BS 2G 232-1987 Specification for electric cables for general airframe or equipment interconnect use (135 C) wrapped insulation《普通飞机机体或设备互连用(135℃)绕扎绝缘电缆规范》.pdf

1、BRITISH STANDARD AEROSPACE SERIES BS 2G 232: 1987 (Superseding BSG232:1984) Specification for Electric cables for general airframe orequipment interconnect use(135 C), wrapped insulation UDC 629.7.064.5:621.315.33-408.4BS 2G 232:1987 This British Standard, having been prepared under the directionof

2、the Aerospace Standards Committee, was published under the authority ofthe Board of BSI and comesintoeffect on 30September1987 BSI 12-1999 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment 85/71991 DC ISBN 0 580 15920 5 Committees responsib

3、le for this British Standard The preparation of this British Standard was entrusted by the Aerospace Standards Committee (ACE/-) to Technical Committee ACE/6, upon which the following bodies were represented: BEAMA Ltd. British Airways British Rubber Manufacturers Association Civil Aviation Authorit

4、y Electric Cable Makers Confederation Electronic Components Industry Federation Ministry of Defence National Supervising Inspectorate Society of British Aerospace Companies Limited Amendments issued since publication Amd. No. Date of issue CommentsBS2G232:1987 BSI 12-1999 i Contents Page Committees

5、responsible Inside front cover Foreword ii 1 Scope 1 2 Classification 1 3 Construction 1 4 Designation and marking 2 5 Packaging and labelling 2 6 Tests 2 7 Reference samples 6 Figure 1 Variation of resistance of copper with temperature 15 Table 1 Type 01, class 1: single-core unscreened interconnec

6、t cables (135 C) 6 Table 2 Type 02, class 1: single-core unscreened airframe cables (135 C) 6 Table 3 Type 01, classes 2, 3 and 4: multi-core unscreened, twisted interconnect cables without jacket (135 C) 7 Table 4 Type 02, classes 2, 3 and 4: multi-core unscreened, twisted airframe cables without j

7、acket (135 C) 7 Table 5 Type 03, classes 2, 3 and 4: multi-core unscreened, twistedinterconnect cables with jacket (135 C) 8 Table 6 Type 04, classes 2, 3 and 4: multi-core unscreened, twisted airframe cables with jacket (135 C) 8 Table 7 Type 05, classes 1, 2, 3 and 4: single-core screened with jac

8、ket, and multicore twisted and screened with jacket, interconnect cables (135 C) 9 Table 8 Type 06, classes 1, 2, 3 and 4: single-core screened with jacket, and multi-core twisted and screened with jacket, airframe cables (135 C) 9 Table 9 Test application 10 Table 10 Specific test parameters 12 Tab

9、le 11 Current ratings in amperes for general purpose135 C airframe cable 14 Publications referred to Inside back coverBS 2G 232:1987 ii BSI 12-1999 Foreword This revision of this British Standard, having been prepared under the direction of the Aerospace Standards Committee, specifies requirements f

10、or a range of lightweight thin-wall insulated cables that are individually suitable for general airframe or equipment interconnect use. It supersedes BSG232:1984, which is withdrawn. It updates the 1984 edition and incorporates additional tests for type05 and type06 cables. The dielectric insulation

11、 material is spirally lapped with an overall coating toprovide the necessary colour coding and to provide a base for printed identification legends. The standard requires the application of the dielectric material so as to provide the minimum penalties of weight and space whilst offering reliable pe

12、rformance over a full airframe life of not less than50000h. Cables manufactured to this standard are not required to meet the fire resistance requirements of BS3G100-3.13, but they are required to satisfy the flammability requirements of BSG230. NOTEThis cable may not be suitable for termination by

13、certain soldering techniques. The user should ascertain that the cable and terminations are completely compatible. Attention is drawn to BSG230 which specifies the general requirements for aircraft electric cables (second series). A British Standard does not purport to include all the necessary prov

14、isions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages1 to 16, a

15、n inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover.BS2G232:1987 BSI 12-1999 1 1 Scope This British Standard specifies construction and performance

16、requirements for a range of lightweight cables with wrapped insulation suitable for general airframe use in the size range26 to0000, and for equipment interconnect in the size range26 to18. The following types of cable are specified. The cables are suitable for continuous use where the maximum stabi

17、lized conductor temperature does not exceed135 C. They are suitable for applications involving flexing at temperatures down to65 C. The cables are suitable for use where the potential between conductors or between a conductor and screen, or the aircraft structure, does not exceed600Vr.m.s. and the f

