d) 9.552.11.202.2 / H
e) 9.552.11.203.2 / H
f) 9.552.81.100.2 / H

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 380

2. Approval Title : Para Mini Flex & Para Mini Flexmet Cables of sizes
0.35, 0.75, 1.0, 1.5 and 2.5 mm2
As substitute for USSR Grade DPVLM & BPVLME

3. Validity of Approval : 03 Jan 1992

4. Developer of the Item : INCAB Industries Limited

Pune - 411013
5. Governing Specification : a) TU-16-505.911-76
b) TU-72-72-06 (III Edition)
6. Characteristics of Wire

a) Classification : External Non-Heat Resistant

b) Voltage Rating : 500 Volts
c) Operating Frequency : Up to 2000 Hz
d) High Voltage Withstand : 3500V, 50 Hz for one minute
(Normal Condition)
e) Insulation Resistance : > 500 MΩ / Mtr
f) Conductor : Tinned Copper
g) Insulation : PVC insulation (Vinylchloride)
h) Temperature Range : -600 C to +700 C
7. End Use of the Item : Different grades of these wires are used in different Aircraft
systems such as internal lighting, fuel and power systems.
BPVLM cables are combustible but durable to oil petrol
mixture.

79
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 421

2. Approval Title : Aircraft Cables PRANYVIN PT.No.500, 600 & 700

3. Validity of Approval : 30 Jun 1999

4. Developer of the Item : INCAB Industries Limited

Pune - 411013

5. Governing Specification : i) AIR 4524E. 1955

ii) AIR 4524E, 1980
iii) BSG 212, Mar 1971
iv) BSG 222

6. Characteristics of Wire

a) Classification : Non-flammable, Aero fluid resistant

b) Voltage Rating : 600 Vrms

c) Operating Frequency : -

d) Conductor : Tinned annealed Electrolytic Copper – Type 500

Tinned or Nickel plated annealed electrolytic copper – Type 600

Nickel plated annealed electrolytic copper – Type 700

e) Insulation : PVC Insulation – Type 500

FEP or PTFE – Type 600

Sintered PTFE – Type 700

f) Temperature Range : -400 C to +1050 C: Peak +1350 C – Type 500

-500 C to +1400 C: Peak +1700 C – Type 600

-500 C to +2750 C – type 700

7. End Use of the Item : Aircraft use

80
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 515

2. Approval Title : Tinned copper Flexible Cable Braids

3. Validity of Approval : 31 Dec 2014

4. Developer of the Item :

M/s Metal Cloth Products (P) Ltd., , Bangalore – 560 025

5. Governing Specification : QQ-B-575

6. Characteristics of Braid

a) Conductor : Tin coated copper braid

7. End Use of the Item : For aircraft use

8. : Type Nos. of the items

Other Details

81
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 533

2. Approval Title : Indigenous Aircraft Cables

12 Types
3. Validity of Approval : 30 Jun 1999

4. Developer of the Item : INCAB Industries Limited

Pune - 411013
5. Governing Specification : a) AIR 4524E, 1955 Issue
b) AIR 4524, 28 Aug 1980 issue
c) BSG 212 Mar 71
d) BSG 222

6. End Use of the Item : For aircraft use

7. Other Details : Part Nos. of 12 type cables
i. Paranyvinmetsheath, Part No. 500 H/1
ii. Duparanyvinmetsheath, Part No. 500 H/2
iii. Triparanyvinmetsheath, Part No. 500 H/3
iv. Quadraparanyvinmetsheath Part No. 500 H/4
v. Paranytefmesheath, Part No. 600 H/1
vi. Duparanytefmesheath, Part No. 600 H/2
vii. Triparanytefmesheath, Part No. 600 H/3
viii. Quadraparanytefmesheath, Part No. 600 H/4
ix. Paratefmetsheath, Part No. 700 H/1
x. Duparatefmetsheath, Part No. 700 H/2
xi. Triparatefmetsheath, Part No. 700 H/3
xii. Quadraparatefmetsheath, Part No. 700 H/4

82
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 83
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 84
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 85
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 86
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 593

2. Approval Title : a) Para Tefmet Sheathex – T200

b) Paranyflon T-140-ATC
c) Paranyflon Metsheath T-140
3. Validity of Approval : 05 Feb 1993

4. Developer of the Item : INCAB Industries Limited

Pune - 411013
5. Governing Specification : a) AIR/4524-E (1980)
b) MIL-C-7870T
6. Characteristics of Wire

a) Classification : Non-flammable; aero fluid resistant

b) Voltage Rating : 600 Vrms
c) Conductor : Nickel plated annealed electrolytic Copper for T200
Tin annealed electrolytic Copper for T-140
d) Insulation : Sintered PTFE for T200
FEP for T-140
e) Temperature Range : -50°C to +200OC: Peak 230 OC for T200
-50°C to +140OC Peak 170 OC for T-140
7. End Use of the Item : For aircraft use

8. Other Details : a) Para Tefmet Sheathex–T200 – NPC Conductor/PTFE

INS/ Helical Screen of SPC wires/ FEP Jacket – Size
22 to 16 AWG Single, Twin & Three Cores

b) Paranyflon T-140-ATC – ATC conductor /FEP INS/

Polyamidesheath, Size 22 to 10 AWG

c) Paranyflon Metsheath T-140 – Paranyflon Core or

Cores, Helical Screen of ATC wires &
Polyamidesheath, Size 22 to 10 AWG Single, Twin and
Three Cores

87
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 667

2. Approval Title : Uninyvin Cables

3. Validity of Approval : 30 Jun 2001

4. Developer of the Item : M/s Jai Bharat Industries

New Delhi – 110 020
5. Governing Specification : a) BSG-177
b) DTD-1085C
6. Characteristics of Wire

a) Classification :
b) Voltage Rating : 600 Vrms
c) Operating Frequency : Up to 1600 Hz (max)
d) High Voltage Withstand : 1500 Vrms for one minute
e) Conductor : ATC wire
f) Insulation : High Temp. PVC
g) Temperature Range : -40°C to +105OC
7. End Use of the Item : For aircraft use like Chetak, Cheetah, AVRO, Ajeet, Kiran,
Canberra, HPT etc.,
8. Other Details : Group-I 22 to 16 AWG
Group-II 14 to 12 AWG
Group-III 10 to 2 AWG
Group-IV 1 to 0000 AWG

88
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 673
2. Approval Title : KAPTON Polyimide wires and cables

3. Validity of Approval : 30 Jun 2017

4. Developer of the Item : M/s Sanghvi Aerospace Pvt Ltd,
Ahmadabad
5. Governing Specification : a) MIL-W-81381/7 & 9 for basic /core
wires
b) MIL-DTL-27500H for cables
6. Characteristics of Wire
a) Classification : Internal / External ; heat / wear / thermal resistant wires
b) Voltage Rating : 600 V DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : Silver plated Copper / Copper Alloy conductor
e) Insulation : Polyimide insulation (wrapped)
f) Temperature Range : -60°C to +260OC
7. End Use of the Item : In electrical equipments & aircraft electrical wiring harness and
airborne armaments systems

8. Other Details : Sanghvi Aerospace Part No.

381(07/09)-**-▲ (wires) &
381(07/09)-**-s(SK/SKK) (for cables)
is same as
M81381(/07/09)-** (for wires) and
M27500(A/D)**M(R/T)nS(11/12) for cables respectively
(where ** indicates size of conductor, ‘n’ indicates No. of cores)

Decoding of Part No. of Wire

♦ SAPL PART NUMBERING SYSTEM - WIRE

381XX - ## - *

Basic MIL specification identifier

(eg. 381 represents MIL-DTL-81381 specification)

Slash sheet identifier

(eg. 07 represents slash sheet 7 of MIL-DTL-81381 specification)

Gauge size of the conductor in AWG

Colour code designators in accordance with MIL-STD-681

Example : 38107-22-2 = 22 AWG, red colour wire as per MIL-DTL-81381/7

89
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
♦ SAPL PART NUMBERING SYSTEM - CABLE

381XXX - ## - # XXX

Basic specification identifier

(eg. 381 represents basic core wire as per MIL-DTL-81381
Specification and cables as per MIL-DTL-27500 specification)

Slash sheet identifier

[eg. 07 represents slash sheet 7 of MIL-DTL-81381 (refer Note B)]

Identification method of cable wire, % shield coverage and colour of

core wire (Refer Note A)

Gauge size of the conductor in AWG

Number of basic core wires in cable (Refer Note C)

Shield style and material (Refer Note D)

Jacket material (Refer Note E)

Example : 38107D-22-3SKK = 22 AWG, 3 core wire (White, Blue, Orange) as per MIL-DTL-81381/7,
Silver plated Copper shielded with 90% coverage, jacket of natural Polyimide tape comBIN/BIN-Ned
with FEP having Polyimide as a outer surface and heat sealed

90
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 767

2. Approval Title : Light Weight Series Flexible PTFE, PFA/FEP Insulated

Cables Types
UNIFLUOR
200BJ (16 AWG & 22 AWG)
2001 (22 AWG)
2501 (16 AWG & 22 AWG)
3. Validity of Approval : 30 Jun 1999

4. Developer of the Item : M/s Universal Cables Ltd.,

SATNA (MP)-485 005
5. Governing Specification : AIR 4524E 1980

6. Characteristics of Wire
a) Classification : -
b) Voltage Rating : 600 Vrms
c) Insulation Resistance : ≥ 500MΩ / km
d) Construction : Unifluor 200BJ - UNISTAR make fluroplastic flexible
screened cables of single, two or three cores of Uniflour
type 2001 of sizes 12 AWG to 22 AWG with collective braid
of ATC wires and overall jacketed with polyamide

Unifluor 2501 - UNISTAR make fluroplastic flexible

screened cable of nickel plated copper conductor, insulated
with Teflon PFA for sizes 22 AWG to 12 AWG, single core
cable

Unifluor 2001 - UNISTAR make fluroplastic flexible cables

of Annealed tinned copper conductor insulated with Teflon
FEP and jacketed with Polyamide cables of sizes 24 AWG
to 12 AWG, single core

e) Temperature Range : -500C to +2500C for Unifluor 200BJ

-500C to +2500C for Unifluor 2501
-500C to +1500C for Unifluor 2001
7. End Use of the Item : For Aircraft use

91
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 882

2. Approval Title : Wire, Electrical, Fluorocarbon

Polymer (modified PTFE) / Polyimide
insulated, Tin / Silver / Nickel coated
copper conductors and cables
3. Validity of Approval : 30 Jun 2018

4. Developer of the Item : M/s Sanghvi Aerospace (P)Ltd,

Ahmadabad
5. Governing Specification : a) MIL-DTL-22759/80 to 92A for
basic/core wire
b) MIL-DTL-27500H for cables
6. Characteristics of Wire
a) Classification : Airframe wire
b) Voltage Rating : 600 V DC
c) Operating Frequency : Up to 2000 Hz

d) Dielectric Voltage withstand : 1500V RMS for one minute

(between cores)
e) Conductor : Tin / Silver /Nickel plated Copper /Copper Alloy

f) Insulation : − FP (Modified PTFE) / Polyimide / FP Composite and

FP film for wire
− PTFE or FP/PI & FP film for sheath of cable

g) Temperature Range : -600C to +2000C for SPC (Silver Coated)

-600C to +2600C for NPC (Nickel Plated)
-600C to +1500C for TPC (Tin Plated)

7. End Use of the Item : In electrical equipments & aircraft electrical wiring harness
and airborne armaments systems. Extensively used in HJT-
36, LCA and other projects.
8. Other Details :

Decoding of Part No. of Wire

♦ SAPL PART NUMBERING SYSTEM - WIRE

759XXX - ## - *
Basic MIL specification identifier
(eg. 759 represents MIL-DTL- 22759 specification)

Slash sheet identifier

(eg. 80A represents slash sheet 80A of MIL-DTL-22759
specification)

Gauge size of the conductor in AWG

Colour code designators in accordance with MIL-STD-681

Example : 75986A-22-9 = 22 AWG White colour wire as per MIL-DTL-22759/86A

92
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
♦
♦ SAPL PART NUMBERING SYSTEM - CABLE

759XXX - ## - # XXX

Basic specification identifier

(eg. 759 represents core wire as per MIL-DTL- 22759
specification and cables as per MIL-DTL-27500 specification)

Slash sheet identifier

[eg. 80 represents slash sheet 80A of MIL-DTL-22759
(refer Note B)]

Identification method of cable wire and shield coverage

(Refer Note A)

Gauge size of the conductor in AWG

Number of basic core wires in cable (Refer Note C)

Shield style and material (Refer Note D)

Jacket material (Refer Note E)

Example : 75986A-22-3S06 = 22 AWG, 3 core wire (White, Blue, Orange) as per MIL-DTL-
22759/86A, Silver plated Copper shielded with 85% coverage, taped and heat sealed white PTFE
jacketed cable

93
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 883

2. Approval Title : Wires, Electrical, PTFE /

Polyimide insulated, light
normal weight Tin/Silver/Nickel
coated conductors and cables
3. Validity of Approval : 30 Jun 2003

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) MIL-W-22759/80 to 92 for
wires
b) MIL-C-27500 G for Cables

6. Characteristics of Wire / Cable

a) Classification : -

b) Voltage Rating : 600 Vrms

c) Dielectric Withstand Voltage : Should withstand 1.5KV for one minute

(between core to core & core
to shield)

d) Insulation resistance : > 1525 MΩ / km

e) Life Cycle Test : 230°C for 500 hrs

f) Conductor : Tin/Silver/Nickel coated conductors

g) Insulation : PTFE / Polyimide insulation

h) Temperature Range : -65 to +150° C for Tin Coated Copper

-65 to + 200°C for Silver Coated Copper / Copper alloy
-65 to + 260°C for Nickel Coated Copper / Copper alloy

7. End Use of the Item : Electrical wires and cables for aircraft harness

94
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 884

2. Approval Title : High Tech Polyimide Insulated

wires and cables

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.

5. Governing Specification : a) MIL-DTL-81381/8C,10D &11C,

b) MIL-DTL-27500H

6. Characteristics of Wire

a) Classification : Internal / External ; heat / wear / thermal resistant wires

b) Voltage Rating : 600 V DC

c) Operating Frequency : Up to 2000 Hz

d) Conductor : Nickel plated Copper conductor

e) Insulation : Polyimide insulation (wrapped)

f) Temperature Range : -60°C to +260OC

7. End Use of the Item : In electrical equipments & aircraft electrical wiring harness
and airborne armaments systems

8. Other Details : Sanghvi Aerospace Part No.

381(08/10/12)-**-▲ (wires) &
381(08/10/12)-**-n(SK/SKK) (for cables)
is same as
M81381(/08/10/12)-** (for wires) and
M27500(A/D)**M(S/V/W)nS(11/12) for cables respectively
(where ** indicates size of conductor, ‘n’ indicates No. of
cores)

95
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 885

2. Approval Title : High Temperature & High

Voltage Ignition Cable

Part No. JB-257-0000

3. Validity of Approval : 30 Jun 2013

4. Developer of the Item : M/s Jai Bharat Industries

New Delhi – 110 020
5. Governing Specification : a) PBCTY Cable TU-OM4-505-
003-56 (R11F)

b) B3C-350-6.5 Cable TU16-

505-236-71 (R-25)

6. Characteristics of Wire

a) Classification : Ignition Cable

b) Nominal Impulse voltage : Cable shall withstand 15 kV

c) Breakdown Voltage : ≥ 35 kV

d) High Voltage test : 19kV for one minute

e) Insulation Resistance : 10MΩ / mtr

f) Resistance of Core : 2000 Ω / km

g) Conductor : Stainless Steel Wire of AISI-304 standard

h) Insulation : PTFE Insulation (Fluro Plastic tape)

7. End Use of the Item : For use in electrical accessories of R11F & R25 series
engines in main manifold and after burner manifold of MiG
aircrafts

96
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 886

2. Approval Title : BIN type wear and heat

resistant cables
Part No. JB-777-0035, JB 777-
0050, JB 777-0075
3. Validity of Approval : 30 Jun 2013

4. Developer of the Item : M/s Jai Bharat Industries

New Delhi – 110 020
5. Governing Specification : TY-16-505-620-74

6. Characteristics of Wire

a) Classification : Wear and Heat Resistant

b) Voltage Rating :
c) Insulating Resistance : ≥1000Ω / Km
d) High Voltage withstanding : 1.5KV, 50 c/s for one minute
e) Conductor : Silver plated copper stands
f) Insulation : PTFE, fibre glass thread impregnated with suspension of
fluroplast wrapped and braided with FG thread coated with
suspension of fluroplast
g) Temperature Range : -60 to +250° C
7. End Use of the Item : For use in electrical accessories of R11F, R25, R-29B and
RD-33 series engines of MiG aircrafts
8. Other Details

97
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 889

2. Approval Title : Polytetrafluroethylene/Polyimide

tape insulated & sintered
Electrical Wires & Cables
Part No.RW22780 to RW22792-
26 to 04AWG & Cables Part
No.RC22792-2UJ to 4UJ/ITJ to
4TJ/ISJ to 4SJ/INJ to 4NJ-26 to
10AWG
3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s Radiant Cables Limited

Hyderabad – 500 018
5. Governing Specification : a) MIL-W-22759/80-92
b) MIL-C-27500G

6. Characteristics of Wire

a) Classification : Advanced Arc track resistant Normal / light weight

b) Voltage Rating : 600 Vrms
c) Insulation Resistance : 5000 MΩ
d) Conductor : Standard Tin / Silver / Nickel coated high strength / ultra
high strength copper alloy
e) Insulation : Composite Tape (FP/ Polyimide/FP) and FP tape
f) Temperature Range : -65 to +150° C for Tin Coated Copper
-65 to + 200°C for Silver Coated Copper / Copper alloy
-65 to + 260°C for Nickel Coated Copper / Copper alloy
7. g) Life Cycle Test 500 hrs at 230°C
8. End Use of the Item : Airborne application inclusive of Naval Air platforms. Like
LCA, Dornier, Jaguar, Helicopter, Avionics and any other
military aviation industry as Electronic equipment and
aircraft electrical wiring harness

98
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 890

2. Approval Title : Polytetrafluroethylene/Polyimide

tape insulated & sintered
Electrical Wires & Cables
Part No.RW81088-26 to 10AWG
& Cables Part No.RC81088 – IJT
to 4J\TJ-26 to 10 AWG
3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s Radiant Cables Limited

Hyderabad – 500 018
5. Governing Specification : a) MIL-W-81044
b) MIL-W-81044/12B
c) MIL-C-27500G
6. Characteristics of Wire

a) Classification : Advanced Arc track resistant Normal / light weight

b) Voltage Rating : 600 Vrms
c) Insulation Resistance : 5000 MΩ
d) Conductor : Standard Tin coated copper
e) Insulation : Polytetrafluroethylene /Polyimide Insulation
f) Temperature Range : -65 to +150° C
7. g) Life Cycle Test : 500 hrs at 230°C
8. End Use of the Item : Electrical wires and cables for aircraft harness

99
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 100
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 891

2. Approval Title : Polytetrafluroethylene/polyimide tape

insulated & sintered Electrical Wires,
Part No. RW 22780 to RW 22792A-26 to
4AWG & Cables Part No. RC 22780A to
RC22792A-2UJ TO 04UJ/ITJ to 4TJ/ISJ
TO 4SJ/INJ to 4NJ-26 TO 10AWG
3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s Radiant Cables Limited

Hyderabad – 500 018
5. Governing Specification : c) MIL-DTL-22759/80A-92A
d) MIL-C-27500G
e) MIL-DTL-27500H
6. Characteristics of Wire
a) Classification : Advanced Arc track resistant
b) Voltage Rating : 600 Vrms
c) Insulation Resistance : 5000 MΩ
d) Conductor : Standard Tin / Silver / Nickel coated high strength / ultra
high strength copper alloy
e) Insulation : Composite Tape (FP/ Polyimide/FP) and FP tape
f) Temperature Range : -65 to +150° C for Tin Coated Copper
-65 to + 200°C for Silver Coated Copper / Copper alloy
-65 to + 260°C for Nickel Coated Copper / Copper alloy
g) Life Cycle Test ; 500 hrs at 230°C
7. End Use of the Item : Airborne application inclusive of Naval Air platforms
Like LCA, Dornier, Jaguar, Helicopter, Avionics and any
other military aviation industry as Electronic equipment and
aircraft electrical wiring harness

101
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 896

2. Approval Title : PTFE Insulated Fibre Glass Braided and Lacquered

Wires and Cables
Part No. 177T, 178T, 1177T, 1178T, 140T, 250NT, 1140T
& 1350NKT
3. Validity of Approval : 31 Dec 2003

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) AIR 4524E, Issue 1980
b) BS G 177 Mar 1961
c) MIL-DTL-27500
6. Characteristics of Wire

a) Classification : -
b) Voltage Rating : 600 Vrms
c) Operating Frequency : 1600 Hz
d) Insulation Resistance : ≥ 500 MΩ
e) Conductor : Silver / Nickel Plated Copper
f) Insulation : PTFE Insulation wrapped and sealed
g) Temperature Range : -65 to +250° C for Nickel plated copper
-65 to + 200°C for Silver plated copper
-50 to + 140°C for Silver plated copper / copper alloy
7. End Use of the Item : Used as electrical cable and wires for electrical harness

8. Other Details : These cables are used as a substitute of NYVIN cable of

BS G 177.

102
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 897

Aircraft Cables 6 Types

2. Approval Title : (BIN, BINE, PTL-200, 250, PTLE-
200, 250)

3. Validity of Approval : 31 Dec 2013

M/s Jai Bharat Industries,

4. Developer of the Item :
New Delhi- 110 020

a) TU-16-505.620-74 (Cable BIN

and BINE)
Governing Specification
5. : b) TU-16-505.280-71(Cable PTL
and PTLE)

6. Characteristics of Wire
a) Classification : External Heat Resistant
b) Voltage Rating : 250 V
Upto 2000 Hz (Cable BIN and BINE)
c) Operating Frequency :
Upto 5000 Hz(Cable PTL and PTLE)
BIN Copper Silver Plated /
d) Conductor : BIN-N Copper Nickel plated &
PTL Tinned Copper
e) Insulation : Glass Fluoro Plastic
-60 to +250° C (Cable BIN and BINE)
f) Temperature Range : -60 to + 200°C (Cable PTL and PTLE)

7. End Use of the Item − Used in MiG 21 & MiG27 aircraft

− This cable is meant for fixed installation and used for
: aircraft wiring in the fuselage. These cables are
resistant to wear and tear and heat they are durable to
oil and fuel.
Other Details
Part Nos of the Cables

103
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 898

2. Approval Title :
Aircraft Cables 4 Types
(MGSHV, MGSHVE, MGSHV-1,
MGSHVE-1)

3. Validity of Approval : 30 Jun 2015

4. Developer of the Item : M/s Jai Bharat Industries,

New Delhi- 110 020
5. Governing Specification : TU-15-505.437-73/82 (Russian)

6. Characteristics of Wire

a) Classification : Internal Non Heat Resistant Flexible

b) Voltage Rating : 250 V

c) Operating Frequency : Up to 5000 Hz

d) Conductor : Tinned Copper

e) Insulation : Polychlorovinyl, Electrical Insulation Fibres

f) Temperature Range : - 50°C to + 70°C

7. End Use of the Item : − For aircraft electrical harness in MiG series aircraft

− These cables have two layers of impregnate natural

silk. These are used in internal control circuits.

Other Details: Part Nos. of the cables

104
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 899

2. Approval Title : Cables 4 Types (BPVL, BPVLE,

BPVLM, BPVLME)
3. Validity of Approval : 30 Jun 2015

4. Developer of the Item : M/s Jai Bharat Industries,

New Delhi- 110 020

5. Governing Specification : TU-16-505.911-76 (Russian)

6. Characteristics of Wire

a) Classification : External Non-Heat Resistant

b) Voltage Rating : 500V

c) Operating Frequency : Up to 2000 Hz

d) Insulation strength : Should Withstand 1500 V / 50Hz

e) Insulation Resistance : > 500 MΩ

f) Conductor : Copper Tinned

g) Insulation : Vinyl chloride

h) Temperature Range : -60°C to +70°C

7. End Use of the Item : Different grades of these wires are used in different Aircraft
systems such as internal lighting, fuel and power systems.
BPVLM cables are combustible but durable to oil petrol
mixture.

Other Details: Part Nos. of the Cables

105
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 918

2. Approval Title :
Cables – Radio Frequency &
Semirigid with PTFE Dielectric

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : MIL-DTL-17H
6. End Use of the Item : − For use on Aircraft / Helicopter / Avionic Systems
Application.
− Used in Wiring of Apparatus of Aircraft Electrical
Circuit.
− This cable is useful in high temperature and high
frequency applications.

Other Details: Part Nos. of the cables

106
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F188 (Ref. MIL PART NO: M17/113-RG316)

CONSTRUCTIONS DETAILS

←⎯1 Inner 7 strands of silver plated copper covered steel.

1
conductor Strand dia:0.17mm,Overall Dia:0.51 ± 0.025mm
Dielectric Solid PTFE (Tape wrapped & sintered)
2
←⎯2 core Dia:1.52 ± 0.076mm
Outer Single braid of silver plated copper wire
3
←⎯3 conductor (strand dia 0.1mm) Coverage 95% nom.

