1、 MIL-HDBK-522 26 October 2010 DEPARTMENT OF DEFENSE HANDBOOK GUIDELINES FOR INSPECTION OF AIRCRAFT ELECTRICAL WIRING INTERCONNECT SYSTEMS This handbook is for guidance only. Do not cite this document as a requirement. AMSC N/A FSC 6145 INCH-POUND Provided by IHSNot for ResaleNo reproduction or netwo
2、rking permitted without license from IHS-,-,-MIL-HDBK-522 ii FOREWORD 1. This handbook is approved for use by all Departments and Agencies of the Department of Defense (DoD). 2. This handbook is for guidance only. This handbook cannot be cited as a requirement. If it is, the contractor does not have
3、 to comply. 3. This handbook is a guide for aircraft Electrical Wiring Interconnect System (EWIS) inspection. In case of conflict between the aircraft/platform-specific maintenance manual and this handbook, the platform specific manual will take precedence. Not all possible wire systems factors have
4、 been addressed. This handbook captures in one document, under suitable subject heading, fundamental installation criteria guidelines. The opportunity to focus on a single document results in substantial savings to the Government. 4. All aircraft are filled with miles of wiring and hundreds of wirin
5、g devices that connect and transfer power and signals to and from electrical components. Virtually all aircraft systems rely heavily on some type of wiring for safe operation. Much like the structural components of an aircraft, the health and integrity of the EWIS can be significantly compromised du
6、e to premature aging, damage, and failure of wiring insulation. It is integral to the overall maintenance and sustainment of all aircraft that the EWIS be treated as a system and as a system be afforded the same level of importance as the aircraft structure and other critical flight control systems.
7、 5. The majority of aircraft wiring in military service is of a thin-walled construction, and by its very nature, is susceptible to mechanical damage. However, there are several factors that may contribute to premature aging, damage, and failure of wiring insulation, including but not limited to: a.
8、 Wire/Bundle location (Severe Wind and Moisture Problem (SWAMP) Areas) b. Temperature cycling c. Contamination d. Improper installation e. Mishandling f. Poor maintenance practices g. Lack of effective inspection and maintenance training h. Battle damage 6. This handbook was prepared by, and is regu
9、larly updated through, the cooperative efforts of Government and industry. Applicable documents are listed in each individual guideline. Additional information regarding aerospace vehicle wiring requirements are found in SAE-AS50881 “Aerospace Vehicle Wiring.” Copies of SAE-AS50881 are available fro
10、m the Society of Automotive Engineers at the address given in section 2 of this handbook. 7. When a Joint Service manual is referenced throughout this document, the Navy equivalent is listed in each guideline. For other services technical manual numbers, refer to table I. See 2.2 for information on
11、how to obtain copies of maintenance manuals referenced in this handbook. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 iii TABLE I. Topic and tri-service maintenance manual cross reference. 8. Comments, suggestions, questions or additi
12、onal information on this document should be addressed to: Naval Air Warfare Center Aircraft Division, Code 4L8000B120-3, Highway 547, Lakehurst, NJ 08733-5100 or by email to michael.sikoranavy.mil. The technical content contained in this handbook has been provided by NAVAIR Wiring Systems Branch AIR
13、 4.4.5.3 (48298 Shaw Road Bldg. 1461, Patuxent River, MD 20670-1161) and through the Joint Service Wiring Action Group (JSWAG) email: jswagnavy.mil; web site: http:/www.navair.navy.mil/jswag. Manual Topic Navy Air Force Army USMC General Wiring 01-1A-505-1 1-1A-14 1-1500-323-24-1 01-1A-505-1 Circula
14、r Connectors 01-1A-505-2 00-25-255-1 1-1500-323-24-2 01-1A-505-2 Rectangular Connectors 01-1A-505-3 00-25-255-2 1-1500-323-24-3 01-1A-505-3 Fiber Optics 01-1A-505-4 1-1A-14-4 1-1500-323-24-4 01-1A-505-4 Soldering/ESD 01-1A-23 00-25-259 5895-45/1C 5895-45/1D Corrosion Program and Corrosion Theory 01-
15、1A-509-1 1-1-689-1 1-1500-344-23-1 01-1A-509-1 Avionics and Electronics Cleaning and Corrosion Prevention/Control 01-1A-509-3 1-1-689-3 1-1500-344-23-3 01-1A-509-3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 iv CONTENTS 1. SCOPE . 1
16、2 . APPLICABLE DOCUMENTS 1 3. DEFINITIONS 2 4. GENERAL GUIDELINES 5 5. DETAIL GUIDELINES 5 6. NOTES 5 GUIDELINE 1 6 INTRODUCTION AND INSPECTION TECHNIQUES 6 GUIDELINE 2 8 INCOMING WIRE INSPECTION FROM THE SUPPLY SYSTEM 8 GUIDELINE 3 11 INSULATION INSPECTION . 11 GUIDELINE 4 14 CONNECTOR MATING INSPE
