1、BRITISH STANDARD AEROSPACE SERIES BSG237:1987 Specification for Electric cables for general airframe or equipment interconnect use(200 C), extruded insulation with nickel plated conductors UDC629.7.064.5:621.315.33-036BSG237:1987 This BritishStandard, having been prepared under the directionof the A
2、erospace Standards Committee, was published under the authorityofthe Board of BSI andcomesintoeffect on 30September1987 BSI01-2000 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment85/71995 DC ISBN 0 580 16071 8 Committees responsible for th
3、is BritishStandard The preparation of this BritishStandard 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 Authority Electric
4、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 CommentsBSG237:1987 BSI 01-2000 i Contents Page Committees responsible
5、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 14 Table 1 Type01, class1: single-core unscreened interconnect cables(200 C
6、) 6 Table 2 Type02, class1: single-core unscreened airframe cables(200 C) 6 Table 3 Type01, classes2,3 and4: multi-core unscreened, twisted interconnect cables without jacket(200 C) 7 Table 4 Type02, classes2,3 and4: multi-core unscreened, twisted airframecables without jacket(200 C) 7 Table 5 Type0
7、3, classes2,3 and4: multi-core unscreened, twisted interconnect cables with jacket(200 C) 7 Table 6 Type04, classes2,3 and4: multi-core unscreened, twisted airframecables with jacket(200 C) 8 Table 7 Type05, classes1,2,3 and4: single-core screened with jacketandmulti-core twisted and screened with j
8、acket, interconnect cables(200 C) 9 Table 8 Type06, classes1,2,3 and4: single-core screened with jacket andmulti-core twisted and screened with jacket, airframe cables(200 C) 9 Table 9 Test application 10 Table 10 Specific test parameters 11 Table 11 Current ratings in amperes for general purpose200
9、 C airframecable 13 Publications referred to Inside back coverBSG237:1987 ii BSI 01-2000 Foreword This BritishStandard, having been prepared under the direction of the Aerospace Standards Committee, specifies requirements for a range of lightweight thin-wall insulated cables that are individually su
10、itable for general airframe or equipment interconnect use. The dielectric insulation material is applied by extrusion or extrusions over the conductor. The standard requires the application of the dielectric material so as to provide the minimum penalties of weight and space whilst offering reliable
11、 performance over a full airframe life of not less than20000h. Cables manufactured to this standard are not required to meet the fire resistance requirements of BS3G100:Sub-section 3.13, but they are required to satisfy the flammability requirements of BSG230. Attention is drawn to BSG230 which spec
12、ifies the general requirements for aircraft electric cables (second series). A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself conf
13、er immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pagesi andii, pages1 to14, an 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
14、 the amendment table on the inside front cover.BSG237:1987 BSI 01-2000 1 1 Scope This BritishStandard specifies construction and performance requirements for a range of lightweight cables with extruded insulation suitable for general airframe use in the size range24 to0000, and for equipment interco
15、nnect in the size range24 to18. The following types of cable are specified. The cables are suitable for continuous use where the maximum stabilized conductor temperature does not exceed200 C. They are suitable for applications involving flexing at temperatures down to65 C. The cables are suitable fo
16、r use where the potential between conductors or between a conductor and screen, or the aircraft structure does not exceed600Vr.m.s. and the frequency does not exceed2000Hz. Interconnect cables are suitable for use in areas with some physical protection, such as behind panels or bulkheads, and may al
17、so be used as the basis for cables having additional protection, such as a jacket or screen and jacket. They also have an application for the internal wiring of equipment. Airframe cables are of sufficiently robust construction to be used for open aircraft wiring. The continuous and short-term curre
18、nt 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: 3 Construction 3.1 General The materials and method of co
19、nstruction 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 processes unless it can be shown to the satisfaction of the Approving Authority that the performance and handling propertie
20、s 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 shall comply with BSG231 before fabricating into completed cable. 3.2.2 Copper strands and copper alloy strands shall be
21、nickel plated. 3.3 Insulation The insulation for interconnect cables shall consist of one or more homogeneous extruded layers of dielectric material, and for airframe cables, two or more extruded layers. An overall coating may also be provided which, for the purposes of this standard, shall be regar
22、ded as part of the cable. The insulation shall be of a suitable material such that the performance requirements of this standard are satisfied. Only100% new materials that have been through only those processes essential to their manufacture and application shall be used. Where two layers are used,
23、they shall be of contrasting colours. 3.4 Screen The screen shall be constructed of a braid having a coverage of85% minimum, and a lay factor of less than3 when calculated in accordance with Appendix A of BSG230. There shall be no joints in the complete screen. Where breaks in individual strands occ
24、ur, 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 which the braid is constructed shall be nickel plated and co
25、mply with BSG231 before braiding. 3.5 Jacket The jacket shall be made of insulating material and shall be constructed in such a manner that the performance requirements of this standard are satisfied. Type01 interconnect Single core or twisted multi-cores only Type02 airframe Type03 interconnect Two