PTFE (Tape wrapped & sintered)

4 Jacket
←⎯4 Dia:2.49 ± 0.1mm

TECHNICAL CHARACTERISTICS
Continuous working voltage : 900 Vrms max.
Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 275.92 Ω/Km
(max at 20oC)
Conductor Elongation : 10 % minimum
Conductor Tensile strength : 50 Klbs/in2 min.
Weight : 18 Kg/Km max.
Voltage withstanding : 2000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1200 Vrms min.
Characteristic Impedance : 50 ± 2.0 ohms
Frequency (GHz) : 0.05 0.1 0.4 1.0 3.0
Attenuation(dB/100m max.) : 24.6 36 68.8 108 190
Structural return loss(dB min.) : 30 30 23 21 17
Power rating (Watts max.) : 600 450 240 160 80

107
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TEF TYPE NO: F187 (Ref. MIL PART NO: M17/94-RG179)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner 7 strands of silver plated copper covered steel.

conductor Strand dia:0.1mm,Overall Dia:0.3 ± 0.025mm
2 Dielectric Solid PTFE (Tape wrapped & sintered)
←⎯2 core Dia:1.6 ± 0.076mm
3 Outer Single braid of silver plated copper wire
←⎯3 conductor (strand dia 0.1mm) Coverage 93% nom.
4 Jacket PTFE (Tape wrapped & sintered)
Dia:2.54 ± 0.13mm
←⎯4

TECHNICAL CHARACTERISTICS

Continuous working voltage : 900 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 802.16 Ω/Km
(max at 20oC)
Conductor Elongation : 8 % minimum
Conductor Tensile strength : 50 Klbs/in2 min.
Weight : 16.07 Kg/Km max.
Voltage withstanding : 2000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1200 Vrms min.
Capacitance : 75 Pf/m max.
Characteristic Impedance : 73 ± 3.0 ohms
Frequency (GHz) : 0.1 0.4 1.0 3.0
Attenuation (dB/100m max.) : 32 69 82 141
Power rating (Watts max.) : 570 310 200 110

108
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F196 (Ref. MIL PART NO: M17/093-RG178)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner 7 strands of silver plated copper covered steel.

conductor Strand dia:0.1mm,Overall Dia:0.30 ± 0.025mm
2 Dielectric Solid PTFE (Tape wrapped & sintered)
←⎯2 core Dia:0.84 ± 0.05mm
3 Outer Single braid of silver plated copper wire
conductor (strand dia 0.1mm) Coverage 96% nom.
←⎯3 4 Jacket PTFE (Tape wrapped & sintered)
Dia:1.8 ± 0.1mm

←⎯4

TECHNICAL CHARACTERISTICS

Continuous working voltage : 750 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 802.16 Ω/Km
(max at 20oC)
Conductor Elongation : 10 % minimum
Conductor Tensile strength : 50 Klbs/in2 min.
Weight : 9.3 Kg/Km max.
Voltage withstanding : 2000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1000 Vrms min.
Capacitance : 105 Pf/m max.
Frequency (GHz) : 0.05 0.1 0.4 1.0 3.0
Attenuation (dB/100m max.) : 38 52.5 108 170 308
Structural return loss (dB min.) : 26 25 22 19 14
Power rating (Watts max.) : 380 250 123 78 41

109
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F141 (Ref. MIL PART NO: M17/111-RG303)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner Solid silver plated copper covered steel. Overall

conductor Dia:0.94 ± 0.025mm
2 Dielectric Solid PTFE (Tape wrapped & sintered)
←⎯2 core Dia:2.95 ± 0.13mm
3 Outer Single braid of silver plated copper wire
←⎯3 conductor (strand dia 0.12mm) Coverage 95% nom.
4 Jacket PTFE (Tape wrapped & sintered)
Dia:4.32 ± 0.13mm
←⎯4

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1400 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 58.92 Ω/Km
(max at 20oC)
Conductor Elongation : 1 % minimum
Conductor Tensile strength : 110 Klbs/in2 min.
Weight : 46.13 Kg/Km max.
Voltage withstanding : 5000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1900 Vrms min.
Capacitance : 105 pF/m max.
Characteristic Impedance : 50 ± 2 Ohms
Frequency (GHz) : 0.05 0.4 1.0 3.0
Attenuation (dB/100m max.) : 8.9 28.2 49.2 92
Structural return loss (dB min.) : 28 26 24 21.3
Power rating (Watts max.) : 3400 1100 650 350

110
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F142 (Ref. MIL PART NO: M17/060-RG142)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner Solid silver plated copper covered steel. Overall

conductor Dia:0.94 ± 0.025mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered)
core Dia:2.95 ± 0.13mm
3 Outer Double braid of Silver Platted Copper Wire
←3a conductor (strand dia 0.12mm)
a) Inner Braid - Coverage 95% nom.
←3b b) Outer Braid – Coverage 93% nom.

4 Jacket PTFE (Tape wrapped & sintered)

←⎯4 Dia:4.95 ± 0.13mm

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1400 Vrms max.

Operating frequency : 12.4 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 63.97 Ω/Km
(max at 20oC)
Conductor Elongation : 1 % minimum
Conductor Tensile strength : 110 Klbs/in2 min.
Weight : 64 Kg/Km max.
Voltage withstanding : 5000 Vrms + 10%
Insulation resistance : 23000 MΩ-Km min.
Corona extinction voltage : 1900 Vrms min.
: 50 ± 2 ohms
Characteristics Impedance
Capacitance : 105 Pf/m max.
Frequency (GHz) : 0.05 0.1 0.4 1.0 3.0 8.0
Attenuation (dB/100m max.) :13.12 18 38.38 62.3 115 216.5
Structural return loss (dB min.) : 25.5 -- 23.8 22.0 17.0 17.0
Power rating (Watts max.) : 3500 2400 1100 650 330 180

111
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F400 (Ref. MIL PART NO: M17/128-RG400)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner 19 strands of silver plated copper wire each strand

conductor 0.2mm , Overall Dia. : 0.98 ± 0.025mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered) Dia:2.95 ±
core 0.13mm
3 Outer Double braid of Silver Platted Copper Wire
←3a conductor (strand dia 0.12mm)
a) Inner Braid - Coverage 95% nom.
←3b b) Outer Braid - Coverage 94% nom.

4 Jacket PTFE (Tape wrapped & sintered)

←⎯4 Dia:4.95 ± 0.13mm

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1400 Vrms max.

Operating frequency : 12.4 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance (max at : 29.85 Ω/Km
20oC)
Conductor Elongation : 10 % minimum
Conductor Tensile strength : not applicable
Weight : 74.5 Kg/Km max.
Voltage withstanding : 3000 Vrms + 10%
Insulation resistance : 23000-MΩ-Km min.
Corona extinction voltage : 1900 Vrms min.
: 50± 2 ohms
Characteristics Impedance
Capacitance : 104.98 Pf/m max.
Frequency (GHz) : 0.05 0.1 0.4 1.0 3.0 10 12.4
Attenuation (dB/100m max.) : 10.5 14.8 34.4 55.7 125 256 295
Structural return loss (dB min.) : 25.5 25.5 23.8 22 17 17 17
Power rating(Watts max.) : 3500 2400 1100 650 350 140 --

112
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F144 (Ref. MIL PART NO: M17/062-RG144)

CONSTRUCTIONS DETAILS

←1 1 Inner 7 strands of silver plated copper covered steel.

←2 conductor Stand Dia:0.44mm,Overall Dia:1.33±0.025mm
2 Dielectric Solid PTFE (Tape wrapped & sintered) Dia:7.24 ±
←3 core 0.13mm
3 Outer Single braid of Silver Platted Copper Wire
←4a conductor (strand dia 0.16mm), Coverage 94%
←4b
4 a) Barrier Barrier of unsintered PTFE Tapes (0.50 mm
b) tapes thickness)
←5a
5 a) Jacket Double braid of Fibre Glass impregnated with
b) Silicone Varnish. Dia:10.41 ± 0.25
←5b

TECHNICAL CHARACTERISTICS

Continuous working voltage : 3700 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance (max at : 45.6 Ω/Km
20oC)
Conductor Elongation : 1 % minimum
Conductor Tensile strength : 110 Klbs/in2
Weight : 208.32 Kg/Km max.
Voltage withstanding : 10000 Vrms + 10%
Insulation resistance : 23000-MΩ-Km min.
Corona extinction voltage : 5000 Vrms min.
Capacitance : 72 Pf/m max.
Characteristic Impedance : 75 ± 3 Ω
Frequency (GHz) : 0.1 0.4 1.0 3.0
Attenuation (dB/100m max.) : 5.2 14.8 23 59
Power rating (Watts max.) : 6300 2800 1700 880

113
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO:F402(Ref.MIL PART NO:M17/130-RG402 For Bare Copper)
F402T(Ref.MIL PART NO:M17/130-00001 For Tin Plated)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner Solids silver plated copper covered steel.

conductor Dia. : 0.92 ± 0.018mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered) Dia:2.97 ±
core 0.025mm
3 Outer For F402 Bare Copper Tube.
←⎯3 conductor For F402T Tin Plated Copper Tube.
Diameter: 3.58 ± 0.025mm.

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1900 Vrms max.

Operating frequency : 20 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -40o C to +125o C
Conductor D.C. resistance : 67.58 Ω/Km
(max at 20oC)
Conductor Elongation : 10 % minimum
Conductor Tensile strength : 40Klbs/in2
Weight : F402 – 51.18 Kg/Km ,
F402T – 52.23 Kg/Km.
Voltage withstanding : 5000 Vrms ± 10%
Corona extinction voltage : 1900 Vrms min.
Capacitance : 98.10 Pf/m max.
Characteristic Impedance : 50 ± 1 Ω
Frequency (GHz) : 0.5 1.0 3.0 5.0 10 20
Attenuation(dB/100m max.) : 26 39 69 95 148 230
Structural return loss (dB min.) : 30 28.5 24.6 23 22.2 20.6
Power rating (Watts max.) : 600 450 250 180 120 70

ENGINEERING NOTE: This cable is useful in Critical RF Performance Applications.

114
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F393 (Ref. MIL PART NO: M17/127-RG393)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner 7 strands of silver plated copper wire each strand

conductor 0.79mm , Overall Dia. : 2.39 ± 0.025mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered) Dia:7.24 ±
core 0.13mm
3 Outer Double braid of Silver Platted Copper Wire
←3a conductor (strand dia 0.16mm)
a) Inner Braid - Coverage 96% nom.
←3b b) Outer Braid – Coverage 98% nom.

4 Jacket PTFE (Tape wrapped & sintered)

←⎯4 Dia:9.9 ± 0.25mm

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1875 Vrms max.

Operating frequency : 11 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 4.98 Ω/Km
(max at 20oC)
Conductor Elongation : 20 % minimum
Conductor Tensile strength : not applicable
Weight : 260.40 Kg/Km max.
Voltage withstanding : 7500 Vrms + 10%
Insulation resistance : 23000-MΩ-Km min.
Corona extinction voltage : 2500 Vrms min.
: 50 ± 2 ohms
Characteristics Impedance
Capacitance : 104.98 Pf/m max.
Frequency (GHz) : 0.05 0.1 0.4 3.0 11
Attenuation (dB/100m max.) : 5.5 8.53 16.4 59 147.6
Structural return loss (dB min.) : -- 25 24 20 16
Power rating (Watts max.) : 9000 6300 2800 880 --

115
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F195 (Ref. MIL PART NO: M17/95-RG180)

CONSTRUCTIONS DETAILS

←⎯1 1 Inner 7 strands of silver plated copper covered steel.

conductor Strand dia:0.1mm,Overall Dia:0.3 ± 0.025mm
2 Dielectric Solid PTFE (Tape wrapped & sintered) Dia:2.59 ±
←⎯2 core 0.076mm
3 Outer Single braid of silver plated copper wire
conductor (strand dia 0.1mm) Coverage 91% nom.
←⎯3 4 Jacket PTFE (Tape wrapped & sintered)
Dia:3.58 ± 0.1mm

←⎯4

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1100 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 802.16 Ω/Km
(max at 20oC)
Conductor Elongation : 8 % minimum
Conductor Tensile strength : 50 Klbs/in2 min.
Weight : 29.46 Kg/Km max.
Voltage withstanding : 2000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1500 Vrms min.
Capacitance : 57 Pf/m max.
Characteristic Impedance : 95 ± 5.0 ohms
Frequency (GHz) : 0.1 0.4 1.0 3.0
Attenuation(dB/100m max.) : -- 55.8 -- --
Power rating (Watts max.) : 800 400 250 135

116
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: W 1703/3
Reference Datasheet : FILICA 1703/3, dt 2/1980

CONSTRUCTIONS DETAILS

1 Inner 7 strands of silver plated copper each

conductor Strand dia:0.81mm,Overall
Dia:2.43±0.025mm

2 Dielectric Solid PTFE (Tape wrapped & sintered)

core Dia:7.00 ± 0.13mm
3 Inner Braid of silver plated copper wire
Shield (strand dia 0.16mm) Coverage 94% nom.
4 Inner A layer of polyimide (Kapton ) Tape
Jacket Thickness : 0.06 mm

5 Outer PTFE ( Tape wrapped & sintered)

Jacket Dia :8.40 ± 0.25mm
Color : Brown .

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1875 Vrms max.

Operating frequency : 11 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance (max at : 4.98 Ω/Km
20oC)
Conductor Elongation : 20 % minimum
Weight : 168.00 Kg/Km max.
Voltage withstanding : 7500 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 2500 Vrms min.
Capacitance : 105 pF/m max.
Characteristic Impedance : 50 ± 2.0 ohms
Frequency (GHz) : 0.05 0.1 0.4 3.0 11
Attenuation (dB/100m max.) : 5.5 8.53 16.4 59.0 147.6
Structural return loss ( dB min) :- 25 - 23 20

117
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: W 1703/4
Reference Datasheet : FILICA 1703/4, dt 2/1980

CONSTRUCTIONS DETAILS

1 Inner 7 strands of silver plated copper each

conductor Strand dia:0.33mm,Overall
Dia:0.99±0.025mm

2 Dielectric Solid PTFE (Tape wrapped & sintered)

core Dia:2.95 ± 0.13mm
3 Inner Braid of silver plated copper wire
Shield (strand dia 0.13mm) Coverage 94% nom.
4 Inner A layer of polyimide (Kapton ) Tape
Jacket Thickness : 0.06 mm

5 Outer PTFE ( Tape wrapped & sintered)

Jacket Dia :3.95 ± 0.13mm
Color : Brown .

TECHNICAL CHARACTERISTICS

Continuous working voltage : 1400 Vrms max.

Operating frequency : 12.4 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance (max at : 33.0 Ω/Km
20oC)
Conductor Elongation : 15 % minimum
Weight : 36.5 Kg/Km max.
Voltage withstanding : 5000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1900 Vrms min.
Capacitance : 105 pF/m max.
Characteristic Impedance : 50 ± 2.0 ohms
Frequency (GHz) : 0.05 0.1 0.4 1.0 3.0 10.0
Attenuation (dB/100m max.) : 10.5 14.8 34.4 55.7 125 256
Structural return loss ( dB min) : 28 - 26 24 21.3 21.3

118
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F400S (EQUIVALENT TO: M17/028-RG058)

CONSTRUCTIONS DETAILS

1 Inner 19 strands of silver plated copper wire each

←⎯1 conductor strand 0.2mm , Overall Dia. : 0.96 ±
0.025mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered)
core Dia:2.95 ± 0.13mm
←⎯3 3 Outer Single braid of silver plated copper wire
conductor (strand dia 0.12mm) Coverage 94% nom.
←⎯4 4 Jacket PTFE (Tape wrapped & sintered)
Dia:4.20 ± 0.13mm
TECHNICAL CHARACTERISTICS

Continuous working voltage : 1400 Vrms max.

Operating frequency : 3 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 29.85 Ω/Km
(max at 20oC)
Conductor Elongation : 10 % minimum
Conductor Tensile strength : not applicable
Weight : 45 Kg/Km max.
Voltage withstanding : 3000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km
Corona extinction voltage : 1900 Vrms min.
Capacitance : 104.98 Pf/m max.
Characteristic Impedance : 50 ± 2.0 Ohms
Frequency (GHz) : 0.1 0.4 1.0 3.0
Attenuation (dB/100m max.) : 14 34 66 134
Structural return loss (dB min.) : -- 23.8 22 17
Power rating (Watts max.) : 2400 1100 650 350

ENGINEERING NOTE: This cable is useful in high temperature and high frequency
applications.

Note: This cable is one to one replacement RG 58. RG 58 is not recommended for
use in aerospace applications as per MIL standard MIL-STD-454G since it uses
PVC material.

119
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 TYPE NO: F107 (Ref. BS PART NO: URM 107)

CONSTRUCTIONS DETAILS

1 Inner 7 Strands of silver plated copper wire.

←⎯1 conductor Strand Dia: 0.82, Overall Dia:2.46 ±
0.05mm
←⎯2 2 Dielectric Solid PTFE (Tape wrapped & sintered)
core Dia:7.25 ± 0.15mm
←⎯3 3 Outer Single braid of silver plated copper wire
conductor (strand dia 0.16mm) Coverage 94% nom.
←⎯4 4 Jacket PTFE (Tape wrapped & sintered)
Dia:9.00 ± 0.25mm
TECHNICAL CHARACTERISTICS

Continuous working voltage : 5000 Vrms max.

Operating frequency : 11 GHz max.
Velocity of propagation : 69.5 % nom.
Operating temperature range : -55o C to +200o C
Conductor D.C. resistance : 4.73 Ω/Km
(max at 20oC)
Conductor Elongation : 20 % minimum
Conductor Tensile strength : not applicable
Weight : 180 Kg/Km max.
Voltage withstanding : 10000 Vrms ± 10%
Insulation resistance : 23000 MΩ-Km min.
Corona extinction voltage : 4000 Vrms min.
Capacitance : 105 Pf/m max.
Frequency (GHz) : 0.05 0.1 0.2 0. 3 0.6 1.0 3.0
Attenuation (dB/100m max.) :6 6.3 9.2 11.8 17.6 23.4 47.9
Structural return loss (dB min.) : -- 25 23 20
Power rating (Watts max.) : 3350 2350 1900 1300 1000 545

120
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 925

2. Approval Title : Fire Resistance wires & cables

3. Validity of Approval : 30 Jun 2014
4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.
Ahmadabad 382 405
5. Governing Specification : a) MIL-DTL-25038G for basic /
core wire
b) MIL-DTL-27500H for cables
6. Characteristics of Wire
a) Classification : Internal / External ; heat / fire resistant, flight critical wires
(Resistant to Aero Fluids)
b) Voltage Rating : 600V DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : Nickel Plated Copper
e) Insulation : High temp. insulation in the form fiber, tape and film
f) Temperature Range : 500C to +2600C (Rated), but capable to withstand 10900 C
flame applied for min. 15 minutes under 250V DC without
loosing electrical integrity
7. End Use of the Item : Flight critical, fire resistant aircraft wiring, especially in
engine zone and critical data recording systems in case of
fire etc.

8. Other Details : Sanghvi Aerospace Part No.

25038(1/3)-**-▲ (for wires) &
M27500A(1/3)-**-nC07 (for cables) is equivalent to
M25038/ (1 or 3)-**- ▲ and
M27500A-**J(A/F)-nC07 where ** indicates size of
conductor of wire and n indicates No. of core wires in cable
Sr. No. MIL Part No SAPL Part No
1 M25038/1-22- * 250381-22
2 M25038/1-20- * 250381-20
3 M25038/1-18- * 250381-18
4 M25038/1-16- * 250381-16
5 M25038/1-14- * 250381-14
6 M25038/1-12- * 250381-12
7 M25038/1-10- * 250381-10
8 M25038/1-8- * 250381-8
9 M25038/1-6- * 250381-6
10 M25038/1-4- * 250381-4
11 M25038/1-2- * 250381-2
12 M25038/1-1- * 250381-1
13 M25038/1-0- * 250381-0
14 M25038/1-00- * 250381-00
15 M25038/1-000- * 250381-000
16 M25038/1-0000- * 250381-0000
17 M25038/3-22- * 250383-22
18 M25038/3-22H- * 250383-22H
19 M25038/3-20- * 250383-20
20 M25038/3-18- * 250383-18
21 M25038/3-16- * 250383-16
22 M25038/3-14- * 250383-14
23 M25038/3-12- * 250383-12
1, 2 & 3 Core Shielded & Jacketed Cable
also available

121
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1015

2. Approval Title : PTFE Electrical Wires and

cables 177T, 178T, 1177T & 1178

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : a) AIR 4524E for wires

b) MIL-DTL-27500H for cables

6. Characteristics of Wire

a) Classification : -

b) Voltage Rating : 600V rms

c) Operating Frequency : Up to 1600Hz

d) Conductor : 177T,1177T Silver plated copper

178T,1178T Nickel plated copper

e) Insulation : PTFE Insulation

f) Temperature Range : 177T : -65OC to+2000C,

178T,1178T: -65OC to+2500C

7. End Use of the Item : Use on aircraft electrical system

8. : 177T & 178T – as a substitute for NYVIN type cables

Other Details
1178T – As a substitute to UNINYVIN DYNYVIN and
TRINYVIN Met Sheathed Cables

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 123
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 124
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 125
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1016

2. Approval Title : PTFE Electrical Wires and

cables 250NT & 1250NKT

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : a) AIR 4524 for wires

b) MIL-DTL-27500H for cables

6. Characteristics of Wire

a) Classification : -

b) Voltage Rating : 600V rms

c) Conductor : Nickel plated copper conductor

d) Insulation : PTFE Insulation

e) Temperature Range : -500C to +2500C

7. End Use of the Item : Use on aircraft electrical system

126
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 AIRCRAFT WIRES & CABLES
PTFE INSULATED LIGHT WEIGHT FLEXIBLE TYPES

PRODUCT CARD PRODUCT NO - 250 T

Voltage Rating : 600 V RMS

(Operating Temperature ) : -500 C to +2500 C
( ambient + rise ) 2800 C at peak

CONSTRUCTION :
[1] A Stranded conductor made up of Nickel Plated Copper
or Nickel Plated Copper alloy ( alloy providing a good
mechanical behavior

[2] A PTFE insulation - wrapped / sealed.

COLOUR CODING : 2 1
AWG Colour
24-20-16-12 Light Blue
22-18-14-10 White

Other colours available on request

PART Cross American MECHANICAL ELECTRICAL
NUMBER Sectional Wire CONDUCTOR CORE D.C. Current
Area Gauge Construction Nominal Tensile Overall Average Resistanc Rating
e
0
Dia. Strength Dia. Weight at 20 C
+0.0mm (mini.) +/-0.05 ( maxi. )
-0.10mm
2
sq. mm AWG n x mm mm. N/mm mm. g/m Ohms/km A

250NT - 24 0.21 24 19 X 0.12/NPC A LL 0.60 350 1.20 3.88 107.0 4

250NT - 22 0.38 22 12 X 0.20 / NPC 0.85 220 1.46 6.17 54.5 7
250NT - 20 0.60 20 19 X 0.20 / NPC 1.00 220 1.66 8.66 34.4 11
250NT - 18 0.93 18 19 X 0.25 / NPC 1.25 220 1.95 12.7 22.0 16
250NT - 16 1.34 16 19 X 0.30 / NPC 1.50 220 2.20 17.2 15.3 22
250NT -14 1.91 14 27 X 0.30 / NPC 1.85 220 2.47 22.9 10.8 32
250NT - 12 3.18 12 45 X 0.30 / NPC 2.40 220 2.98 35.7 6.4 41
250NT - 10 4.65 10 37 X 0.40 / NPC 2.80 220 3.76 54.0 3.51 50

NPC = Nickel Plated Copper. NPC ALL = Nickel Plated Copper Alloy. n = Numbers of Strands
NOTE : - The currents shown are valid for single wire in Air.

CHARACTERISTICS : TECHNICAL REQUIREMENTS

Wiring of sub-assemblies at medium temperature AND CONTROL CONDITIONS
up to 2800 C at peak.
Air 4524 E Specification of August 1980
* They are non-flammable
* They withstand most solvents.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 PTFE INSULATED SCREENED -Polyimide + PTFE SHEATHED TYPES
PRODUCT CARD PRODUCT NO - 1250NKT

Voltage Rating : 600 V RMS

Operating Temperature : -500 C to + 2500 C
0
( ambient + risc ) 280 C at peak.

CONSTRUCTION :
1 to 6 Cores Type 250 NT covered with :
[1] A Braided Screen made up of Nickel Plated Copper ( 70%
Coverage ).
[2] A Polyimide (Kapton) Sheath
[2] A wrapped and Sintered PTFE sheath.

