1、 Reference number ISO 2635:2003(E) ISO 2003INTERNATIONAL STANDARD ISO 2635 Second edition 2003-11-15 Aircraft Conductors for general purpose aircraft electrical cables and aerospace applications Dimensions and characteristics Aronefs Conducteurs pour cbles lectriques pour usage gnral aronautique et
2、pour applications arospatiales Dimensions et caractristiques ISO 2635:2003(E) PDF disclaimer This PDF file may contain embedded typefaces. In accordance with Adobes licensing policy, this file may be printed or viewed but shall not be edited unless the typefaces which are embedded are licensed to an
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5、ound, please inform the Central Secretariat at the address given below. ISO 2003 All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission
6、in writing from either ISO at the address below or ISOs member body in the country of the requester. ISO copyright office Case postale 56 CH-1211 Geneva 20 Tel. + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyrightiso.org Web www.iso.org Published in Switzerland ii ISO 2003 All rights reservedISO
7、 2635:2003(E) ISO 2003 All rights reserved iiiForeword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each mem
8、ber body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International El
9、ectrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is to prepare International Standards. Draft International Standards ado
10、pted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this document may be the subject of pat
11、ent rights. ISO shall not be held responsible for identifying any or all such patent rights. ISO 2635 was prepared by Technical Committee ISO/TC 20, Aircraft and space vehicles, Subcommittee SC 1, Aerospace electrical requirements. This second edition cancels and replaces the first edition (ISO 2635
12、:1979), which has been technically revised. ISO 2635:2003(E) iv ISO 2003 All rights reservedIntroduction The need for International Standardization in the Aerospace industry cannot be overemphasized. Multinational projects abound in the construction industry and all major airlines use equipment prod
13、uced in different continents. The mixture of specifications and standards combine to increase the chances of maintenance errors, no more so than in the interconnection system. Power plant manufacturers in France may use conductors and terminations manufactured in Europe mating at the firewall with t
14、erminations and conductors manufactured in North America. This can result in different contacts, crimp tools and settings, and insulating stripping tools being required to work on mating connectors. The same would apply to many types of equipment. The requirement for close or “clipped” tolerance, li
15、ghtweight conductors can provide the opportunity to address many of these problems by overcoming the long-standing issue of AWG versus metric sizes. This revision of ISO 2635 introduces a list of lightweight conductors for airframe cables. This list supplements the existing list of standard metric c
16、onductors which has not received worldwide acceptance. The list is derived from NEMA standard WC 67 which includes the constructions in previous and existing specifications ISO 2635:1979, EN 2083, prEN 4434, BS 3G 231 and MIL-W-29606. It has also been compared with those used by airframe constructor
17、s. The conductor codes in Table 1 are taken from WC 67. The constructions presented are those which are considered to be standards within the existing rules governing aircraft cables, e.g. 19 strands minimum, copper alloy for size 24 and smaller. However, it does take advantage of the lightest weigh
18、t for each size. The resultant standard is therefore a mixture of conductors with metric and imperial origins which gives the greatest advantage to constructors and users for the future. This International Standard: obeys existing rules regarding conductors for aircraft; gives the lightest weight fo
19、r each size/rating presently used; standardizes the conductor cross sectional area throughout the world aerospace industry; enables the standardization of terminations and the crimp tools used to produce the joints; reduces the number of insulation stripping tools required to service aircraft; enabl
20、es the world industry to concentrate its efforts on improving interconnection technology knowing that a world market exists; enables regulatory authorities (CAA, FAA, JAA, etc.) to make rules regarding the interconnection system which applies internationally. All these will, by reducing complexity,
21、reduce servicing errors and contribute to aircraft safety. INTERNATIONAL STANDARD ISO 2635:2003(E) ISO 2003 All rights reserved 1Aircraft Conductors for general purpose aircraft electrical cables and aerospace applications Dimensions and characteristics 1 Scope This International Standard specifies
22、the dimensions, electrical characteristics and mechanical characteristics of multi-strand conductors for general-purpose aircraft electrical cables and aerospace applications. It applies to stranded conductors over the nominal cross-sectional area range 0,12 mm 2 to 107 mm 2inclusive. It is not appl
23、icable to conductors for fire-resistant cables or for thermocouple extension cables. Conductors for fire-resistant cables are specified in ISO 1967 and for thermocouple extension cables are specified in ISO 8056-1. 2 Normative references The following referenced documents are indispensable for the a
24、pplication of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 8815, Aircraft Electrical cables and cable harnesses Vocabulary 3 Terms and definitions For the purposes of
25、 this document, the terms and definitions given in ISO 8815 and the following apply. 3.1 conductor code numeric or alphanumeric code which designates conductor size and properties 3.2worldwide wire gauge WWG identification system, similar to the American wire gauge (AWG) system from which it has bee
26、n derived, for an international designation of wire cable sizes 4 Required characteristics 4.1 General The dimensions, electrical resistance, mechanical properties and mass of the conductors shall conform to the values given in Table 1 or Table 2. Table 2 should be used for new designs. ISO 2635:200
27、3(E) 2 ISO 2003 All rights reserved4.2 Materials 4.2.1 Conductors of nominal cross-sectional area 0,25 mm 2to 0,12 mm 2shall be produced from high- strength copper alloy, and conductors of nominal cross-sectional areas greater than 0,25 mm 2shall be produced in copper of electrotechnical quality (i.