17、CTION 14 GUIDELINE 5 17 COAXIAL CABLE INSTALLATION INSPECTION . 17 GUIDELINE 6 19 PROPER CAPPING AND STOWAGE OF CONNECTORS . 19 GUIDELINE 7 22 PROPER MARKING OF WIRE/FIBER OPTIC AND CABLE HARNESSES . 22 GUIDELINE 8 24 MECHANICAL STRIPPING WIRE INSPECTION . 24 GUIDELINE 9 28 MECHANICAL STRIPPING/SHIE
18、LDING REMOVAL INSPECTION . 28 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 v CONTENTS GUIDELINE 10 30 THERMAL/LASER STRIPPING CABLE JACKET INSPECTION . 30 GUIDELINE 11 32 HARNESS ROUTING INSPECTION 32 GUIDELINE 12 34 CABLE HARNESS COV
19、ERING OR PROTECTION INSPECTION . 34 GUIDELINE13 . 38 CABLE HARNESS BEND RADIUS INSPECTION 38 GUIDELINE 14 40 PRIMARY SUPPORT CABLE CLAMP INSPECTION 40 GUIDELINE 15 47 WIRE/HARNESS CLEARANCE INSPECTION . 47 GUIDELINE 16 49 SPOT TIE/LACING TAPE/CORD INSPECTION . 49 GUIDELINE 17 54 HARNESS DRIP LOOP IN
20、SPECTION 54 GUIDELINE 18 56 TIE DOWN STRAP, PLASTIC, SELF-CLINCHING (ZIP TIE) INSPECTION . 56 GUIDELINE 19 58 EMI SHIELD WRAP-AROUND REPAIR INSPECTION . 58 GUIDELINE 20 60 SHIELD CRIMP RING INSPECTION . 60 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-
21、,-,-MIL-HDBK-522 vi CONTENTS GUIDELINE 21 62 CONTACT CRIMP INSPECTION . 62 GUIDELINE 22 64 TERMINAL LUG CRIMP INSPECTION 64 GUIDELINE 23 67 SPLICE INSPECTION 67 GUIDELINE 24 70 SOLDER SLEEVE/SHIELDING TERMINATION INSPECTION . 70 GUIDELINE 25 72 SOLDER INSPECTION 72 GUIDELINE 26 74 BONDING STRAP/JUMP
22、ER INSPECTION . 74 GUIDELINE 27 76 LOCK WIRE/SAFETY CABLE INSPECTION . 76 GUIDELINE 28 80 TERMINAL BOARD, GROUND STUD, AND BACKSHELL INSPECTION 80 GUIDELINE 29 84 CONNECTOR INSPECTION . 84 GUIDELINE 30 88 CONNECTOR STRAIN RELIEF INSPECTION . 88 GUIDELINE 31 90 CONNECTOR BACKSHELL INSPECTION . 90 Pro
23、vided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 vii CONTENTS GUIDELINE 32 92 PRESERVATION OF CONNECTOR COMPONENT INSPECTION 92 GUIDELINE 33 95 CIRCUIT BREAKER INSPECTION 95 CONCLUDING MATERIAL . 98 Provided by IHSNot for ResaleNo reproducti
24、on or networking permitted without license from IHS-,-,-MIL-HDBK-522 1 1. SCOPE 1.1 Guidelines applicable to aircraft Electrical Wiring Interconnect Systems (EWIS). This handbook provides guidance and lessons learned in the inspection of EWIS. This handbook is for guidance only and cannot be cited a
25、s a requirement. If it is, the contractor does not have to comply. 1.2 Re-dating. Although individual guidelines are reviewed and updated or validated at least once every eighteen months, guidelines are not re-dated unless technical changes are made. 1.3 Method of reference. Guidelines contained her
26、ein should be referenced by specifying this handbook and the guideline number for guidance only. 1.4 Interrelationship of guidelines. Each guideline is intended to cover some discipline in the inspection of EWIS, such as a procedure, a process, or the selection and application of parts and materials
27、. Many of these disciplines, however, cannot retain a clear-cut separation or isolation from others so that when guidelines of MIL-HDBK-522 are referenced in a specification some guidelines will undoubtedly have a direct interrelationship with other guidelines. This interrelationship should be taken
28、 into consideration when referencing these guidelines. 2. APPLICABLE DOCUMENTS 2.1 Individual guidelines. See section 2 of each individual guideline for a listing of applicable documents. Documents referenced in the individual documents apply to the extent specified herein. (Copies of military docum
29、ents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2 Copies of maintenance manuals. Copies of maintenance manuals NA 01-1A-505-1 thru -4, may be obtained by DoD employe
30、es and uniformed users by going to the NATEC site https:/mynatec.navair.navy.mil/ and using their Common Access Card (CAC) to access the documents. Commercial entities requesting copies of these documents should reference this site for maintenance manual access via the freedom of information act req
31、uests. 2.3 Industry addresses. Addresses for obtaining documents referenced in the guidelines but not obtainable from the Government are as follows: NEMA National Electrical Manufacturers Association 1300 North 17th Street Suite 1752 Roslyn, Virginia 22209 Online: http:/www.nema.org SAE Society of A
32、utomotive Engineers 400 Commonwealth Drive Warrendale, PA 15096-0001 USA Online: http:/www.sae.org Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 2 3. DEFINITIONS 3.1 Airborne, space, aerospace. “Airborne“ denotes those applications pec
33、uliar to aircraft and missile or other systems designed for operation primarily within the earths atmosphere; “space“ denotes application peculiar to spacecraft and systems designed for operation near or beyond the upper reaches of the earths atmosphere; and “aerospace“ includes both airborne and sp
