Wires & Cables for Aerospace Applications

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Melvin Lambert
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1 Wires & Cables for Aerospace Applications Aerospace Business Unit

2 Draka Fileca S.A.S. is part of the Prysmian Group, the world leader in the cable systems industry, listed on the Milan Stock Exchange. With a global presence and a long-term industrial experience, the Group is strongly positioned in high-tech markets and offers the widest possible range of products, services, technologies and know-how. Guided by a spirit of conquest and innovation, Draka Fileca supports major aeronautic and space enterprises worldwide with their most ambitious projects. For over 50 years, the company is continuously developing and manufacturing wiring solutions through technological excellence. Draka Fileca offers a wide portfolio of products and the core competencies of its highly skilled and experienced specialists focus on improving all aspects of the cable performance, such as high temperature resistance, reducing weight and enhancing the communication data rates. To ensure the highest quality levels, the whole organization is certified under ISO 900, EN 900, ISO 00 as well as OHSAS 800. Wires & Cables for Space Applications Aerospace Business Unit Did you know? Draka Fileca s Wires and Cables for Space Applications catalog, dedicated to ESAcertified products, is now available as well. Directly download the brochure at : Draka Fileca is proud member of the following organizations : For more information please visit: Icons in this Catalog: Copper Conductor Copper-Clad Aluminum Conductor Aluminum Conductor High Temperature Light Weight High Voltage

DRAKA FILECA PRODUCTS EXCELLENCE IN A VARIETY OF APPLICATIONS Civil

examples : - Lights - Actuators - Flight-Test Cable families : DR,

UAVs Feeder cables 6 Application examples : - Electrical power

9353 DG, EN 85-003 DG, DH, AD 5 High-Voltage Cables 3 5 Application

Data-Transmission Cables Application examples : - I

Inflight-Entertainment - Avionics - Health-Monitoring Cable families

3 DRAKA FILECA PRODUCTS EXCELLENCE IN A VARIETY OF APPLICATIONS Civil Airplanes & Helicopters Airframe Hook-Up Wires Application examples : - Lights - Actuators - Flight-Test Cable families : DR, CF, DM, AD, M759, M7500, BG, VF Defense Airplanes, Helicopters and UAVs Feeder cables 6 Application examples : - Electrical power generation (High Power Systems) Cable families : A75 (DASSAULT), NSA 9353 DG, EN DG, DH, AD 5 High-Voltage Cables 3 5 Application examples : - Power Generation Cable families : AZ, DZ 6 Data-Transmission Cables Application examples : - I nflight-entertainment Systems - Avionics Cable families : COAX, TWINAX, QUAD, ETHERNET, USB.0, HDMI Optical Fiber 5 6 Application examples : - Inflight-Entertainment - Avionics - Health-Monitoring Cable families : MMF (semi-loose/tight) SMF (semi-loose/tight) various designs Application examples : - Equipment Interconnect - Temperature Sensoring Cable families : BF, BN, NEMA HP3, Thermocouples 5