18、requency does not exceed2000Hz. Interconnect cables are suitable for use in areas with some physical protection, such as behind panels or bulkheads. They also have an application for the internal wiring of equipment. Airframe cables are of sufficiently robust construction to be used for open aircraf

19、t wiring. The short-term and long-term current ratings for the cables are specified in this standard. NOTEThe titles of the publications referred to in this standard are listed on the inside back cover. 2 Classification Cables are classified according to the number of cores as follows: class 1:singl

20、e core class 2:two core class 3:three core class 4:four core 3 Construction 3.1 General The materials and method of construction used for the formation of the cables shall be defined and controlled to the satisfaction of the Approving Authority 1) . No change shall be made to such materials or proce

21、sses unless it can be shown to the satisfaction of the Approving Authority that the performance and handling properties of the cable have not been degraded. The cable shall be made of materials such that the performance requirements of this standard are satisfied. 3.2 Conductors 3.2.1 Conductors sha

22、ll comply with BS G231 before fabricating into completed cable. 3.2.2 Copper strands shall be tin plated and high strength copper alloy strands shall be silver plated. 3.3 Insulation The insulation for interconnect cables shall consist of one or more overlapped tapes of insulating material and, for

23、airframe cables, two or more overlapped tapes. An overall coating may also be provided which, for the purposes of this standard, shall be regarded as part of the cable. The insulating material shall be such that the performance requirements of this standard are satisfied. Only100% new materials that

24、 have been through only those processes essential to their manufacture and application shall be used. 3.4 Screen The screen shall be constructed of a braid having a coverage of85% minimum, and a lay factor less than3 when calculated in accordance with AppendixA of BSG230. There shall be no joints in

25、 the complete screen. Where breaks in individual strands occur, the ends shall be brazed or tucked into the weave ensuring that the cut end is on the outside of the screen. There shall be not more than one such break in any300mm length of cable or in any10m length of individual strand. Strands from

26、which the braid is constructed shall be tin plated and comply with BSG231 before braiding. 3.5 Jacket The jacket shall be made of an insulating material, and shall be constructed, such that the performance requirements of this standard are satisfied. Type 01 interconnect Single-core or twisted Type

27、02 airframe multi-cores only Type 03 interconnect Two or more cores, Type 04 airframe with an outer jacket Type 05 interconnect Single- or multi-core, Type 06 airframe with a screen and outer jacket 1) The Approving Authority is either: a) for UK Civil Aviation products, the Civil Aviation Authority

28、 (or their accredited representatives); or b) for UK military products, information is available from the Procurement Executive, Ministry of Defence, Directorate General of Defence Quality Assurance, Directorate of Standardization, Kentigern House, 65 Brown Street, Glasgow G2 8EX.BS 2G 232:1987 2 BS

29、I 12-1999 3.6 Single-core cables The mass and dimensions of single-core cables shallbe as given inTable 1 andTable 2 as appropriate. 3.7 Multi-core cables The mass and dimensions of multi-core cablesshallbe as given inTable 3 toTable 8 asappropriate. The cables shall consist of two ormore single cor

30、es complying with3.6, twisted together with a lay of approximately12times thepitch circle diameter for sizes26 to4 and approximately 16times the pitch circle diameter for sizes2 to0000. Types01 and02 shall consist of twisted assemblies of single-core cable, types03 and04 of twisted assemblies with a

31、n outer jacket, and types05 and06 of twisted assemblies with a screen and outer jacket. 3.8 Colour The colour of the insulation for class1 cables, the core insulation for multi-core cables and the jackets shall comply with BSG230. 4 Designation and marking 4.1 Manufacturers marking and designation T

32、he designation and marking of the cables shall be in accordance with BSG230. 4.2 User applied marking 4.2.1 The surface of the insulation or coating of type02 (airframe) cable shall be suitable for the acceptance of user applied identification marks byat least one of the following methods: a) hot st

33、amp marking; b) laser marking; c) ink jet. The cable manufacturer shall declare which method is suitable and the tests given in clause6 shall be performed using cables that have been so marked. 4.2.2 Appropriate methods of marking the outer jacket of cable types03,04,05 and06 shall be declared by th

34、e manufacturer who may specifically prohibit the use of hot stamp or laser marking. 4.2.3 Type 01 (interconnect) cable shall not be required to accept hot stamp or laser marking or anyother method that may degrade the insulation material. 5 Packaging and labelling The cables shall be packaged and la

35、belled in accordance with BSG230. 6 Tests The following tests shall be carried out in accordance with BSG230. Specific requirements ofthis standard are given against the appropriate test. The application of each test for qualification approval, production quality testing, inspection lot testing and