34、ace applications. 3.2 Bend radius. Maximum amount a wire, cable, fiber, or fiber cable can be bent without causing damage. Usually called minimum safe bending radius. 3.3 Bird Cage. Defect in stranded wire where the strands in the stripped portion between the covering of an insulated wire and a sold
35、ered connection (or an end-tinned lead) have separated from the normal lay of the strands. 3.4 Bonded assembly. Connector assembly in which the components are bonded together using an electrically appropriate adhesive in a sandwich type structure. Provides sealing against moisture and other environm
36、ental conditions which weaken electrical insulating properties. 3.5 Chamfer. Funnel type angle on the inside edge of the barrel entrance of a connecter insert and/or socket contact, which permits easier insertion of a pin contact into the barrel. 3.6 Coaxial cable. Cable consisting of two cylindrica
37、l conductors with a common axis. The two conductors are separated by a dielectric. The outer conductor or shield, normally at ground potential, acts as a return path for current flowing through the center conductor and prevents energy radiation from the cable. The outer conductor is commonly used to
38、 prevent external radiation from affecting the current flowing in the inner conductor. The outer conductor consists of woven strands of wire or is a metal sheath. 3.7 Conduit. Tube or trough in which insulated wires and cables are run. 3.8 Connector. Describes all interface devices, either plug or r
39、eceptacle, used to provide rapid connect/disconnect service for electrical cable and wire interconnections. A fixed connector is used for attachment to a rigid surface, while a free connector mates with the wire or cable. Connectors used in military applications generally fall into three broad categ
40、ories: single contact coaxial connectors, circular multi-contact connectors, and rectangular multi-contact connectors. 3.9 Discrepancy. A clearly identifiable deviation from the original design of the system as identified in the source data. 3.10 Dust Cover. Item that is specifically designed to cov
41、er the mating end of a connector for mechanical and/or environmental protection. 3.11 Electrical Wiring Interconnect System (EWIS). Known as aircraft wiring, is defined as any wire, fiber optic link, wiring or fiber device, or a combination of these items (including Provided by IHSNot for ResaleNo r
42、eproduction or networking permitted without license from IHS-,-,-MIL-HDBK-522 3 terminations) installed in any area of the aircraft for the purpose of transmitting electrical energy, signals, or data between two or more electrical end points. 3.12 Electromagnetic Interference (EMI). Frequency spectr
43、um of electromagnetic radiation extending from subsonic frequency to X-rays. Shielding materials for the entire EMI spectrum are not readily available. 3.13 Environmentally sealed. Device that is provided with gaskets, seals, grommets, potting, or other means to keep out moisture, dirt, air, or dust
44、 which might reduce performance. Does not include non-physical environments such as Radio Frequency (RF) and radiation. 3.14 Grommet. Rubber seals that are placed in the cable side of a connector with hole patterns that correspond to the insert configuration. The wires entering the rear of the conne
45、ctor go through the grommet and are affixed to the contacts. Inside the rubber grommet are one or more seals which hold themselves against the wire and prevent moisture and dirt from entering the contact cavity. 3.15 Harness. Assembly of wires and/or cables arranged so they may be installed or remov
46、ed as a unit. 3.16 Heat shrinkable. Term describing tubes, sleeves, caps, boots, films, or other forms of plastic which shrink to encapsulate, protect, or insulate connections, splices, terminations, and other configurations with the application of heat. Heat shrinkable sleeves are typically defined
47、 in SAE-AMS-DTL-23053. 3.17 Lacing tape. Flexible, flat fabric tape for tying harnesses and wire bundles, securing of sleeves and other items, and general lacing and tying applications. Available in various materials and impregnants. 3.18 Lay. Lay of any helical element of a cable is the axial lengt
48、h of a turn of the helix of that element. Among the helical elements of a cable may be each strand in a concentric-lay cable or each insulated conductor in a multi-conductor cable. Lay is often referred to as pitch. 3.19 Lay, direction of. Direction in which the strands or a conductor or components
49、in a cable pass over the top of the bundle as they recede from an observer looking along the axis of the conductor or cable. Termed right hand or left hand (see lay). 3.20 Marker tape. Tape laid parallel to the conductors under the sheath in a cable, imprinted with the manufacturers name and the specification to whic
