Interconnect Technologies You Need on Your Aircraft NOW - APRIL 2019 - Glenair
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GLENAIR • APRIL 2019 • VOLUME 23 • NUMBER 2
Interconnect Technologies
You Need on Your Aircraft NOW
GLENAIR
Electrical Wiring Interconnect System:
Zone-by-Zone Design Guide
A “Systems Approach” to Aircraft Interconnect Cabling Electrical Load Determination
Commercial aircraft manufacturers treat large, interdependent equipment sets as systems: avionics, galleys, cabin System designers must ensure that each aircraft electrical bus can safely support the load
lighting, HVAC, IFE, navigation, and so on. The systems are designed with performance based on the electrical capacity of the aircraft’s electrical generators and distribution
benchmarks tied to the environmental stress factors of the different zones of the system. All electrical devices must be safely controlled or managed by the aircraft’s
aircraft where they are used. The cables and harnesses that interconnect these electrical system, and whenever a device is added, a load analysis should be performed to
equipment sets, the Electrical Wiring Interconnect System (EWIS), is also now treated ensure that the new load on the bus can be powered adequately.
as a discrete system within the aircraft, subject to different requirements and
specifications depending on the zones where it is located. In the past, the EWIS Wire Selection: Size, Substrate, Plating, and Insulation
was treated more as an afterthought, with insufficient consideration given to Wires should be sized so that they have sufficient mechanical strength, do not exceed
best-practice design and zone-by-zone performance standards. The FAA, with allowable voltage drop levels, are protected by circuit protection devices, and meet circuit
the support of the principal aircraft manufacturers, has over the last several current-carrying requirements. Small gauge wires should use high-strength alloy conductors
decades taken steps to change how interconnect technology is specified and and additional support at terminations (grommets, shrink sleeves, etc.) to minimize fatigue.
managed. The key element of this effort was the move to treat wiring and Wires should be plated to defend against surface oxidation. Elevated temperature degradation of
associated interconnect components as a discrete system in its own right. The tin- and silver-plated copper conductors will occur if they are exposed to continuous high-temperature
Electrical Wiring Interconnection System is now defined as: any wire, wiring device, operation.
or combination, including termination devices, installed in any area of the airplane,
While there is no “perfect” insulation system for aerospace wire and cable, the EWIS designer must consider the best
used to transmit electrical energy between two or more intended termination points.
balance of properties (electrical, mechanical, chemical, and thermal) for each application.
EWIS Performance Determining Current-Carrying Capacity
Historically, wiring and interconnect components were installed in aircraft in a “fit and forget” manner—without
EWIS designers must verify that the maximum ambient temperature wire bundles will be subjected to, plus the
sufficient thought given to different aging and degradation impacts on a zone-by-zone basis. While the FAA has always
temperature rise due to wire current loads, does not exceed the maximum conductor temperature rating. In smaller
outlined the top-level variables in EWIS degradation including aging, physical properties, installation and environment,
harnesses, the allowable percentage of total current may be increased as the harness approaches the single wire
and maintenance, cleaning and repair, it is only recently that these environmental stress factors have been exactingly
configuration. Care should be taken to ensure that the continuous current value chosen for a particular
evaluated according to aircraft zones. Service history shows it is not just the manner by which EWIS is installed that
system circuit does not create hot spots within any circuit element which could lead to
directly affects degradation, but more importantly material choices, environmental sealing components, EMC shielding
premature failure.
technologies and so on that are geared for the unique stress factors found throughout the aircraft. Today’s EWIS
designers use DO-160 Environmental Conditions and Test Procedures for Airborne
Equipment to ensure every element of the Electrical Wiring Interconnect
System meets or exceeds requirements for vibration, Causes of EWIS Degradation
shock, ground survival temperature, pressure
Vibration: High-vibration areas tend to accelerate degradation Chemical contamination: Chemicals such as hydraulic fluid,
differential, operating temperature, and moisture
over time, resulting in “chattering” contacts and other fuel, waste system chemicals, cleaning agents, deicing fluids, and
in each specific zone of the aircraft. intermittent problems. It can also cause tie-wraps to damage even soft drinks can contribute to EWIS degradation. EWIS in the
insulation, and exacerbate insulation cracking. vicinity of these chemicals should be inspected for damage or
Designing, Installing Moisture: High-moisture zones accelerate corrosion of degradation. Hydraulic fluids, for example, are very damaging
and Repairing EWIS interconnect components. EWIS installed in clean, dry areas with to connector grommet and wire bundle clamps, and can lead to
Many factors identified by the FAA must be moderate temperatures hold up well. indirect damage such as arcing and chafing. EWIS components
considered when designing, installing or repairing Maintenance and repair: Improper maintenance techniques potentially exposed to hydraulic fluid should be given special
an Electrical Wire Interconnect System, as follows: can contribute to EWIS degradation—for example, leaving attention during inspections.
metal shavings or debris behind after a repair. Wire bundles and Heat: High heat can accelerate degradation, insulation dryness,
connectors should be protected during modification work, and and cracking. Even low levels of heat can degrade EWIS over long
all debris must be cleaned up after work is completed. Generally,
periods of time. This type of degradation can be seen on engines,
EWIS left undisturbed will have less degradation than reworked
in galleys, and behind lights.
EWIS. As EWIS become more brittle with age, this effect becomes
more pronounced. Repairs that conform to manufacturer’s Improper installation: Improper installation can accelerate
recommended maintenance practices are generally considered degradation. Improper routing, clamping, and terminating
permanent and should not require rework if properly maintained. during initial installation or during modifications can lead to
Indirect damage: Events such as pneumatic duct ruptures can EWIS damage. FAA policy states that installation and routing
cause damage that, while not initially evident, can later cause EWIS instructions should be completely defined in detail to allow
problems. When such an event has occurred, surrounding EWIS repeatability of installation, not leaving installation to the
should be carefully inspected to ensure no damage is evident. discretion of the installer.
2 QwikConnect • April 2019 QwikConnect • April 2019 3
GLENAIR
Wire Substitution for Repairs and Maintenance Wire Splicing
EWIS manufacturers are required to perform rigorous qualification testing Improperly crimped splices can cause increased resistance, leading to overheating. Splicing should be kept to a
of wires. The original aircraft manufacturer (OAM) may have special concerns minimum and avoided in high-vibration areas. Splicing of power wires, co-axial cables, multiplex bus, and large gauge
regarding shielding and insulation for certain wiring that performs critical wire should be avoided. Self-insulated splice connectors and environmentally-sealed AS7928 conformant splices are
functions, or wiring chosen based on a set of unique circumstances. It is preferred. Splices should be located to permit inspection, and splices in bundles should be staggered so as to minimize
important to review the aircraft maintenance manual or contact the OAM when any increase in the size of the bundle.
wire replacement is required.