28、e. ETP grade copper). 4.2.2 Conductors shall be manufactured from unused materials that have been exposed only to processes essential to their manufacture and application. 4.2.3 Size 24 and smaller conductors shall be made from high strength copper alloy. The larger sizes shall be electrotechnical g
29、rade copper. NOTE No ISO standards are available which specify aircraft grade copper and copper alloys. 4.2.4 The plating materials shall conform to the appropriate requirements of Clause 6. 4.2.5 These conductors in copper and copper alloy may be unplated (code letter A), tinned (code letter B), si
30、lver-plated (code letter C) or nickel-plated (code letter D) in accordance with the requirements of, and to the thickness required by, the individual specification for which the conductors are being used. The thickness of the silver-plating (code letter C) shall be at least 1,0 m and the thickness o
31、f the nickel-plating, (code letter D), at least 1,25 m. 5 Construction 5.1 Table 1 gives the number of strands to be used for each cross-section of conductor and gives the nominal conductor sizes over the range of nominal cross-sections from 0,15 mm 2to 107 mm 2 . Table 2 gives the required characte
32、ristics for a range of lightweight conductors, as described in the introduction to this International Standard, over the range of nominal cross-sections from 0,12 mm 2to 107 mm 2(WWG28 to WWG0000). 5.2 Strands shall be clean, bright and free from surface irregularities. 5.3 Conductors shall comprise
33、 the number and diameter of strands given in Table 1 or Table 2. Conductors shall be either concentric lay or rope lay. 5.4 There shall be no kinks, joints or other irregularities in the complete conductor. 5.5 Joints in single strands shall be brazed or hard soldered. There shall not be more than o
34、ne such joint in any 50 m of single strand. Joints in single strands shall not be within 300 mm of any other joint in the same layer. 6 Tests and requirements 6.1 Tensile strength and elongation 6.1.1 Method Use a tensile tester capable of 1 % accuracy, with jaw separation rates of 200 mm/min to 300
35、 mm/min (copper) and 40 mm/min to 60 mm/min (copper alloy). Test the whole conductor. The initial jaw separation shall be 245 mm to 255 mm. 6.1.2 Requirement Tensile strength and elongation at break of the conductor prior to insulation shall be as given in Table 1 or Table 2, based on an average of
36、three tests. ISO 2635:2003(E) ISO 2003 All rights reserved 36.2 Mass per unit length Weigh at least 1 m of conductor. The mass per unit length for each size shall be as given in Table 1 or Table 2. 6.3 Resistance 6.3.1 Method Measure the electrical resistance of the conductor (in ohms) and correct t
37、o 20 C using the following formula: for annealed copper: R T= R 20 1 + 0,003 931(T 20), or for copper alloy: R T= R 20 1 + 0,003 500(T 20) where T is the temperature, in degrees Celsius, of the conductor under test; R Tis the resistance of sample at temperature T; R 20 is the resistance at 20 C. 6.3
38、.2 Requirement The values calculated shall not exceed those given in Table 1 or Table 2. 6.4 Strand-plating continuity 6.4.1 Method Take three strands no less than 150 mm in length from a conductor previously straightened by hand. Degrease the strands without causing damage then wipe, using a clean
