Clamp Orientation

90±5°

Correct Incorrect

Correct 90±5° Incorrect

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 Example - Clamp Distortion

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Plastic Snap-in Clamp (Tie Mount)
support
bracket

snap-in tie
mount

release
tail
tab

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 Typical Rubber Clamp
All wires contained
Rubber cushion
in rubber cushion

Clamp Wedge
tabs
No
pinching
Stand off
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 Engage Clamp Tab in Slot

Incorrect

Clamp
tab

Clamp
slot
Correct
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 Clamping

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 Clamping

B
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Wire Bend Radii

4Minimum bend radius - 10 times the

outside diameter of the largest wire
or cable in the group — unsupported
„ Exceptions
4 Terminations/reversing direction in bundle
(supported at both ends of loop) -
3 times the diameter
4 RF cables - 6 times the diameter
4 Thermocouple wire - 20 times the diameter

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 Minimum Bend Radii

No support at Min. bend radius - 10 x

end of bend parameter of wire or cable

Min. bend radius

3 x diameter of wire

Diameter of Support at both

wire or cable ends of wire bend
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 Bend radii okay-
Greater than 3 times diameter
(secured at both ends of loop)

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 Bend radii problem-
Less than 3 times the diameter

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Unused Wires

4Secured
„ Tied into a bundle or secured to a
permanent structure

4Individually cut with strands even

with insulation

4Pre-insulated, closed-end connector

or 1-inch piece of insulating tubing
folded and tied back
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Spare Connector Contact: Single
Contact Attachment to Wire Bundle
Wire Tying tape
bundle

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 Unused wiring
* Improper termination with exposed conductor.
* Should be properly capped (insulated) and
secured to bundle.
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 Coil and Stow Methods
Wire
bundle Wire
bundle
ties
Clamp

Coil and stow short wire bundles

in low vibration areas 15
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 Coil and Stow Methods, cont.

Wire bundle ties

Clamp

Excess wire
Wire bundle

Coil and stow long wire bundles

in low vibration areas
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 Coil and Stow Methods, cont.

Wire
bundle Teflon Wire
tape bundle
ties

Adjacent wire bundle

Coil and stow in medium

and high vibration areas
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 Stowing Unused Wires

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Wire Replacement

4Wires should be replaced when:

„ Chafed or frayed
„ Insulation suspected of being
penetrated
„ Outer insulation is cracking
„ Damaged by or known to have been
exposed to electrolyte, oil, hydraulic
fluid, etc.
„ Evidence of overheating can be seen
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Wire Replacement, cont.

4Wire should be replaced when:

„ Wire bears evidence of being crushed
or kinked
„ Shield on shielded wire if frayed
and/or corroded
„ Wire shows evidence of breaks, cracks,
dirt, or moisture in plastic sleeving
„ Sections of wire have splices occurring
at less than 10-ft intervals
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Wire Replacement, cont.

4Shielding requirements
„ Replacement wires must have the
same shielding characteristics as the
original wire, such as shield optical
coverage and resistance per unit
length

„ Replacement wires should not be

installed outside the bundle shield

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 Adding or Replacing Wires
on a Bundle

Chafing
Incorrect
procedure

Correct
procedure
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 AC 43.13-1b Topic Outline, cont.
4 Electrical load determination
4 Breaker and wire sizing/selection
4 Routing/clamping/bend radii
4Splicing
4 Wire terminals
4 Grounding and bonding
4 Wire marking
4 Connectors and conduits
4 Wire insulation properties
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Wire Splicing

4Keep to a minimum

4Avoid in high vibration areas

4Locate to permit inspection

4Stagger in bundles to minimize

increase in bundle size
4Use self-insulated splice
connector, if possible
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 Staggered Splices

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 Overheated wire at the splice

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 Ganged
wire
splices
(diodes)
with
proper
strain
relief

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 Ganged wire splices
with pre-load condition

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 AC 43.13-1b Topic Outline, cont.
4 Electrical load determination
4 Breaker and wire sizing/selection
4 Routing/clamping/bend radii
4 Splicing
4Wire terminals
4 Grounding and bonding
4 Wire marking
4 Connectors and conduits
4 Wire insulation properties
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Terminals

4Tensile strength of the wire-to-

terminal joint should be at least
the equivalent tensile strength of
the wire

4Resistance of the wire-to-terminal

joint should be negligible relative to
the normal resistance of the wire
WF#

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