Grounding and Bonding
EWIS Routing
One of the more important factors in the design and maintenance of aircraft electrical systems is proper bonding
In general, EWIS should be routed and positioned to avoid chafing against aircraft and grounding—the process of electrically connecting conductive objects to a conductive structure or return path to
structure or other components, to eliminate or minimize use as a handhold or support, to
complete a circuit. Inadequate bonding or grounding can lead to unreliable operation of systems, damage to sensitive
minimize exposure to damage by maintenance crews or shifting cargo, and to avoid exposure
electronics, shock hazard, or lightning strike damage. The design of the ground return circuit should be given as much
to corrosive fluids. Extra wire length should be supplied to allow for at least two re-terminations.
attention as the other leads of a circuit.
EWIS components must be protected in wheel wells and other areas where they may be exposed to damage from
Low impedance paths to aircraft structure are normally required for electronic equipment to provide radio
impact of rocks, ice, mud, etc.
frequency return circuits, and for most electrical equipment to facilitate EMI reduction. Component cases producing
Where practical, EWIS should be routed above fluid lines. Wires and cables routed within 6 inches of any flammable
electromagnetic energy should be grounded to the structure.
liquid, fuel, or oxygen line should be closely clamped and rigidly supported. The compression clamps should be spaced
so that if there is a wire break, the broken wire will not contact hydraulic lines, oxygen lines, pneumatic lines, or other All conducting objects on the exterior of the airframe must be bonded through mechanical joints, conductive hinges, or
equipment whose subsequent failure caused by arcing could cause further damage. bond straps capable of conducting static charges and lightning strikes.
For all types of wire breakouts—“Y,” “T,” and complex multi-branch—there should be sufficient slack in the breakout
wires to avoid strain. Care should be taken when plastic tie wraps are used so that the tie wrap head does not cause
EWIS Identification
chafing damage to the wire bundle at the breakout junction. The proper identification of EWIS components with their circuits and voltages is necessary to provide safe operation
The EWIS design should preclude wire bundles from contacting the aircraft structure, using stand-offs to maintain and ease of maintenance. Each wire and cable should be marked with a part number and CAGE code so that it can
clearance. Employing tape or protective tubing as an alternative to stand-offs should be avoided. be identified as to its performance capabilities, preventing the inadvertent use of lower performance and unsuitable
replacement wire. Unmarked cables are more likely to be reconnected improperly which could cause numerous
Clamping and cable ties problems.
Clamps and cable ties must be constructed of appropriate materials for their installation
environment. Clamps must be properly sized for their wire bundles, snug enough to
Best Practices for EWIS
prevent free movement and chafing, and not used where their failure could result The number and complexity of EWIS has resulted in an increased use of electrical connectors for flexibility and modular
in interference with crucial aircraft controls or movable equipment. Clamps must replacement of electronic equipment. The proper choice and application of connectors is a significant part of the aircraft
be installed with their attachment hardware positioned above them so they are EWIS system. Connectors should be selected and installed to provide maximum safety and reliability to the aircraft.
unlikely to rotate as the result of wire bundle weight or wire bundle chafing. Wire • The connector used for each application should be selected only after a
bundles need to be routed perpendicular to clamps. Appropriate slack needs to careful determination of the electrical and environmental requirements.
be maintained between clamps to protect the wires from stress while keeping Consider the size, weight, tooling, logistic, maintenance support,
the bundle free from contacting the structure. Also, sufficient slack should be left and compatibility with standardization programs.
between the last clamp and the termination or electrical equipment to prevent • For ease of assembly and maintenance, connectors using
strain at the terminal. crimped contacts are generally chosen for all applications
except those requiring a hermetic seal.
Wire Bend Radii • Proper insertion and extraction tools should be used to
The minimum radii of bends in wire groups or bundles must not be less than 10 times install or remove wires from connectors.
the outside diameter of the largest wire or cable, except that at the terminal strips where • Connectors susceptible to corrosion may be treated
wires break out at terminations or reverse direction in a bundle. The bend radius for delicate with a chemically inert waterproof jelly, or an
thermocouple wire is 20 times the diameter, and for RF cables (e.g. coaxial and triaxial) is no less environmentally-sealed connector may be used.
than 6 times the outside diameter of the cable.
• Moisture-proof connectors should be used in all zones
of the aircraft, including the cabin. Service history
Unused Wires and Excess Wire indicates that most connector failures occur due to some
Ensure unused wires are individually dead-ended, tied into a bundle, and secured to a permanent structure. Each form of moisture penetration. Even in the pressurized,
wire should have strands cut even with the insulation and a pre-insulated closed end connector or a 1-inch piece of environmentally-controlled zones of the cockpit and cabin,
insulating tubing placed over the wire with its end folded back and tied. moisture can occur due to condensation.
Coil and stow methods are often used to secure excess length of a wire bundle or to secure unconnected spare bundles. • Consideration should be given to the design of the pin
The wire bundle must be secured to prevent excessive movement or contact with other equipment that could damage arrangement to avoid situations where pin-to-pin shorts could
the EWIS. Coil and stow in medium and high vibration areas requires additional tie straps, sleeving, and support. result in multiple loss of functions and/or power supplies.