PART Cross American CORES 250N T SCREEN AND SHEATH

NUMBER Sectional Wire Construction O.D. of Screen Overall Average
Area Guage the core strands Dia. weight
± 0.05 Dia. (Max.)
(sq.mm) AWG n x mm mm mm mm g/m

1250NKT - 24 - 1 0.21 24 19 x 0.12 /NP ALL 1.20 0.10 2.6 9.83

1250NKT - 22 - 1 0.38 22 12 x 0.20 /NPC 1.46 0.10 2.9 13.1
1250NKT - 20 - 1 0.60 20 19 x 0.20 /NPC 1.66 0.10 3.1 16.4
1250NKT - 18 - 1 0.93 18 19 x 0.25 /NPC 1.95 0.12 3.5 23.0
1250NKT - 16 - 1 1.34 16 19 x 0.30 /NPC 2.47 0.12 3.8 28.6
1250NKT - 14 - 1 1.91 14 27 x 0.30 /NPC 2.98 0.12 4.1 35.5

1250NKT - 24 - 2 0.21 24 19 x 0.12 /NP ALL 1.20 0.12 3.8 18.3

1250NKT - 22 - 2 0.38 22 12 x 0.20 /NPC 1.46 0.12 4.3 24.9
1250NKT - 20 - 2 0.60 20 19 x 0.20 /NPC 1.66 0.12 4.7 31.5
1250NKT - 18 - 2 0.93 18 19 x 0.25 /NPC 1.95 0.12 5.4 41.8
1250NKT - 16 - 2 1.34 16 19 x 0.30 /NPC 2.47 0.12 6.0 53.7
1250NKT - 14 - 2 1.91 14 27 x 0.30 /NPC 2.98 0.12 6.6 67.3

1250NKT - 24 - 3 0.21 24 19 x 0.12 /NP ALL 1.20 0.12 4.0 24.2

1250NKT - 22 - 3 0.38 22 12 x 0.20 /NPC 1.46 0.12 4.5 33.5
1250NKT - 20 - 3 0.60 20 19 x 0.20 /NPC 1.66 0.12 5.0 42.2
1250NKT - 18 - 3 0.93 18 19 x 0.25 /NPC 1.95 0.12 5.7 58.7
1250NKT - 16 - 3 1.34 16 19 x 0.30 /NPC 2.47 0.12 6.4 74.7
1250NKT - 14 - 3 1.91 14 27 x 0.30 /NPC 2.98 0.12 7.0 94.7

1250NKT - 24 - 4 0.21 24 19 x 0.12 /NP ALL 1.20 0.12 4.19 30.8

1250NKT - 22 - 4 0.39 22 12 x 0.20 /NPC 1.46 0.12 4.90 43.6
1250NKT - 20 - 4 0.60 20 19 x 0.20 /NPC 1.66 0.12 5.43 56.0
1250NKT - 18 - 4 0.93 18 19 x 0.25 /NPC 1.95 0.12 6.21 78.6
1250NKT - 16 - 4 1.34 16 19 x 0.30 /NPC 2.47 0.12 7.62 105.6
1250NKT - 14 - 4 1.91 14 27 x 0.30 /NPC 2.98 0.12 8.99 135.3
1250NKT - 24 - 6 0.21 24 19 x 0.12 /NP ALL 1.20 0.12 4.55 46.2
1250NKT - 22 - 6 0.39 22 12 x 0.20 /NPC 1.46 0.12 5.33 67.6
1250NKT - 20 -6 0.60 20 19 x 0.20 /NPC 1.66 0.12 5.93 95.3
1250NKT - 18 - 6 0.93 18 19 x 0.25 /NPC 1.95 0.12 6.80 135.2
1250NKT - 16 - 6 1.34 16 19 x 0.30 /NPC 2.47 0.12 8.36 182.0
1250NKT - 14 - 6 1.91 14 27 x 0.30 /NPC 2.98 0.12 9.89 217.4

NOTE : NPC = Nickel Plated Copper. NP ALL = Nickel Plated Alloy. n = Numbers of Strands

CHARACTRISTICS : TECHNICAL REQUIREMENTS

Same as 250NT T basic cores. Moreover, the PTFE Basic core Air 4524 E Specification of
overall sheath August 1980.
gives the following advantages : Finished Cable MIL-DTL-27500 H

− Very efficient protection of the screen against

oxidation and corrosion
− Easy fitting of the cable.
− Safer handling.

128
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Colour of Cores & Sheath

AWG No of Core Colour Sheath Colour

Cores
24-20-16 1 Light Blue Light Blue
2 Light Blue + Blue Light Blue
3 Light Blue + Blue + Yellow Light Blue
4 Light Blue + Blue + Yellow + Green Light Blue
6 Light Blue + Blue + Yellow + Green + Orange + Light Blue
Red

22-18-14 1 White White

2 White + Blue White
3 White + Blue + Yellow White
4 White + Blue + Yellow + Green White
6 White + Blue + Yellow + Green + Orange + Red White

129
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1017

2. Approval Title : PTFE Electrical Wires and

cables Product No.140T & 1140T

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : a) AIR 4524E (Wires)

b) MIL-DTL-27500H (Cables)

6. Characteristics of Wire

a) Classification : -

b) Voltage Rating : 600 Vrms

c) Conductor : Silver plated copper conductor

d) Insulation : PTFE Insulation

e) Temperature Range : -500C to +1400C

7. End Use of the Item : Use on aircraft electrical system

130
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 PTFE INSULATED LIGHT WEIGHT FLEXIBLE TYPES
PRODUCT CARD PRODUCT NO - 140 T

Voltage Rating : 600 V RMS

(Operating Temperature ) : -500 C to +1400 C
( ambient + rise ) 1700 C at peak

CONSTRUCTION :
[1] A Stranded conductor made up of Silver Plated Copper
or Silver Plated Copper alloy ( alloy providing
a good mechanical behaviour )
[2] A PTFE insulation - wrapped / sealed.
1
COLOUR CODING :
AWG Colour 2
24-20-16-12 Light Blue
22-18-14-10 White

Other colors available on request.

PART Cross American MECHANICAL ELECTRICAL

NUMBER Sectional Wire CONDUCTOR CORE D.C. Current
Area Gauge Construction Nominal Tensile Overall Average Resistanc Rating
e
0
Dia. Strength Dia. Weight at 20 C
+0.0mm (mini.) +/-0.05 ( maxi. )
-0.10mm
2
sq. mm AWG n x mm mm. N/mm mm. g/m Ohms/km A
140 T - 26 0.14 26 19 X 0.10/SP A LL 0.50 350 1.00 2. 144.0 3
140 T - 24 0.21 24 19 X 0.12/SP A LL 0.60 350 1.05 3.0 105.0 4
140 T - 22 0.38 22 12 X 0.20 / SPC 0.85 220 1.28 4.8 50.9 7
140 T - 20 0.60 20 19 X 0.20 / SPC 1.00 220 1.44 7.2 32.2 11
140 T - 18 0.93 18 19 X 0.25 / SPC 1.25 220 1.64 10.5 20.6 16
140 T - 16 1.34 16 19 X 0.30 / SPC 1.50 220 1.92 14.6 14.3 22
140 T -14 1.91 14 27 X 0.30 / SPC 1.85 220 2.30 20.5 10.1 32
140 T - 12 3.18 12 45 X 0.30 / SPC 2.40 220 2.89 33.0 6.0 41
140 T - 10 4.65 10 37 X 0.40 / SPC 2.82 220 3.55 50.5 3.51 50

SPC = Silver Plated Copper. SP ALL = Silver Plated Copper Alloy. n = Numbers of Strands
NOTE: - The currents shown are valid for single wire in Air.

CHARACTERISTICS : TECHNICAL REQUIREMENTS

AND CONTROL CONDITIONS
Wiring of sub-assemblies at medium temperature
Up to 1700 C at peak. Air 4524 E Specification of August 1980

* They are non-flammable

* They withstand most solvents.

131
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 PTFE INSULATED SCREENED - PTFE SHEATHED TYPES
PRODUCT CARD PRODUCT NO - 1140 T
Voltage Rating : 600 V RMS
Operating Temperature : -500 C to + 1400 C
(Ambient + risc) 170º C at peak.

CONSTRUCTION:
1 to 6 Cores Type 140 T covered with:

[1] A Braided Screen made up of Silver

Plated Copper (70% Coverage)
[2] A wrapped and Sintered PTFE sheath

PART Cross American CORES 140 T SCREEN AND SHEATH

NUMBER Sectional Wire Construction O.D. of Screen Overall Average
Area Gauge the core strands Dia. weight
± 0.05 Dia. (Max.)
(sq.mm) AWG n x mm mm mm mm g/m
1140 T- 26 - 1 0.14 26 19 x 0.10/SP ALL 1.00 0.07 1.76 8.2
1140 T - 24 - 1 0.21 24 19 x 0.12 /SP ALL 1.10 0.07 2.0 9.0
1140 T - 22 - 1 0.38 22 12 x 0.20 /SPC 1.33 0.10 2.3 11.0
1140 T - 20 - 1 0.60 20 19 x 0.20 /SPC 1.49 0.10 2.5 14.0
1140 T - 18 - 1 0.93 18 19 x 0.25 /SPC 1.69 0.10 2.7 18.1
1140 T - 16 - 1 1.34 16 19 x 0.30 /SPC 1.97 0.10 3.0 23.3
1140 T - 14 - 1 1.91 14 27 x 0.30 /SPC 2.35 0.10 3.3 30.5
1140T - 12- 1 3.18 12 45 x 0.30 /SPC 2.94 0.12 3.9 57.7
1140 T - 26 - 2 0.14 26 19 x 0.10/SP ALL 1.00 0.10 2.9 13.5
1140 T - 24 - 2 0.21 24 19 x 0.12 /SP ALL 1.10 0.10 3.3 15.5
1140 T - 22 - 2 0.38 22 12 x 0.20 /SPC 1.33 0.10 3.8 21.8
1140 T - 20 - 2 0.60 20 19 x 0.20 /SPC 1.49 0.10 4.1 27.6
1140 T - 18 - 2 0.93 18 19 x 0.25 /SPC 1.69 0.12 4.5 38.7
1140 T - 16 - 2 1.34 16 19 x 0.30 /SPC 1.97 0.12 5.2 50.0
1140 T - 14 - 2 1.91 14 27 x 0.30 /SPC 2.35 0.12 5.9 65.3
1140T - 12- 2 3.18 12 45 x 0.30 /SPC 2.94 0.12 7.0 107.7
1140 T - 24 - 3 0.21 24 19 x 0.12 /SP ALL 1.10 0.10 3.5 19.3
1140 T - 22 - 3 0.38 22 12 x 0.20 /SPC 1.33 0.10 4.0 27.1
1140 T - 20 - 3 0.60 20 19 x 0.20 /SPC 1.49 0.12 4.4 38.4
1140 T - 18 - 3 0.93 18 19 x 0.25 /SPC 1.69 0.12 4.8 50.9
1140 T - 16 - 3 1.34 16 19 x 0.30 /SPC 1.97 0.12 5.5 66.3
1140 T - 14 - 3 1.91 14 27 x 0.30 /SPC 2.35 0.12 6.3 88.7
1140T - 12- 3 3.18 12 45 x 0.30 /SPC 2.94 0.12 7.3 141.5
1140 T - 24 - 4 0.21 24 19 x 0.12 /SP ALL 1.10 0.12 3.7 22.1
1140 T - 22 - 4 0.39 22 12 x 0.20 /SPC 1.33 0.12 4.4 34.6
1140 T - 20 - 4 0.60 20 19 x 0.20 /SPC 1.49 0.12 4.8 44.6
1140 T - 18 - 4 0.93 18 19 x 0.25 /SPC 1.69 0.12 5.3 60.0
1140 T - 16 - 4 1.34 16 19 x 0.30 /SPC 1.97 0.12 6.0 79.9
1140 T - 14 - 4 1.91 14 27 x 0.30 /SPC 2.35 0.12 6.9 108.0
1140T - 12- 4 3.18 12 45 x 0.30 /SPC 2.94 0.12 9.1 193.7
1140 T - 24 - 6 0.21 24 19 x 0.12 /SP ALL 1.10 0.12 4.1 33.20
1140 T - 22 - 6 0.39 22 12 x 0.20 /SPC 1.33 0.12 4.9 48.44
1140 T - 20 -6 0.60 20 19 x 0.20 /SPC 1.49 0.12 5.4 64.40
1140 T - 18 - 6 0.93 18 19 x 0.25 /SPC 1.69 0.12 6.2 90.0
1140 T - 16 - 6 1.34 16 19 x 0.30 /SPC 1.97 0.12 7.1 120.0
1140 T - 14 - 6 1.91 14 27 x 0.30 /SPC 2.35 0.12 8.2 172.8
1140T - 12- 6 3.18 12 45 x 0.30 /SPC 2.94 0.12 10.0 274.6

NOTE: SPC = Silver Plated Copper. SP ALL = Silver Plated Alloy. n = Numbers of Strands

CHARACTRISTICS : TECHNICAL REQUIREMENTS

Same as 140 T basic cores. Moreover, the PTFE overall Basic core Air 4524 E Specification of August
sheath 1980.
gives the following advantages : Finished Cable MIL-DTL-27500 H

− Very efficient protection of the screen against oxidation and

Corrosion.
− Easy fitting of the cable.
− Safer handling.

132
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Colour of Cores & Sheath

AWG No of Core Colour Sheath Colour

Cores
24-20-16-12 1 Light Blue Light Blue
2 Light Blue + Blue Light Blue
3 Light Blue + Blue + Yellow Light Blue
4 Light Blue + Blue + Yellow + Green Light Blue
6 Light Blue + Blue + Yellow + Green + Orange + Red Light Blue

26-22-18-14 1 White White

2 White + Blue White
3 White + Blue + Yellow White
4 White + Blue + Yellow + Green White
6 White + Blue + Yellow + Green + Orange + Red White

133
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1031

2. Approval Title : K Type Thermo Couple

Extension wires & cables

3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.

5. Governing Specification : a) MIL-W-5846, BS-4937, PAN

SP-0-9300 for wires

b) MIL-DTL-27500H for cables

6. Characteristics of Wire

a) Classification : Resistant to Aviation chemicals / fluids, flame

b) Voltage Rating : 600 Vrms

c) Thermo emf @ 260o C : 10.56 mv ± 0.10 mv (± 2.5oC) for class 2

10.56 mv ± 0.06 mv (± 1.5oC) for class 1

d) Conductor : Chromel (Plus). Alumel (Negative)

e) Insulation : High temp. Abrasion resistance, PTFE Insulation

f) Temperature Range : - 75oC to + 260o C

7. Decoding of Part No. of Wire ** : SA - Sanghvi Aerospace make

TE - Thermocouple extension wire
CR - Chromel (Cu + Ni Alloy), Conductor (+ve leg)
AL - Alumel (Al + Ni Alloy), Conductor (-ve leg)

8. End Use of the Item : K Type thermocouple extension Wire in aircraft for
measuring temperature from 0 to 1260o C depending on
size of wire. It has application for the connection in gas
turBIN/BIN-Ne engine exhaust gas temp. conductor of
aircraft / helicopter

9. Other Details : Sanghvi Aerospace Part No. SATE 2013 CR-1, SATE 2013 CR-
2, SATE 2013 AL-1, SATE 2013 AL-2, SATE 1632 CR-1, SATE
1632 CR-2, SATE 1632 AL-1, SATE 1632 AL-2, SATE 6420
CR004, SATE 6420 CR006, SATE 6420 AL004, SATE 6420
AL006

are equivalent to

CRALEFGLASS EL 2013, Ducrasil EL 1632, PAN 6420 YR004 &

006

134
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 1062

2. Approval Title : Data Bus Cable PartNo.10614T

(Substitute to RAYCHEM Data Bus Cable 10614)
3. Validity of Approval : 30 Jun 2014
4. Developer of the Item : M/s. Flu-Tef Industries
Ahmadabad - 382 445
5. Governing Specification : a) Product data sheet W10614T
b) MIL-C-17G
c) MIL-DTL-27500H,
d) JSS51034
6. Characteristics of Wire
a) Classification : Data Bus Cable
b) Voltage Rating : 600 Vrms
c) Conductor : Stranded Silver Plated High Strength Copper Alloy
d) Insulation : PTFE wrapped and sintered
e) Temperature Range : -55°C to +200°C
7. End Use of the Item : Used on aircraft electrical systems. Use on RAYCHEM
data bus cable

CONSTRUCTION: These Radio Frequency ,Twin axial known

as Data bus cable for application in
1. A standard conductor of Electronic Equipment and Systems .The
Silver plated copper alloy (SPHA) 8 cable is primarily intended for
2. A. dielectric layer of spiral interconnection of various equipment/sub
wrapped & sintered PTFE Tape systems used in Digital command/Response
Color : White x Blue Time Division Multiplexing techniques on
3. PTFE filler Aircraft. The requirements for Data bus cable
4. Wrap of Pre sintered PTFE Tape 7 specified herein comply with the
5. Screen 1 Braid of requirements of US Military Standard
Silver plated copper (SPC) 6
6. Screen 2 Wrap of High permeability MIL-STD-1553B: Digital Time Division
tape(HPT) 5 Command/Response Multiplex Data Bus.
7. Screen 3 Braid of 4
Silver plated copper (SPC) Shielding effectiveness: The shield shall
8. Jacket of be selected with electromagnetic
PTFE Tape wrapped & sintered compatibility.
Color : White
3 Concerning the most commonly used types,
2 the choice extends from single braids to
0 0
¾ Temperature rating: -55 C to +200 C complex shield configuration (braid, tape,
braid) showing a very low transfer
¾ Voltage rating : 600 Vrms 1 Impedance.

Physical Characteristics
Type no Size Conductor Core Filler Binder Screen Jacket Wei
AWG Stranding Diameter Tape ght
1 2 3 Nature Dia
n x mm mm g/m
mm mm mm
W10614T 24 19 x 0.12 1.08±0.05 PTFE PTFE 0.10 HPT 0.10 PTFE 4.2 42
tape SPC SPC
Electrical Characteristics
Type no Impedance Velocity of Capacitance Attenuation Surface transfer
Ohms propagation Mutual dB/100 m impedance
% Pf/m maximum maximum milliohms/mtr maxi

W10614T 77 ± 5 69 70 4.0 at 1Mhz 0.2 at 30 Mhz

135
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1063

2. Approval Title : RF Coaxial Part No.FCOX-1000 and

ADF Cable Part No.FCOX-1000-4

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445

5. Governing Specification : a) Product data sheet: FCOX -1000

b) Product data sheet: FCOX-1000-4

c) MIL-C-17G dated 09 Mar 1990

6. Characteristics of Wire

a) Classification : -

b) Voltage Rating : 1000 Vrms

c) Operating Frequency : 3 GHz (Max)

d) Characteristic Impedance : 75Ω ± 3Ω

e) Conductor : Solid Silver Plated High Strength Copper Alloy

f) Insulation : PTFE Insulation wrapped and sintered

g) Temperature Range : -55°C to +200°C

7. End Use of the Item : Aircraft / Avionic Systems application. Used on RAYCHEM
data bus cable

136
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1064

2. Approval Title : PTFE Wires & cables 3 Core

(As a substitute to Filotex type
ETUDE19369)

3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : a) Product data sheet F19369
b) AIR 4524E for Wires
c) MIL-DTL-27500H for cables
6. Characteristics of Wire

a) Classification : Light weight flexible types

b) Voltage Rating : 600 Vrms
c) Conductor : Nickel plated copper wire
d) Insulation : PTFE Insulation wrapped and sintered
e) Temperature Range : -65°C to +250°C
7. End Use of the Item :
Use on JAGUAR AIRCRAFT for aircraft harness

137
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1068
2. Approval Title : Polyimide Insulated wire and Cables
Part No. SABIF/BIFE/BIFEZ
(Corresponding to Russian type SABIF/BIFE / BIFE-N/BIFE /
BIFE-NZ & SABIF-N/BIFE / BIFE-N-Z/BIFE / BIFE-NZ-N)
3. Validity of Approval : 30 Jun 2014
4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.
Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.645-76 (Russian)
b) MIL-W-81381 / 7,8,9,10 & 11 &
c) MIL-C-27500 H
6. Characteristics of Wire
a) Classification : External Heat Resistant (Excellent Cut through Resistant and
Cold flow, Excellent Radiation Resistant, Good Outgassing
Characteristics)
b) Voltage Rating : 600V DC
c) Operating Frequency : Upto 2000Hz
d) Conductor : BIF : Silver plated Copper
BIF-N: Nickel plated Copper
e) Insulation : PI Tape (Polyamide Fluoroplastic)
f) Temperature Range : -650C to +200°C for BIF
-650C to +260°C for BIF-N
7. Decoding of Part No. of Wire ** − BIF – External wear resistant, Fluoro Plastic with Silver
Plated Copper/ Alloy Conductor
− BIFE / BIFE-N- Same as BIF, with shielding with Silver
Plated Copper/ Alloy Conductor
− BIFE / BIFE-NZ – same as BIFE / BIFE-N with protective
jacket with Silver Plated Copper/ Alloy Conductor
− BIF-N – External wear resistant, Fluoro Plastic with
Nickle Plated Copper/ Alloy Conductor
− BIFE / BIFE-N-N- Same as BIF-N, with shielding with
Nickle Plated Copper/ Alloy Conductor
− BIFE / BIFE-NZ-N – same as BIFE / BIFE-N-N with
protective jacket with Nickle Plated Copper/ Alloy
Conductor
8. End Use of the Item : As aircraft armament, radar and airframe harness wires.
These are heat and wear resistant cables.
9. Other Details : Sl. No. Russian Part No SAPL Part No
1. BIF- 0.20 SABIF- 0.20
2. BIF- 0.20 br SABIF- 0.20 br
3. BIF - 0.35 SABIF - 0.35
4. BIF - 0.35 br SABIF - 0.35 br
5. BIF - 0.50 SABIF - 0.50
6. BIF - 0.50 br SABIF - 0.50 br
7. BIF - 0.75 SABIF - 0.75
8. BIF - 1.00 SABIF - 1.00
9. BIF - 1.50 SABIF - 1.50
10. BIF - 2.50 SABIF - 2.50
11. BIF - 4.00 SABIF - 4.00
12. BIF - 6.00 SABIF - 6.00
13. BIF - 10.00 SABIF - 10.00
1, 2 & 3 Core Shielded or Shielded & Jacketed Cable also
available

138
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 1087

2. Approval Title :
75 Ohm Tri axial Cable PT No.
7528 AT (TRIAX)

3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445
5. Governing Specification : a) MIL-C-17-G
b) Product Data sheet 7528AT
(TRIAX)
6. Characteristics of Wire

a) Classification : External Heat Resistant

b) Voltage Rating : 900V rms
c) Operating Frequency : 3 GHz (Max)
d) Characteristic Impedance : 75Ω± 3Ω
e) Velocity of propagation : 69.5 % nom.
f) Conductor D.C. resistance : 244.09 Ω/Km
(max at 20oC)
Conductor Elongation : 6 % minimum

Conductor Tensile : 50 Klbs/in2 min.

strength
Weight : 32.0 Kg/Km max.

Voltage withstanding : 5000 Vrms ± 10%

Insulation resistance : 23000 MΩ-Km

Corona extinction voltage : 1000 Vrms min.

Capacitance : 75 pF/m max.

Attenuation
: 0.1 0.2 0.4
Frequency (GHz)
(dB/100m max.) : 22 39 69

Power rating (Watts max.) : 570 310 200 110

g) Conductor : Stranded silver plated high strength copper alloy

h) Insulation PTFE Insulation
i) Temperature Range -55OC to +200OC
7. End Use of the Item : Used for RF/Video signal transmitting in aircraft. (MiG 27
Upgrade project)
This cable is useful in high temperature and high frequency
applications

139
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 CONSTRUCTIONS DETAILS OF TYPE NO: 7528AT Triax
Inner 7 strands of silver plated copper Alloy.
1 conductor Strand dia:0.127mm,Overall
Dia:0.38±0.025mm

2 Dielectric Solid PTFE (Tape wrapped & sintered)

core Dia:1.97 ± 0.076mm
3 Inner Braid of silver plated copper wire
Shield (strand dia 0.1mm) Coverage 90% nom.
Inner PTFE (Tape wrapped & sintered)
4 Jacket Dia:2.67 ± 0.13mm

5 Outer Braid of silver plated copper wire

Shield ( strand dia 0.1mm) Coverage 90% nom

6 Outer PTFE ( Tape wrapped & sintered)

Jacket Dia :3. 6 ± 0.13mm

---------------------------------------------------------------------------------------------------------------

CABLE RADIO FREQUENCY, FLEXIBLE, FLU-TEF INDUSTRIES

TRIAXIAL, 75 OHMS, DRAWING TYPE 7530ALDT Triax,
CONSTRUCTION DETAILS:
1) Inner : AWG 30,7strands of silver plated
Conductor : high strength copper Alloy
Strand dia:0.1mm,
Diameter:0.30±0.025mm
2) Dielectric: ePTFE /PTFE Taped and Sintered
core Diameter:1.22 ± 0.076mm

3) Inner Shield : Braid of silver plated copper wire

strand dia 0.08mm, Coverage 90%
min.

4) Inner Jacket : PTFE (Tape wrapped & sintered)

Diameter:2.08 ± 0.1mm
Color : Black.

5)Outer Shield : Braid of silver plated copper wire

strand dia: 0.08 mm, Coverage 90%
min 1 2 3 4 5 6

6)Outer Jacket : PTFE ( Tape wrapped & Sintered ) TRIAXIAL CABLE

Diameter : 2.95 ±0.13 mm
Color : Black.

140
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1088

2. Approval Title : 1553 B Data bus Cable Twinax

single shield Pt No. F10612T

3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445.
5. Governing Specification : a) RAYCHEM SPEC 1200,
Issue 7 Rev E, 1982
b) MIL-C-17 & MIL-C-17/176D
c) JSS 51034 (for basic core),
d) MIL-DTL-27500H (finished
cable)
e) Product Data sheet F10612T
6. Characteristics of Wire

a) Classification : External Heat Resistant

b) Voltage Rating : 750 Vrms (max)
c) Operating Frequency : Up to 10 MHz
d) Dielectric withstanding voltage : 1500V for 1 minute
e) Rate : 1 M bits / s
f) Impedance : 75Ω ± 7 Ω
g) Conductor : Stranded silver plated high strength copper alloy
h) Insulation PTFE Insulation
i) Temperature Range -55OC to +200OC
7. End Use of the Item : − Used for avionics system in aircraft (MiG 27 Upgrade
project.)
− Useful in general high temperature application in
accordance with MIL-STD-1553
− Aircrafts, Fighters & Helicopters.
− Military :Weapon systems, Tanks, Missiles, Test benches
− Space: Launch vehicles, Telecommunication, Space
station

141
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Twinax Databus cable in compliance with MIL-STD- TYPE NO : F10612T
1553B
CONSTRUCTION DETAILS:

A. Conductor : Stranded silver plated high A

Strength copper alloy wire.