4 en color codes, gauges, marking unshielded EN67-XXX Y zzz Z unshielded & jacketed EN66-XXX Y zzz Z shielded & jacketed EN73-XXX Y zzz Z EN7-XXX Y zzz Z S: Color Code (single-core) P: Color Code (multi-core) 007 : DMA-Family 008 : DM-Family* 009 : DRA-Family 00 : DR-Family* 0 : DZA-Family 0 : DZ-Family* * Suitable for P: Color Code (multi-core) 007 : CF-Family 008 : Dassault Specification F: Color Code (single/multi-core) 0 : CF-Family 0 : Dassault Specification F: Color Code (single/multi-core) 0 : DM-Family 03 : DR-Family (ML) 0 : DR-Family (MM) Code Y Gauge () Color 00 6 (Light Yellow) 00 (White) 00 (Light Green) 006 to 30 0 to (White) 5 Color code s - single-core - Color code p & COLOR CODE F - multi-core - - single/multi-core - No. of Cores in Cables Colors Color Code P (Unshielded) Color Code F () A * X B X X C 3 X X D X X E 5 X X F 6 X X G 7 X X H 8 X X I 9 X X J 0 X X * Light Green for 00 ( ) and Light Yellow for 00 ( 6) Jacket Color (if present): s 00/006/0 ( /0/6): Light Blue. All other Gauges: White. Colors (J, from left to right): Red-Blue-Yellow-Green-White-Black-Brown-Orange-Purple-Grey Gauge Nominal Cross Code Section (mm²) ,5 00 0,5 00 0, , , gauge sizes Gauge Nominal Cross Code Section (mm²) International color codes & en norms Natural Red: or A Green: 5 or D Grey: 8 or K Black: 0 or F Orange: 3 or H Blue: 6 or B White: 9 or E Brown: or G Yellow: or C Purple: 7 or J Cable Family en-standard cables : dr-series Arc-Tracking Resistant -65 C to +60 C 5 V AC ( to 0) High-Strength Alloy ( 6 & ) DR-SERIES Number Min. Max. of Cores Spiral Braid SINGLE CORE 6 DR EN67-00A 6 0 DRA EN67-009A 6 0 MULTI CORE DRB EN67-009B 6 0 x DRA DRC EN67-009C x DRA DRD EN67-009D 6 08 x DRA SHIELDED & JACKETED MLA EN7-03A 6 0 x DRA MLB EN7-03B 6 0 x DRA MLC EN7-03C x DRA MLD EN7-03D 6 0 x DRA MME EN7-0E x DRA MMX EN7-0X x DRA* * Available upon Request. DR-SERIES: DASSAULT SPECIFICATIONS According to Dassault Specifications -55 C to +00 C 5 V AC ( to 0) High-Strength Alloy ( 6 & ) Polyimide and Fluoropolymer Topcoat Silver Plated Copper Cable Family Min. Max. Spiral Braid MULTI CORE DRP EN66-008B 6 x DRA DRT EN66-008C 6 3 x DRA DRQ EN66-008D 6 x DRA SHIELDED AND JACKETED MNA EN73-0A 6 0 x DRA MNB EN73-0B 6 x DRA MNC EN73-0C 6 3 x DRA MND EN73-0D 6 6 x DRA Airfame Hook-Up

5 Cable Family CF-U PF QF RF SJ-U TK-U UD-U VL EN-STANDARD CABLES: retro-fit Low Temperature Airframe Wires, Retro-Fit -55 C to +00 C 5 V AC ( to 0) High-Strength ( 6 & ) Polyimide Tapes and FEP Topcoat Polyimide Tapes and FEP Topcoat s ASNE06 EN66-005A CF-SERIES Min. Max. Spiral Braid SINGLE CORE High Temperature, Arc-Tracking Resistant, Retro-Fit -65 C to +60 C 5 V AC ( to 06) High-Strength Alloy ( 6 & ) MULTI CORE ASNE06 x 6 0 EN66-003B ASNE06 or EN66 ASNE066 3 x 6 0 EN66-003C ASNE06 or EN66 ASNE068 x 6 0 EN66-003D ASNE06 or EN66 SHIELDED & JACKETED ASNE070 6 x EN73-007A 6 0 ASNE06 or EN66 ASNE07 6 x EN73-007B 6 0 ASNE06 or EN66 ASNE x EN73-007C 6 ASNE06 or EN x EN73-007D 6 ASNE06 or EN66 DM-SERIES Cable s Family MIn. Max. Spiral Braid SINGLE CORE DM EN67-008A 6 06 DMA EN67-007A 6 06 MULTI CORE PN EN67-007B 6 06 x DMA QL EN67-007C x DMA RK EN67-007D 6 06 x DMA SHIELDED & JACKETED GJ EN7-0A 6 0 x DMA MH EN7-0B 6 0 x DMA UU EN7-0C x DMA VV EN7-0D 6 x DMA MJ EN7-0E 8 5 x DMA ultra-light airframe hook-up wire Cable Family AD-SERIES Arc-Tracking Resistant, Light Weight -55 C to +80 C 5 V AC -Clad Aluminum compliant with color codes, gauges, marking 8 Min. Max. Spiral Braid SINGLE CORE AD ABS099 0 ADA ABS35 0 MULTI CORE ADB ABS35 0 x ADA ADC ABS x ADA ADD ABS35 0 x ADA SHIELDED & JACKETED VNA ABS356 0 x ADA VNB ABS356 0 x ADA VNC ABS x ADA VND ABS356 x ADA unshielded single core ad zz fr a yy unshielded single core ada zz fr a yy multi-core adb zz fr a yy adc zz fr a yy add zz fr a yy Year Code Color code cores Color of insulation No. of Cores in Cables 3 Color of Black Colors (from left to right ) : Grey, Red-Blue, 3 Red-Blue-Yellow, Red-Blue-Yellow-Green Year Code Year Code Color code Color of insulation (No. of cores = ) Color of (Grey) All Gauges except Blue Green shielded & jacketed single core VNA zz fr a yy multi-core VNb zz fr a yy VNc zz fr a yy VNd zz fr a yy Color of jacket Gauge () Color of Grey Color code jacket Blue Green Airfame Hook-Up