4 QwikConnect • April 2019 QwikConnect • April 2019 5
GLENAIR
DO-160, ENVIRONMENTAL CONDITIONS AND TEST
COMMERCIAL AIRCRAFT
PROCEDURES FOR AIRBORNE EQUIPMENT AND
ZONE 2: INSTRUMENT PANEL,
AIRCRAFT ZONES CONSOLE, AND EQUIPMENT RACK
Electrical Wiring
Effective EWIS design is best accomplished by aligning DO-160, Pressurized
Environmental Conditions and Test Procedures for Airborne Fluids - Condensation, Humidity
Equipment, with the empirical environmental performance levels Typical Temperature Range -65° to +95°C
targeted for each zone, section, and equipment set on the aircraft. Moderate Dynamic Vibration Range
Interconnect Systems
Flammability, Smoke, and Toxicity
Requirements
ZONE 1: FUSELAGE
Pressurized
Fluids - Condensation, Humidity
Aircraft Zones and Glenair Signature Typical Temperature Range -65° to +95°C
Moderate Dynamic Vibration Range
Series Interconnect Technologies Flammability, Smoke, and Toxicity Requirements
T his interconnect design and application guide is broken down into traditional
aircraft zones as defined in RTCA/ DO-160. Interconnect technology for individual
sections and equipment-sets within each zone is presented in enough detail to
enable EWIS designers to understand the broad range of options available and
make sound specifications within each area of responsibility. Leveraging the talents ZONE 8: CABIN INTERIOR VOLUME
of EWIS engineer Bob Johnson, Glenair has developed a number of Signature ZONE 7: EMPENNAGE AND
VERTICAL STABILIZER TIP Pressurized
interconnect technologies for commercial aircraft, which are presented in the Fluids - Condensation, Humidity
context of each zone. High Vibration
Typical Temperature Range -65° to +95°C
Extreme Temperature Range
Moderate Dynamic Vibration Range
-55° to +200°C
AIRCRAFT ZONES: Flammability, Smoke, and Toxicity
De-Icing Exposure
1. Fuselage Requirements
Wide Pressure Changes
2. Instrument Panel Console and Equipment Rack
3. Nacelle and Pylon
4. Engine and Gear Box
5. Wing and Wheel Well
6. Landing Gear
ZONE 6: LANDING GEAR ZONE 4: ENGINE AND GEAR BOX
7. Empennage and Vertical Stabilizer Tip
High Vibration Dynamic Vibration Environment
8. Cabin interior volume
Wide Temperature Range Extreme Temperature Range
-55° to +150°C -65° to +200°
To assist designers in the specification of appropriate interconnect components Fluid Exposure Firewall
for use in each zone, each spread in this document presents applicable “DO-160 Wide Pressure Changes Fuels and Fluids
Environmental Conditions and Test Procedures for Airborne Equipment,” and the
Glenair interconnect technologies that meet or exceed these requirements. As
ZONE 5: WING AND WHEEL WELL ZONE 3: NACELLE AND PYLON
application guidelines for key environmental stress factors including vibration,
High Vibration Dynamic Vibration Environment
shock, ground survival temperature, pressure differential, operating temperature,
Extreme Temperature Range Extreme Temperature Range
and moisture can change with each zone, only those applicable specification -55° to +200°C -65° to +200°
references are noted. Fluid Exposure Firewall
Wide Pressure Changes Fuels and Fluids
CATALOG VERSUS CUSTOM / TAILORED TECHNOLOGIES AIRCRAFT ZONES: MACRO ENVIRONMENTS
This design guide primarily presents proven-performance electrical interconnect technologies that can be sourced Significant variability exists between the various macro environments of a modern commercial aircraft (dynamic
directly from catalog offerings. This includes the Bob Johnson signature series technologies which are highlighted for stimulus, moisture, humidity, thermal extremes, and so on). Environmental stress factors place a demand on the electrical
each zone. Designers looking to resolve long-standing problems or improve performance in such areas as size, weight, interconnect components that must perform for the expected life of 20 years. Macro environments range from the cabin
and power frequently turn to custom / tailored solutions. In both events, selections must be aligned with Federal Aviation interior—where the challenge is mainly moisture / humidity—to extreme unpressurized zones such as wing and wheel
Administration 14 CFR 25.1701 which states that EWIS components must be of a kind and design appropriate to its wells where extreme dynamic stimuli combined with thermal extremes can rapidly degrade the performance and life
intended function and perform the function for which it was intended without degrading the airworthiness of the airplane. expectancy of interconnect technologies.
Responsibility for these determinations resides with the aircraft manufacturer.
QwikConnect • April 2019 QwikConnect • April 2019 7
Qualified Glenair Interconnect FIBER OPTICS • Suitable for use in Aircraft Zones 1, 2, 3, 4, 5, 6, 7, and 8
Technologies for Aircraft Electrical
Wiring Interconnect Systems
Organized by type with zone designators
SuperNine® MIL-DTL-38999 Series III type Series 806 Mil-Aero Qualified fiber optic termini
tight-tolerance fiber optics high-density fiber optics
ELECTRICAL CONTACTS / SEALING CONTACTS • Suitable for use in Aircraft Zones 1, 2, 3, 4, 5, 6, 7, and 8
POWER CONNECTORS AND PRESSURE BOUNDARY FEEDTHRUS • see below for zone designators
Standard and high- Extended-duty High-speed, RF, and Lightweight sealing plugs
density signal signal (up to 1500 cycles) El Ochito® contacts and dummy sealing contacts
PowerLoad™ power distribution connectors PowerLoad™ bulkhead feedthru Pressure boundary and firewall feedthrus
ULTRAMINIATURE CIRCULARS • Suitable for use in Aircraft Zones 1, 2, 3, 4, 5, 6, 7, and 8 Suitable for Zones 1, 2, 3, 4, and 7 Suitable for Zones 1, 2, 3, 4, and 7 Suitable for Zones 1 – 7
EMI/RFI BRAIDED SHIELDING AND PROTECTIVE COVERING • Suitable for use in Aircraft Zones 1 – 8
Series 806 Mil-Aero: small form-factor Series 806 Mil-Aero Series 806 Mil-Aero
equivalent for MIL-DTL-38999 glass-sealed hermetics CODE RED-sealed hermetics
MIL-AERO CIRCULARS • Suitable for use in Aircraft Zones 1, 2, 3, 4, 5, 6, 7, and 8 Band-Master ATS® advanced ArmorLite microfilament Lightweight, flexible MasterWrap side-entry
shield termination system EMI/RFI shielding ground straps and HSTs wraparound shielding
CONNECTOR BACKSHELLS AND ACCESSORIES • Suitable for use in Aircraft Zones 1 – 8
QPL MIL-DTL-38999 Series III SuperNine® MIL-DTL-38999 Series III + SuperNine® MIL-DTL-38999 Series III + ProSeal spring-action Environmental Swing-Arm FLEX Swing-Arm standard and
Suitable for Zones 1 and 2 only Better than QPL™ performance glass- and CODE RED-sealed hermetics protective covers protective covers composite backshells wide-mouth composite backshells
HIGH-SPEED DATALINK CONNECTORS • see below for zone designators
SPECIAL-PURPOSE EWIS TECHNOLOGIES • see below for zone designators
Advanced rectangular aviation Receptacle / bulkhead SpliceSaver time- and labor- Polymer- and metal-core conduit
SuperSeal™ MIL-DTL-38999 RJ45 SuperSeal™ MIL-DTL-38999 USB 2.0 GateLink Pro high-speed data uplink backshells (ARINC 600 shown) connector nut plates saving wire splice replacement wire protection systems
Suitable for Zones 1, 2, and 8 Suitable for Zones 1, 2, and 8 Suitable for Zone 2 Suitable for Zones 1, 2, 5, 6, 7, 8 Suitable for Zones 1 – 8 Suitable for Zones 1, 2, 7, and 8 Suitable for Zones 5, 6, and 8
8 QwikConnect • April 2019 QwikConnect • April 2019 9
ZONE 1 GLENAIR
Fuselage Mid-Wing
Glenair standard and signature
interconnect technologies
Crown Wiring
SATCOM / Ku Band Antennas,
IFE, Lighting, Cabin Audio
System, Oxygen System,
Redundant Electrical Systems
Production Break
ZONE 1
Fuselage Mid-Wing
Aft Pressure Bulkhead
Feedthru Connectors, Pressure
Seal Bulkhead Feedthrus
Forward barrel section plus Below Passenger Floor Wiring
Left and Right Main Longitudinal Wiring Runs,
Cargo Hold Wiring, Flight Control Wiring,
center section and aft-of-wing Generator and APU Power Feeders
barrel section (pressurized
passenger / crew cabin) Electrical Feedthrus
to Main Landing Gear
T he main passenger cabin, crew and galley areas are housed in the fuselage
mid-wing. This pressurized zone is characterized by moderate environmental
stress factors such as fluid condensation, humidity, temperatures in the -65° to
Glenair SpliceSaver™
Crimp wire termination
Electrical Feedthrus
and Pressure Seals
Wing and Engine Control
