Cable Clamp Installation and Selection

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Questions and Answers

What is the recommended insulating sleeve length for a 2 AWG wire splice?

2-1/8 inches

2-13/32 inches (correct)

2-15/16 inches

2-25/32 inches

Why should splicing of electrical wire be kept to a minimum?

It is time-consuming

It is subject to extreme vibrations (correct)

It is prone to faults

It is only allowed in specific locations

What type of splice connector is preferred for use in aircraft?

Splice connector with a metal sleeve

Non-insulated splice connector

Insulated splice connector with a plastic sleeve

Self-insulated splice connector (correct)

What is the maximum number of splices allowed in one wire segment between connectors?

One splice Signup and view all the answers

What is the purpose of covering a non-insulated splice connector with plastic sleeving?

To insulate the splice Signup and view all the answers

Why should splicing of individual wires in a group or bundle require engineering approval?

To ensure the splice is located for periodic inspection Signup and view all the answers

When is it acceptable to have multiple splices in one wire segment?

All of the above Signup and view all the answers

What is the recommended approach to splicing electrical wires in aircraft?

Minimize splicing and avoid it in locations subject to extreme vibrations Signup and view all the answers

What is the characteristic of splice pre-insulation?

It extends over the wire insulation Signup and view all the answers

What is the purpose of the colour-coding on splices?

To match the colour-coding of insulated copper terminal lugs Signup and view all the answers

What is the approved tool for crimping M81824 environmental splices?

M22520/5 and M22520/10 crimp tools with appropriate dies Signup and view all the answers

How many times must the crimping operation be performed for M81824 environmental splices?

Twice Signup and view all the answers

Where should mount cable clamps be directly attached to?

Z members of the structure Signup and view all the answers

What is the purpose of the inspection hole in the splice?

To check the wire ends after crimping Signup and view all the answers

What type of bracket should be used when the structural member is angled?

An angle bracket with two mounting screws Signup and view all the answers

What is the stripping length for #26 and #24 wires?

5/32 Signup and view all the answers

What is used to provide electrical and mechanical protection to uninsulated splices?

Heat-shrink tubing or transparent flexible sleeving Signup and view all the answers

What is the primary consideration when selecting clamps for wire bundles?

A snug fit without pinching wires Signup and view all the answers

What is the recommended test to ensure the clamp is secure on RF cables?

Apply a slight axial pull Signup and view all the answers

What is the characteristic of uninsulated splices?

They are used for large copper wires Signup and view all the answers

Why should metal clamps be avoided on coaxial RF cables?

They may distort the RF cable's original cross-section Signup and view all the answers

What should be installed when there is less than 1 cm clearance between the bulkhead cut-out and the wire bundle?

A suitable grommet Signup and view all the answers

Why should the attachment hardware of cable clamps be positioned above them?

To prevent the clamp from rotating due to wire bundle weight or chafing Signup and view all the answers

What can be used to achieve a snug fit on wire bundles when required?

Electrical tape Signup and view all the answers

What is a major concern when installing and maintaining coaxial cable?

Erroneous electronic equipment indications and interference Signup and view all the answers

What is the recommended practice for routing coaxial cable around corners?

Use a minimum bend radius of 6 times the diameter of the cable Signup and view all the answers

Why should cable ties not be used with coaxial cable?

They can crush the dielectric and damage the cable Signup and view all the answers

What is the purpose of grounding the braided outer conductor of coaxial cable?

To protect electronic circuitry Signup and view all the answers

Why is it important to support coaxial cable at regular intervals?

To prevent damage from being stepped on Signup and view all the answers

What can happen if a coaxial cable becomes kinked or dented?

Electrical interference may occur Signup and view all the answers

What should be done when installing coaxial cable?

Route the cable as directly and as short as possible Signup and view all the answers

What can happen if the length of a coaxial cable is changed during maintenance?

The cable may malfunction or cause interference Signup and view all the answers

At what maximum interval should wires and cables be supported by suitable clamps or devices?

24 in. Signup and view all the answers

Why must metal stand-offs be used to maintain clearance between wires and structure?

To prevent damage to equipment shock mounts Signup and view all the answers

What is the purpose of insulating tubing?

To protect wires and cables from abrasion Signup and view all the answers

Why should wires and cables be routed carefully?

To prevent chafing against the airframe Signup and view all the answers

What is the recommended way to secure insulating tubing?

Tying, tie straps or clamps Signup and view all the answers

What is prohibited in place of stand-offs for maintaining clearance?

Insulating tubing Signup and view all the answers

Why is it important to properly support wires and cables?

To prevent excessive movement in areas of high vibration Signup and view all the answers

What should be done with wires and cables in junction boxes, panels, and bundles?

Properly support and lace them Signup and view all the answers

Study Notes

Mounting Cable Clamps

Mount cable clamps directly to Z members of the structure.
Use an angle bracket with two mounting screws if the structural member is angled.

Cable Clamps on Wire Bundles

Select clamps to achieve a snug fit without pinching wires.
Ensure clamps do not allow the bundle to move through the clamp when a slight axial pull is applied.

Cable Clamps on RF Cables

Ensure clamps fit without crushing the cable.
Select clamps that are snug enough to prevent the cable from moving freely through the clamp but allow the cable to slide through the clamp when a light axial pull is applied.

Wire Bundles Near Bulkheads

Install a suitable grommet if there is less than 1 cm (3/8 of an inch) clearance between the bulkhead cut-out and the wire bundle.

Clamp Installation

Install clamps with their attachment hardware positioned above them, wherever practicable, to prevent rotation due to wire bundle weight or chafing.

Splicing

Splicing Procedure for M81824 Environmental Splices

Crimp twice, once for each end of the splice.
Strip wires according to the table below:
- #26 and #24: 5/32 inches
- #22 - #14: 7/32 inches
- #12 - #10: 5/16 inches
Check that wire ends are visible through the inspection hole after crimping.

Splicing Large Copper Wires

Use uninsulated splices for large copper wires (No. 8 through No. 4/0).
Insulate splices with either heat-shrink tubing or transparent flexible sleeving after assembly.

General Requirements for Splicing

Keep splicing to a minimum and avoid splicing in locations subject to extreme vibrations.
Avoid splicing individual wires in a group or bundle without engineering approval.
Use self-insulated splice connectors or non-insulated splice connectors with plastic sleeving.

Coaxial Cable Installation Precautions

Install coaxial cables directly and as short as possible to minimize radio frequency interference (RFI) hazards.
Ground the braided outer conductor at one or both ends to protect electronic circuitry.
Avoid using cable ties, which can crush the dielectric and damage the cable.
Route cables with a minimum bend radius of 6 times the diameter of the cable to prevent kinking.

Wire Support

Support wires and cables at intervals of not more than 24 in. with suitable clamps, grommets, or other devices.
Ensure supports do not restrict wires or cables in a manner that interferes with equipment operation.
Use metal stand-offs to maintain clearance between wires and structure.
Insulating tubing is secured by tying, tie straps, or clamps, but not used as an alternative to stand-offs for maintaining clearance.

Protection

Route wires and cables to prevent chafing against the airframe or other components.

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Description

Learn about the proper installation and selection of cable clamps, including mounting considerations and wire bundle fitting. Ensure secure and damage-free connections.