SAE ARP 6216-2017 EWIS Wiring Insulation Breakdown Testing.pdf

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1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/ARP6216 AEROSPACE RECOMMENDED PRACTICE ARP6216 Issued 2017-07 EWIS Wiring Insulation Breakdown

5、 Testing RATIONALE Standardization of Electrical Wiring Interconnect Systems (EWIS) insulation breakdown testing for aerospace systems is critical for safety of maintenance personnel and preservation of aircraft systems. Reliable electrical insulation is a critical component of EWIS airworthiness. W

6、ire insulation is constantly stressed over its life. Dirt, moisture, various fluids, corrosion, vibration, electrical spikes and surges, mechanical stresses from pulling and tugging, and many other factors add up to further deteriorate insulation. This can be instantaneous, but is more likely to be

7、a slow and steady decline over time. The remaining life of the insulation could be measured in years, or it could break down at the next startup. Hipot (high potential voltage testing) or insulation breakdown testing can assist in finding wiring faults when electrical systems or components are funct

8、ioning intermittently due to a wiring faults. This ARP provides guidance in effective and safe ways of performing insulation break down testing (hipot) through the use of a Low-Energy High Voltage (LEHV) signal, which induces a spark at a defect location. As with all wire test methods, adherance to

9、recommended process and understanding the limitations of the test equipment and unit under test is pivotal to personnel safety and test outcome. SAE INTERNATIONAL ARP6216 Page 2 of 11 TABLE OF CONTENTS 1. SCOPE 3 2. REFERENCES 3 2.1 Applicable Documents 3 2.1.1 SAE Publications . 3 2.1.2 U.S. Govern

10、ment Publications 3 2.2 Related Publications 4 2.3 Definitions 4 3. EQUIPMENT REQUIREMENTS . 4 3.1 Copper Wiring . 4 3.2 Coaxial Cable, Triaxial, and Quadrax Cable . 4 3.3 Dielectric Withstand Voltage Tester (Hipot Tester) . 4 4. GENERAL TESTING PREPARATION 5 4.1 Warnings, Caution, Notes and System

11、Setup . 5 4.1.1 Warnings . 5 4.1.2 Cautions 5 4.1.3 System Setup 6 5. TEST PROCEDURES . 6 5.1 Specific Tests Voltages . 6 5.1.1 Specific Tests 6 5.1.2 Cautions 7 5.1.3 Test Setup . 7 5.1.4 Test Results 7 5.1.5 Test Cleanup . 7 5.1.6 Test Equipment . 7 5.1.7 Flow Chart . 8 6. NOTES 11 6.1 Revision In

12、dicator 11 Figure 1 Test points . 8 Figure 2 Test points showing test equipment connected 8 Figure 3 Spark created between wires when fault found 8 Figure 4 Shop-made adapters for hipot testing . 9 Figure 5 Hipot set to continuous mode will cause arcing damage to connector . 9 Figure 6 Pin to pin ar

13、cing . 9 Figure 7 Test flow chart . 10 SAE INTERNATIONAL ARP6216 Page 3 of 11 1. SCOPE This SAE Aerospace Recommended Practice (ARP) identifies the minimum requirements for the testing of insulated electrical wiring for on-aircraft, aeronautical and aerospace applications. The testing requirements d

14、efined herein, ensure that a wire fault can be found safely when using a high potential voltage tester (hipot). This test is intended to aid in finding a breach in the wire insulation, and not for the identification of the resistance of the insulation. The test method defined herein is limited to eq

15、uipment which ia able to control and limit the DC output to 1500 VDC maximum. This type of wire dielectric tester is typically designed to trip on current leakage and not necessarily on arc detection. This test method is solely designed to identify gross/large wire insulation damage or degradation.