+95°C range, and moderate dynamic vibration. The electrical wiring interconnect solution saves time and Wiring / Sensors
system utilizes mostly conventional interconnect technology, with an emphasis on labor over manual DO150
general weight reduction, reliability, and speed-of-assembly. Production breaks splicing
are a significant challenge for the EWIS engineer, with cost control of interconnect Ideally suited for crown
interfaces a principal design requirement. The pressurized interface between the and floor wiring in Zone 1 Qualified Glenair Technologies for Zone 1: Fuselage Mid-Wing
mid-wing fuselage and the wings requires careful attention in the specification and Three versions: single-
use of pressure bulkhead feedthrus. • SuperNine® MIL-DTL-38999 Series III + • Advanced rectangular aviation backshells
piece, Spiralock®, and
• SuperSeal™ RJ45 and USB 2.0 • Series 806 Mil-Aero nut plates
bussed
Zone 1 Application Guidelines • MIL-DTL-38999 Series III Fiber Optics • Band-Master ATS® shield termination system
Environmental Stress Factors Applicable RTCA/DO-160 Requirements
Features Stinger™ crimp
• Series 806 Mil-Aero High-Performance Ultraminiature • ArmorLite™ lightweight microfilament EMI/RFI braid
contact technology with
Vibration DO-160 Category S and H (Table 8-1) • Series 806 Mil-Aero Fiber Optics • ArmorLite™ ground straps
integrated retention
Shock DO-160 Category A, Test Procedure 1
mechanism • AS39029 signal / high-speed contacts / El Ochito® • MasterWrap™ side-entry EMI/RFI shielding
Ground Survival Temperature -65° to 95°C; DO-160 Category A3 (Table 4-1) • DCSP Dummy Contact Sealing Plugs • SpliceSaver™ connectors
Pressure Differential Sea level to 10kft; DO-160 Category A3 (Table 4-1) Small form-factor and
• ProSeal™ spring-action protective covers • PowerLoad™ connectors and bulkhead feedthrus
-55° to 85°C; DO-160 category A3 (Table 4-1) with Temperature lightweight composite
Operating Temperature • Connector protective covers • Pressure seal bulkhead fittings
change rate per DO-160 Category A (10 C min per minute) Supports 1–3 wire
• Swing-Arm FLEX® composite backshells • Hermetic connectors
Moisture Exposure to humidity and condensation; DO-160 Category B terminations
10 11
ZONE 1 FEATURED TECHNOLOGY GLENAIR
LABOR-SAVING SpliceSaver™ Fast and reliable replacement
EWIS SPLICE
CONNECTOR
Crimp wire termination for wire splice and terminal block technologies
solution saves time and labor
over manual DO150 splicing
SPLICESAVER AVAILABLE CONFIGURATIONS—FEATURES AND SPECIFICATIONS
Triple ripple grommet
wire seal for sealing at
high altitude
Machined contact
utilizes mil-spec crimp
tooling
Contacts are removable
allowing corrections to
circuits during testing if
required
Single-Piece
SpliceSaver™
Specifications
Altitude immersion:
75,000 ft.
DWV rating at altitude:
>800 V
Dielectric Withstanding
Voltage Ratings:
22AWG = 5 amps/contact
20AWG = 7.5 amps/contact
Material and finish options
(for compatibility with available
EMI/RFI braid materials):
Cadmium-plated aluminum
Nickel-plated aluminum
Glenair SpliceSaver™ reduces manual wire Spiralock® Threaded
Nickel-plated brass
splice and terminal block operations SpliceSaver™
Weight Analysis
S pliceSaver™ is an innovative interconnect technology developed by Glenair for
use in aircraft wiring operations that rely on heat shrink splicing of aircraft signal,
sensor, and data transmission wiring. Single-piece SpliceSaver designs allow remote
Lightweight construction
Conductive (plated) or
Receptacle connector:
1.6 grams including contacts
non-conductive versions and seals
harness assembly facilities to pre-terminate each line with a crimp-and-poke contact.
During aircraft wire harness installation, cabling is routed to interconnection points Crimp contact technology:
Plug connector:
and the contact-equipped wires are quickly and easily installed into the lightweight front release/rear removal 1.66 grams including contacts
single-piece SpliceSaver connector. Two-piece Spiralock® SpliceSaver designs enable Three to nineteen
and seals
the harness facility to terminate wires to the small form-factor, lightweight “connector” circuits per unit Total connector mass:
for subsequent mating on the aircraft. A special bussed version is also available. All 5.66 grams (all contact locations
Environmentally sealed
installed)
SpliceSaver styles feature integrated banding platforms for the termination of EMI
Full-mate indicator
Accessories: Add the variable
shielding utilizing qualified banding technology—one-piece design features three
platforms for termination at both ends and in the center. Compared to legacy terminal Replaces labor-intensive
mass of two or three nano
blocks and wire splice technology, SpliceSaver offers faster, cleaner, and more reliable terminal blocks and bands trimmed to length of
routing and termination of discrete wiring. splices grooves in the split sleeve
Bussed
12 13
ZONE 2 GLENAIR
Instrument Panel Console / Equipment Rack
Glenair standard and signature
interconnect technologies
ZONE 2
Instrument Panel
Console and Flight Deck Avionics
Equipment Rack
Gatelink
Within the forward fuselage
T he instrument panel console and equipment rack zone of the aircraft, Zone 2, is
housed within the forward section of the fuselage. Zone 2 has the most diverse
range of interconnect technologies found in the aircraft, meeting a diverse set
GateLink Pro™
High-speed data uplink
Production Break
Equipment Bay Racks
of application and performance requirements. This section includes the flight connector for gate-to-
Forward Bulkhead
deck with its extensive set of avionic displays, control panels, communications aircraft applications Pressure Seal Bulkhead
equipment, data uplink and downlink interfaces, antennae, and so on. These Ideally suited for Zone 2
Connectors and Feedthrus
equipment sets interface with the avionics and flight management computers
Durable pogo pin contact
located in the lower part of the forward fuselage in the equipment bay. The
system rated to tens of
equipment bay also hosts power panels and power conversion panels located Qualified Glenair Technologies for Zone 2: Instrument Panel Console and Equipment Rack
thousands of mating
adjacent to the equipment racks. This section of the aircraft may also contain a
cycles
galley, depending on airline configuration. • MIL-DTL-38999 Series III QPL • Swing-Arm FLEX® composite backshells
Sealed receptacle
• SuperSeal™ RJ45 and USB 2.0 • Advanced rectangular aviation backshells
available with ProSeal™
Zone 2 Application Guidelines
spring-action protective • MIL-DTL-38999 Series III Fiber Optics • Band-Master ATS® shield termination system
Environmental Stress Factors Applicable RTCA/DO-160 Requirements
covers • Series 806 Mil-Aero High-Performance Ultraminiature • ArmorLite™ lightweight microfilament EMI/RFI braid
Vibration DO-160 Category S and H (Table 8-1) • Series 806 Mil-Aero Fiber Optics • ArmorLite™ ground straps
Rugged overmolded plug
Shock DO-160 Category A, Test Procedure 1
cable (turnkey) • Series 79 ultraminiature crimp rectangulars • MasterWrap™ side-entry EMI/RFI shielding
Ground Survival Temperature -65° to 95°C; DO-160 Category A3 (Table 4-1) • AS39029 electrical contacts • SpliceSaver™ connectors
Pressure Differential Sea level to 10kft; DO-160 Category A3 (Table 4-1) Environmentally sealed
• DCSP Dummy Contact Sealing Plugs • PowerLoad™ connectors and bulkhead feedthrus
-55° to 85°C; DO-160 category A3 (Table 4-1) with Temperature breakaway design
Operating Temperature • ProSeal™ spring-action protective covers • Pressure seal bulkhead fittings
change rate per DO-160 Category A (10 C min per minute) Proven commercial
• Connector protective covers • Hermetic connectors
Moisture Exposure to humidity and condensation; DO-160 Category B airframe performance
14 QwikConnect • April 2019 QwikConnect • April 2019 15
ZONE 2 FEATURED TECHNOLOGY GLENAIR
HIGH-SPEED GateLink Pro™
QUICK-DISCONNECT
GateLink Pro™ IP68 sealed high-speed data uplink connector
DATA UPLINK High-Speed Data
Uplink Connector
GATELINK PRO APPLICATIONS AND SOLUTIONS
Wired datalink interconnect access to the aircraft from the airline terminal gate supports various information domains
and data types including aircraft traffic control, airline information services, passenger entertainment, weather, and so on.
