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1、BRITISH STANDARD AEROSPACE SERIES BS 2G 232: 1987 (Superseding BS G 232:1984) Specification for Electric cables for general airframe or equipment interconnect use (135 C), wrapped insulation UDC 629.7.064.5:621.315.33-408.4 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00 20
2、06, Uncontrolled Copy, (c) BSI BS 2G 232:1987 This British Standard, having been prepared under the direction of the Aerospace Standards Committee, was published under the authority of the Board of BSI and comes into effect on 30 September 1987 BSI 12-1999 The following BSI references relate to the
3、work on this standard: Committee reference ACE/6 Draft for comment 85/71991 DC ISBN 0 580 15920 5 Committees responsible 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 followin
4、g bodies were represented: BEAMA Ltd. British Airways British Rubber Manufacturers Association Civil Aviation Authority Electric Cable Makers Confederation Electronic Components Industry Federation Ministry of Defence National Supervising Inspectorate Society of British Aerospace Companies Limited A
5、mendments issued since publication Amd. No.Date of issueComments Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2G 232:1987 BSI 12-1999i Contents Page Committees responsibleInside front cover Forewordii 1Scope1 2Classification1 3Construc
6、tion1 4Designation and marking2 5Packaging and labelling2 6Tests2 7Reference samples6 Figure 1 Variation of resistance of copper with temperature15 Table 1 Type 01, class 1: single-core unscreened interconnect cables (135 C)6 Table 2 Type 02, class 1: single-core unscreened airframe cables (135 C)6
7、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 jacket (135 C)7 Table 5 Type 03, classes 2, 3 and 4: multi-core unscreened, twisted interconnect
8、 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 jacket, and multicore twisted and screened with jacket, interconnect cables (135 C)9 Table 8 Type 06
9、, 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 application10 Table 10 Specific test parameters12 Table 11 Current ratings in amperes for general purpose 135 C airframe cable14 Publications referred toI
10、nside back cover Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 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 requirem
11、ents for a range of lightweight thin-wall insulated cables that are individually suitable for general airframe or equipment interconnect use. It supersedes BS G 232:1984, which is withdrawn. It updates the 1984 edition and incorporates additional tests for type 05 and type 06 cables. The dielectric
12、insulation material is spirally lapped with an overall coating to provide 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
13、reliable performance over a full airframe life of not less than 50 000 h. Cables manufactured to this standard are not required to meet the fire resistance requirements of BS 3G 100-3.13, but they are required to satisfy the flammability requirements of BS G 230. NOTEThis cable may not be suitable f
14、or termination by certain soldering techniques. The user should ascertain that the cable and terminations are completely compatible. Attention is drawn to BS G 230 which specifies the general requirements for aircraft electric cables (second series). A British Standard does not purport to include al
15、l 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 confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and
16、 ii, pages 1 to 16, 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 the amendment table on the inside front cover. Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00
17、2006, Uncontrolled Copy, (c) BSI BS 2G 232:1987 BSI 12-19991 1 Scope This British Standard specifies construction and performance requirements for a range of lightweight cables with wrapped insulation suitable for general airframe use in the size range 26 to 0000, and for equipment interconnect in t
18、he size range 26 to 18. The following types of cable are specified. The cables are suitable for continuous use where the maximum stabilized conductor temperature does not exceed 135 C. They are suitable for applications involving flexing at temperatures down to 65 C. The cables are suitable for use
19、where the potential between conductors or between a conductor and screen, or the aircraft structure, does not exceed 600 V r.m.s. and the frequency does not exceed 2 000 Hz. Interconnect cables are suitable for use in areas with some physical protection, such as behind panels or bulkheads. They also
20、 have an application for the internal wiring of equipment. Airframe cables are of sufficiently robust construction to be used for open aircraft 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 s
21、tandard are listed on the inside back cover. 2 Classification Cables are classified according to the number of cores as follows: class 1: single 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
22、 the cables shall be defined and controlled to the satisfaction of the Approving Authority1). 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 properties of the cable have not been degraded.