16、For additional related information on this topic and related test methods, refer to the documents cited in Section 2. They are intended to aid the reader in the direction of this ARP and to provide more indepth information on wire and component insulation testing. 2. REFERENCES 2.1 Applicable Docume

17、nts The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this d

18、ocument and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, P

19、A 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. ARP1278 Oscilloscopic Method of Measuring Spark Energy AS4373 Test Methods for Insulated Electric Wire AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy AS50151 Connectors,

20、Electrical, Circular Threaded, AN Type, General Specification For AS85485 Cable, Electric, Filter Line, Radio Frequency Absorptive 2.1.2 U.S. Government Publications Copies of these documents are available online at http:/quicksearch.dla.mil. MIL-DTL-38999 Connectors, Electrical, Circular, Miniature

21、, High Density, Quick Disconnect (Bayonet, Threaded, And Breech Coupling), Environment Resistant, Removable Crimp and Hermetic Solder Contacts, General Specification For MIL-STD-1560 Insert Arrangements for MIL-DTL-38999, MIL-DTL-27599 and SAE-AS29600, Series A Electrical Circular Connectors MIL-T-8

22、1490 Transmission Lines, Transverse Electromagnetic Mode MIL-DTL-17 Cable, Radio Frequency, Flexible and Semi-Rigid, General Specification For MIL-PRF-28800 Test Equipment For Use With Electrical And Electronic Equipment, General Specification For SAE INTERNATIONAL ARP6216 Page 4 of 11 2.2 Related P

23、ublications The following publications are provided for information purposes only and are not a required part of this SAE Aerospace Technical Report. ArcSafe White Paper Defining Safe Operating Envelope of Low-Energy High-Voltage Techniques to Identify all tests shall be performed only after being i

24、solated from the component or aircraft ground plane and from any other devices or components. Testing specifications and methods are defined in the following sections. 3.2 Coaxial Cable, Triaxial, and Quadrax Cable For coaxial cabling, triaxial, quadrax cabling, and other transmission lines; the use

25、 of high voltage potential test gear is not approved. This restriction does not apply to twisted pair or shielded twisted pair wiring. 3.3 Dielectric Withstand Voltage Tester (Hipot Tester) This test is limited to Dielectric Voltage Withstand DC testers rated at, or below 1500 V. A suitable tester i

26、s required for aircraft use which meets the explosion proof performance requirement as per MIL-STD-810. The tester must be able to output a DC voltage capable of being ramped to 1500 VDC maximum, with current limiting to 5 mA peak (3.5 mA rms), with adjustable output frequency mode, and ability to s

27、hut down immediately after the fault is detected (spark event). An advanced hipot tester which can also identify the distance to fault utilizing signal processing software can make it easier to locate the fault. Conventional battery powered high potential voltage testers are prohibited. They can onl

28、y reliably aid in fault location utilizing continuous mode. Since this device continues to energize the wire while an arcing event is occuring, energy continues to disapate at the location of the arc. This energy can cause damage at the connector such as when it arcs from pin to pin. Additional perf

29、ormance requirements may apply as per procuring activity application needs, such as those in MIL-PRF-28800. SAE INTERNATIONAL ARP6216 Page 5 of 11 4. GENERAL TESTING PREPARATION 4.1 Warnings, Caution, Notes and System Setup 4.1.1 Warnings Due to high voltages (up to 1500 VDC) used in this procedure

30、it is critical that only trained and knowledgeable personnel perform these procedures and follow all safety precautions listed in test equipment instructions. Performance of these procedures without proper knowledge of platform systems can result in loss of aircraft systems, loss of aircraft and/or

31、injury or death to personnel. Ensure that the area is free from flammable and explosive materials. Never connect or disconnect High Potential Test Equipment while system is performing a test. This equipment, together with its accessories, works at high voltages. Any careless handling or non-observan

32、ce of the operating instructions can have dangerous consequences. Personnel fitted with a heart-pacemaker must not operate the instrument nor approach the test setup while it is in operation. Personnel working in areas where there are potential electrical hazards must be provided with and use person

33、al protective equipment (PPE) that is appropriate for the specific work to be performed. The electrical tools and protective equipment must be specifically approved, rated, and tested for the levels of voltage of which a person may be exposed. Continuous operation mode shall not be utilized (see Fig

34、ures 5 and 6). Ensure all aircraft electronic equipment is turned off and de-energized. The test area should be made out of bounds for unauthorized personnel. Ensure the harness is not shorted or connected to any components by testing with an ohmmeter (or equivalent) before hipot testing. The test m