26、 or more cores, with an outer jacket Type04 airframe Type05 interconnect Single or multi-core, with a screen and outer jacket Type06 airframe class1: single core class2: two core class3: three core class4: four core 1) The Approving Authority is either: a) for UK civil aviation products, the Civil A
27、viation Authority (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 G28EX.BSG2
28、37:1987 2 BSI 01-2000 3.6 Single-core cables The mass and dimensions of single-core cables shall be as given in Table 1 and Table 2 as appropriate. 3.7 Multi-core cables The mass and dimensions of multi-core cables shall be as given in Table 3 to Table 8 as appropriate. The cables shall consist of t
29、wo or more single cores complying with3.6, twisted together with a lay of approximately12times the pitch circle diameter for sizes24 to4 and approximately16times the pitch circle diameter for sizes2 to0000. Types01 and02 shall consist of twisted assemblies of single-core cable, types01 and04 of twis
30、ted assemblies with an 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 mark
31、ing and designation The 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 by at least one of the follow
32、ing methods: a) hot stamp marking; b) laser marking. 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 decl
33、ared by the manufacturer who may specifically prohibit the use of hot stamp or laser marking. 4.2.3 Type01 (interconnect) cable shall not be required to accept hot stamp or laser marking or any other method that may degrade the insulation material. 5 Packaging and labelling The cables shall be packe
34、d and labelled in accordance with BSG230. 6 Tests The following tests shall be carried out in accordance with BSG230. Specific requirements of this standard are given against the appropriate test. The application of each test for qualification approval, production quality testing, inspection lot tes
35、ting and production routine testing shall be as given in Table 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
36、considered 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. Group1.Sizes24, type02, classes1 to4 Group2.Sizes22 t
37、o16, type02, classes1 to4 Group3.Sizes14 to10, type02, class1 Group4.Sizes8 to2, type02, class1 Group5.Sizes1 to0000, type02, class1 Group6.Sizes24, type01, classes1 to4 Group7.Sizes22 to18, type01, classes1 to4 Group8.Sizes24 to16, type06, classes1 to4 Group9.Sizes24 to18, type05, classes1 to4BSG23
38、7:1987 BSI 01-2000 3 BSG230 test no. Test applicable to cable types01 and02 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 given in Table 1 to Table 6 3. Conductor composition 4. Visual ex
39、amination of strands 5. Insulation thickness and concentricity Minimum values shall be as given in Table 1 and Table 2 6. Core and cable outer diameters Minimum and maximum values shall be as given inTable 1 to Table 6 7. Tensile strength and elongation at break of copper or copper alloy conductors
40、Values shall be as follows: Strand diameter Tensile strength Elongation Min. Max. Min. mm Copper alloy 0.08 to0.12 N/mm 2 350 (for7strands) N/mm 2 % 6 Copper 0.08 to0.12 0.15 to0.45 220 220 300 300 9 10 9. 10. 11. 12. 15. 16. 16(a). 16(b). a 16(c). a 17. 18. 19. 20. 21. 22. 23. Strand plating contin
41、uity Strand plating adherence Strand plating thickness Electrical resistance of conductor Conductor strand adhesion High voltage Immersion Dry spark Dry impulse Insulation resistance Surface resistance Accelerated ageing Thermal endurance Adherence of insulation on conductor Delamination and shrinka
42、ge Delamination and insulation blocking Maximum values shall be as given in Table 1 to Table 6 2500 75V r.m.s. 5000 150V r.m.s. 8000 250V peak Test temperature285 2 C. Time168h. Mandrel diameter and force shall be as given in Table 10 20000h minimum at200 2 C Minimum adherence forces shall be as giv
43、en in Table 10 Five cycles from room temperature to200 2 C holding 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 sizes24 to10, and one-quarter maximum outside diameter for sizes8 to0000 Test
44、temperature200 2 C. Time100h Mandrel diameter and tension shall be as given in Table 10 a Either test16(b) or16(c) may be carried out.BSG237:1987 4 BSI 01-2000 BSG230 test no. Test applicable to cable types01 and02 Specific requirements of this standard 24. 25. 26. 27. 28. 28(a). 28(b). 29. 30. 31.
45、35. 36. 37. 38. 38(a). 39. 40. 42. Room temperature bend Cold bend Dynamic cut-through Notch propagation resistance Flammability Method1 Method2 Resistance to fluids Scrape abrasion Overload resistance Climatic Identification durability Cable to cable abrasion Pliability Method1 Colour fastness to l
46、ight Current ratings Wet arc tracking Mandrel diameter and tension shall be as given in Table 10 Mandrel diameter and tension shall be as given in Table 10. Test temperature65 2 C. Time6h Test temperature200 2 C,6000g/min 10% at the sample. Minimum force to cut-through shall be as given inTable 10 F
47、ive specimens,15s exposure to flame Five specimens,15s exposure to flame Test temperature200 2 C. Force and cycles shall be as given in Table 10 T 1 =250 5 C T 2 =400 10 C Humidity. Carry out the test in accordance with clause2 c) of BSG229 a . Category A for type01 and category B for type02. Prepar
48、e the specimens by winding at least six turns on a mandrel of the diameter specified for test23 in Table 10. On removal from the chamber unwind the cable from the mandrel. It shall show no sign to normal vision of deterioration and the identification shall remain legible. The specimen shall then be
49、subjected to the immersion test test16(a), except that the specimen length may be reduced. Fungus resistance. Carry out the test in accordance with clause2 j) of BSG229 b . Category F. There shall be no sign to normal vision of fungus growth. Test temperature20 5 C. Minimum cycles100. Applied force2 0.1N Test to be applied to type02, class1 size20 only. Minimum cycles to failure: 0.5kg 5g,18 10 6cycles 1.0kg 10g,6 10 6cycles 2.5kg 25g,2.5 10 6cycles To be carried out on sizes24,22,