6 Voltage Rating: Core: Braid: m759/x-y f 868 rev z m759 series AS 759 WIRES High-Performance Hook-Up Wires M759/80-/9: Smooth Outer Surface 600 V (rms)* T : Tin Coated Copper S : Silver Coated Copper S+ : Silver Coated High-Strength (0- ) or Ultra-High-Strength (6 ) Copper Alloy N : Nickel Coated Copper N+ : Nickel Coated High-Strength (0- ) or Ultra-High-Strength (6 ) Copper Alloy Special Meta-Aramid Fiber Revision of the Specification 9 Manufacturer s Identification Reference (X: 80-9/80-9) Temperature ( C) Core Weight Braid Min. Max. Min. Max. T S S+ N N+ Light Normal M759/80 - /9 AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ M759/80 - /9 AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ AS759/ * This insulation system has been used in aerospace applications that employ 5 V (phase to neutral), 00 Hz AC and 8 V DC. Verification of the suitability of this product for use in other electrical system configurations is the responsibility of the user. M7500 SERIES NEMA WC 7500 CABLES Special purpose and power electrical cables designed for aerospace, commercial, and military applications and high-performance vehicles. m WK N Jacket Material (VI) Numbers of Wires in Cable (IV) Conductor Size (II) Identification Number Characteristics Shield Style and Material (V) Basic Wire Specification (III) Identification Method of Cable Wire and Coverage (I) Operating Temperature: -65 C to +50 C/+00 C/+60 C* (ambient temperature + current heating) s and Specifications Cable Specification: NEMA WC 7500 Wires Specification: AS759/80 to /9 and AS759/80 to /9 Combination Possibilities** ID Number I II III IV V VI M DB NF (prev.: *) 00 A DC ND (prev.: #) 06 B DE 3 HS (prev.: $) C 0 DF HD (prev.: +) D 8 DG 5 A E 6 DH 6 B 5 F DJ 7 C 56 G DK 8 D 6 H 0 DL 9 E 6 J 8 DM 0 F 7 K 6 DN G 75 L DP H M DR 3 I N WB J P 0 WC 5 K R 0 WE L S 03 WF M T 0 WG N U WH P V WJ Q WK R WL S WM T WN U WP V WR W X Y Z *Depending on the type of basic wires, shield or jacket requested. ** 0 Airfame Hook-Up

flight-test cables POWER FEEDER cables BG/SU/TV/VF/HK-CABLES A75-, DG - CABLES Operating Voltage: Jacket Color: Flight-Test Cables Thermocouple Cable (HK): Temperature sensing, applicable in harsh