35、ust be monitored throughout its duration. After testing is concluded, ensure all wires are allowed to discharge any potential accumulated charge that may have built up during testing. Do not touch the cable during hipot testing. No wire shall be tested if installation is routed through a fuel tank,

36、or if terminated to an explosive device. Ensure every individual cable/wire being tested, is disconnected and/or isolated from the component or aircraft ground plane and from any other devices or components. Failure to do so may result in damage to equipment or injury to personnel. 4.1.2 Cautions RE

37、FER TO THE AIRCRAFT MAINTENANCE MANUAL BEFORE CONDUCTING ANY HIGH VOLTAGE TESTING, TO AVOID CAUSING DAMAGE TO HARNESSES. DO NOT CONDUCT TESTING ON ENGINE HARNESSES (I.E., HARNESSES REMAINING WITH ENGINE AFTER REMOVAL FROM AIRCRAFT. Do not apply high voltages to wiring that has in-line components (di

38、odes, capacitors, resistors, etc). Failure to ensure in-line components are completely disconnected can result in damage to aircraft systems.Only apply minimum required voltage to perform the test in order to limit degradation to wire and connectors. SAE INTERNATIONAL ARP6216 Page 6 of 11 4.1.3 Syst

39、em Setup Ensure aircraft is grounded and safe for maintenance. Isolate any related circuit/harness to be tested (disconnect battery/pull circuit breaker). Disconnect wire harness under test from all other devices. Gain access to, and disconnect all equipment connectors, grounds, and wire terminating

40、 devices. Prior to application of any high voltage inspect test setup, ensure all equipment is properly disconnected and any disconnected terminals are stowed to prevent arcing to structure. Setup all equipment in accordance with manufacturers instructions. Ensure all safety related devices are inst

41、alled and equipment is in working order and is used per manufacturers directions. 5. TEST PROCEDURES 5.1 Specific Tests Voltages Typically, 1500 VDC is needed to find a wire to shield fault. A wire fault is detected when a spark is produced between the wires because of the breakdown voltage of the a

42、ir dielectric (see Figure 3). An arc will be created and cause potential damage if the hipot tester is not set to trip as soon as the fault is found (spark event). Arcing can cause damage to wire and connectors and should be avoided (see Figure 5 and 6). The breakdown voltage of air varies depending

43、 on the distance, temperature, humidity, altitude, and the presence of wire contamination. The higher the temperature, humidity, altitude, and ionic contamination the less voltage that is needed for the breakdown in the air dielectric (spark event) and the opposite is true - the lower the temperatur

44、e, humidity, altitude, and ionic contamination the higher the voltage that is needed to breakdown the dielectric of air (spark event). The wire dielectric tester is typically designed to trip on current leakage not necessarily on arc detection. This test method is solely designed to identify gross/l

45、arge wire insulation damage or degradation. 5.1.1 Specific Tests To troubleshoot wire-to-shield, or wire-to-wire using a typical high potential voltage tester with an auto shutdown feature, use the ramp up mode and set the voltage to ramp up to 1500 VDC. If a fault is found, the tester will shut dow

46、n and display the breakdown voltage for the wire under test. Time to ramp up to 1500 VDC is about 25 seconds if no fault is found. For advanced high potential voltage testers the test may take 60 seconds, as unit ramps up in voltage levels, through a stepped approach. An optional high voltage test i

47、s apply the test voltage from zero to 1500 VDC at the rate of approximately 500 VDC per second as uniformly as possible. The duration of the application of the 1500 VDC should not exceed 60 seconds. Upon completion of the test, the voltage should be gradually reduced to avoid surges. The test must b

48、e monitored throughout its duration. Always connect the return lead of the test equipment first. The high voltage test lead should be handled only by the insulator. Never touch the metal clip directly. Prior to starting the test, double check and verify that the harness under test is disconnected on

49、 both ends and the test connections are correctly attached and secure. Hipot testers usually connect one side of the supply to safety ground (Earth ground). Connect the other side of the supply to the metal conductor being tested. With the supply connected like this there are two places a given conductor can be connected: high voltage or ground. When you have more than two contacts to be tested, connect one of the contacts to high volta