B. Insulation : PTFE Taped and fused.

C. Filler : 2 PTFE rod filler D

Twisting : 2 Core twisted together

with 2 filler

B
D. Shield : Round Braided shield of
silver Plated high strength
copper alloy wire . A
Coverage : 90 % minimum

E. Jacket : PTFE taped & sintered. C

(Thickness : 0.25mm nom)
Color : Light blue

CORE CABLE
Conducto No of Conductor Primary Filler No of core Braid Diameter Weight
r strands diameter wire diamete strand
x mm diameter r diameter mm g/m
Strand mm nominal mm maximum maximum
AWG diamete mm
r
n x mm
24/19/36 19x 0.58± 0.02 1.08± 0.05 0.80
2 0.10 3.4 26.8
0.12 white x
blue
ELECTRICAL CHARACTERISTICS
Characteristics Capacitance Nom Velocity of Attenuation Insulation Voltage
Impedance pF / meter Propagation dB/100 meters resistance withstanding
Ohms maximum maximum MΩ-km betn
at 1 MHz minimum Core & shield
Volts
77 ± 7 78 69 % 4.5 1524 1000

142
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1090

2. Approval Title : Electrical wires & Cables

Type BPGRL of size 0.5,
0.75, 1.00, 1.50, 2.50 mm2
3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s Uniflex Cables Ltd,

Umbergaon, U.P – 396 171
5. Governing Specification : TU-16-505.124-78 (Russian)

6. Characteristics of Wire

a) Classification : External Heat Resistant

b) Voltage Rating : 250V
c) Operating Frequency : Up to 1000Hz
d) AC Voltage Test : 1500 V, 50 Hz for 1 minute
e) Conductor : Copper Silver plated
f) Insulation : Silicone Insulation (Rubber)
g) Temperature Range : -60°C to +125° C
7. End Use of the Item : Used in MiG Series aircraft for preparing movable looms

143
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1117

2. Approval Title : Electrical wires & Cables SA-EQ-MGSHV & SA-EQ-

MGSHVE
(Equivalent to Russian wire MGSHV and MGSHVE
respectively)
3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.437-73 (Russian)
b) MIL-W-16878 for wire
c) MIL-DTL-27500H for MGSHVE cable
6. Characteristics of Wire

a) Classification : Internal No Heat Resistant Flexible

b) Voltage Rating : 380V AC for 500V DC up to 0.14 mm2
1000V AC for 1500V DC from 0.20 mm2 to 1.5 mm2
c) Operating Frequency : Up to 5000Hz
d) Conductor : Silver plated copper
e) Insulation High Temperature Insulation (Polychlorovinyl, Electrical
Insulation Fibres
f) Temperature Range -65°C to +200° C
7. Decoding of Part No. of Wire ** − MGSHV – Interior Flexible Silk braiding Vinylchloride
− MGSHVE - Same as MGSHV, with shielding
8. End Use of the Item : Aircraft equipment / interconnect contact circuits. For
aircraft harness

9. Other Details : Sr. Russian Part SAPL Part No

No. No
1 MGSHV – 0.12 SA-EQ-MGSHV – 0.12 (TA - SCQ – 0012)
2 MGSHV – 0.14 SA-EQ-MGSHV – 0.14 (TA - SCQ – 0014)
3 MGSHV – 0.20 SA-EQ-MGSHV – 0.20 (TB - SCM – 0020)
4 MGSHV – 0.35 SA-EQ-MGSHV – 0.35 (TB - SCM – 0035)
5 MGSHV – 0.50 SA-EQ-MGSHV – 0.50 (TB - SCQ – 0050)
6 MGSHV – 0.75 SA-EQ-MGSHV – 0.75 (TB - SCQ – 0075)
7 MGSHV – 1.00 SA-EQ-MGSHV – 1.00 (TB - SCQ – 0100)
8 MGSHV – 1.50 SA-EQ-MGSHV – 1.50 (TB - SCM – 0150)
Also 1 core Shielded cable available

144
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1119
2. Approval Title : Electrical wires & Cables
Type SA-EQ-MGTFL & SA-EQ-MGTFLE
(Equivalent to Russian wire MGTFL and MGTFLE
respectively)
3. Validity of Approval : 30 Jun 2016

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-OMTs-505.029-58 (Russian)
b) MIL-W-16878 for wire
c) MIL-DTL-27500H for MGTFLE cable
6. Characteristics of Wire
a) Classification : Internal Heat Resistant Wire, resistant to Aircraft fluids
b) Voltage Rating : 600VDC
c) Operating Frequency : Up to 2000Hz
d) Conductor : Silver plated copper
e) Insulation High Temperature Insulation (Fluoroplastic Insulation)
f) Temperature Range -65°C to +200° C
7. Decoding of Part No. of Wire ** − MGTFL – Interior Flexible heat resistant fluoroplastic
insulated and varnished
− MGTFLE - Same as MGTFL, with shielding
8. End Use of the Item : General purpose aircraft wiring durable to aero fluids

9. Other Details : Sr. Russian Part SAPL Part No

No. No
1 MGTFL – 0.10 SA-EQ-MGTFL – 0.10 (HB - SCQ – 0010)
2 MGTFL – 0.14 SA-EQ-MGTFL – 0.14 (HB - SCQ – 0014)
3 MGTFL – 0.20 SA-EQ-MGTFL – 0.20 (HB - SCQ – 0020)
4 MGTFL – 0.25 SA-EQ-MGTFL – 0.25 (HB - SCQ – 0025)
5 MGTFL – 0.35 SA-EQ-MGTFL – 0.35 (HB - SCM – 0035)
6 MGTFL – 0.50 SA-EQ-MGTFL – 0.50 (HB - SCQ – 0050)
7 MGTFL – 0.75 SA-EQ-MGTFL – 0.75 (HB – SCQ – 0075)
8 MGTFL – 1.00 SA-EQ-MGTFL – 1.00 (HB – SCQ – 0100)
9 MGTFL – 1.50 SA-EQ-MGTFL – 1.50 (HB – SCM – 0150)
Also 1 core Shielded cable available

145
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1124

2. Approval Title : RF Coaxial 4 core electrical

Cable (ADF Cable)
3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445.
5. Governing Specification : a) MIL-C-17G
b) Product Data Sheet FCOX
1000-4S
6. Characteristics of Wire
a) Classification : External Heat Resistant
b) Voltage Rating : 1000 Vrms
c) Operating Frequency : 3 GHz Max
d) Dielectric Strength : 2000 V rms
e) Characteristic Impedance : 75 Ω ± 3Ω
f) Velocity of Propagation : 69.5 % nominal
g) Capacitance 73pf/Mtrs Max
h) Conductor : Stranded silver plated high strength copper alloy
i) Insulation : PTFE insulation
j) Temperature Range : -55°C to +200° C
7. End Use of the Item : Use on aircraft and avionics system application

146
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1126

2. Approval Title : Electrical wires & Cables Type SA-EQ-BIN & SA-EQ-BINE
(SA-EQ-BIN/BINE/BINEZ and SA-EQ-BIN-N/BINE-N/BINEZ-N
equivalent to Russian wire BIN/BINE/BINEZ and BIN-N/BINE-
Z/BINEZ-N respectively)
3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.620-74 (Russian)
b) MIL-DTL-27500H
c) MIL-DTL-22759/86A
6. Characteristics of Wire
a) Classification : External Heat Resistant (Arc Track Resistant, Resistant to
Aero Fluids and Mould & Fungus resistant)
b) Voltage Rating : 600V DC
c) Operating Frequency : Up to 2000Hz
d) Insulation strength : 3000V AC, 50 Hz
e) Conductor : BIN/BIN-N : Silver plated Copper
BIN/BIN-N-N : Nickel plated Copper
f) Insulation : High Temperature Insulation (Glass Fluoro Plastic)
g) Temperature Range : -65°C to +200° C
7. Decoding of Part No. of Wire : BIN/BIN-N – External wear resistant, heat resistant
BIN/BIN-NE - Same as BIN/BIN-N, with shielding
BIN/BIN-NEZ – same as BIN/BIN-NE with protective jacket
BIN/BIN-N-N – External wear resistant, heat resistant
BIN/BIN-NE-N - Same as BIN/BIN-N-N, with shielding
BIN/BIN-NEZ-N – same as BIN/BIN-NE-N with protective
jacket
8. End Use of the Item : As airframe wires in fuselage. They are durable to aerofluids
9. Other Details : Sr. No. Russian Part No SAPL Part No
1 BIN/BIN-N-0.35 SABIN/SABIN-N – 0.35
2 BIN/BIN-N – 0.50 SABIN/SABIN-N – 0.50
3 BIN/BIN-N – 0.75 SABIN/SABIN-N – 0.75
4 BIN/BIN-N – 1.00 SABIN/SABIN-N – 1.00
5 BIN/BIN-N – 1.50 SABIN/SABIN-N – 1.50
6 BIN/BIN-N – 2.50 SABIN/SABIN-N – 2.50
7 BIN/BIN-N – 4.00 SABIN/SABIN-N – 4.00
8 BIN/BIN-N – 6.00 SABIN/SABIN-N – 6.00
9 BIN/BIN-N – 10.00 SABIN/SABIN-N – 10.00
10 BIN/BIN-N – 16.00 SABIN/SABIN-N – 16.00
11 BIN/BIN-N – 25.00 SABIN/SABIN-N – 25.00
12 BIN/BIN-N – 35.00 SABIN/SABIN-N – 35.00
13 BIN/BIN-N – 50.00 SABIN/SABIN-N – 50.00
14 BIN/BIN-N – 70.00 SABIN/SABIN-N – 70.00
Also Shielded 1,2 &3 core and 1 Core shielded + Jacketted cable
available.

147
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1180

2. Approval Title : Twinax Electrical Wires& Cables120 Ohms

Part No. 2524A2S06
3. Validity of Approval : 31 Dec 2015

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445.
5. Governing Specification : a) Product data sheet : 2424A2S06
b) AIR 4524E for Basic Core
c) MIL-DTL-27500H for cable
d) BS 2316S for electrical

6. Characteristics of Wire

a) Classification : Heat resistant winding wire

b) Voltage Rating : 1000V AC RMS
c) Impedance : 120 ±10 ohms
d) Capacitance : 40 pf /meter nominal
e) Velocity ratio : 69 %
f) Conductor : Stranded silver plated high strength copper alloy
g) Insulation : PTFE Taped and Sintered
h) Temperature Range : -550C to +2000C
7. End Use of the Item : Used to carry mission computer signals to head up display
unit in JAGUAR AIRCRAFT for DARIN II navigation system

TECHNICAL SPECIFICATION
Item Description :PTFE Insulated & Sheathed 120 OHMS Twinax Cable
Type No : 2524A2S06

D C B A
Construction Details
A Conductor : Stranded silver plated high strength copper alloy
Size : AWG 24/19/36
Strand diameter : 0.127mm Nom
No of strands : 19
Dia of conductor : 0.64mm Nom
B Dielectric : PTFE Taped and sintered
Core dimensions : 2.05 +/- 0.1mm
No of core : 2 ( Twin Twisted )
Core colour : White x Blue
C Shield : Braid of silver plated copper wire, coverage > 90%
D Jacket : PTFE Taped and sintered
Colour : white
Finished cable dia : 5.0 mm max.
Weight : 36 g/m avg.

148
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 1. Type Approval No. : 1181

2. Approval Title : PTFE Electrical wires and cables

Type SA-EQ-22759/6

3. Validity of Approval : 31 Dec 2015

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.

5. Governing Specification : a) MIL-W-22759/6B for Wire

b) MIL-DTL-22759/87A for Cable

6. Characteristics of Wire

a) Classification : Wear resistant wire, resistant to aero fluids and arc tracking
resistant

b) Voltage Rating : 600V DC

c) Operating Frequency : Up to 2000 Hz

d) Conductor : Nickel plated Copper conductor

e) Insulation High temp. and wear resistant insulation (FP/Polyimide/FP

tape)

f) Temperature Range -600C to +2500C

7. End Use of the Item : Used in wiring of apparatus of aircraft electrical circuit.

8. Other Details : Sanghvi Aerospace Part No. SA-EQ-M22759/6-**

is equivalent to

MIL22759/6-**

149
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1182
2. Approval Title : Heavy film insulated,
aromatic polyimide
Lacquared round copper
wire (magnet wire)
3. Validity of Approval : 31 Dec 2015
4. Developer of the Item : M/s. Sanghvi Aerospace Pvt,
Ltd.
Ahmadabad 382 405.
5. Governing Specification : a) NEMA MW 1000/ 16C
(Heavy)
b) MW 1000-1997, Rev 2
(other equivalent JW
1177/15B, IEC 6031717, IS
13730-7, BS 4663)
6. Characteristics of Wire
a) Classification : Heat resistant winding wire
b) Voltage Rating : 600 V
c) Dielectric strength : ≥ 7600V
d) Conductor : Copper Conductor
e) Insulation : Aromatic Polyimide resin
f) Temperature Range : -650C to +240oC
7. End Use of the Item : Used in motors / generators / transformers / coils and
other high temp operating apparatus as winding wires
for continuous use up to 240" C. Used in sealed relays,
hermetic refrigeration system, liquid filled transformers
etc.
8. Other Details : Sanghvi Aerospace Part No. MW16C@**(S/A)WG
@ indicates type of coating S for Single type H for
Heavy type T for Triple type and Q for Quadruplicate
** indicates size of conductor
are equivalent to
NEMA part No. MW016C*x*****Unc
@ indicates type of coating S for Single type H for
Heavy type T for Triple type and Q for Quadruplicate
***** indicates size of conductor

150
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 AWG Size NEMA Part No. SAPL Part No.
4 MW016C*x00004Unc MW16C*4AWG
5 MW016C*x00005Unc MW16C*5AWG
6 MW016C*x00006Unc MW16C*6AWG
7 MW016C*x00007Unc MW16C*7AWG
8 MW016C*x00008Unc MW16C*8AWG
9 MW016C*x00009Unc MW16C*9AWG
10 MW016C*x00010Unc MW16C*10AWG
11 MW016C*x00011Unc MW16C*11AWG
12 MW016C*x00012Unc MW16C*12AWG
13 MW016C*x00013Unc MW16C*13AWG
14 MW016C*x00014Unc MW16C*14AWG
15 MW016C*x00015Unc MW16C*15AWG
16 MW016C*x00016Unc MW16C*16AWG
17 MW016C*x00017Unc MW16C*17AWG
18 MW016C*x00018Unc MW16C*18AWG
19 MW016C*x00019Unc MW16C*19AWG
20 MW016C*x00020Unc MW16C*20AWG
21 MW016C*x00021Unc MW16C*21AWG
22 MW016C*x00022Unc MW16C*22AWG
23 MW016C*x00023Unc MW16C*23AWG
24 MW016C*x00024Unc MW16C*24AWG
25 MW016C*x00025Unc MW16C*25AWG
26 MW016C*x00026Unc MW16C*26AWG
27 MW016C*x00027Unc MW16C*27AWG
28 MW016C*x00028Unc MW16C*28AWG
29 MW016C*x00029Unc MW16C*29AWG
30 MW016C*x00030Unc MW16C*30AWG
31 MW016C*x00031Unc MW16C*31AWG
32 MW016C*x00032Unc MW16C*32AWG
33 MW016C*x00033Unc MW16C*33AWG
34 MW016C*x00034Unc MW16C*34AWG
35 MW016C*x00035Unc MW16C*35AWG
36 MW016C*x00036Unc MW16C*36AWG
37 MW016C*x00037Unc MW16C*37AWG
38 MW016C*x00038Unc MW16C*38AWG
39 MW016C*x00039Unc MW16C*39AWG
40 MW016C*x00040Unc MW16C*40AWG
41 MW016C*x00041Unc MW16C*41AWG
42 MW016C*x00042Unc MW16C*42AWG
43 MW016C*x00043Unc MW16C*43AWG
44 MW016C*x00044Unc MW16C*44AWG
• Indicates type of coating denoted by S= Single,
H= Heavy, T=Triple, Q=Quadruple

151
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1207

2. Approval Title : Polyimide/PTFE Insulated Electrical wires & Cables

(Equivalent to Russian type BPVL/ BPVLE, BPVLM & BPVLME)
3. Validity of Approval : 31 Dec 2015

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.911-76 (Russian)
b) MIL-DTL-22759/86A,
c) MIL-W-22759,
d) MIL-DTL-27500H
6. Characteristics of Wire
a) Classification : External Non Heat Resistant
b) Voltage Rating : 600V DC
c) Operating Frequency : 200 Hz
d) Conductor : Silver plated Copper Conductor
e) Insulation : High temperature insulation
f) Temperature Range : -65°C to +200°C
7. Decoding of Part No. of Wire : BPVL/BPVLM- Onboard cable with fluoropolymer plastic
insulation with varnished cotton braid
BPVLE/BPVLME- Same as BPVL / BPVLM with Shielding
8. End Use of the Item : As Hook-up wires in Armament, radio / electrical /experimental
equipment, AC circuit of Russian aircraft/ helicopters
9. Other Details : Sr. No. Russian SAPL Part No
Part No
1 BPVL-0.35 SA-EQ-BPVL-0.35 (HB – SCP – 0035)
2 BPVL-0.50 SA-EQ-BPVL-0.50 (HB – SCP – 0050)
3 BPVL-0.75 SA-EQ-BPVL-0.75 (HB – SCP – 0075)
4 BPVL-0.88 SA-EQ-BPVL-0.88 (HB – SCM – 0088)
5 BPVL-1.00 SA-EQ-BPVL-1.00 (HB – SCM – 0100)
6 BPVL-1.25 SA-EQ-BPVL-1.25 (HB – SCM – 0125)
7 BPVL-1.50 SA-EQ-BPVL-1.50 (HB – SCM – 0150)
8 BPVL-1.93 SA-EQ-BPVL-1.93 (HB – SCM – 0193)
9 BPVL-2.50 SA-EQ-BPVL-2.50 (HB – SCM – 0250)
10 BPVL-3.00 SA-EQ-BPVL-3.00 (HB – SCP – 0300)
11 BPVL-4.00 SA-EQ-BPVL-4.00 (HB – SCM – 0400)
12 BPVL-5.15 SA-EQ-BPVL-5.15 (HB – SCM – 0515)
13 BPVL-6.00 SA-EQ-BPVL-6.00 (HB – SCP – 0600)
14 BPVL-8.80 SA-EQ-BPVL-8.80 (HB – SCP – 0880)
15 BPVL-10.00 SA-EQ-BPVL-10.00 (HB – SCP – 1000)
16 BPVL-13.00 SA-EQ-BPVL-13.00 (HB – SCM – 1300)
17 BPVL-16.00 SA-EQ-BPVL-16.00 (HB – SCM – 1600)
18 BPVL-21.00 SA-EQ-BPVL-21.00 (HB – SCM – 2100)
19 BPVL-25.00 SA-EQ-BPVL-25.00 (HB – SCM – 2500)
20 BPVL-35.00 SA-EQ-BPVL-35.00 (HB – SCM – 3500)
21 BPVL-41.00 SA-EQ-BPVL-41.00 (HB – SCM – 4100)
22 BPVL-50.00 SA-EQ-BPVL-50.00 (HB – SCM – 5000)
23 BPVL-70.00 SA-EQ-BPVL-70.00 (HB – SCP – 7000)
24 BPVL-95.00 SA-EQ-BPVL-95.00 (HB – SCM – 9500)
25 BPVLM-0.35 SA-EQ-BPVLM-0.35 (HB – SCP – 0035)
26 BPVLM-0.50 SA-EQ-BPVLM-0.50 (HB – SCP – 0050)
27 BPVLM-0.75 SA-EQ-BPVLM-0.75 (HB – SCP – 0075)
28 BPVLM-1.00 SA-EQ-BPVLM-1.00 (HB – SCM – 0100)
29 BPVLM-1.50 SA-EQ-BPVLM-1.50 (HB – SCM – 0150)
30 BPVLM-2.50 SA-EQ-BPVLM-2.50 (HB – SCM – 0250)
Also 1 core Shielded cable available

152
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1215

2. Approval Title : Fuel Gauge Coaxial Cable

(Equivalent to imported cable

part No. S4006-12)

3. Validity of Approval : 30 Jun 2011

4. Developer of the Item : M/s. Flu-Tef Industries

Ahmadabad 382 445.

5. Governing Specification : a) MIL-C-17G

b) M17/93-RG178
c) Imported data sheet No.
S4006-12
d) Product data sheet F 4006
6. Characteristics of Wire

a) Classification : Fuel Gauge cable

b) Voltage Rating : 750 Vrms

c) Operating Frequency : Up to 3 GHz

d) Dielectric Strength : 2000 Vrms for 1 minute

e) Conductor : Solid Silver plated Copper clad steel wire

f) Insulation : PTFE

g) Temperature Range : -55°C to +200°C

7. End Use of the Item : Used in Jaguar Aircraft in fuel gauging system. It
interconnects the entire fuel tank unit (fuel probes) and fuel
amplifier unit.

Useful in high temperature and high frequency application

153
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1232

2. Approval Title : Polyimide+PTFE Insulated Electrical wires & Cables

Type SA-EQ-PTL-200/250/250 & SA-EQ-PTLE-200/250
(Equivalent to Russian wire PTL- 2001250 and PTLE-
2001250 respectively)
3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.280-79 (Russian)
b) MIL-DTL-22759/86A
c) MIL-DTL-27500H
6. Characteristics of Wire
a) Classification : External Heat Resistant
b) Voltage Rating : 600V DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : Silver plated Copper Conductor
e) Insulation : High Temperature Insulation (Flouro Plastic, Varnished
Fibre Glass Sheath Insulation)
f) Temperature Range : -60°C to +250°C
7. Decoding of Part No. of Wire : − PTL-200/250/250– wire heat resistant varnished
− PTLE – 200/250 - Same as PTL-200/250/250, with
shielding
8. End Use of the Item : As heat resistant cable in engine harness, fire protection
and high power electrical circuits
9. Other Details : Sr. Russian Part No SAPL Part No
No.
1 PTL-200/250 – 0.35 SAPTL-200/250– 0.35
2 PTL-200/250 – 0.50 SAPTL-200/250– 0.50
3 PTL-200/250 – 0.75 SAPTL-200/250– 0.75
4 PTL-200/250 – 1.00 SAPTL-200/250– 1.00
5 PTL-200/250 – 1.50 SAPTL-200/250– 1.50
6 PTL-200/250 – 2.50 SAPTL-200/250– 2.50
7 PTL-200/250 – 4.00 SAPTL-200/250– 4.00
8 PTL-200/250 – 6.00 SAPTL-200/250– 6.00
9 PTL-200/250 – 10.00 SAPTL-200/250–10.00
10 PTL-200/250 – 16.00 SAPTL-200/250–16.00
11 PTL-200/250 – 25.00 SAPTL-200/250–25.00
12 PTL-200/250 – 35.00 SAPTL-200/250–35.00
13 PTL-200/250 – 50.00 SAPTL-200/250–50.00
14 PTL-200/250 – 70.00 SAPTL-200/250–70.00
15 PTL-200/250 – 95.00 SAPTL-200/250–95.00
Also 1 core Shielded cable available

154
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1256

2. Approval Title : Tin Plated Tubular Copper

Braids 7 -Types
3. Validity of Approval : 30 Jun 2012
4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.
Ahmadabad 382 405.
5. Governing Specification : a) MIL-DTL-27500H,
b) ASTM-B-33 &
c) Russian spec OTY 22-223-66

6. Characteristics of Wire • Excellent Shield

• Easy assembly / disassembly
• Extra flexible
• High expansion ratio (2:1)
• Optical coverage: Min. 93% to max. 100%
• Compatible with standard connectors
a) Classification : Tin Plated Tubular Copper Braids
b) Tensile Strength : 214 to 250 N/ mm2
c) Elongation : 16 to 27 (% min)
d) Electrical Resistance : 0.01700 Ω* mm2/m at 200C
7. End Use of the Item : Electrical screening on Aircraft electrical Wire/ Cable for
project Takshak electrical looms in MiG 27 Upgrade
(Electrical screening of wire / cable bundles of aircraft
equipments / interconnect contact circuits to have low
noise transmission of electrical signals through conductor.)