Airline operating center applications (flight plans, schedules, advisories) are quickly and reliably uploaded to the aircraft
during turnarounds at the gate. Mechanical and environmental damage to the datalink interface is a common problem
solved by GateLink Pro.
Overmolded environmental plug. IP68 sealed receptacle. CAD drawing Mated GateLink Pro™ plug and
CAD drawing shows polarized shape shows integrated ProSeal™ protective receptacle. CAD drawing shows
of mating interface as well as internal cover and Autoshrink™ environmental shielded twisted pair cabling and
sealing and retention spring. sealing / strain relief boot. overmold cross-section of available
turnkey cable assembly
GATELINK PRO SPECIFICATIONS GATELINK PRO AVAILABLE ACCESSORIES
Durable pogo pin
Environmentally-sealed contact system rated Voltage rating 500 VAC
Anti-vibration and shock spring-action solution •
breakaway design for high-speed
Current rating 5 amps
to tens of thousands Self-aligning environmental seals
Contact resistance 20 milliohms maximum
mating cycles
data transfer between terminal gate Sealed receptacle
Plug-to-receptacle
ground resistance
ZONE 3 GLENAIR
Nacelle and Pylon
Glenair standard and signature
interconnect technologies
Engine Firewall
High-Temperature
Bulkhead Connectors
and Pressure Boundary
Feedthrus
Nacelle
ZONE 3
Nacelle and Pylon
Immediate adjacency to
engine and gear box plus wing Thrust Reversers
and wheel well Pylon
Vapor Seal
Electrical Connectors
Firewall and Pressure
T his zone of the aircraft experiences high vibration, heat, frequent maintenance
cycles, and susceptibility to chemical contamination. There are critical variable
temperature zones within the engine cowling. Typically, the region around the fan
Boundary Feed-Thrus
High-grade engineering
Nacelle
is cooler, with temperatures in the range of 85°– 95°C. Aft of the fan, temperatures thermoplastic or machined
increase dramatically. Design coordination with the aircraft manufacturer is metal
required for all EWIS technologies routed in and out of the nacelle and via the pylon. Solid and split-shell
Qualified Glenair Technologies for Zone 3: Nacelle and Pylon
versions
Zone 3 Application Guidelines Ideally suited for pressure,
• SuperNine® MIL-DTL-38999 Series III + • Swing-Arm composite and SS backshells
Environmental Stress Factors Applicable RTCA/DO-160 Requirements vapor, and firewall • MIL-DTL-38999 Series III Fiber Optics • Band-Master ATS® shield termination system
Vibration DO-160 Category S and H (Table 8-1) bulkheads throughout the • Series 806 Mil-Aero Fiber Optics • ArmorLite™ lightweight microfilament EMI/RFI braid
Shock DO-160 Category D, Test Procedure 1 aircraft including Zone 3 • AS39029 electrical contacts • ArmorLite™ ground straps
Ground Survival Temperature -65° to 200°C; DO-160 Category D3 O-ring sealed panel and
• DCSP Dummy Contact Sealing Plugs • PowerLoad™ connectors and bulkhead feedthrus
Pressure Differential Sea level to 50kft; DO-160 Category D3 box mounting interface
• ProSeal™ spring-action protective covers • Firewall / pressure-seal feed-thrus
Operating Temperature -55° to 200°C; DO-160 category D3 Conductive and non-
• Connector protective covers • Hermetic connectors
Moisture Exposure to humidity and condensation; DO-160 Category B conductive finish options
18 QwikConnect • April 2019 QwikConnect • April 2019 19ZONE 3 FEATURED TECHNOLOGY GLENAIR
FIREWALL AND
PRESSURE SEAL
Firewall / Pressure Seal Feed-Thrus
FEED-THRU Versatile cable feed-thrus Solid and split-shell designs for high-temperature
for pressure, vapor, and and vapor seal applications
firewall applications
PRESSURE BOUNDARY, FIREWALL, AND SPLIT-SHELL FEED-THRUS
High-grade engineering thermoplastic
or machined metal
Wide range of pressure-boundary feed-
thru layouts with accommodation for
1 – 6 cables
Split-shell jam nut versions with EMI/RFI
shield termination porch
O-ring sealed panel and box mounting
Pressure boundary EMI/RFI split-shell interface
composite feed-thru metal feed-thru
Firewall pressure
boundary feed-thru
INSERT ARRANGEMENTS: CONSULT FACTORY FOR BEST AVAILABILITY ON TOOLED DESIGNS
øH øJ
øH øK øH
øJ øH
øJ
øM øL
øH øM øL
øJ
øJ øH
øJ øH øK øH øK
øJ øN øK
DASH 01 DASH 02 DASH 03 DASH 04 DASH 05 DASH 06 DASH 07 DASH 08
øH øJ øH øH øH
øH øH øH
øL øM
øM øL øK
øL
øJ
øH
øJ øK øK øK øJ
øJ øK øJ
DASH 09 DASH 10 øN DASH 11 DASH 12 DASH 13 DASH 14 DASH 15 DASH 16
øH øL øK
øH øH øH øH øH øH
øK øN
øK øH
øJ øL
øK øJ
Universal shell size
FAA qualified pressure-boundary feed-thrus for with over 40 insert øK
øK
øM
high temperature and vapor seal applications arrangements øJ øJ øJ
øL øJ øJ øL
øK
DASH 17 DASH 18 DASH 19 DASH 20 DASH 21 DASH 22 DASH 23 DASH 24
Full wire size øM
including jet engine firewalls
øH øH øN
øH øH øH øH øH
accommodation range up øL
øL
øL
øH
øL
to 1" (25.4 mm)
G lenair is the go-to design partner for innovative solutions to electrical wire
interconnect system problems in airframe applications. Our backshell and
connector accessory design engineers are responsible for more
Stainless steel (Z1)
material and finish for DASH 25 DASH 26
øJ
DASH 27
øK
DASH 28
øJ øJ
DASH 29
øK
DASH 30
øJ
øK
DASH 31
øJ øK
DASH 32 øJ
firewall applications øH
øK
øH øR øM øM
øH
øH øH
øH
problem-solving innovation in our industry than every other øK øL
øK øK
øK
Lightweight composite
øL
connector accessory supplier combined. Take our new øH øH
firewall and pressure boundary feed-thru fittings, for material and finish (XB) for
example. Available in both one-piece and split-shell pressure and vapor seal øN øJ øJ
øJ
applications
øL øJ øJ øS øL øJ øL øJ
designs, these FAA-qualified cable feed-thrus provide
DASH 33 DASH 34 øK DASH 35 DASH 36 DASH 37 DASH 38 DASH 39 DASH 40
øH øR øM
Catalog solutions as well
øM øH
fast, trouble-free installation and life-of-system øK øL
øL
Insert arrangements shown
as fast turnaround on øH Available insulator types:
performance. Solid and split insulators add additional for hole location only. Size is
Split (left) and
flexibility in installation. All designs supplied for “D” made-to-order øN Solid (right)
not to scale. Consult factory
configurations, typically for dimensional details and
øK
panel cutout profiles with jam nut attachments and øJ
øJ
order information.
only two to three weeks
øL øJ øS
O-rings for reliable fitting-to -bulkhead sealing. DASH 41 DASH 42 øK DASH 43
20 QwikConnect • April 2019 QwikConnect • April 2019 21GLENAIR
what’s the largest three-digit number you can make
Find the
missing 60 If...
number
This five-letter word
6 10 123 = 18
becomes shorter when
30 ? you add two letters 233 = 24
to it. 132 = 12
5 9 What is the word? 532 = 20
45 by moving ONLY TWO
then 142 = ?
dummy contact sealing plugs?
Which
+ =5 Find the mistake…
tank will
BBBB DDDD FFFF
fill up
+ =8 HHHH JJJJ LLLL first?
1
5
NNNN PPPP RRRR
4 2
+ =7 TTTT UUUU 6
XXXX ZZZZ 3
what are the number values for each shape?
WHAT ARE THE NUMBERS Which of the numbers are reversed? Solve the puzzle.
5
7 A, B, C, or D?
OF THE PARKING SPACES
4
WITH AIRPLANES IN THEM?
2
7
?
5
68 88 98 One of the spirals is made from one continuous rope,
2
joined at the ends.
4
The other is made from two separate pieces.
4
Which is which?
A B C D
22 QwikConnect • April 2019 QwikConnect • April 2019 23ZONE 4 GLENAIR
Engine and Gear Box
Glenair standard and signature
interconnect technologies
Engine and Gear Box
ZONE 4
Engine and Generator /
Starter
Gear Box
Adjacent to and interconnected
with aircraft via engine pylon
and the wing/body fairing
E WIS components exposed to high heat can experience accelerated degradation,
insulation dryness, and cracking. Direct contact with a high-heat source can
quickly damage insulation. Even lower levels of engine and gearbox heat can
PowerLoad™ Connectors
Electrical Engine
Control Unit
Back-Up Generator
degrade the EWIS over time. Standard-construction cable harnesses used for High-vibe, high-temp,
interconnection of FADEC equipment or in areas of Zone 5 not in direct contact high-density power Engine and Gear Box
with the engine may incorporate material types capable of withstanding operating connector series
temperatures up to 200°C. Aircraft manufacturers prefer stainless steel connectors Ideally suited for backup
and accessories, and cabling shielded with temperature-resistant metallic braid. generators in Zone 4 as
EWIS cabling transitioning from the engine and gearbox into the adjacent nacelle well as power transmission Qualified Glenair Technologies for Zone 4: Engine and Gear Box
and pylon zone require pressure and temperature boundary sealing. throughout the aircraft
• SuperNine® MIL-DTL-38999 Series III + • Band-Master ATS® shield termination system
Low-resistance contact
Zone 4 Application Guidelines delivers lower temperature • SuperNine® MIL-DTL-38999 Series III + Fiber Optics • ArmorLite™ lightweight microfilament EMI/RFI braid
Environmental Stress Factors Applicable RTCA/DO-160 Requirements rise under load • Series 806 Mil-Aero ultraminiature • ArmorLite™ ground straps
Vibration DO-160 Category S and H (Table 8-1) Removable wire sealing
• AS39029 electrical contacts • PowerLoad™ connectors and bulkhead feedthrus
Shock DO-160 Category D, Test Procedure 1 grommet and wire • DCSP Dummy Contact Sealing Plugs • Pressure seal bulkhead fittings
Ground Survival Temperature -65° to 200°C; DO-160 Category D3 separator for easy rear • ProSeal™ spring-action protective covers • Hermetic connectors
Pressure Differential Sea level to 50kft; DO-160 Category D3 release of contacts and • Connector protective covers • Indirect lightning strike HST Sleeves
Operating Temperature -55° to 200°C; DO-160 category D3 improved sealing of tape-
Moisture Exposure to humidity and condensation; DO-160 Category B
• Swing-Arm composite and SS backshells • AutoShrink™ cold-action shrink tubing and boots
wrapped wire
24 QwikConnect • April 2019 QwikConnect • April 2019 25ZONE 4 FEATURED TECHNOLOGY GLENAIR
RUGGEDIZED
Backup and integrated PowerLoad™ Series
POWER
CONNECTOR drive generator connectors Aircraft power distribution connectors
for power distribution
applications
AVAILABLE INSERT
POWERLOAD™ AVAILABLE CONFIGURATIONS
ARRANGEMENTS
Six size #8 contacts
Three size #2 contacts
Three size #1/0
contacts
Panel-mount receptacle with Cable plug with high-vibration Bulkhead feed-thru for
integrated wire sealing backshell coupler and ground spring firewall applications
POWERLOAD™ EXPLODED VIEWS
WIRE SEPARATOR
Plug
REMOVABLE
WIRE SEALING GROMMET
BACKSHELL ADAPTER AND
STRAIN RELIEF ASSEMBLIES
(45 DEGREE SHOWN)
P owerLoad™ is a high-vibration, high-temperature resistant connector series
designed for high altitude aircraft power distribution applications. An innovative
combination of low-resistance contacts and a one-piece composite thermoplastic
PowerLoad 28-6 layout
connector is rated at 500
volts at 50,000 ft. with a
HIGH-PERFORMANCE
260°C-RATED CONTACTS
HIGH-VIBRATION
insulator with aggressive contact cavity isolation results in a reliable high-current current of 45 amps per INNOVATIVE
INSERT DESIGN WITH SELF-LOCKING COUPLER
solution that optimizes wire-to-contact termination and weight reduction in power contact with 3 phase CAVITY ISOLATION WITH HIGH-TEMP EMI SPRING
distribution cables. Designed for use in integrated drive generator and backup power in parallel at a WIRE SEPARATOR
generator applications, PowerLoad is available in three- and six-contact layouts frequency of 3600 hertz
for both multiphase and high-frequency power systems. Removable wire-sealing Available configurations
REMOVABLE
grommet and wire separator allow for easy rear release of contacts and improved Receptacle
include a high-vibration WIRE SEALING GROMMET
sealing of tape-wrapped wire. self-locking coupling
nut plug, panel-mount RAPID-ADVANCE STUB ACME
MATING THREADS
receptacle with stub- BACKSHELL ADAPTER AND
STRAIN RELIEF ASSEMBLIES