36、production routine testing shall be as given inTable 9. All qualification approval test specimens shall be marked in accordance with clause4 before commencement of testing. NOTEFor qualification approval testing, specimens selected from a particular size within the following groups may be considered

37、 as proving the requirements for all sizes within that group of a given type (see clause1). Qualification of type05 cable may be considered as proving the requirements of type03, classes2 to4, and type06 as proving type04, classes2 to4. Group 1. Sizes 26 to 24, type 02, classes 1 to 4 Group 2. Sizes

38、 22 to 16, type 02, classes 1 to 4 Group 3. Sizes 14 to 10, type 02, class 1 Group 4. Sizes 8 to 2, type 02, class 1 Group 5. Sizes 1 to 0000, type 02, class 1 Group 6. Sizes 26 to 24, type 01, classes 1 to 4 Group 7. Sizes 22 to 18, type 01, classes 1 to 4 Group 8. Sizes 26 to 16, type 06, classes

39、1 to 4 Group 9. Sizes 26 to 18, type 05, classes 1 to 4BS2G232:1987 BSI 12-1999 3 BSG230 test no. Test applicable to cable types 01 and 02 Specific requirements of this standard 1. Appearance and identification of finished cable 2. Mass per unit length of finished cable Maximum values shall be as gi

40、ven inTable 1 toTable 6 3. Conductor composition 4. Visual examination of strands 5. Insulation thickness and concentricity Minimum values shall be as given inTable 1 andTable 2 6. Core and cable outer diameters Minimum and maximum values shall be as given inTable 1 toTable 6 7. Tensile strength and

41、 elongation at break of copper or copper alloy conductors Values shall be as follows: Strand diameter Tensilestrength Elongation Min. Max. Min. mm N/mm 2 N/mm 2 % Copper alloy: 0.08 to 0.12 350 (for 7 strands) 6 Copper: 0.08 to 0.12 0.15 to 0.45 220 220 300 300 9 10 9. Strand plating continuity 10.

42、Strand plating adherence 12. Electrical resistance of conductor Maximum values shall be as given inTable 1 toTable 6 14. Solderability 14(a). Method 1 This test shall be carried out on sizes20 to26 only. Usenon-activated flux complying with4.6.2 of BS2011-2.1T:1981 and solder of grade KP of BS219. S

43、older bath temperature235 3 C. Wetting time2.0s 14(b). Method 2 15. Conductor strand adhesion 16. High voltage 16(a). Immersion 2500 75Vr.m.s. 16(b). a Dry spark 5000 150Vr.m.s. 16(c). a Dry impulse 8000 250Vpeak 17. Insulation resistance 18. Surface resistance 19. Accelerated ageing Test temperatur

44、e200 2 C. Time168h. Mandrel diameter and force shall be as given inTable 10 20. Thermal endurance 50000h minimum at135 2 C 21. Adherence of insulation on conductor Minimum adherence forces shall be as given inTable 10 22. Delamination and shrinkage Five cycles from room temperature to135 2 C holding

45、 the top temperature for1h and allowing the cable to return to room temperature between cycles. Maximum length of conductor exposed at each end is1.0mm for sizes26 to10, and one-quarter maximum outside diameter for sizes8 to0000 23. Delamination and insulation blocking Mandrel diameter and tension s

46、hall be as given inTable 10. Test temperature135 2 C. Time100h a Either test 16(b) or 16(c) may be carried out.BS 2G 232:1987 4 BSI 12-1999 BSG230 test no. Test applicable to cable types 01 and 02 Specific requirements of this standard 24. Room temperature bend Mandrel diameter and tension shall be

47、as given inTable 10 25. Cold bend Mandrel diameter and tension shall be as given inTable 10. Test temperature65 2 C. Time 6 h. 26. Dynamic cut-through Test temperature135 2 C, 6000g/min 10% at the sample. Minimum force to cut-through shall be as given inTable 10 27. Notch propagation resistance 28.

48、Flammability 28(a). Method 1 Five specimens,15s exposure to flame 28(b) Method 2 Five specimens,15s exposure to flame 29. Resistance to fluids 30. Scrape abrasion Test temperature135 2 C. Force and cycles shall be as given inTable 10 31. Overload resistance T 1= 250 5 C T 2= 400 10 C 32. Delaminatio

49、n Ageing temperature T 2= 250 5 C Test temperature T 1= 135 2 C Force shall be as given inTable 10 35. Climatic Humidity. Carry out the test in accordance with clause2 c) of BSG229 a . Category A for type 01 and Category B for type02. Prepare the specimens by winding at least six turnson a mandrel of the diameter specified for test23 inTable 10. On removal from the chamber, unwind the cable from the mandrel. It shall show no sign to normal vision of deterioration and the identific