8. Other Details : Can be supplied in custom made size also

Sanghvi Aerospace Part No . for Standard Sizes
Sr. Tin Plated Nickel Plated Silver Plated
No. Copper Braid Copper Braid Copper Braid

1 SATB101-3.0 SATB103-3.0 SATB102-3.0

2 SATB101-4.0 SATB103-4.0 SATB102-4.0
3 SATB101-6.0 SATB103-6.0 SATB102-6.0
4 SATB101-7.5 SATB103-7.5 SATB102-7.5
5 SATB101-10.0 SATB103-10..0 SATB102-10.0
6 SATB101-12.5 SATB102-12.5
7 SATB101-20.0 SATB102-20.0
8 SATB101-30.0 SATB102-30.0
9 SATB101-40.0 SATB102-40.0

155
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1361

2. Approval Title : PTFE + Polyimide+Glass Fibre Thread Insulated Nickel

Electro Plated Copper Electrical Wires & Cables
Type SABFS, SABFSE, SABFSEZ
(equivalent to Russian wire BFS/BFSE/BFSEZ
3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : TU 16-705.014-77 (Russian)
& aircraft 9-12 overhaul manual
6. Characteristics of Wire
a) Classification : External Heat Resistant (Aircraft Fluid Resistant)
b) Voltage Rating : 350V DC or 250 AC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : BFS : Stranded Nickel plated Copper / Copper alloy
Conductor
e) Insulation : Temp. resistant film, Skived PTFE film, Polymide film with
Fluroplastic coating, fibre glass tape / thread impregnated
with PTFE, Braiding of fibre glass threads coated with
PTFE
f) Temperature Range : -60°C to +250°C
Short Term Exposure – upto +300°C
7. Decoding of Part No. of Wire : − BFS – External heat & wear resistant, Fluoro plastic
insulated cable
− BFSE- Same as BFS, with shielding
− BFSEZ – same as BFSE with protective jacket
8. End Use of the Item : All type of Russian Aircrafts including Helicopter.
For Fixed mounting of onboard power supply systems,
aircraft harness, as heat & wear resistant cables

9. Other Details : Sr. No. Russian Part No SAPL Part No

1 BFS–0.20 br * SABFS–0.20 br *
2 BFS – 0.35 SABFS – 0.35
3 BFS – 0.35 br * SABFS–0.35 br *
4 BFS – 0.50 SABFS – 0.50
5 BFS – 0.50 br * SABFS–0.50 br *
6 BFS – 0.75 SABFS – 0.75
7 BFS – 1.00 SABFS – 1.00
8 BFS – 1.50 SABFS – 1.50
9 BFS – 2.50 SABFS – 2.50
10 BFS – 4.00 SABFS – 4.00
11 BFS – 6.00 SABFS – 6.00
12 BFS – 10.00 SABFS – 10.00
13 BFS – 16.00 SABFS – 16.00
14 BFS – 25.00 SABFS – 25.00
15 BFS – 35.00 SABFS – 35.00
16 BFS – 50.00 SABFS – 50.00
17 BFS – 70.00 SABFS – 70.00
18 BFS – 95.00 SABFS – 95.00
1, 2 & 3 Core Shielded or Shielded & Jacketed Cable
also available

156
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1434

2. Approval Title : PTFE Polyimide Insulated wires and Cables BPDO,

BPDOE, BPDOU, BPDOUE
3. Validity of Approval : 30 Jun 2014

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.
5. Governing Specification : a) TU-16-505.941-76 (BPDO,BPDOE -Russian)
b) MIL-DTL-22759/86A
c) MIL-W-22759
d) MIL-DTL-27500H and SAPL Data Sheet
6. Characteristics of Wire
a) Classification : External Non Heat Resistant, Arc Tracking Resistant &
Aircraft Fluid Resistant
b) Voltage Rating : 750 V DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : Silver Plated Copper / Copper alloy Conductor
e) Insulation : High Temperature Insulation
(Flurocarbon Polymer (FP) Insulation)
f) Temperature Range : -60°C to +200°C
7. End Use of the Item : All type of Russian Aircrafts including Helicopter as Hook-
up wires in power, starting and propeller feathering circuits.
The screened versions used in Radio, Fuel and Air-
conditioning system of aircraft.
8. Other Details : Sanghvi Aerospace Part No. SA-EQ-BPDO / BPDOE and
SA-EQ-BPDOU/ BPDOUE is equivalent to Russian wire
BPDO/BPDOE & BPDOU/BPDOUE
Sr. No. Russian Part No SAPL Part No
1 BPDO–0.20 SA-EQ-BPDO–0.20
2 BPDOY–0.20 SA-EQ-BPDOY–0.20
3 BPDO–0.35 SA-EQ-BPDO–0.35
4 BPDOY–0.35 SA-EQ-BPDOY–0.35
5 BPDO–0.50 SA-EQ-BPDO–0.50
6 BPDOY–0.50 SA-EQ-BPDOY–0.50
7 BPDO–0.75 SA-EQ-BPDO–0.75
8 BPDO–1.00 SA-EQ-BPDO–1.00
9 BPDO–1.50 SA-EQ-BPDO–1.50
10 BPDO–2.50 SA-EQ-BPDO–2.50
11 BPDO–4.00 SA-EQ-BPDO–4.00
12 BPDO–6.00 SA-EQ-BPDO–6.00
13 BPDO–10.00 SA-EQ-BPDO–10.00
14 BPDO–16.00 SA-EQ-BPDO–16.00
15 BPDO–25.00 SA-EQ-BPDO–25.00
16 BPDO–35.00 SA-EQ-BPDO–35.00
17 BPDO–50.00 SA-EQ-BPDO–50.00
18 BPDO–70.00 SA-EQ-BPDO–70.00
19 BPDO–95.00 SA-EQ-BPDO–95.00
Also Shielded 1 core cable available

157
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1522

2. Approval Title : Thermo Couple Extension

Cable

Part No.SATE 3320 YH 006

3. Validity of Approval : 31 Dec 2015

4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.

Ahmadabad 382 405.

5. Governing Specification : a) MBBN 3320 YH,

b) PAN Spec.SP-75-6420
c) BS4937
d) MIL-STD-27500H
e) MIL-W-5846C
f) ASTM-E-220

6. Characteristics of Wire

a) Classification : Excellent resistance to Aviation chemicals and fluids

b) Voltage Rating : 600 Vrms

c) Wire Size : 20 AWG

d) Insulation Resistance : ≥ 100MΩ

a) Thermo emf at 260°C : 10.56 mV ± 0.12 mV (±3°C) (Class 1)

10.56 mV ± 0.06 mV (±1.5°C) (Class 2)

e) Conductor : Nickel Chromium (Plus wire)

Nickel Aluminum (Minus wire)

f) Insulation : PTFE tape wrapped and sintered

g) Temperature Range : -55°C to +260°C

7. End Use of the Item : As thermocouple extension cable for use on LCA

158
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1691
2. Approval Title : Electrical Wires & Cables
Type No. SAMS 16/16/26/36-13/33
SAMSE 16/26/36-13/33
And
SAMSEO 16/26/36-13/33
3. Validity of Approval : 31 Dec 2016
4. Developer of the Item : M/s. SanghviAerospace Pvt, Ltd.
Ahmadabad 382 405.
5. Governing Specification : a) TU 16-505.083-78 Issue–Nil dated 09 Dec 2005
(Russian)
b) SAPL Data Sheet
6. Characteristics of Wire

a) Classification : Internal Heat resistant wire. Indigenous Hook up wires,

Fluid Resistant
b) Voltage Rating : • 100V/250V/500V AC,
• 150/350/700V DC
c) Operating Frequency : Upto 10000 Hz
d) Conductor : Silver Plated Copper / Copper alloy Conductor
e) Insulation : High Temperature Insulation. Fluro Plastic like PTFE taped
and sintered Insulation
f) Temperature Range : -60°C to +200°C
7. Decoding of Part No. of Wire : − MS - Internal Heat Resistant Wire (M- Interior, S-
Sintering Insulation)
− MSE- Same as MS with Shielding
− MSEO- Same as MSE with sheath
8. End Use of the Item : Use in Russian Fleet, Helicopters and Aircraft including
MiG series and SU-30 MK-I aircraft.
As Hook-up wires in aircraft starting system, fuel system
and airborne missile launchers.
9. Other Details : Sr. No. Russian Part No SAPL Part No
1 MS 16–13–0.02 SAMS 16–13–0.02
2 MS 16–13–0.03 SAMS 16–13–0.03
3 MS 16–13–0.05 SAMS 16–13–0.05
4 MS 16–13–0.08 SAMS 16–13–0.08
5 MS 16–13–0.12 SAMS 16–13–0.12
6 MS 16–13–0.20 SAMS 16–13–0.20
7 MS 16–13–0.35 SAMS 16–13–0.35
8 MS 16–13–0.50 SAMS 16–13–0.50
9 MS 26–13–0.05 SAMS 26–13–0.05
10 MS 26–13–0.08 SAMS 26–13–0.08
11 MS 26–13–0.12 SAMS 26–13–0.12
12 MS 26–13–0.20 SAMS 26–13–0.20
13 MS 26–13–0.35 SAMS 26–13–0.35
14 MS 26–13–0.50 SAMS 26–13–0.50
15 MS 26–13–0.75 SAMS 26–13–0.75
16 MS 26–13–1.00 SAMS 26–13–1.00
17 MS 26–13–1.50 SAMS 26–13–1.50
18 MS 26–13–2.50 SAMS 26–13–2.50
19 MS 36–13–0.05 SAMS 36–13–0.05
20 MS 36–13–0.08 SAMS 36–13–0.08
21 MS 36–13–0.12 SAMS 36–13–0.12
22 MS 36–13–0.20 SAMS 36–13–0.20
23 MS 36–13–0.35 SAMS 36–13–0.35
24 MS 36–13–0.50 SAMS 36–13–0.50
25 MS 36–13–0.75 SAMS 36–13–0.75
26 MS 36–13–1.00 SAMS 36–13–1.00
27 MS 36–13–1.50 SAMS 36–13–1.50
28 MS 36–13–2.50 SAMS 36–13–2.50

159
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1692

2. Approval Title : Electrical Wires & Cables

Type No. SA-EQ-MS 16/26/36-P and
SA-EQ-MSE 26-P
3. Validity of Approval : 31 Dec 2016
4. Developer of the Item : M/s. SanghviAerospace Pvt, Ltd.
Ahmadabad 382 405.
5. Governing Specification : TU 16-505.195-80 dated 20 Sep 2003 (Russian)

6. Characteristics of Wire
a) Classification : Internal Heat resistant wire. Indigenous Hook up wires,
Fluid Resistant
b) Voltage Rating : • 100V/250V/500V AC,
• 150/350/700V DC
c) Operating Frequency : Up to 10000 Hz
d) Conductor : Silver Plated Copper Conductor
e) Insulation : High Temp Insulation like Fluro Plastic like PTFE Insulation
f) Temperature Range : -60°C to +200°C
7. Decoding of Part No. of Wire : − MS - Internal Heat Resistant Wire (M- Interior, S-
Sintering Insulation)
− MSE- Same as MS with Shielding
8. End Use of the Item : Use in Russian Fleet, Helicopters and Aircraft including
MiG series and SU-30 MK-I aircraft
As Hook-up wires in aircraft starting system, fuel system
and airborne missile launchers.
9. : Sr. Russian Part No. SAPL Part No
Other Details No.
1 MS 16 - P– 0.05 SA-EQ-MS 16 - P– 0.05
2 MS 16 – P – 0.08 SA-EQ-MS 16 – P – 0.08
3 MS 16 – P – 0.12 SA-EQ-MS 16 – P – 0.12
4 MS 16 – P – 0.20 SA-EQ-MS 16 – P – 0.20
5 MS 26 – P – 0.08 SA-EQ-MS 26 – P – 0.08
6 MS 26 – P – 0.12 SA-EQ-MS 26 – P – 0.12
7 MS 26 – P – 0.20 SA-EQ-MS 26 – P – 0.20
8 MS 26 – P – 0.35 SA-EQ-MS 26 – P – 0.35
9 MS 36 – P – 0.20 SA-EQ-MS 36 – P – 0.20
10 MS 36 – P – 0.35 SA-EQ-MS 36 – P – 0.35
11 MS 36 – P – 0.50 SA-EQ-MS 36 – P – 0.50
12 MS 36 – P – 0.75 SA-EQ-MS 36 – P – 0.75
13 MS 36 – P – 1.00 SA-EQ-MS 36 - P– 1.00
14 MS 36 – P – 1.50 SA-EQ-MS 36 – P – 1.50
15 MS 36 – P – 2.50 SA-EQ-MS 36 - P– 2.50
Also Shielded 1 core cable available in MS26-P Style

160
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1740

Thermocouple Extension Cable

2. Approval Title :
Part Nos. No. SATE 3320 YH 004

3. Validity of Approval : 31 Dec 2017

M/s. Sanghvi Aerospace Pvt, Ltd.

4. Developer of the Item :
Ahmadabad 382405.
a) MBBN 3320 YH
Governing Specification b) PAN Spec. 6420/SP-P-99300
5. :
c) BS 4937
d) MIL-W-5846C
6.
Characteristics of Wire

a) Classification : -
b) Voltage Rating : 600 Vrms
c) Thermo emf at 260°C : 10.56 mV ± 0.12 mV
d) Conductor : Nickel Chromium (Plus Wire), Nickel Aluminum (Minus Wire)
− PTFE Tape Wrapped
e) Insulation : − Polyimide Film Wrapped
− PTFE Tape Wrapped and Sintered
f) Temperature Range : -55°C to +260°C
Use in Electrical looms of temperature sensors in
7. End Use of the Item :
Advance Light Helicopter.

8. Other Details : K-Type (Cromel / Alumel) Extension Cable

161
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1815

2. Approval Title : Indigenous Mil-Std-1553B Data Bus Network for Bison

Aircraft As a Substitute for Russian Supplied Mil-Std-1553B
Data Bus Network 21.7771-40

3. Validity of Approval : 31 Dec 2018

4. Developer of the Item : M/s Compu power Pvt. Ltd., Hyderabad

5. Governing Specification : a) MIL 1553 B &

b) Test Schedule No. AURDC/MIG-21 BISON/DOC/002

6. Characteristics of Wire

a) Classification : MIL BUS 1553 B

b) Voltage Rating : 600V

c) Operating Frequency : 1000 Hz

d) Conductor : -

e) Insulation : -

f) Temperature Range : -550C to 850C

7. End Use of the Item : Data communication purpose of various systems in Bison
aircraft

8. Other Details : MIL-STD 1553B Data Bus Network developed by M/s.

Compu Power Pvt. Ltd., Hyderabad as a substitute for
Russian supplied MIL-STD 1553B Data Bus Network
21.7771-40

162
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1841

2. Approval Title : Electrical Wires and Cables of type SABIFM / BIFM-

N/SABIFM / BIFM-NE /SABIFM / BIFM-NEZ & SABIFM /
BIFM-N-N / SABIFM / BIFM-NE-Z /SABIFM / BIFM-NEZ-N
3. Validity of Approval : 31 Dec 2019
4. Developer of the Item : M/s. Sanghvi Aerospace Pvt, Ltd.
Ahmadabad 382405.
5. Governing Specification : a. TU16-505.945-76
b. MIL-DTL-81381C
c. MIL-@-81381/12C
d. MIL-DTL-27500H
e. MIL-STD-2223
f. ASTM-B-355
6. Characteristics of Wire

a) Classification : External Heat Resistant Wire

b) Voltage Rating : 600 Volts DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : BIF - Silver plated Copper
BIF-N - Nickel plated Copper
e) Insulation : PI Tape Polyamide Fluoroplastic

f) Temperature Range : -650C to +2000C for BIF

-650C to +2600C for BIF-N
7. Decoding of Part No. of Wire : − BIFM / BIFM-N – External wear resistant, Fluoro
Plastic
− BIFM / BIFM-NE- Same as BIF, with shielding
− BIFM / BIFM-NEZ – same as BIFE / BIFE-N with
protective jacket
− BIFM / BIFM-N-N – External wear resistant, Fluoro
Plastic
− BIFM / BIFM-NE-N- Same as BIF-N, with shielding
− BIFM / BIFM-NEZ-N – same as BIFE / BIFE-N-N with
protective jacket
8. End Use of the Item : Used on Armament, Radar and Power Supply looms used
in SU-30MKI Aircraft
9. Other Details : RUSSIAN PART NO. SAPL PART NO .
2
(Size in mm ) (Size in mm2)
BIFM / BIFM-N-0.20 SABIFM / BIFM-N -0.20
BIFM / BIFM-N-0.20 br* SABIFM / BIFM-N -0.20 br*
BIFM / BIFM-N-0.35 SABIFM / BIFM-N -0.35
BIFM / BIFM-N-0.35 br* SABIFM / BIFM-N -0.35 br*
BIFM / BIFM-N-0.50 SABIFM / BIFM-N -0.50
BIFM / BIFM-N-0.50 br* SABIFM / BIFM-N -0.50 br*
BIFM / BIFM-N-0.75 SABIFM / BIFM-N -0.75
BIFM / BIFM-N-1.00 SABIFM / BIFM-N -1.00
BIFM / BIFM-N-1.50 SABIFM / BIFM-N -1.50
BIFM / BIFM-N-2.50 SABIFM / BIFM-N -2.50
BIFM / BIFM-N-4.00 SABIFM / BIFM-N -4.00
BIFM / BIFM-N-6.00 SABIFM / BIFM-N -6.00
BIFM / BIFM-N-10.00 SABIFM / BIFM-N -10.00
1, 2 & 3 Core Shielded & Shielded +Jacketed Cable also
available.

163
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 164
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1851

2. Approval Title : 100 Ohms Digital Video Cable, Part No. 1026A2S06-
4CS06
3. Validity of Approval : 31 Dec 2019
4. Developer of the Item : FLU TEF INDUSTRIES
89/7, PHASE - I, G.I.D.C. INDUSTRIAL ESTATE
NR. FEROMATIC MALACRON, VATVA
AHMEDABAD - 382 445.
5. Governing Specification : a) MIL-C-17G
b) ASTM-B- 298 & ASTM-B-624
c) MIL-W-16878
d) MIL-DTL-27500H
e) RC/ALH/DSE/TS/0341, Issue-III, Rev-A dated 14-01-
2008.
f) QATP No. FT/QATP/DVC/ALH/02, Issue-02, Rev-01
dated 26-12-2007
6. Characteristics of Wire

a) Classification : -
b) Voltage Rating : 1000 Volts RMS
c) Operating Frequency : -
d) Conductor : 2 core twisted Stranded silver plated high strength
copper alloy
e) Insulation : PTFE taped & sintered and PTFE sheathed 4 pair cable
f) Temperature Range : -500C to +2000C
7. End Use of the Item : For use on the Advanced Light Helicopter (ALH) In IADS
configuration
8. Other Details : Applicable only for LRUs, Assy, Sub Assy (Not Applicable if
Fuel, Oil, Greases, Paints,
Warnishes, Raw material etc.).

165
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 166
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Provisional Clearance No. : RCMA(NSK)/PC/1175

2. Approval Title : Twin Core Cable

3. Validity of Approval :

4. Developer of the Item : M/s INCAB Industries, Pune

5. Governing Specification : a) TU-16-505-941-76 (Russian)

b) MIL-DTL-22759/86
c) MIL-W-22759,
d) MIL-DTL-27500H
6. Characteristics of Wire

a) Classification : -

b) Voltage Rating : --

c) Operating Frequency : -

d) Conductor : -

e) Insulation : -

f) Temperature Range : -

7. End Use of the Item : For use on Pigtail of extension Lamp and Rear View Prism

8. Other Details :

167
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Provisional Clearance No. : RCMA(NSK)/PC/1473

2. Approval Title : Indigenous U- Cable part No. 310D/101168U for

SARBE-8 system of Aircrew Survival Jacket (ASJ)

3. Validity of Approval : 29 Jan 2012

4. Developer of the Item : M/s MerlinHawk Aerospace(P)Ltd, Bangalore

5. Governing Specification : JSS 51100/MIL –C- 17G

6. Characteristics of Wire

a) Classification : RF Co-axial cable

b) Voltage Rating : 1400 Vrms

c) Operating Frequency : 12.4 GHz

d) Conductor : Silver plated copper clad steel (SCCS) or Silver plated

copper (SPC)

e) Insulation : Dielectric layer of spiral wrapped & fused PTFE Tape

f) Temperature Range : - 550C to + 2000C

7. End Use of the Item : Used to connect the SARBE-8 Personal Rescue Beacon
(PRB) to transmitter antenna carried in ASJ (Aircraft
Survival Jacket) by the aircrew.

8. Other Details : U CABLE SARBE – 8

Pt No.310D/101168U
GIG No.1356063

168
Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Provisional Clearance No. : RCMA/(N)/PC/1498

2. Approval Title : Electrical cables of type

BIFE / BIFE-N/BIFE / BIFE-NZ & BIFE / BIFE-N-Z/BIFE /
BIFE-NZ-N
3. Validity of Approval : 22 Jul 2014
4. Developer of the Item : M/s Sanghvi Aerospace(P)Ltd, Ahmadabad

5. Governing Specification : a) TU-16-505.945-76 (Russian)

b) MIL-DTL-81381/7 & 9,
c) MIL-DTL-27500H
6. Characteristics of Wire

a) Classification : External Heat Resistant Wire

b) Voltage Rating : 600 Volts DC
c) Operating Frequency : Up to 2000 Hz
d) Conductor : BIF - Silver plated Copper
BIF-N - Nickel plated Copper
e) Insulation : PI Tape

f) Temperature Range : -650C to +2000C for BIF

-650C to +2600C for BIF-N
7. Decoding of Part No. of Wire : − BIF – External wear resistant, Fluoro Plastic
− BIFE / BIFE-N- Same as BIF, with shielding
− BIFE / BIFE-NZ – same as BIFE / BIFE-N with
protective jacket
− BIF-N – External wear resistant, Fluoro Plastic
− BIFE / BIFE-N-N- Same as BIF-N, with shielding
− BIFE / BIFE-NZ-N – same as BIFE / BIFE-N-N with
protective jacket
8. End Use of the Item : As aircraft armament, radar and airframe harness
wires. These are heat and wear resistant cables
9. Other Details :
RUSSIAN PART NO. SAPL PART NO . RUSSIAN PART NO. SAPL PART NO .
2 2 2 2
(Size in mm ) (Size in mm ) (Size in mm ) (Size in mm )
BIFE / BIFE-N-0.20 SABIFE / SABIFE-N -0.20 BIFEZ / BIFENZ-0.20 SABIFEZ / SABIFEZ-N-0.20
BIFE / BIFE-N-0.20 br* SABIFE / SABIFE-N -0.20 br* BIFEZ / BIFENZ-0.20 br* SABIFEZ / SABIFEZ-N -0.20 br*
BIFE / BIFE-N-0.35 SABIFE / SABIFE-N -0.35 BIFEZ / BIFENZ-0.35 SABIFEZ / SABIFEZ-N -0.35
BIFE / BIFE-N-0.35 br* SABIFE / SABIFE-N -0.35 br* BIFEZ / BIFEZ-N 0.35 br* SABIFEZ / SABIFEZ-N -0.35 br*
BIFE / BIFE-N-0.50 SABIFE / SABIFE-N -0.50 BIFEZ / BIFEZ-N-0.50 SABIFEZ / SABIFEZ-N -0.50
BIFE / BIFE-N-0.50 br* SABIFE / SABIFE-N -0.50 br* BIFEZ / BIFEZ-N-0.50 br* SABIFEZ / SABIFEZ-N -0.50 br*
BIFE / BIFE-N-0.75 SABIFE / SABIFE-N -0.75 BIFEZ / BIFEZ-NZ-0.75 SABIFEZ / SABIFEZ-N -0.75
BIFE / BIFE-N-1.00 SABIFE / SABIFE-N -1.00 BIFEZ / BIFEZ-N-0.75 br* SABIFEZ / SABIFE-N -0.75 br*
BIFE / BIFE-N-1.50 SABIFE / SABIFE-N -1.50 BIFEZ / BIFEZ-N-1.00 SABIFEZ / SABIFEZ-N -1.00
BIFE / BIFE-N-2.50 SABIFE / SABIFE-N -2.50 BIFEZ / BIFEZ-N-1.50 SABIFEZ / SABIFEZ-N -1.50
BIFE / BIFE-N-4.00 SABIFE / SABIFE-N -4.00 BIFEZ / BIFEZ-N-2.50 SABIFEZ / SABIFEZ-N -2.50
BIFE / BIFE-N-6.00 SABIFE / SABIFE-N -6.00
BIFE / BIFE-N-10.00 SABIFE / BIFE-N -10.00

2 & 3 Core Shielded & Shielded +Jacketed Cable also available.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Provisional Clearance No. : CEMILAC/3005/GDS/PC/051
2. Approval Title : RF AND MICROWAVE CABLE
ASSEMBLIES
PART NOS. SPS-1501-394-SPS;
SPS-1801-394-SPS; SPS-2301-394-
SPS; SPS-2801-394-SPS;
KPS-1501-394-KPS; KPS-
1801-394-KPS AND
TPS-1501-394-TPS
3. Validity of Approval : 24 Nov 2014
4. Developer of the Item : M/s N.K.RF Products and Services
Pvt Ltd., Bangalore
5. Governing Specification : a) MIL-STD-17G (for cable)
b) MIL-STD-348 & MIL-PRF -39012
(for Connector)
c) MIL-STD-810F(Environmental)
6. Characteristics of Wire
a) Classification : RF cables
b) Operating Voltage : 1000 V
c) Operating Frequency : − DC-18 GHz
− DC-40 (KPS-1501-394-KPS)
− DC-32 (KPS-1801-394-KPS)
d) Conductor : Silver Plated OFHC Copper as per ASTM B-298
e) Insulation : Multi-Ply Laminate Expanded PTFE Type F-6 as per Mil-C-
17
f) Temperature Range : - 650C to + 1350C
7. End Use of the Item : For airborne use

8. Other Details :
Part No. Nomenclature Nominal
Diameter of
cable
SPS-1501-394- 1501 cable assembly 3.55 mm
SPS with SMA(M)
connectors
SPS-1801-394- 1801 cable assembly 4.83 mm
SPS with SMA(M)
connectors
SPS-2301-394- 2301 cable assembly 5.73 mm
SPS with SMA(M)
connectors
SPS-2801-394- 2801 cable assembly 7.75 mm
SPS with SMA(M)
connectors
KPS-1501-394- 1501 cable assembly 3.55 mm
KPS with 2.92 mm / K type
connector
KPS-1801-394- 1501 cable assembly 4.83 mm
KPS with 2.92 mm / K type
connector
TPS-1501-394- 1501 cable assembly 3.55 mm
TPS with TNC connector

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Sl No. Cable Manufacturer & Address Contact Details
1. M/s Garg Associates Pvt. Ltd.,
5, Nai Abadi -
GHAZIABAD, U.P
2. M/s Metal Cloth Products Private Phone: +91-80-41121817
Limited Fax: +91-80-22111859
Flat No. 5/7, Hussainabad, No. 5 E mail: [email protected]
Langford Road,
Langford Town
BANGALORE – 560 025
3. INCAB Industries Limited,
Cable House Phone: 212 670011 (4 lines)
Hadapsar Industrial Estate Fax: 212 672045
PUNE – 411 013 TELEX: 145-243 NCAB IN

4. M/s Mayfair Electricals,

177 Chittaranjan Avenue Phone: 34 – 7071
P.B.No. 6725 34 – 5304
CULCUTTA - 7 Telegram: MAFAIELEC

5. M/s Jai Bharat Industries

C-59/4, Okhla Industreis Area Phone: 91-11-6848926,
Phase II 6848373, 6862090
NEW DELHI – 110 020 Fax: 91-11-6862830, 91-11-
6843767
E mail: [email protected]

6. Universal Cables Ltd., Bangalore office

Post Box No. 9 Phone: 3342484 / 3348179
Birla Vikas Grams: ‘UNISTAR’
SATNA (MP) – 485 001 Telex: 0845-2653 U CLB IN
Fax: 080-3348179

7. M/s Sanghvi Aerospace Private

Ltd., Tel: +91-79-2535 07 56, 2532
B/h, Lalit Warehouse 34 60
Narol-Sarkhej Highway NAROLI Fax:+91-79-2535 87 38, 2539
AHMEDABAD – 382 405 41 00
E mail:
[email protected]
Website:www.sanghviaerospac
e.com

8. M/s Radiant Cables Limited

PB No. 1918, B1, Industrial Phone:91-40-23704470-73
Estate Fax: 91-40-23703421
Sanathnagar, E mail:
HYDERABAD – 500 018 [email protected]

9. M/s Flu-Tef Industries

89/7 GIDC Estate, Phase 1, Tel: (F) 2583 1045, 2583 1405
Near Torrent Lab, Vatva (R) 2692 5926
AHMEDABAD – 382 405 Fax: (079) 2583 5623 2535
8738
E mail: [email protected]
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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 10. M/s Uniflex Cables Ltd.,
158-163, GIDC, Phone : +91-260-2562412 /
Umbergaon – 396 171 2563412 / 2562954 / 2561354 /
Dist. Valsad, 2561212
GUJARAT Fax : +91-260-2562950 / 2563950
11. M/s Compu Power Pvt Ltd., Phone: 91-40-23354583
8-2-350/2/B Road No.03 Tel/Fax: 91-40-23352538
Banjara Hills Fax:91-40-23394654
HYDERABAD – 500 034 Email:compupowerindia@yaho
o.com,

[email protected]
12. M/s. Merlin Hawk Aerospace Pvt.
Ltd.,
# 57/5, 6th Cross, Tank Bund
Road, NS Palya, BTM Layout 2nd
Stage,
BANGALORE – 560 076
13. M/s N.K.RF Products and Tel: 080-2528 1840 / 2528 3350
Services Pvt Ltd. Fax: 080-2528 0429
# 2, 2nd Cross, Rustam Bagh,
Off. Old Airport Road
BANGALORE – 560 017

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American Wire Gauge (AWG) Sizes and Properties Chart / Table
Table 1 lists the AWG sizes for electrical cables / conductors. In addition to wire size, the table provides
values load (current) carrying capacity, resistance and skin effects. The resistances and skin depth noted are
for copper conductors. A detailed description of each conductor property is described below Table 1.