ACME mating threads, (STRAIGHT SHOWN)
and bulkhead feed-thru
for firewall applications
Aluminum class
LOW RESISTANCE
connectors are rated 260°C-RATED CONTACTS
WITH THICK GOLD PLATING
to 200°C operating
temperature; passivated LONG RECEPTACLE NOSE FOR SEALED
stainless steel designs SHELL-TO-SHELL BOTTOMING IN MATED CONDITION
rated to 230°C
26 QwikConnect • April 2019 QwikConnect • April 2019 27ZONE 5 GLENAIR
Wing and Wheel Well
Glenair standard and signature
interconnect technologies
Wing
ZONE 5
Wing and
Flight
Control Surfaces
Electrical Interface
Wiring
Wheel Well
Wing Tip Lighting
An unpressurized, harsh
environmental zone Series 806 Mil-Aero
Side-of-Body Wing, Wheel Well
W ing leading and trailing edges are harsh environments for EWIS installations.
EWIS wire harnesses in this zone are exposed on some aircraft models whenever
the flaps or slats are extended. Other potential sources of mechanical damage
Series 806 Mil-Aero:
Advanced-performance
ultraminiature circular
Electrical Feedthrus
and Pressure Seals
Wing and Engine Control
include slat torque shafts and bleed air ducts. connector Wiring / Sensors
Wheel wells are also subject to severe external environmental stress factors Ideally suited for all
including impact damage from rocks, ice, and mud, as well as from vibration and unpressurized aircraft
chemical contamination. Adequate protection of EWIS cabling in these areas zones including Zone 5
includes shielding, jacketing, and in some applications, enclosure in metal-core One-to-one equivalent
Qualified Glenair Technologies for Zone 5: Wing and Wheel Well
or polymer-core conduit. performance to MIL-
DTL-38999 Series III, • SuperNine® MIL-DTL-38999 Series III + • Band-Master ATS® shield termination system
Zone 5 Application Guidelines including high-altitude • SuperNine® MIL-DTL-38999 Series III + Fiber Optics • ArmorLite™ lightweight microfilament EMI/RFI braid
Environmental Stress Factors Applicable RTCA/DO-160 Requirements immersion and DWV • Series 806 Mil-Aero High-Performance Ultraminiature • ArmorLite™ ground straps
Vibration DO-160 Category S and H (Table 8-1) Outstanding anti-
• AS39029 electrical contacts • Pressure seal bulkhead fittings
Shock DO-160 Category D, Test Procedure 1 decoupling performance, • DCSP Dummy Contact Sealing Plugs • Hermetic connectors
Ground Survival Temperature -65° to 200°C; DO-160 Category D3 even in small shell sizes • ProSeal™ spring-action protective covers • Indirect lightning strike HST Sleeves
Pressure Differential Sea level to 50kft; DO-160 Category D3 Significant size and weight
• Swing-Arm FLEX® composite backshells • Polymer and Metal-Core Conduit
Operating Temperature -55° to 200°C; DO-160 category D3 savings compared to MIL- • Advanced rectangular aviation backshells
Moisture Exposure to humidity and condensation; DO-160 Category B DTL-38999 Series III
28 QwikConnect • April 2019 QwikConnect • April 2019 29ZONE 5 FEATURED TECHNOLOGY GLENAIR
ULTRAMINIATURE
SERIES Advanced performance, Series 806 Mil-Aero
AVIATION
CONNECTOR 806 reduced size and weight Ultraminiature Circular Connectors
connector series IAW
MIL-AERO For harsh unpressurized zone applications
MIL-DTL-38999
SERIES 806 MIL-AERO: FEATURES / SPECIFICATIONS SERIES 806 MIL-AERO PLUG
High-density #20HD and #22HD
Coupling Nut Retainer Ring
Stainless steel
arrangements for reduced size and weight
Coupling Nut
Supported wire sizes:
Aluminum alloy
#20HD contacts 20–24 AWG Insert Retention Ring
#22HD contacts 22–28AWG Stainless steel
Wire Seal
Dielectric withstanding voltage
fluorosilicone rubber
#20HD layouts: 1800 Vac Insulators
#22HD layouts: 1300 Vac Glass-filled rigid dielectric
Reduced pitch triple-start modified anti-
Contacts
Anti- Gold-plated copper
decoupling stub ACME mating threads Decoupling Plug Barrel
+200°C operating temperature
Spring High strength
Stainless steel alloy
“Triple ripple” wire sealing grommet
Interfacial Seal
(75,000 ft. rated) fluorosilicone rubber
Snap in, rear release crimp contacts
EMI Ground Spring
Nickel-plated BeCu
Metal contact retention clips
Integral Nano-Band shield termination
platform SERIES 806 MIL-AERO RECEPTACLE
EMI shielding effectiveness per D38999M
Insert Retention Ring
Stainless steel
para. 4.5.28 (65 dB min. leakage attenuation Wire Seal
@ 10GHz) fluorosilicone rubber
10,000 amp indirect lightning strike
Insulators
Glass-filled rigid dielectric
MIL-S-901 Grade A high impact shock
Jam Nut
Aluminum alloy
Shell /
AVAILABLE LIGHTWEIGHT ALUMINUM Mating
“CODE RED” HERMETICS Interface
S
Aluminum,
eries 806 offers significant size and weight savings while meeting key Next-generation small
CODE RED is a lightweight encapsulant sealing and Panel O-ring modified
performance benchmarks for a broad range of applications such as commercial form factor aerospace- application process with 50% package-weight savings
Fluorosilicone triple-start
and military aerospace, robotics, transportation, and more. Designed for general grade circular connector compared to glass-to-metal seal Kovar/stainless steel Shell Body
use in harsh vibration, shock, and environmental settings—as well as high-altitude, Aluminum alloy
Designed for harsh
solutions. Non-outgassing
unpressurized aircraft zones with aggressive voltage ratings and altitude immersion application zones CODE RED (IAW NASA/
standards—the Series 806 Mil-Aero features numerous design innovations including including aircraft wings ESA) provides durable
durable mechanical insert retention, radial seals and triple-ripple grommet seals. hermetic and vapor
Its reduced thread pitch and re-engineered ratchet prevent decoupling problems,
Upgraded environmental,
sealing with better
particularly in small shell sizes, solving one of the major problems of shell size 9
electrical and mechanical than 1X10-7 leak rate
performance SMALLER AND LIGHTER WITH EQUAL D38999
and 11 MIL-DTL-38999 Series III connectors. performance. Gold-
plated copper contacts PERFORMANCE?