23、 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 BS G 231 before fabricating into completed cable. 3.2.2 Copper strands shall be tin plated and high strength copper alloy strands shall be si
24、lver plated. 3.3 Insulation The insulation for interconnect cables shall consist of one or more overlapped tapes of insulating material and, for 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
25、of the cable. The insulating material shall be such that the performance requirements of this standard are satisfied. Only 100 % new materials that 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 bra
26、id having a coverage of 85 % minimum, and a lay factor less than 3 when calculated in accordance with Appendix A of BS G 230. There shall be no joints in 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 t
27、he outside of the screen. There shall be not more than one such break in any 300 mm length of cable or in any 10 m length of individual strand. Strands from which the braid is constructed shall be tin plated and comply with BS G 231 before braiding. 3.5 Jacket The jacket shall be made of an insulati
28、ng material, and shall be constructed, such that the performance requirements of this standard are satisfied. Type 01interconnectSingle-core or twisted Type 02airframemulti-cores only Type 03interconnectTwo or more cores, Type 04airframewith an outer jacket Type 05interconnectSingle- or multi-core,
29、Type 06airframewith a screen and outer jacket 1) The Approving Authority is either: a) for UK Civil Aviation products, the Civil Aviation Authority (or their accredited representatives); or b) for UK military products, information is available from the Procurement Executive, Ministry of Defence, Dir
30、ectorate General of Defence Quality Assurance, Directorate of Standardization, Kentigern House, 65 Brown Street, Glasgow G2 8EX. Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2G 232:1987 2 BSI 12-1999 3.6 Single-core cables The mass and
31、 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 two or more single cores complying with 3.6, twisted toget
32、her with a lay of approximately 12 times the pitch circle diameter for sizes 26 to 4 and approximately 16 times the pitch circle diameter for sizes 2 to 0000. Types 01 and 02 shall consist of twisted assemblies of single-core cable, types 03 and 04 of twisted assemblies with an outer jacket, and typ
33、es 05 and 06 of twisted assemblies with a screen and outer jacket. 3.8 Colour The colour of the insulation for class 1 cables, the core insulation for multi-core cables and the jackets shall comply with BS G 230. 4 Designation and marking 4.1 Manufacturers marking and designation The designation and
34、 marking of the cables shall be in accordance with BS G 230. 4.2 User applied marking 4.2.1 The surface of the insulation or coating of type 02 (airframe) cable shall be suitable for the acceptance of user applied identification marks by at least one of the following methods: a) hot stamp marking; b
35、) laser marking; c) ink jet. The cable manufacturer shall declare which method is suitable and the tests given in clause 6 shall be performed using cables that have been so marked. 4.2.2 Appropriate methods of marking the outer jacket of cable types 03, 04, 05 and 06 shall be declared by the manufac
36、turer 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 any other method that may degrade the insulation material. 5 Packaging and labelling The cables shall be packaged and labelled i
37、n accordance with BS G 230. 6 Tests The following tests shall be carried out in accordance with BS G 230. Specific requirements of this standard are given against the appropriate test. The application of each test for qualification approval, production quality testing, inspection lot testing and pro
38、duction routine testing shall be as given in Table 9. All qualification approval test specimens shall be marked in accordance with clause 4 before commencement of testing. NOTEFor qualification approval testing, specimens selected from a particular size within the following groups may be considered
39、as proving the requirements for all sizes within that group of a given type (see clause 1). Qualification of type 05 cable may be considered as proving the requirements of type 03, classes 2 to 4, and type 06 as proving type 04, classes 2 to 4. Group 1. Sizes 26 to 24, type 02, classes 1 to 4 Group
40、2. Sizes 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,
41、classes 1 to 4 Group 9. Sizes 26 to 18, type 05, classes 1 to 4 Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2G 232:1987 BSI 12-19993 BS G 230 test no. Test applicable to cable types 01 and 02Specific requirements of this standard 1.Ap
42、pearance 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 examination of strands 5.Insulation thickness and concentricity Minimum values shall be as given in Table 1 and Table 2 6.Cor
43、e and cable outer diametersMinimum and maximum values shall be as given in Table 1 to Table 6 7.Tensile strength and elongation at break of copper or copper alloy conductors Values shall be as follows: Strand diameter Tensile strengthElongation Min.Max.Min. mm N/mm2N/mm2 % Copper alloy: 0.08 to 0.12
44、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.Strand plating adherence 12.Electrical resistance of conductorMaximum values shall be as given in Table 1 to Table 6 14.Solderability 14(a).Method 1This test shall be carried out on sizes 20 t
45、o 26 only. Use non-activated flux complying with 4.6.2 of BS 2011-2.1T:1981 and solder of grade KP of BS 219. Solder bath temperature 235 3 C. Wetting time 2.0 s 14(b).Method 2 15.Conductor strand adhesion 16.High voltage 16(a).Immersion2 500 75 V r.m.s. 16(b).aDry spark5 000 150 V r.m.s. 16(c).aDry
46、 impulse8 000 250 V peak 17.Insulation resistance 18.Surface resistance 19.Accelerated ageingTest temperature 200 2 C. Time 168 h. Mandrel diameter and force shall be as given in Table 10 20.Thermal endurance50 000 h minimum at 135 2 C 21.Adherence of insulation on conductor Minimum adherence forces
47、 shall be as given in Table 10 22.Delamination and shrinkageFive cycles from room temperature to 135 2 C holding the top temperature for 1 h and allowing the cable to return to room temperature between cycles. Maximum length of conductor exposed at each end is 1.0 mm for sizes 26 to 10, and one-quar
48、ter maximum outside diameter for sizes 8 to 0000 23.Delamination and insulation blocking Mandrel diameter and tension shall be as given in Table 10. Test temperature 135 2 C. Time 100 h a Either test 16(b) or 16(c) may be carried out. Licensed Copy: sheffieldun sheffieldun, na, Tue Nov 28 14:15:28 G
49、MT+00:00 2006, Uncontrolled Copy, (c) BSI BS 2G 232:1987 4 BSI 12-1999 BS G 230 test no. Test applicable to cable types 01 and 02 Specific requirements of this standard 24.Room temperature bendMandrel diameter and tension shall be as given in Table 10 25.Cold bendMandrel diameter and tension shall be as given in Table 10. Test temperature 65 2 C. Time 6 h. 26.Dynamic cut-throughTest temperature 135 2 C, 6 000 g/min 10 % at the sample. Minimum force to cut-through shall be as given in Ta
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