Table 1: American Wire Gauge (AWG) Cable / Conductor Sizes and Properties

Diameter Diameter Area Resistance Resistance Max Current Max Frequency

AWG
[inches] [mm] [mm2] [Ohms / 1000 ft] [Ohms / km] [Amperes] for 100% skin depth
0000 (4/0) 0.46 11.684 107 0.049 0.16072 302 125 Hz
000 (3/0) 0.4096 10.40384 85 0.0618 0.202704 239 160 Hz
00 (2/0) 0.3648 9.26592 67.4 0.0779 0.255512 190 200 Hz
0 (1/0) 0.3249 8.25246 53.5 0.0983 0.322424 150 250 Hz
1 0.2893 7.34822 42.4 0.1239 0.406392 119 325 Hz
2 0.2576 6.54304 33.6 0.1563 0.512664 94 410 Hz
3 0.2294 5.82676 26.7 0.197 0.64616 75 500 Hz
4 0.2043 5.18922 21.2 0.2485 0.81508 60 650 Hz
5 0.1819 4.62026 16.8 0.3133 1.027624 47 810 Hz
6 0.162 4.1148 13.3 0.3951 1.295928 37 1100 Hz
7 0.1443 3.66522 10.5 0.4982 1.634096 30 1300 Hz
8 0.1285 3.2639 8.37 0.6282 2.060496 24 1650 Hz
9 0.1144 2.90576 6.63 0.7921 2.598088 19 2050 Hz
10 0.1019 2.58826 5.26 0.9989 3.276392 15 2600 Hz
11 0.0907 2.30378 4.17 1.26 4.1328 12 3200 Hz
12 0.0808 2.05232 3.31 1.588 5.20864 9.3 4150 Hz
13 0.072 1.8288 2.62 2.003 6.56984 7.4 5300 Hz
14 0.0641 1.62814 2.08 2.525 8.282 5.9 6700 Hz
15 0.0571 1.45034 1.65 3.184 10.44352 4.7 8250 Hz
16 0.0508 1.29032 1.31 4.016 13.17248 3.7 11 k Hz
17 0.0453 1.15062 1.04 5.064 16.60992 2.9 13 k Hz
18 0.0403 1.02362 0.823 6.385 20.9428 2.3 17 kHz
19 0.0359 0.91186 0.653 8.051 26.40728 1.8 21 kHz
20 0.032 0.8128 0.518 10.15 33.292 1.5 27 kHz
21 0.0285 0.7239 0.41 12.8 41.984 1.2 33 kHz
22 0.0254 0.64516 0.326 16.14 52.9392 0.92 42 kHz
23 0.0226 0.57404 0.258 20.36 66.7808 0.729 53 kHz
24 0.0201 0.51054 0.205 25.67 84.1976 0.577 68 kHz
25 0.0179 0.45466 0.162 32.37 106.1736 0.457 85 kHz
26 0.0159 0.40386 0.129 40.81 133.8568 0.361 107 kHz
27 0.0142 0.36068 0.102 51.47 168.8216 0.288 130 kHz
28 0.0126 0.32004 0.081 64.9 212.872 0.226 170 kHz
29 0.0113 0.28702 0.0642 81.83 268.4024 0.182 210 kHz
30 0.01 0.254 0.0509 103.2 338.496 0.142 270 kHz
31 0.0089 0.22606 0.0404 130.1 426.728 0.113 340 kHz
32 0.008 0.2032 0.032 164.1 538.248 0.091 430 kHz
33 0.0071 0.18034 0.0254 206.9 678.632 0.072 540 kHz
34 0.0063 0.16002 0.0201 260.9 855.752 0.056 690 kHz
35 0.0056 0.14224 0.016 329 1079.12 0.044 870 kHz
36 0.005 0.127 0.0127 414.8 1360 0.035 1100 kHz
37 0.0045 0.1143 0.01 523.1 1715 0.0289 1350 kHz
38 0.004 0.1016 0.00797 659.6 2163 0.0228 1750 kHz
39 0.0035 0.0889 0.00632 831.8 2728 0.0175 2250 kHz
40 0.0031 0.07874 0.00501 1049 3440 0.0137 2900 kHz

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Definitions & Interconnections Product Terms

Accessories: Mechanical devices, such as cable added to connector shells and other such
hardware that are attach-able to connectors to make up the total connector configuration;
while providing wire support and/or wire sealing.

Bayonet Coupling: A non-threaded, ramp type of coupling.

Cable Assembly: A cable with plugs or connectors on each end.

Configuration: Arrangement of contacts in a multiple-con-tact connector.

Contacts: Mechanical component to which electrical engagement is accomplished.

Contact Size: (Also known as Wire Gauge) - the largest wire that can be used with a
specific contact.

Contact Spacing: The distance between the center-lines of adjacent contact areas.

Coupling Nut: Outer threaded or grooved ring which holds mated pair together.

Crimp Contact: A contact to which wire is joined by mechanical squeeze.

EMI or RFI Back shell: A type of accessory to terminate wire shielding.

Environmentally Sealed: Connector provided with gaskets, seals, potting or other devices
to keep out moisture, dirt, air or dust that might reduce its performance.

Extraction/Removal Tool: A handheld tool used for removing a contact from a connector.

Fiber Optic Termini: Comparable to electrical pin and socket contacts, except they
transmit data optically through fibers instead of electrically through wires.

Gland - Resilient ring in rear accessory, provides seal on jacketed cable

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Grounding Fingers: A metal strap around plug shell for positive shell-to-shell
conductivity/shielding.

Grommet: Resilient part at back of insert (attached or sepa-rate); gives wire moisture seal.

Hermetic: A connector with fused glass insert for air tightness.

Insert: The dielectric or insulating inner core, holds contacts.

Insert Arrangement: The number, spacing and arrange-ment of contacts in a connector.

Insertion Tool: A small, handheld tool used to insert con-tacts into a connector.

Interfacial Seal: A resilient part on the face of pin inserts which provides moisture seal.

Jam Nut: Hex nut that holds receptacle to a panel.

Mating Pair: Two connectors that couple together. Shell size insert arrangement and
rotation must be compatible.

Mating/Unmating Forces: Torque required to couple/ uncouple a mating pair of

connectors or contacts.

“O” Ring: Doughnut-shaped ring of rubber used as a seal around the mating insulator
interface of cylindrical connectors.

Pin Contact: Male half of a mated pair of contacts Plating - The metal finish applied to
contacts and or shell components (protective) to resist corrosion and wear.

Plug: The cable/coupling half of a mating pair

Potting Boot: A type of accessory which forms a mold for potting compound

Rear Termination: An accessory which threads to back of shell

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Receptacle: The panel/receiving half of a mating pair

Sealing Plug: Plastic type slug, placed in unused grommet holes to seal

Service Rating (Also known as Current Rating): The maximum voltage or current that a
connector is designed to carry continuously.

Shell: Houses insert and contacts

Socket Contact: Female half of a mated pair of contacts

Solder Contact: A contact to which wire is joined by soldering. Has a cup, hollow cylinder,
eyelet or hook to accept a wire for conventional soldered termination.

Strain Relief (Also known as Cable Clamp): A type of accessory which clamps wires for
support.

Alternate Rotations: In cylindrical connectors: Rotation of either an insert or designated

key/keyway locations (Alternate Keying) in a connector shell to a different angle than
normal position. Allows for variations of mating two halves of cylindrical connectors.

Anodize: Formation of a protective, insulating oxide layer on metal bay electrolytic action.

Arc Resistance: The characteristic of insulating materials to resist carbonization (also

known as tracking) of the material surface between electrodes resulting from voltage break-
down.

Attenuation: (this term is used in Filters) The ratio of the input to output power levels in a
network (transmission line) when it is excited by a matched source and terminated in a
matched load.

Back-mounted: When a connector is mounted from the inside of a panel or box with its
mounting flanges inside the equipment.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Circuit: A complete path or electron flow from a negative ter-minal of voltage source
through a conductor and back to the positive terminal.

Closed Entry Socket Contacts: A female contact designed to prevent the entry of a pin or
probing device having a cross-sectional dimension greater than the mating pin.

Coaxial Cable: A high-bandwidth cable consisting of two concentric cylindrical conductors

with a common axis that is used for high speed data communication and video signals.

Compliant Contact: A press-fit type contact used to attach to a printed circuit board. Has
an eyelet end.

Conductivity: The ability of a material to conduct electric current, expressed in terms of the
current per unit of applied voltage. It is reciprocal of resistivity.

Contact Durability: Endurance measured by the number of insertion and withdrawal

cycles that a connector withstands remaining within its specified performance level.

Contact Engaging and Separating Force: Force needed to either engage or separate
pins and sockets when they are out of connector inserts. Values are generally established
for maximum and minimum forces.

Contact Resistance: Maximum permitted electrical resis-tance of pin and socket contacts
when assembled in a con-nector under typical service use.

Contact Retention: The minimum axial load in either direc-tion that a contact must
withstand while remaining firmly fixed in its normal position within the connector insert or
housing.

Continuity: A continuous path for the flow of current in an electrical circuit.

Corrosion: The destruction of the surface of a metal by chemical reaction.

Coupling Torque: Force required to rotate a coupling ring or jackscrew when engaging a
mating pair of connectors. .

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Dielectric: Any insulating medium that intervenes between two conductors.

Dielectric Withstanding Voltage: Maximum potential gradi-ent that a dielectric material

can withstand without failure.

Discontinuity: A broken connection or the loss of a specific connection characteristic.

Edge Connector: One piece receptacle, containing female contacts designed to receive
the edge of a printed circuit board and interconnect on which the male contacts are etched
or printed. The connector may contain either a single or double row of female contacts.

Edgeboard Connector: connector that mates with printed wiring leads running to edge of
a PC board.

Feed-through: A conductor that connects patterns on oppo-site sides of a PC board. Also

called interfacial connection.

Fiber Optics: A data transmission medium consisting of glass fibers. Light-emitting diodes
send light through the fiber to a detractor, which then converts the light back into electri-cal
signals.

First Article: A sample part or assembly manufactured prior to the start of production for
the purpose of assuring that the manufacturer is capable of manufacturing a product that
will meet the requirements.

Front-mounted: A connector is front-mounted when it is attached to the outside or mating

side of a panel. (Can only be installed or removed from the outside of the equipment.

Front Release Contacts: Connector contacts are released from the front side of the
connector and then removed from the back wire side of the connector. The removal tool
engages the front portion of the contact and pushes it out the back where it is removed by
hand.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Harsh or Hostile Environment Connector: A connector designed and engineered for
operation in hostile environment conditions, such as extreme high temperatures of 677°C
(1,250°F), extreme low temperatures of absolute zero and severe water tight conditions.

Header: A feed through device that introduces a conductive path through an insulating
plate.

Hermaphroditic Connector: Interconnecting device in which both mating parts are

identical at their mating surfaces. (Also called Sexless Connector)

Hermaphroditic Contact: A contact in which both mating elements are precisely alike at
their mating face.

Input/Output Connector: A mating pair of connectors used to carry signals into and out of
a panel-mounted subsystem. An example is connector pair that interconnects the individual
back panels in a large array of panels.

Insert Retention: Axial load in either direction that an insert must withstand without being
dislocated from its normal posi-tion in the connector shell.

Insertion Force: The effort, usually measured in ounces, required to engage mating
components.

Interchangeable: Characteristic of connectors in which one manufacturer’s connector can

be replaced by the connector of another manufacturer and provide the same function in the
same panel space as the connector it is replacing.

Intermateable: Characteristic of connectors in which a connector half manufactured by one

connector will mate directly with a connector half manufactured by a different company

Keying: Mechanical arrangement of guide pins and sockets, keying plugs, contacts,
bosses, slots, keyways, inserts or grooves in a connector housing, shell or insert that allows
connectors of the same size and type to be lined up without the danger of making a wrong
connection.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Lanyard: A device attached to certain connectors that permit uncoupling and separation of
connector halves by a pull on a wire or cable.

Life Cycle: A test that indicates the time span before failure; the test occurs in a controlled,
usually accelerated, environ-ment.

Mass Termination: Method of termination in which terminals that pierce flat cable
insulation without stripping to cold flow mate with conductors and form a metal-to-metal
joint.

Motherboard: A printed board used for interconnecting arrays of plug-in electronic

modules.

Operating Temperature: Maximum internal temperature resistant capabilities of a

connector in continuous service.

Outgassing: De-aeration or other gaseous emission from a printed board assembly

(printed board, component of connector) when exposed to a reduced pressure or heat, or
both.

Panel-mount: Fixing a connector half to a board, panel or frame. Usually, the female
portion of the connector is mounted, and the male half is the removable portion.

Plated Through-Hole: A hole-formed deposition of metal on the sides of the hole and on
both sides of the base to provide electrical connection from the conductive pattern on one
side to that on the opposite side of the PC board.

Poke-Home Contact: Term applied to a male or female con-tact to which a wire has been
permanently affixed prior to the assembly of the contact into the insert.

Positioner: Device attached to the crimping tool to position conductor barrels between the
indenters.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Potting: Sealing of a component (for example the cable end of a multiple contact
connector) with a plastic compound or material to exclude moisture, prevent short circuits
and pro-vide strain relief.

Pre-tinned: Solder applied to an electrical component prior to soldering.

Pre-tinned Solder Cup: Solder cups with inner surfaces that have been pre-coated with a
small amount of tin lead solder or RoHs approved solder.

Press-fit Contact: Either a solid pin or a pin having a com-pliant member that makes an
interference connection with a through-hole on a PC board. The pressure developed
between interconnecting surfaces is sufficient to provide gas-tight electrical reliability
without the use of solder.

Qualified Products List (QPL): A list of commercial prod-ucts that have been pretested
and found to meet the requirements of a specification, especially government
specifications.

Quick-disconnect Coupling: A design feature, apparent in the quick-disconnect

connector; it permits relatively rapid joining and separation.

RADSOK® Contact*: A unique socket contact design with a stamped and formed twisted
inner grid. Socket cylinder within the female contact has several equally space longitudinal
beams twisted into a hyperbolic shape. As male pin is inserted, axial members in the
female half deflect, imparting high current flow across the connections.

Ramp: The sloped channel that accepts the detent pin in a bayonet connector.

Rear Release Contacts: Connector contacts are released and removed from the rear (wire
side) of the connector. The removal tool engages the contact from the rear and pulls the
contact out of the connector contact retainer.

Rear Seal: Design feature that provides an environmental seal at the rear of plug or
receptacle.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Removable Contact: A contact that can be mechanically joined to or removed from an
insert. Usually, special tools are required to lock the contact in place or remove it for repair
or replacement.

RoHS (Restrictions of Hazardous Substances): The RoHS Directive bans the placing on
the EU market of new electrical and electronic equipment containing more than agreed
levels of lead, cadmium, mercury, hexavalent chro-mium, polybrominated biphenyl (PBB)
and polybrominated diphenyl ether (PBDE) flame retardants.

Scoop Proof: Design feature whereby exposed contacts of a connector cannot be touched
or damaged by any portion of the mating connector.

Serrations: Small grooves or indentations within a terminal wire barrel that increase the
tensile strength and electrical conductivity of the crimped termination.

Soldering: Process of joining metallic surfaces with solder, without the melting of the base
metals. Soldering is an eco-nomical, versatile and fast termination method. A soldered
connection has metallic continuity and excellent long term reliability.

Splice Connector: A joint connecting conductors with good mechanical strength and good
conductivity; a terminal that permanently joins two or more wires.

Surface Mounting: The electrical connection of components to the surface of a conductive

pattern without utilizing component holes.

Thermal Shock: The effect of heat or cold applied to a material at such a rate that non-
uniform thermal expansion or contraction occurs. In connectors, the effect can cause
inserts and other insulation materials to pull away from metal parts.

Thermocouple Contact: A contact of special material used in connectors employed in

thermocouple applications. Materials often used are iron, constantan, copper, chromel and
alumel.

Tuning Fork Contact: U-shaped female contact that resembles a tuning fork. It can be
stamped or formed.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Umbilical Connector: A connector used to connect cables to a rocket or missile prior to
launching, and which is removed from the missile at the time of launching.

Wire-Wrapped Connection (Also known as Solder less Wrap): A solder less connection
made by wrapping bare wire around a square or rectangular terminal with a power or hand
tool.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 CHAPTER I

1.0 Construction of Connectors Mated Pair

1.1 Nomenclature: Cylindrical Connectors

Basic Components

1. Shell (Houses Inserts & Contacts)

2. Insert (Dielectric Contact Insulator) Pin or Socket
3. Contact (Wire End Termination) (Electrical Engagement)
4. Coupling Nut
5. Accessories (Wire Seals, Cable Seals, Wire Support, etc.)

PLUG RECEPTACLE Rear Accessory

SHELL

COUPLING NUT

INSERT ENVIRONMENTAL

SEALING GROMMET

CONTACTS

REAR ACCESSORIES

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
Shell Styles

WALL MOUNT RECEPTACLE LINE MOUNT RECEPTACLE OR BOX MOUNT RECEPTACLE

DESIGNATION: 00 CABLE CONNECTING RECEPTACLE* DESIGNATION: 02
DESIGNATION: 01

SOLDER MOUNT RECEPTACLE JAM NUT RECEPTACLE STRAIGHT PLUG

(HERMETIC) DESIGNATION: 07 DESIGNATION: 06
DESIGNATION:IH

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Inserts
1.2 Nomenclature: Cylindrical Connectors
Insert Insert &
and Contacts (Pin or Socket) Grommet Assy.

Shell Styles (Cont’d.)

Coupling
Threaded, Bayonet

Shell Sizes (Typical MIL-DTL-5015)

8S, 10S, 10SL, 12S, 12,
14S, 14, 16S, 16, 18
20, 22, 24, 28, 32, 36, 40, 44, 48
“S” designates short shell and short contacts • Solder
• Crimp
Shell size denotes mating thread diameter in 16ths of an inch. • Metal Clip Retention
For example, a size 8 shell denotes 8/16 of an inch with a • Dielectric Retention
.5000-28 UNEF thread.
May include a soft front interfacial seal (Bonded) if dielectric
is hard, and a rear sealing grommet separate or attached.
Style Designation
PLUG SHELL STYLES Contact and Contact Termination Style
06 Straight
08 Angle
09 Flange Mount Receptacle
Pin – Crimp*
05 Straight, Less Rear Accessory

RECEPTACLE SHELL STYLES

00 Wall Mount
01 Cable Connecting or Socket – Crimp*
Line Mount Receptacle
02 Box Mount
03 Wall Mount, Less Rear Accessory
04 Line Mount, Less Rear Accessory Pin – Solder
07 Jam Nut
IH Solder Mount Hermetic

Socket – Solder

*Crimp is removable

Sizes by Wire Gauge, Examples:

4/0 American
Wire Gauge 4/0

22D American Wire Gauge 22-2

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Contact Versatility - Several types of Contacts can
Nomenclature: Cylindrical Connector and be designed into a Connector Shell

Contacts, cont. MIL-DTL-38999 connectors allow users to mix a variety of

differ-ent power, signal, shielded, fiber optic and high speed
contact styles within a common insert.
Contacts The insert arrangement below is an arrangement for Tri-Start MIL-
Pin Socket DTL-38999 Series III connectors. It shows the variety of con-tacts
that can be designed into a shell size 25. Typically, custom-ers
specify the contacts sizes and power they require and chose an
Crimp or Solder existing arrangement that fits their needs. For special new
configurations, engineering will design the arrangement of con-tacts
Usually separate from insert, Usually installed in insert, fre- to fit within material and performance criteria.
shipped loose or in bulk, tools quently bonded in place.
needed to crimp, install and remove.
A
P B
Y R
N d Z C
X e S
n
M p D
W m q g T
c s t a
Contact Options: L
K
k
j
r
i
h E

Solderless Wrap (Wire Wrap), b

F
V U
PC Tail, Coaxial, Thermocouple, J G
Triaxial, Fiber Optic, Filter, Twinax, Quadrax H

Insert Arrangement 25-41

Contact Sizes
Number of Contacts 22 3 11 2 3
Contact Size 22D 22M 22 20 16
Contact Size 22D 20 16 12 Coax 8 Twinax

American Wire Gauge 22-28 24-28 22-26 20-24 16-20

Wire Size (AWG)
Contact Legend 8 10 12 16 20 22D

Contact Size 12 8 4 0

American Wire Gauge 12-14 8-10 4-6 0-2 Contacts and Fiber Optic Termini for
Wire Size (AWG) Cylindrical Connectors
Broad contact product range for Cylindrical Connectors
Accessories
includes:
• Adapters • Standard 500 cycle and 1500 cycle, M39029 type power
– straight, 90°, 75° and signal contacts
– conduit, environmental, open wire bundle, EMI, etc.
• Crimp contacts for front or rear release connector applications
• Compression ring – wire seal • Solder type, fixed contacts with cup or eyelet termination
• Clamp – cable sealing • Thermocouple contacts
• Stain relief – clamp, kellems grip • Spring-loaded and push-pull types
• Potting boot • Filter contacts: Pi type tubular or Pi type planar for MF,
– Straight, angle, universal HF, VHF, and UHF frequencies
• High frequency shielded coax, triax and twinax contacts
• High speed differential twinax and quadrax contacts
• For cylindrical connector attachment to Printed Circuit Boards:
• PC tail contacts for signal and power applications, in
coax, twinax, triax, differential twinax and quadrax designs
• Compliant pin (Press fit) contacts
• Fiber optic Termini: MIL-T-29504 type or MT ferrules or
ARINC 801 termini

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1.3 TYPES OF CONNECTORS (Russian & MIL Specifications)

The various types of Russian connectors used in aircraft and equipments are as
enumerated below:-

Sl.
Russian English Fleet on which used
No.
nomenclature translation
MIG-29, AN-32, MI-8, MI-17 and
1. ШP SHR
LAUNCHERS (5P73 )

2. ШPг SHRG AN-32 & MI-8

3. CШP SSHR LAUNCHER( 5P73)

4. 2PTT 2RTT MIG-23, MIG-27,AN-32

5. PBH RVN AN-32

6. P R AN-32 & P-18 RADAR

7. 2PM 2RM MIG-23,MIG-27, MIG-29, and AN-32

8. 2PMT 2RMT MIG-23, MIG-27, MIG-29 and AN-32

9 2PMД 2RMD MIG-23, MIG-27, MIG-29 and AN-32

10. 2PMДT 2RMDT MIG-23, MIG-27, MIG-29 and AN-32

11. 2PMгПД 2RMGPD MIG-23, MIG-27, MIG-29 and AN-32

12. PП-15 RP-15 MIG-29

13. PП -10 RP-I0 ST -68 R(U)

14. PC RS MIG-29
15. PПKM RPKM MIG-29

16. CHц SNTs MIG-29

17. 2PT 2RT MIG-23 & MIG-29

18. ШPA SHRA AN-32

19. MC MS AN-32

20. PPH RRN MIG-29

21. ПпЛM SHPLM MIG-29

22. ШPAП SHRAP MI-8 MI-17,AN-32

23. 3y EU MIG-23 & AN-32

24. XФ KHF MIG-29 & AN-32

25. OCШP OSSHR AN-32

26. ЬMP BMR MIG-23

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27.
ЬШЛ BSHL MIG-23

2PHД 2RND MIG-23& MIG-29

28
29. Г30-364-12Ty GEO .364-126TU KIPS (Msl testing vehicle)

30. ЬT3 BT3 SNR-125(Msl guidance radar)

31. CP-50,CP-75 SR-50,SR-75 MIG-29,AN-32, PMGR & ST-68 R(U)

32. Г3 GE AN-32

33. PT06A PT06A AN-32

1.3.1 CYLINDRICAL SHAPED NORMAL SIZE CONNECTORS-FOR ELECTRICAL

RADIOAND ELECTRONIC EQUIPMENT (SHR, SHRG, SSHR, 2RTT)
These are cylindrical shaped low frequency, low voltage connectors. It covers the following
range of connectors:-
(a) SHR (b) SHRG (c) SSHR
(d) 2RTT (e) R

1.3.1.1 General characteristics:

The SHR, SHRG, SSHR, 2RTT, R are designed for connection and disconnection of
electrical circuits in electrical and radio electronic equipment operating at DC or AC power
having frequency up to 3 MHz.
The connectors include two parts i.e., a receptacle and a plug. The receptacle and the
plug parts are drawn together by means of the thread provided on the receptacle insert and
plug-coupling nut. This group of connector is classified on the basis of common unitized
shells available in 10 different sizes.
Contact resistance of any joint of mated parts of these connectors is as follows:

Connector type Contact diameter Contact resistance,

(mm) Ohms
1.5 0.0025
SHR,SHRG 2.5 0.001
SSHR,2RTT,R 3.5 0.00075
5.5 0.0003
9.0 0.00015

Insulation resistance between any contact pairs and also between contactor body and
any contact pair under normal condition (+20° c and RH 98%) is 1000 Mega ohms.