39、dry cloth. Ensure that any strands cleaned in this manner are not touched by hand. Immerse the strands for 30 s in a solution of sodium polysulfide of density 1,142 g/cm 3 at 20 C, then wash carefully in distilled water. In addition immerse silver- and nickel-coated strands for 15 s in a hydrochlori
40、c acid solution of density 1,088 g/cm 3at 20 C and wash carefully in distilled water. Examine the strands under a magnification of 30. 6.4.2 Requirement No adherent or distinct black spots shall be observed. Any blackening occurring less than 15 mm from each end shall be disregarded. 6.5 Strand-plat
41、ing adherence 6.5.1 Method Take three strands not less than 150 mm in length from a conductor previously straightened by hand. Wind each strand around itself, using half the specimen length as a mandrel so as to form 10 adjacent turns. Examine the strands under a magnification of 100. 6.5.2 Requirem
42、ent The plating shall not exhibit any detachment or cracks. ISO 2635:2003(E) 4 ISO 2003 All rights reserved6.6 Strand-plating thickness When measured by any approved method the thickness of silver shall be 1,0 m minimum and nickel plating shall be 1,25 m minimum. 7 Packaging and labelling 7.1 Conduc
43、tors conforming to this International Standard shall be uniformly wound on reels, bobbins or in coils and shall be protected against damage and the ingress of moisture. 7.2 Each reel, bobbin or coil shall have firmly attached to it a label bearing the following details: Name of conductor Identificat
44、ion block Table 1 Conductor, electric cable, in copper and copper alloy Conductor code Nominal cross- sectional area Approxi- mate wire gauge with reference to AWG Number of strands in conductor Nominal strand size Conductor diameter Electrical resistance at 20 C max. Mechanical properties Types A a
45、nd C Types B and D Elonga- tion Mass per unit length Ultimate breaking load mm 2mm min. mm max. mm /km /km min. % max. kg/km min. N 001 a0,15 26 19 0,10 0,46 0,53 149 160 6 1,60 46 002 a0,25 24 19 0,12 0,55 0,62 106 114 6 2,18 67 004 0,4 22 19 0,15 0,72 0,80 55,3 60,0 10 3,43 71 006 0,6 20 19 0,20 0
46、,94 1,04 31,0 33,2 10 5,95 127 010 1 18 19 0,25 1,18 1,29 19,6 21,1 10 9,16 198 012 1,2 16 19 0,30 1,39 1,53 13,6 14,5 10 13,2 285 020 2 14 37 0,25 1,68 1,82 10,2 10,9 10 18,0 385 030 3 12 37 0,32 2,12 2,28 6,40 6,80 10 28,5 645 050 5 10 37 0,40 2,69 2,88 4,00 4,20 10 46,0 1 000 090 9 8 117 4,40 2,3
47、0 2,40 10 86,1 140 14 6 127 5,50 1,50 1,55 10 133 220 22 4 182 6,80 0,910 0,940 10 214 340 34 2 201 8,60 0,585 0,620 10 333 420 42 1 245 9,50 0,480 0,500 10 402 530 53 0 322 10,7 0,375 0,390 10 526 680 68 00 416 12,1 0,295 0,305 10 685 850 85 000 513 13,6 0,233 0,240 10 849 107 107 0000 660 15,2 0,1
48、83 0,190 10 1 090 aHigh-strength copper alloy. ISO 2635:2003(E) ISO 2003 All rights reserved 5 Table 2 Conductor, electric cable, lightweight, in copper and copper alloy Conductor code (worldwide Mechanical properties wire gauge, WWG) Nominal cross- sectional area Rope construction Number of strands
49、 in conductor Nominal strand size Missing strands Diameter b (tight tolerance) mm Resistance (/km) max. Elonga- tion Mass per unit length Ultimate breaking load mm 2mm max. min. max. Plating code A and C Plating code D Plating code B min. % max. kg/km min. N W28 a0,12 19 0,09 0 0,41 0,44 164 176 N/A 6 1,30 36 W26 a0,15 19 0,10 0 0,45 0,49 149 160 N/A 6 1,40 46 W24 a0,25 19 0,12 0 0,55 0,59 106 114 N/A 6 2,00 67 W22 0,4 19 0,15 0