Integrated anti-
SAVE SIZE AND WEIGHT WITH SERIES 806 CONNECTORS decoupling technology deliver outstanding High-Density “Top Hat” Triple Ripple
low-resistance current Layouts Insulator Wire Seal
Higher density 20HD
carrying capacity. Twice as many contacts High voltage rating, Reliable 75,000 ft.
and 22HD contact in a smaller package foolproof alignment altitude immersion
Series 806 Mil-Aero MIL-DTL-38999 arrangements
Smallest Size Smallest Size
.500 In. Mating Threads .625 In. Mating Threads Hermetic, vapor seal, and
3 #20 Contacts or 7 #22 3 #20 Contacts or 6 #22 EMI/RFI filter versions
contacts contacts
+200°C temperature rating
30 QwikConnect • April 2019 QwikConnect • April 2019 31ZONE 6 GLENAIR
Landing Gear
Glenair standard and signature
interconnect technologies
ZONE 6
Landing Gear
An unpressurized, harsh
environment zone
Main Landing Gear
C ommercial airplanes use a nose landing gear and two main landing gears. The
nose gear has the steering function, and typically a junction box located midway
down the landing gear itself. The main landing gear has an extensive amount of
Electric Brakes, Wheel
Speed Sensors / Antilock
Wired metal and polymer-core
Nose Landing Gear conduit assemblies
wiring that interfaces with wheel speed sensors, antilock braking equipment, Electrical Feedthrus and
and electric brake systems. The area is exposed to severe external environmental Pressure Seals
Turnkey Wire Protection
conditions in addition to vibration and chemical contamination. EWIS harnesses
interconnecting the landing gear are hardened against impact from rocks, ice, Assemblies for Wheel Sensor
and mud, and may be housed within special metal-core or polymer core conduit. and Braking Systems
FAA qualified flexible
Zone 6 Application Guidelines polymer and metal-core
Environmental Stress Factors Applicable RTCA/DO-160 Requirements conduit materials Qualified Glenair Technologies for Zone 6: Landing Gear
Vibration DO-160 Category S and H (Table 8-1) Ideally suited for rugged
Shock DO-160 Category D, Test Procedure 1* aircraft zones including • SuperNine® MIL-DTL-38999 Series III + • Band-Master ATS® shield termination system
Ground Survival Temperature -65° to 150°C; DO-160 Category D3 Zone 2 • SuperNine® MIL-DTL-38999 Series III + Fiber Optics • ArmorLite™ lightweight microfilament EMI/RFI braid
Pressure Differential Sea level to 50kft; DO-160 Category D3
Impact-resistant and
• AS39029 electrical contacts • ArmorLite™ ground straps
Operating Temperature -55° to 150°C; DO-160 category D3
immune to chemical • DCSP Dummy Contact Sealing Plugs • Pressure seal bulkhead fittings
Exposure to humidity and condensation; driving rain, de-icer,
Moisture hydraulic fluids, fuel; EIA-364-10 with the fluids defined in DO-160 contamination • ProSeal™ spring-action protective covers • Hermetic connectors
Table 11-1 Integrated overbraiding
• Swing-Arm composite and SS backshells • Metal- and Polymer-Core Conduit assemblies
*note: landing gear environment must be coordinated with airplane manufacturer for specific dynamic for added strength and • Advanced rectangular aviation backshells • Indirect lightning strike HST Sleeves
environment definition EMI/RFI immunity
32 QwikConnect • April 2019 QwikConnect • April 2019 33ZONE 6 FEATURED TECHNOLOGY GLENAIR
TURNKEY
Conduit components and wired Conduit Wire Protection Systems
CONDUIT
ASSEMBLIES assemblies with innovative Flexible, impact resistant alternatives to
polymer and metal-core wire lighter-duty jacketed cable assemblies
protection materials
COMPLEX, MULTIBRANCH ASSEMBLIES WITH INNOVATIVE LIGHTWEIGHT POLYMER-CORE WIRE
PROTECTION CONDUITS
Ultra-flexible Lightweight, halogen-free
polymer-core point- PEEK wire conduit assembly
to-point fiber optic
conduit assembly
PEEK, PFA, ETFE, Siltem
polymer core and Glenair
signature high-temperature
polymer core conduit solutions
and user-installable fittings
Turnkey integrated box assembly and
wired polymer-core interconnect system
A ll of the metal-core conduit and polymer-core convoluted tubing systems we fabricate at Glenair may be wired and
assembled at our factory with tamper-proof crimp ring or solder terminations according to customer requirements.
Reduced size and weight factory terminated conduit assemblies offer the utmost in environmental ruggedness, reliability
COMPLEX, MULTIBRANCH ASSEMBLIES WITH HEAVY-DUTY METAL-CORE CONDUIT AND
OVERBRAIDING WIRE PROTECTION MATERIALS
and durability. Certified factory assemblers and calibrated tooling guarantee reliable long-term performance. Glenair’s
expertise in wired conduit systems extends from simple point-to-point jumpers to complex multibranch assemblies as
well as turnkey integrated systems and LRUs with flexible conduit interconnect cabling.
TURNKEY FACTORY-TERMINATED CONDUIT ASSEMBLIES
Brass, SST, or nickel-iron metal-
core conduit material types with
innovative microfilament and
Complex multibranch aircraft electrical Lightweight multibranch wire protection drawn filament braiding. Factory
wire conduit assembly with high- conduit assembly with high-temperature Crush-resistant commercial aerospace Turnkey wheel well impact-resistant Metal-core conduit wire protection terminated or for use with user-
temperature polymer-core conduit polymer-core convoluted tubing metal-core conduit assembly metal-core conduit assembly aircraft brake assembly installable fittings.
34 QwikConnect • April 2019 QwikConnect • April 2019 35You can also read