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 Internal diameter of connector receptacle shells (mm).

SHR, SHRG : 12(For unsealed connectors only)

20, 28,32,36,40,48,55,60
SSHR : 20, 28,32,36,40,48,55,60
R : 16(For unsealed connector only)
20, 28,32,36,40,48,55,60
2RTT : 12,16,20,28,32,36,40,48,55,60

Number of contacts.
SHR,SHRG : 1-10,12,14-16,20,23,26,30,31,35,45,47
SSHR : 2-4, 7, 10,15,20,26,30,45,50
R : 1, 4,7,9,14,17,28,38,47
2RTT : 1-10,12,14-16,20,23,26,30,31,35,45,47

1.3.1.2 Environmental characteristics

Environmental operating conditions of these connectors are as follows:-

Effects of Values of affecting factor

environment SHR SHRG SSHR R 2RTT
Max. Acceleration,
g at vibration within
frequency 5-2000 30 30 30 30 10
Hz.
Ambient -60 to -60 to -60 to -60 to -60 to
temperature, 0C +60 +60 +85 +85 +100
Max. relative 98 98 98 98 98
humidity, %

SHR

The decoding of part number SHR-12-P (PK,SK,U)-1-E-G-9 is as follows:-

SHR Type of connector

12 Shell internal diameter
P Receptacle without hood or Plug with straight end
PK Receptacle with straight hood
SK Receptacle with angle type hood
U Plug with angle type hood

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1 No. of contacts
E Type of hood end nut (E for screened cable and N for not
screened cable)
G Types of contacts of socket (in receptacle), SH- pins
9 Arbitrary number of contact set

For example a connector with part number SHR-32-P-12-E-SH-1 means

as follows:-
SHR Type of connector
32 External diameter of housing
P Plug with straight end
12 Number of contacts
E Type of hood end nut for shielded cable
SH Pins
1 Scheme number of locating pins (jacks)

SHRG
The decoding of part number SHRG-16-P-1-E-SH-8 is as follows:-
SHRG Type of connector
16 Shell internal diameter (mm)
P Without hood (PK-straight hood)
1 Number of contacts
E Type of hood end nut for screened cable (N-for not screened
cable)
SH Type of contact pins in receptacle
8 Scheme number of locating pins

For example a connector of AN-32 aircraft having part number SHRG-32-

PK-12-N-SH-1 means as follows:-

SHRG Type
32 Shell internal diameter (mm)
PK Straight type of hood
12 Number of contacts
N Type of hood for not screened cable
SH Pins i.e. type of contacts in receptacles
1 Scheme number of locating pins
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2RTT
These are fixed mount connector used for high temperature tropical. The
Decoding of part number 2RTT-48-B-P-E-20-SH-1 is as follows:-
2RTT Type
48 Internal diameter of receptacle shell
B Type of receptacle shell (K-plug shell)
p Straight type hood (U-angle type)
E Type of hood end nut for screened cable (N-for not screened)
20 No. of contacts
SH Type of contacts in plug (SH-pins), In receptacle (G-socket)
1 Scheme number of locating pins

For example, a connector of MiG-23 aircraft having part no 2RTT-60 means as follows:-
2RTT Type
60 Internal diameter of receptacle shell (mm)
B Type of receptacle shell
47 No. of contacts
SH Type of contacts in SH-pins
37 Scheme number of locating pins

SSHR
Decoding of SSHR type of connector is of similar nature as that SHRG
With internal diameter of receptacle shell (mm) varies from 20, 28, to 60
and number of contacts 2,4,7,15,20,26,30,45,50.

1.3.2 CYLINDRICAL SHAPED SMALL SIZED CONNECTORS FOR ELECTRICAL AND

RADIO ELECTRONIC EQUIPMENT (2RM, 2RMD)
These are cylindrical shape, low frequency, low voltage, small size connectors. The 2
RM & 2 RMD series connectors find their application in electrical and radio electronic
equipment for high quality electrical connection. The 2 RM & 2 RMD connectors differ in the
contact layout and are not interchangeable. The connector shells are unitized and have
similar mounting and connection dimensions.

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 The RM series covers the following types:-
(a) 2RM (b) 2RMG (c) 2RMGP
(d) RMG (e) 2RMT

The RM series covers the following types:-

(a) 2RMD (b) 2RMGD
(c) 2RMGPD (d) 2RMDT

1.3.2.1 General characteristics

Unsealed connectors type 2RM, 2RMD, 2RMG, 2RMDT consist of receptacle and
plugs. The receptacles are furnished with hoods for clamping of cables or for bunched
conductor.

The sealed connectors of type 2RMG, 2RMGD, 2RMGP, 2RMGPD, RMG and RMGK
are connector receptacles intended to provide a vacuum tight seal between outside and
inside of an apparatus. 2RMG, 2RMGD, 2RMGP & 2RMGPD connectors have steel shells
and glass insulator (insert with contact pins). Sealing is by fusing the glass to the metal. RMG
& RMGK connectors have an insulator with pins moulded in it and are additionally sealed with
epoxy compound .For better sealing of the shell the insulators of RMG connectors have a
rubber sealing ring .The 2RM connectors are provided with contacts having nominal
diameters of 1,1.5,2.0 and 3.0 . The 2RMDseries connectors employ contacts 1.5, 2.0 and
3.0 mm in diameter. Whose terminal lugs are 2 and 3 mm in diameter and is intended for
connection of heavy conductors. T connector contacts are plated with gold, silver, palladium,
and nickel (for sealed parts connector only).

Bore diameter of connector receptacle shells (mm)

(a) Series 2RM : 14,18,22,24,27,30,33,36,39,42
(b) Series 2RMD types
(i) 2RMD, 2RMDT : 18, 24, 27,30,33,36,39,42,45
(ii) 2RMGD : 18, 24, 27, 30, 33,36,39,42
(iii) RMGPD : 18, 24, 27, 30, 33,36,39,42

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Number of contacts:-
(a) Series 2RM : 4,7,10,19,20,22,24,30,32,45,50
(b) Series 2RMD types
(i) 2RMD, 2RMDT : 4,7,8,10,19,20,22,24,32,45,50
(ii) 2RMGD : 4, 7, 8,10,19,20,22,24,32
(iii) RMGPD : 4, 7, 8,10,19,20,22,24,32

Specifications

The specifications of 2RM and 2RMD series of connectors are as follows:-

(a) Operating temperature -60 to +1000 C for connectors with silver-plated contacts
and -600 C for gold plated contacts.
(b) Type of terminating wire into contact: “Soldering”.

2RM

The decoding of part number 2RM-14-B-P-E-20-G-4-V-1-L is as follows:

2RM Type of connector

14 Shell diameter from the contact terminal end
B Receptacle
P Straight barrel (U-angle type)
E View of end barrel nut for screened cable (N-for
Unscreened)
20 No. of contacts
G Type of contacts (G-for sockets, SH-for pins)
4 Scheme no of locating pins
V Contacts plating silver (A-gold, E-nickel)
1 Temperature rating +1000 C (2-upto +2000 C)
L Left Receptacle

2RMD

These are small sized, high temperature through type connectors used for long
circuits. The decoding of part number 2RMD-45-K-P-N-50-G-5- V-I is as follows:

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2 Number of development
R Connector
M Small sized
D For long circuits
45 External diameter of casing (mm)
K Cable
p Straight (U-angular)
N Unshielded (E – shielded)
50 No of contacts
G Jacks (SH – pins)
5 Scheme number of locating pins
V Silver plating of contacts
1 100°c

2RMGPD

These are hermetically sealed through type connectors used for long circuits.
Connector with part number 2RMGPD-42-K-P-N-50-SH-2-A-1 means as follows:

2RM Type of connector

G Hermetically sealed
P Through type
D For long circuits
42 External diameter of connector
K Cable (B-unitized)
p Straight branch pipe (U-angular)
N Unshielded (E-shielded)
50 Number of contacts
SH Pins (G-Jacks)
2 Scheme number of locating pins
A Coating of contacts gold plating (B-silver plated, E-nickel
plated, P-palladium plated)
1 Temperature rating up to 1000 C (2-up to 2000 C)

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1.3.3 RECTANGULAR SHAPED COMBINED CONNECTORS (RP-15) :

1.3.3.1 General characteristics

The RP-15, rectangular shape combined connectors are used for electrical connection
of MiG-29 aircraft in low frequency and high frequency circuits of electrical and radio
electronic equipment. The connectors are assigned designation including numbers and
letters that stand for certain classification features. Composition of designation and their
decoding is explained in the succeeding paragraphs.

Specification

(a) Contact resistance of high frequency contacts and joint between shells
is 0.01 Ohms.
(b) Insulation resistance under normal conditions is 5000 Mega ohms
And at raised temperature are 50 Mega ohms.
(c) Ambient temperature is from -60°C to + 125°C.
(d) Maximum permissible value of 'g’ at vibration of frequency of 5000 Hz
Is 50g.

Coding of part number

The decoding of part number RP-15-9-SH-A-I-K. Means as follows: -
RP : Connector type
15 : Serial no assigned to given construction
9 : Number of low frequency contacts including
10,14,15,23,32,36,50
SH : Type of contact pins (G --sockets)
A : Gold plating (V- silver)
1 : Arbitrary number of high frequency contacts
K : Use of hood for clamping of cables or use of a locking device
to lock The connector in a mated state.

For example a connector of MiG -29 aircraft having part number RP-15-23-Sh-V means as
follows:-
RP : Connector type
15 : Serial number assigned to type of construction
23 : No of low frequency contacts
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 Sh : Type of contact pins
V : Plating metal (Silver)

1.3.4 CYLINDRICAL SHAPED SUBMINIATURE CONNECTORS FOR ELECTRICAL AND

RADIO ELECTRONIC EQUIPMENT (TYPE -RS) :

These are cylindrical shaped low frequency, low voltage subminiature connectors. The
RS series connectors are intended for electrical connections in electrical and radio
equipment. The connectors are subdivided into internal, inter-unit, unsealed and sealed.
Internal connectors insist of an equipment plug and a cable socket, which are coupled by
means of a union nut. The inter-unit connectors include two-equipment parts i.e., a plug and
a receptacle for plug -in connections. The connector is automatically plugged in and
withdrawn when the units or assemblies are interconnected.

1.3.4.1 General characteristics

The equipment plug is available in two versions "sealed" and "unsealed". The
Unsealed connectors are RS, RSA, RST, RSAT and sealed tropicalised connectors are RSG,
RSGA, RSGT and RSGT. The super sealed connectors are RSGS and RSGSP.

Classed with the inter unit connectors are tropicalised unsealed connectors of type
RSB, RSBA, RSBT and RSBAT. The sealed tropicalised connectors are RSGB, RSGBA,
RSGBT and RSGBAT. Unsealed connectors have unsealed plugs and receptacles. Sealed
connectors have sealed plugs mating with unsealed receptacles. There are 18 types of RS
series connectors based on construction and application. Except RSGS and RSGSP each
type of connector has six different sizes, whereas RSGS has four different sizes and RSGSP
has three different sizes.

Specifications

Operating voltage ranges from 1 mV to 200 V. Minimum current is from 1μA at a

contact circuit electro-motive force of not less than 1mV for connectors having gold plated
contacts; 1 μA at 0.1 V for connectors furnished with silver plated contacts; and to10 μA at
0.2 V for the connectors of types RSGS and RSGSP.

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. The ambient temperature varies from -60°C to +85° C for RS series connector except -60°C
to + 100°C for RSGS and RSGSP.

Decoding of part number

A connector with part number RS-19-A for internal connections means as follows:

RS : Unsealed type of connector (RSG, RSGS & RSGSP - sealed)

19 : Number of contacts (RSG : 7, 10,19,32,50.
RSGS : 10,19,30,50 RSGSP: 19, 32 and 50)
A : Gold- plated contact plating
(Silver plated contacts have no designation)
For example Part no RS-19-B-A for inter unit connections means as follows:-
RS : Unsealed type of Connector
19 : Number of contacts
B : Inter unit connector
A : Gold plated contact plating

1.3.5 CYLINDRICAL SHAPED, LOW-VOLTAGE CONNECTORS (TYPE RVN2, RVN3)

The cylindrical connectors, type RVN2 and RVN3 are used for low voltage DC or AC
up to frequency of 3 MHz. The connector consists of 2 parts i.e., a plug and a receptacle.
Connectors have a catch, which locks it in the inserted position and provides quick easy
insertions and withdrawals.

1.3.5.1 General characteristics

All connector contacts are 1 mm in diameter. Type RVN2 & RVN3 connectors are
similar in constructions. They differ only in the contact plating. The RVN2 connectors have
silver-plated contacts, while the contact of RVN3 connector is gold plated. Each type has two
no of contacts 5 & 7. The plugs and receptacles are assigned designation letter depending on
classification.

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 Specifications

(a) Current drawn for connector with 5 contact is 13 Amps and with 7
Contact is 15 Amps.
(b) Minimum current per contact is 1μA and maximum is 5 A.
(c) Operating voltage (amplitude value) min. is 1 mV & max 300V.
(d) Contact overheating temperature (max) is 15° C.
(e) Contact resistance (max) is 0.005 ohms & insulation resistance is
1000 Mega Ohm
(f) Ambient temp is -60°C to +85°C.

Decoding of part number

A Connector with part number RVN2-5-1-SH-7 means as follows: -

RVN2 : Type of silver-plated contacts (RVN3 - for gold plated- Contacts)
5 : Number of contacts
1 : Scheme number of locating the pins
SH : Contact pins (G -for contact of socket)
7 : Type of Shell (Cable with straight barrel for unscreened
Cable)

1.3.6 CYLINDRICAL SHAPED LOW FREQUENCY SMALL SIZE, ELECTRIC COUPLERS

(SNTs) :

The SNTs subminiature connectors are low frequency, low voltage, cannon size,
bayonet type, multi position electric couplers of all climate design, with gold pIated contacts
connected to the wires by crimping. They are used for mechanical coupling uncoupling the
AC and DC electric circuits having the frequency of up to 3 MHz, voltage up to 700V.

1.3.6.1 General characteristics

The SNTs 23 couplers have gold plated separable (detachable) contacts, which are
connected to the wires by squeezing. They are intended for the internal wiring of the boxes.
The delivery set of coupler SNT 23 placed in one PVC bag includes the following: -
(a) The plug or receptacle without holders and shells.
(b) The holder or shell (straight or angular) and the set of contacts.
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 (c) The set of sealing plugs provided, for the holes in the rubber insulators are for
installing the contacts not coupled with the wires.
(d) The mounting tools for installing and removing the contacts coupled with the
wires.

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Specifications

(a) Type of terminating wire into contacts is by crimping. Diameters of contacts and
wire cross sections is 1 mm (0.2-0.75mm2), 1.5 mm to (0.75-1.5) mm2, and 2mm to (2.5-4)
mm2.
(b) Grades of wire terminated into connectors are "wires with solid insulation,
grades BPDO, BIF, BFS and MS.
(c) The operating temperature of these type of connectors is -60°C to + 105°C

Decoding of part number

For example a connector with part number SNTs 23-4-14-V(R)-1-a (6, b, g) – v means
as follows: -

SNTs 23 : Type of connector

4 : Number of contacts
14 : Conventional dimensions of casing
V(R) : Connector parts (V-plug, R-receptacle)
1 : Indicates design features
I : instrument section without housing
2 : instrument section with straight housing
4 : instrument section with angular housing
6 : cable section with straight housing
8 : cable section with angular housing
11 : cable section without housing
12 : instrument section with holder for heat shrinkage she
13 : cable section with holder for heat shrinkage shoe
a (x ,b ,g ) : Angular position of insulator in connector casing (with
The insulator placed in normal position the letter index is
Absent.
V : All weather construction.

A connector with part number SNT 23-4- V-2-a- V means as follow: -

S : Connector
N : Low frequency
Ts : Cylindrical
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 4 : Number of contacts (3, 7, 10, 19, 24, 28, 32, 41, 43, 55, 61)
V : Plug
2 : Instrument section with straight housing
a : Angular position of insulator in connector casing
V : All weather

1.3.7 HEAT RESISTANT THREADED CONNECTORS, (TYPE: 2RT) :

These are heat resistant threaded type straight or angular connectors and are used in
electrical connections of Mig -23 and Mig -29 aircraft electrical circuits.

Specifications

(a) The operating temperature of these type of connector is -60°C to + 1000 C

(b) Type of terminating wire into contact is soldering.
(c) Diameters of contacts and wire cross-section corresponding to
These types of connectors are 1.5 mm & 0.35-1.5 mm² and
2.5 mm & 0.35-2.5 mm².
(d) Grades of wire terminated into connectors can be of any grades.

Decoding part number

A connector with part number 2RT-20-PK-9-N-Sh-8-A means as follows:-

2RT : Threaded connectors
T : Heat resistant
20 : External diameter of casing (mm) 12, 16, 20, 28, 32, 36, 40,
48, 55, 60
P : Instrument section without branch pipe
PK : With straight branch pipe (UK- With angular one)
9 : Number of contacts
N : Unshielded (E - Shielded)
Sh : Pins (G - socket)
8 : Scheme of locating contacts
A : Material of insulator

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1.3.8 RECTANGULAR SHAPED SMALL SIZED LOW & HIGH FREQUENCY COMBINED
CONNECTORS (RPKM)

These type of connectors are used in low and high frequency electrical and radio
electronic equipment of MiG -29 aircraft electrical circuits.

Specifications

(a) The operating temperature of these type of connector is.-60°C to + 100°C.

(b) The type of terminating wire into contacts is by soldering.
(c)) Diameter of contact and wire cross-section of these connectors is For Low and
high frequency contacts.

Decoding of part numbers

A connector with part number RPKMl-57-SH-1 means as follows: -

R : Connector
P : Rectangular
K : Combined
M : Small sized
1 : Single connector with silver-plated contact
2 - Single connector .with gold plated contact
3 - Paired connector with silver- plated contact
4 - Paired connector with gold- plated contact
57 : Number Of contacts
SH : Plug (G - receptacle)

1.3.9 RECTANGULAR SHAPE LOW-FREQUENCY LOW-VOLTAGE CONNECTORS

TYPE (RP-1O) :

1.3.9.1 General characteristics

The RP-10 connectors are intended for electrical connection in electrical and radio
electronic equipment. The connectors are available for mounting on equipment. The plugs
have hoods with terminals for attachment of the cable. To lock the plugs and receptacles in
the mated position the connector receptacles are furnished with special lock nuts at the plugs
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have locking pins. The connectors are assigned designations composed letters and numbers
which correspond to a certain classification features.

Specifications

(a) The current per contact min is 0.001 Amp and max is 15 Amp.
(b) Insulation resistance under normal conditions is 1000 Mega ohm.
(c) Ambient temperature is -60°C to +125°C.

Decoding of part number

. A connector with part number RP-10-7-L-P-T means as follows: -

RP-IO : Connector type
7 : Number of contacts (can be -11, 15, 22, 30, and 42)
L : With catcher: ('3' with lock nut)
P : Shell type (straight), U - angle type, B - side type
T : Tropicalise

Current per connector is given in the table below: -

Number of Total current per Permitted number of contacts
contacts connector (Amp) carrying 15 Amps of current
7 73.5 3
11 115.5 4
15 135 5
22 165 6
30 180 7
42 220.5 8

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1.3.10 CONNECTOR TYPE: RRN
These types of connectors are having threaded connections and their contact material
is either aluminum, or chromium or copper.

Specifications

(a) The operating temperature of these type of connector is between -600C to and
2000 C.
(b) Type of wire fitting into contact is by crimping.
(c) Grades of wires tolerable to be fitted into connector is thermo-electrode, type
PTFDE-
NM-MT.
d) Specific requirement is to use these connectors ill the thermocouple circuits.

Decoding of part number

A connector with part numberR-RN-25M-20-18-SH-2-V-4-X means as follows:-

R : Connector
RN : Threaded connection
25M : Development number
20 : Number of contacts
18 : Diagram number
SH : Pins (G - sockets)
2 : Sleeve type
V : All climates
4 : Arbitrary number of contact set
X : Contact material, chrome (A - Alum, K - Copper)

1.3.11 Interchangeable Connectors

Russian connectors are interchangeable as recommended in the table below:

Main Variant Tolerable interchange

2RM… 2RMT…
2RMT. 2RM…
2RMD… 2RMDT
2RMDT. 2RMD
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 2RM...AL 2RM…B1
2RMA2
2RM…V1 2RMA1
2RMD…AL 2RMDV1
2RMDA2
SHR 2RT…
2RMD…V1 2RMD…A1
2RM…A2 No interchange possible
SNTs23 No interchange possible

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1.4 MIL STD Connectors

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 208
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 209
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 SERVICE RATING**
Suggested Operating Voltage
Service (Sea Level) Test Voltage Test Voltage Test Voltage Test Voltage
Rating (Sea Level) 50,000 Ft. 70,000 Ft. 110,000 Ft.
AC (RMS) DC

M 400 500 1300 VRMS 550 VRMS 350 VRMS 200 VRMS
N 300 450 1000 VRMS 400 VRMS 260 VRMS 200 VRMS
I 600 850 1800 VRMS 600 VRMS 400 VRMS 200 VRMS
II 900 1250 2300 VRMS 800 VRMS 500 VRMS 200 VRMS

FINISH DATA
Aluminum Shell Components Non-Hermetic

Suffix
Finish Indicated Finish Standard for Standard for LJT Types
JT Types Listed Below Listed Below
Military Proprietary
Cadmium Plated Nickel Base MS (A) – JT/JTG/JTL/JTP LJT/LJTP
Anodic Coating (Alumilite) MS (C) (005) JTS/JTPS/JTLS LJTPS/LJTS
Chromate Treated (Iridite 14-2) (011) JTN/JTPN/JTLN LJTN/LJTPN
Olive Drab Cadmium Plate Nickel Base MS (B) (014)
Electroless Nickel MS (F) (023)

Hermetic Connectors

Suffix
Material Finish Indicated Finish Standard for Indicated Finish Standard for
JT Types Listed Below LJT Types Listed Below
Military Proprietary
Carbon Steel Shell JT ( ) H/JT ( ) Y
LJT ( ) Y/LJT ( ) H
Tin Plated Shell and Contacts JTL ( ) H/JTL ( ) Y
Carbon Steel Shell (452) special termination
MS (D)
Tin Plated Shell and Gold Plated Contacts (468) solder cup
Stainless Steel Shell JTS ( ) Y
MS (E) (162) LJTS ( ) Y
Gold Plated Contacts JTLS ( ) Y

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 MIL-SPEC Cross Reference Data and General Information

Contact Contact Sizes in

Coupling Other
MIL-Spec Description Termination & Series
Method Notes
Removal (Wire Gauge)

MIL-DTL-5015 Power type connectors, large con- Solder or crimp, 16 thru 0 Threaded 310X solder,

tacts front or rear removal 340X crimp F. R.,

Older series had solder contacts; 345X crimp R. R.,

newer has crimp GT Series Reverse

Bayonet Coupling

MIL-DTL-26482 Miniature connector. Contacts are Solder or crimp, 20, 16, 12 Bayonet thread, 311X solder,

medium size, both power and signal front or rear removal version Non-Mili- 312X crimp F. R.

* Series 1 crimp currents, solder or crimp tary 347X crimp R. R.

MIL-DTL-38999 Subminiature - medium and high Crimp, rear removal 22D, 20, 16, 12, Bayonet Intermates with

contact density, crimp contacts. and coax sizes 8, Series I of MIL-DTL-

Series I - scoop-proof 12, 16 27599

Series II - lightweight, low profile Crimp, rear removal 22D, 20, 16, 12, Bayonet Intermates with

and coax sizes Series II of MIL-DTL-

12, 16 27599

Series III - High performance, but Crimp, rear removal 22D, 20, 16, 12, Threaded Available in Class K

suited for general duty and coax sizes 8, Firewall and Lan-

12, 16 yard Release Break-

away

Series IV Breech-Lok, Crimp, rear release 22D, 20, 16, 12, Breech-Lok Does not meet total

expensive design, can be difficult to and coax sizes 8, performance require-

mate 12, 16 ments of Series III

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Qualified Products List by Connector Specification

QPL No./Date Qualified Product List Manufacturer

QPL-5015-43 Series I, Solder Type
Amphenol, ITT Cannon
(6/07) MS3100 Series
Series II, Front Release Crimp
ElecSys. Inc., J-Tech, TRW Cinch
MS3400 Series
Series III, Rear Release Crimp
Amphenol/Matrix, ITT Cannon, J Tech, Aero Electric, ElecSys. Inc.
MS3450 Series
Glenair, Sunbank, Electro-Adapter, Electro-Sonic Components,
Accessories only*
Raychem, Triangle Electronics
QPL-26482-100 Series I, Solder
Amphenol, Array, ITT Cannon, Souriau
(4/08) MS3110 Series
Hermetics only Amphenol, ITT Cannon, Glasseal, Deutsch, Sealtron, CIA, Herm Seal
Series I, Crimp
Amphenol, Burndy, Cannon, Veam, Souriau, Array
MS3120 Series
Series II, Hermetic
Deutsch, Glasseal, Herm Seal, Array, Sealtron
(MS3400) Series
Series II, Crimp
Amphenol, Aero Electric, ITT Cannon, Deutsch, Corsair, Souriau
MS3470 Series
Accessories only* Sunbank, Glenair, Array
QPL-83723-66 Series I Superseded by and transferred to MIL-DTL-26482 Series II
(11/06) Series II ITT Cannon
Amphenol, TRW Cinch, Deutsch, Pyle-National, Aero Electric,
Series III
ITT Cannon
Hermetics only Connector Industries, Herm Seal, Sealtron
Accessories only* Glenair, Joslyn Sunbank
QPL-38999 Amphenol/Pyle, Amphenol Limited, Amphenol Socapex, Souriau, ITT Cannon,
Series I
(4/08) Deutsch, Aero Electric, JEC, Hi Rel
Series II Amphenol, ITT Cannon, Deutsch, Souriau, Aero Electric, Hi Rel
Hermetics only Herm Seal, Sealtron, American Micro Products, Glenair
Amphenol, Amphenol Socapex, Amphenol/Pyle, TEC, Deutsch, Souriau,
Series III ITT Cannon, Amphenol Limited, Deutsch LTD, Hi Rel, Aero Electric,
American Micro Products, Glenair
Series IV G & H Technology, Deutsch, Glenair
ESC, Joslyn
Accessories only* Sunbank
QPL-22992-38 MS17340 Series (QWLD) Amphenol, ITT Cannon
(1/08) Class “L” (MS90555) Series) Amphenol, General Connector
QPL-27599-14
38999 Solder Amphenol
(12/07)
QPL-26500-70 Miniature Cylindrical Amphenol/Pyle, TRW Cinch, Aero Electric, Herm Seal, RMS
(12/05) Accessories only* Glenair, ESC
QPL-81511-9
Amphenol, Deutsch
(12/98)
QPL-AS39029-2 MIL-C-26482 Series 1, Contacts Amphenol/Pyle, Deutsch, ITT Cannon, Tri-Star, Cinch, Veam
(7/07) MIL-C-26482 Series 2, Contacts Amphenol/Pyle, Deutsch, ITT Cannon, Tri-Star, NCMI
MIL-DTL-38999, Contacts Amphenol/Pyle, ITT Cannon, Tri-Star, AMP, General Connector
MIL-C-22992, Class “L”,
Amphenol, General Connector
Contacts
May include all of the above, plus:
Other Contacts Continental Connector, AMP, J Tech. Precision Technology,
Winchester and others

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 Chapter-II

Performance Requirements for Connectors (MIL-DTL-83527B)

2.1 Performance Requirements: Connectors, inserts, shells, backshells, contacts,

and accessories shall be designed to meet the performance requirements specified
herein when tested in accordance with the specified methods.

Examination of product: Contacts, inserts, shells, backshells, connectors, and

accessories shall be examined as specified and shall meet the requirements
indicated herein.

Nonmagnetic materials: The relative permeability of the wired assembled, and fully
mated connector assembly shall be less than 2.0 when measured.

Mating and separating forces: When tested the maximum force needed to mate or
separate counterpart plugs and receptacles shall not exceed 1446 newtons (325 lbf)
for size 2, 1780 newtons (400 lbf) for size 3, and 2113 newtons (475 lbf) for size 4.

Maintenance aging, contact insertion and removal forces: After testing as

specified, connectors shall be capable of meeting the performance requirements of
this specification. After testing, the individual contact insertion and removal forces
shall not exceed the values listed in table III below. Failure to complete these
operations shall be cause for rejection.

Contact retention: When tested, the axial displacement of the contacts shall not
exceed 0.3 mm. No dislodging or damage to contacts or inserts shall result.

Thermal shock (temperature cycling): When tested, connectors shall meet the
performance requirements of the remaining test sequence. There shall be no
damage detrimental to the operation of the connectors.

Insert retention: When tested, connectors shall retain their inserts in their proper
location in the shell. The maximum axial displacement allowed shall be 0.25 mm.
Evidence of cracking, breaking, separation from the shell, or loosening shall be
cause for rejection of parts.

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Salt spray (corrosion): After testing, unmated connectors and individual contact
samples shall show no exposure of basic metal (due to corrosion), which will
adversely affect performance.

Contact resistance: The contact resistance shall be in accordance with the

applicable specification sheet of MIL-C-39029 and shall be tested.

Insulation resistance at ambient temperature: When tested, the insulation

resistance between any pair of contacts and between any contact and the shell shall
be greater than 1,000 megohms.

Insulation resistance at elevated temperature: When tested, the insulation

resistance between any pair of contacts and between any contact and the shell shall
be greater than 1,000 megohms.

Withstanding voltage. When tested, connectors shall show no evidence of

flashover or breakdown.

Durability. When tested, the connector shall show no defects detrimental to the
operation of the connectors and shall meet the subsequent test requirements.

Vibration. When tested, a current discontinuity of 1 microsecond or more, evidence

of cracking, breaking, or loosening of parts shall be cause for rejection. Damaged
fixtures or tie downs may be repaired or replaced to complete the test.

Shock: When tested, a current discontinuity of 1 microsecond more shall be cause

for rejection. Evidence of cracking, breaking, or loosening of parts shall be cause for
rejection. Damaged fixtures or tie downs may be repaired or replaced to complete
the test.

Static load: When tested, during and after the application of the specified forces,
connectors shall show no evidence of damage detrimental to their normal operation
nor shall there be any interruption of electrical continuity. The connectors shall
withstand a compressive load of 10888 newtons (2450 lbf), a vertical load of 5115
newtons (1150 lbf), and a side load of 2265 newtons (509 lbf).

Shell-to-shell and shell-to-bulkhead resistance: When tested, plugs and

receptacles shall be electrically conductive. The maximum potential voltage between
the shells of the connector pair shall not exceed 2.5 millivolts.

Humidity: When tested, the insulation resistance shall be 100 megaohms or

greater. Connectors shall show no deterioration or damage that will adversely affect
performance.

EMI shielding: When tested, the EMI shielding capabilities of mated shells shall not
be less than that specified in table IV below at the specified frequencies.

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Ozone exposure: When tested, the connectors shall show no evidence of cracking
of dielectric material, deterioration of resilient seals, or other damage due to ozone
exposure that will adversely affect performance.

Fluid immersion: After immersion in the fluids, connectors shall unmate and mate
properly and resilient materials shall show evidence of material reversion. Shells,
plating, and dielectric materials shall show no evidence of deterioration, distortion, or
material reversion.

Altitude immersion: When tested, the mated connector shall meet the
requirements of dielectric withstanding voltage.

Contact walkout: When tested as specified, contacts shall not become dislodged
from their normal position.

Installing and removal tool abuse. When tested, there shall be no evidence of
damage to the contacts, the connector inserts, or the contact retaining mechanism.

Contact stability (sizes 22, 20, 16, and 12 crimp contacts): When tested in
accordance with the total displacement of the contact tip end shall not exceed 0.25
mm for the size 22 socket contact, 1.0 mm for the size 20 pin contact, and 1.5 mm
for the size 16 and size 12 pin contact.

Temperature life with contact loading: When subjected to the test, the contacts
shall maintain their previously measured location with not more that 0.3 mm change.

Size 8 concentric twinax cavity grounding: When tested, the maximum potential
drop between the size 8 concentric twinax outer body and the connector mounting
flange shall not exceed 10.0 mV.

Interchangeability: The connector plugs, receptacles, inserts, contacts, and

accessories supplied to the specification shall meet the requirements of the
applicable specification sheet and shall be completely interchangeable with the
components having the same part or identifying numbers (PIN) but supplied by
another qualified connector manufacturer.

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2.2 Marking:

Connectors and accessories: Connectors and accessories shall be marked in

accordance with method 1 of MIL-STD-1285, and shall include the military part or
identifying number the manufacturer’s name or code symbol, Manufacturer’s
Commercial and Government Entity (CAGE), and data code. The characters shall
be a minimum of 1.5 millimeters in height. If used, metal stamping shall be
accomplished before plating. Connector shell marking and insert marking shall
remain legible after completion of the tests.

Insert identification: The military Part or Identifying Number (PIN), manufacturer’s

identification, Manufacturer’s Commercial and Government Entity (CAGE), and date
code shall appear on the side of the insert in a contrasting color.

Contact designation: Contact locations shall be designated with identifiable

characters as indicated on the applicable specification sheet. All positions shall be
identified on the front and rear faces of the insert except where space limitations
make this impracticable. Location of contact identifying characters shall be in close
proximity to the holes but need not be placed exactly where indicated on the
standard. Inserts containing size 22 contacts shall be marked with a 5 by 5 grid
pattern rear face in accordance with DOD-STD-1842.

Workmanship: The connector shall be fabricated in a manner such that the criteria
for appearance, fit, and adherence to specified tolerances are observed. Particular
attention shall be given to neatness and thoroughness of marking parts. Plating,
welding, soldering, riveting, staking, bonding, and parts shall be free of burrs and
sharp edges.

2.3 VERIFICATION

Classification of inspections: The inspections requirements specified herein are

classified as follows:
a. First article inspection.
b. Conformance inspection.

First article inspection: First article inspection shall consist of materials inspection;
all the tests in table V below as applicable to the contact or purchase order, and
examinations of this specification.

2.4 Conformance inspection

Inspection of product for delivery. Inspection of product for delivery shall consist
of group A inspection.

Inspection lot: An inspection lot shall consist of all connectors covered by one
specification sheet, produced under essentially the same condition, and offered for
inspection at one time.

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Group A inspection: Each connector shall be subjected to the individual test
shown in table VI below. For group A inspection, the documentation and standard
test conditions of EIA 364, do not apply.

Visual examination: Each connector shall be visually examined for completeness,

workmanship, and identification requirements. Attention shall be given to those
assemblies that require a seal to determine the condition of that seal. Seals missing,
twisted, buckled, kinked, or damaged in a manner affecting functional performance
shall be cause for rejection.

Testing and inspections

Test equipment and inspection facilities: Test and measuring equipment and
inspection facilities of sufficient accuracy, quality, and quantity to maintained by the
contractor. The establishment and maintenance of a calibration system to control
the accuracy of the measuring and test equipment shall be in accordance with
ANSI-Z540.1. Testing and inspections shall be performed at a laboratory acceptable
to the Government.

Hydrolytic stability: Certification of hydrolytic stability is required, specify material

tested and water absorption report as specified in ASTM D570.

Fungus resistance certification: Certification that materials used are fungus inert
is required.

Inspection conditions: Unless otherwise specified, all inspections shall be

performed in accordance with the test conditions specified in the “General
requirements” of EIA-364 and MIL-STD-202.

Sample size: A minimum of 14 plugs and receptacles shall be subjected to the

examinations and tests in table V above, in the sequence shown.

Test groups I, and II, III and IV: Each test group shall consist of a minimum of
three completely assembled plugs and receptacles representing the class (1.2.1),
shell size, and each of the insert arrangements (DOD-STD-1842) for which first
article inspection is desired.
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Test group V: Sample shall consist of a modified size 2 shell, plug and receptacle.

Test group VI: Test group VI shall consist of a completely assembled mated pair of
a plug and receptacle connector using a shell size 2A.

Preparation of samples: Unless otherwise specified, for signal-power contacts

(size 22, 20, 16, and 12), half the number of each contact size in each connector
shall be wired with the largest allowable AWG size using MIL-W-22759/43 wires.
The remaining number of contacts shall be wired with the smallest allowable AWG
size using MIL-W-22759/33 or MIL-W-22759/43 wires. Samples of group VI, altitude
immersion, may exclude AWG 24 and 26 wires. For shielded contacts and
concentric twinax contacts, use applicable cables in accordance with MIL-C-17.
Termination tools shall be in accordance with appendix A in the Spec MIL-DTL-
83527B.

Qualification of contacts: If a manufacturer submits first article samples of MIL-

DTL-83527 connectors, contacts supplied with the samples shall be either qualified
to MIL-C-39029 or contacts that have been deemed acceptable by the procuring
activity.

Failures: Any failure shall be cause for refusal to grant compliance to first article
inspection.

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 Appendix – E
List of Type Approvals

1. Type Approval No. : 17

2. Approval Title : Terminal Block 2-way

Part No. 5CZ-430 (IND)

3. Validity of Approval : 27 Oct 1971

4. Developer of the Item : M/s Allied Electronics Corporation, Bombay

5. Governing Specification : BS G 197 (Jan 1961)

6. Characteristics of Connector

a) Classification : -

b) Dielectric Withstanding : 2000 V (AC rms), 50 c/s for 5 secs

voltage

c) Insulation Resistance : > 100 M Ω between studs

> 200 M Ω between stud and earth

d) Temperature Range : -40°C to +70°C

7. End Use of the Item : Aircraft Use

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 1. Type Approval No. : 272

2. Approval Title : a) Quick Release Terminals

b) Copper Ring Tongue Terminals
c) Insulated Inline Connector

3. Validity of Approval : 04 Jun 1991

4. Developer of the Item : M/s. Dowell’s Elektro Werke, Bombay

5. Governing Specification : As per Drawings Dowell’s

Cat No. 8013 for QRT
Cat No. 7444, 7445, 7595, 7596, 7600, 8052 for CTT
Cat No. EH 462 for IIC

6. Characteristics of Connector

a) Classification : -

b) Dielectric Withstanding : 1500 V (AC rms), 50 c/s

voltage

c) Conductor : Electrolytic Grade Copper duly Silver Plated for QRT

Electrolytic Grade Copper duly electro-tinned for CTT & IIC

d) Insulation : Insulated with Metal Reinforcement

e) Temperature Range : + 121°C

7. End Use of the Item : For termination of electric cables and wires in any aircrafts,
avionic Instruments and ground equipments electric
circuits.

8. Other Details : • Quick Release Lock hook Terminal

• Copper Ring Tongue Terminal (1.5 sq.mm i.e 16-22
AWG)
• Insulated inline connector (1.5 sq.mm)

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1. Type Approval No. : 284

2. Approval Title : Terminal Blocks 3 ways, 5 ways, 10 ways and 20 ways

3. Validity of Approval : 15 Jul 1988

4. Developer of the Item : M/s. KM Bakelite Industries Ltd.,

Bombay - 400068
5. Governing Specification : a) HAL (BC) Drawing Nos.
b) M 10173, Issue A
c) M 10360, Issue A
d) M 10174, Issue ‘A’
e) M 10175, Issue ‘A’
All dated 20 Oct 1975
6. Characteristics of Connector

a) Classification : -
b) Dielectric Withstanding : 2 kV (AC rms), 50 c/s for one minute
voltage
c) Insulation Resistance : > 1000 M Ω at room temperature
d) Temperature Range : -65°C to +105°C

7. End Use of the Item : Electrical Systems of Aircraft

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1. Type Approval No. : 329

2. Approval Title : Connector type 2PM42

30-pin Connector
3. Validity of Approval : 21 Oct 1991

4. Developer of the Item : M/s. Allied Electronics Corporation,

Bombay - 400002
5. Governing Specification : a) JSS-50500
b) JSS-50803
6. Characteristics of Connector

a) Classification : -
b) Dielectric Withstanding : 2000 V AC, 50 c/s for one minute
voltage
c) Insulation Resistance : > 100 M Ω at room temperature
d) Conductor : Brass
e) Insulation : Glass filled Phenolic

f) Temperature Range : -55°C to +115°C

7. End Use of the Item : Used in Reusable Rocket Pod

8. Other Details : It is a 30 Pin connector

Suitable as a substitute for USSR Grade 2PM42 Connector

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1. Type Approval No. : 343

2. Approval Title : Plug connector WP-55

Type-30 Pin (Drg. No. RP-288)
3. Validity of Approval : 21 Apr 1984

4. Developer of the Item : M/s. HITECH (India) Pvt. Ltd.,

Hyderabad - 500762
5. Governing Specification : a) JSS 50812
b) No. TS/IND/91/03, Issue–I
6. Characteristics of Connector

a) Classification : -
b) Dielectric Withstanding : 2000 V (AC rms), 50c/s for one minute
voltage

c) Insulation resistance : > 100MΩ under normal condition

between neighboring
contacts or body & any
contact

d) Conductor / Pin : Brass

e) Insulation : Glass filled Phenolic
Bakelite (Cable Insulator)

f) Temperature Range : -55°C to +115°C

7. End Use of the Item : Used as a Plug Connector on aircraft

8. Other Details : Suitable as a substitute for USSR Grade Plug Connector

WP55 π 30 H Ш 2

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1. Type Approval No. : 725

2. Approval Title : In Line Data bus coupler Type CP 3001 and CP 3002

3. Validity of Approval : 30 Jun 2013

4. Developer of the Item : M/s. Compu Power Private Limited

Hyderabad – 500 482
5. Governing Specification : a) No. 3000 - TS
b) TS Doc. No. 3001-02 TS
c) SAE Doc. AS4117
d) MIL-STD-1553B Data Bus
6. Characteristics of Connector

a) Classification : MIL-1553B bus couplers

b) Dielectric Withstanding : 600 V (AC rms), 50c/s for one minute
voltage
c) Common Mode Rejection : > 45dB
d) Turns Ratio : 1.41 ± 3%
e) Insulation Resistance : >100 MΩ
f) Coupler bus voltage : Vout / Vin = 0.331 to 0.374
g) Open Circuit Impedance : 3000 Ω from 75KHz to 1MHz
h) Temperature Range : -55°C to +85°C

7. End Use of the Item : For use in Light Combat Aircraft

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1. Type Approval No. : 811

2. Approval Title : Connectorised Data Bus

Coupler
Type DBC-2001 &
DBC-2001TR
3. Validity of Approval : 31 Dec 2013

4. Developer of the Item : M/s. Compu Power Private

Limited
Hyderabad – 500 482
5. Governing Specification : a) No. A/C M(DL) a/ ID-E/
DLC/TSP/01 dated17 Aug
1995,
b) SAE Doc. AS4117
c) QTP 2001-07, Rev.’A’ and
d) MIL-STD-1553B Data Bus
6. Characteristics of Connector

a) Classification : MIL-1553B bus couplers

b) Weight : < 70gms
c) Dielectric Withstanding voltage : 600 V (AC rms), 50Hz for one minute
d) Common Mode Rejection : > 45dB
e) Turns Ratio : 1.41 ± 3%
f) Insulation Resistance : >100 MΩ Signal lead to Shield
>1000Ω Bus to Stub
g) Coupler bus voltage : Vout / Vin = 0.331 to 0.374
h) Open Circuit Impedance : 3000 Ω from 75 KHz to 1MHz
i) Temperature Range : -55°C to +71°C

7. End Use of the Item : For use in Jaguar Aircraft

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1. Type Approval No. : 1051

2. Approval Title : Connectorised Data Bus

Coupler Type
DBC-1002 & DBC-1004
3. Validity of Approval : 31 Dec 2018

4. Developer of the Item : M/s. Compu Power Private

Limited
Hyderabad – 500 482
5. Governing Specification : a) Doc. No. 1000-90, Rev ‘A’
dated 12 May 1998
b) SAE Ref. AS4117 and
c) MIL-STD-1553B
6. Characteristics of Connector

a) Classification : MIL-1553B bus couplers

b) Dielectric Withstanding : 600 V (AC rms), 50Hz
voltage
c) Common Mode Rejection : > 45dB
d) Turns Ratio : 1.41 ± 3%
e) Insulation Resistance : >1000Ω for both Signal lead to Shield & Bus to Stub
f) Coupler bus voltage : Vout / Vin = 0.331 to 0.374
g) Open Circuit Impedance : 3000 Ω from 75 KHz to 1MHz
h) Temperature Range : -55°C to +85°C

7. End Use of the Item : These units provide data bus interface by isolating the
main bus from the LRUs by way of transformer coupling for
MIL-STD-1553B application for both ground and airborne
use.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1078

2. Approval Title : Two Pin Connector (Plocket)

Part No. M20181

3. Validity of Approval : 31 Dec 2014

4. Developer of the Item : M/s. M.E.C Engineers,

Bangalore – 560 032

5. Governing Specification : Test Spec Nos.

a) A/DGM(DL)/309/240/00
b) A/DGM(DL)309/131/2000
dated 21 Feb 2000
6. Characteristics of Connector

a) Classification : -
b) Operating Voltage : 30 V DC
c) Contact rating : 5 Amps
d) Millivolt drop at rated current < 50mv at room temperature
e) Dielectric Withstanding Voltage : 1.5kV AC for 30 secs
f) Insulation Resistance : > 1000 M Ω at room temperature
g) Conductor/ Pin : Brass rod
h) Connector Body : Mould from IPCL polythene granules
i) Temperature Range : -40°C to +85°C

7. End Use of the Item : Used in Kiran Aircraft Pylons and Drop Tanks

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1. Type Approval No. : 1086

2. Approval Title : Igniter Connector Assembly –

Part No. N377-6600-02
3. Validity of Approval : 30 Jun 2016

4. Developer of the Item : M/s. M.E.C Engineers,

Bangalore – 560 032

5. Governing Specification : TS/IND/66/01 (Issue-2) dated 20

Jan 2004
6. Characteristics of Connector

a) Classification : -
b) Supply Voltage : 27 ± 10% V
c) Current Rating : 2.5 A
d) Dielectric Withstanding : 500V AC, 50c/s for one minute
Voltage
e) Insulation Resistance : > 20 M Ω
between contact & body
f) Conductor/contact : Steel 20

g) Pin : Spring Wire II-A

h) Temperature Range : -60°C to +60°C
7. End Use of the Item : It is meant for holding the electric supply cable that
provides electrical input for the explosion of the Pyro-
cartridge PP-3 mounted in Bonnet Head 20S2MIS of fire
extinguishing bottle of MiG-21 aircraft variants

8. Other Details : Assembly is similar to Original Russian assembly GZS.5S

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
1. Type Approval No. : 1790

2. Approval Title : Connectors- 3 Series,

1) A-2RM,
2) A-2RMD &
3) A-2RMDT
3. Validity of Approval : 30 Jun 2018

4. Developer of the Item : M/s. Amphenol

Interconnect India Private Limited', 67,
Keonics Electronic City,
Hosur Road,
Bengaluru - 560 100
5. Governing Specification : No. TS/IND/91/03, Issue-4, Dated: 18 Jul 1994 and
Amendment No. AML-5, Issue-4, Dated: 09 Feb 2010
6. Characteristics of Connector

a) Classification : -

b) Insulation Strength : 2000 Volts, 50c/s

c) Contact Resistance : < 0.0025Ω for contact dia 1.5mm
d) Insulation Resistance : > 100MΩ
between neighboring
contacts or between body &
any contacts
e) Conductor : -
f) Insulation : -
g) Temperature Range : -55°C to +115°C
(Note: Temperature +125 ±5"C for Silver Plated and
200±10"C for Gold Plated Connectors of family 2RMDT)

7. End Use of the Item : Used for operations at frequency up to 3MHz within the
temperature range from -55°C to +'115°C and fitted on looms
of MiG series and Su-30MKl aircraft.

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft
 Appendix– F
List of Connector Manufacturers

Sl No. Manufacturer & address Contact Details

1. M/s Dowell’s Electro Werke Phone: 695381, 695382
Off Aarey Road Telex: 011-3002
Goregaon East Gram: Dowell’s, Bombay - 62
BOMBAY – 400 063
2. M/s KM Bakelite Industries -
Anuj Plastic Industrial Estate
121-122 SV Road
Dhahisar
BOMBAY – 400 068
3. M/s Allied Electronics Corporation Phone: 36 52 94 / 35 75 70
94 Kansara Chawl Gram: BAKULBAUGH, BOMBAY
Kalbadevi Road TELEX: 011/3897 AECO IN
BOMBAY – 400 002

4. M/s Hitech (India) Private Limited -

A-11 Electronic Complex
ECIL Post, Kushaiguda
HYDERABAD – 500 762
5. M/s Compu Power Pvt Ltd., Phone: 91-40-23354583
8-2-350/2/B Road No.03 Tel/Fax: 91-40-23352538
Banjara Hills Fax:91-40-23394654
HYDERABAD – 500 034 E mail: [email protected],
[email protected]

6. M/s Compu Power Pvt Ltd., Phone: 91-40-3354583

F-16, Sri Sai Apartments 91-40-3399990
6-3-596/21/8&9 Erramazil Fax: 91-40-3394654
HYDERABAD – 500 482 E mail: [email protected]

7. M/s MEC Engineers Phone: 3332073

23, Brindavan Layout Fax: 26369050
Kaval Byrasandra E mail: [email protected]
BANGALORE – 560 032
8. M/s. Amphenol Tel: + 91 80 2852 0178
Interconnect India Private Limited', 67, Fax: + 01 80 2852 0418
Keonics Electronic City,
Hosur Road,
Bengaluru - 560 100

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Compendium of Indigenous Wires, Cables & Connectors for Military Aircraft