7 flight-test cables POWER FEEDER cables BG/SU/TV/VF/HK-CABLES A75-, DG - CABLES Operating Voltage: Jacket Color: Flight-Test Cables Thermocouple Cable (HK): Temperature sensing, applicable in harsh environments -55 C to +60 C 50 V, Solderable (BG, SU, TV, VF) Nickel-Chromium/Nickel-Aluminum (HK) PTFE Tape Polyimide Tape and PTFE Tape Orange Cable Family Additional PTFE Tape around Cores Spiral Braid Cable Family Auto-Extinguishing Properties, Non-Flammable 5 V AC -90 C to +60 C (A75) -55 C to +60 C (EN DG) Composite Polyimide, Fiber Glass, PTFE Min. Max. A75 Dassault Spec NSA 9353 DG NSA 9353 DG EN DG EN feeder cables BG ASNE009 SU ASNE00 x BG TV ASNE0 x BG VF ASNE0 x BG THERMOCOUPLE CABLE HK ASNE03 Color: Low-bending Radius 5 V AC -65 C to +60 C Composite PTFE Light Yellow DH - SERIES Cable Family DH ECS Color of PTFE: AD - SERIES Arc-Tracking Resistant, Light-Weight 5 V AC -55 C to +80 C Nickel Plated Aluminum (NPA), Unplated Aluminum* Composite Polyimide, PTFE Grey Cable Family Min. Max. Photo: Vincent Kauffmann AD ABS ADB ABS x ADA ADC ABS x ADA ADD ABS x ADA * Modification pending

Refer to the following Link for the Prysmian Group Sustainability Report: our commitment HIGH-VOLTAGE CABLES (30V) AZ-SERIES Suitable for High-Voltage Networks (30V) Light Weight -65 C to +80 C 30 V

AZB EN68-006 00,, 3 x AZA AZC EN68-006 00,, 3 3 x AZA * Modification pending DZ-SERIES high-voltage Sustainability We develop important initiatives in collaboration with stakeholders, in order to

8 Refer to the following Link for the Prysmian Group Sustainability Report: our commitment HIGH-VOLTAGE CABLES (30V) AZ-SERIES Suitable for High-Voltage Networks (30V) Light Weight -65 C to +80 C 30 V AC Nickel Plated Aluminum, Unplated Aluminium* Cable Family Suitable for High-Voltage Networks (30V) -65 C to + 60 C 30 V AC Spiral Braid SINGLE CORE AZ EN ,, 3 AZA EN ,, 3 MULTI-CORE AZB EN ,, 3 x AZA AZC EN ,, 3 3 x AZA * Modification pending DZ-SERIES high-voltage Sustainability We develop important initiatives in collaboration with stakeholders, in order to improve our economic, environmental and social performance. Cable Family Spiral Braid SINGLE CORE DZ EN67-0 0,, 6 MULTI-CORE DZB EN67-0 0,, 6 x DZ DZC EN67-0 0,, 6 3 x DZ Quality The quality of our optical fibers and innovative cabling solutions enables us to tackle your most difficult and ambitious challenges. Innovation We seek to generate innovation, quality and know-how, with a view on developing innovative products with a lower environmental impact and higher value-added for our customers. Supply Chain Management In order to assess the environmental and social impact of our activities, Prysmian has taken steps towards the sustainable management of the entire supply chain. 3

9 data transmission cables Non-flammable -00 C to +00 C SC: Silver Plated Copper SCCS: Silver Copper-Clad Steel Silver Plated Copper Braid coaxial cables data transmission cables quad cables Inflight-Applications Operating Temperature: -55 C to +5 C, except AS6070/: -55 C to 00 C SCA: Silver Plated Copper Alloy SPC: Silver Plated Copper Fluoropolymer or PTFE Foam Skin or Foam-extruded Fluoropolymer Silver Plated Copper Braid Cable Family/ Reference XF ASNE093 M7/ RG00U Ø max. Suitable for harsh environments -65 C to +00 C Silver-plated Copper Alloy PTFE SC: Silver-plated Copper Braid NC: Nickel-plated Copper Braid twinax-bus cables 5 Z (Ω) Temperature Range ( C) Conductor Material Min. Max. SC SCCS Shield (No. of Braids) Jacket FEP SW ASNE09.95 n/a Polyimide/ FEP F Dassault Spec Tape FEP F703-9 Dassault Spec FEP F709-7U-AG Dassault Spec Tape FEP XK Cable Family/ Reference NSA93538 M7/0 RG30AB Ø max FEP Z (Ω) Temperature Range ( C) Max. Weight (kg/km) Shield Material (No. of Braids) Min. Max. SC NC Jacket Material F703-8U A Dassault Spec FEP Red F703-8U B Dassault Spec FEP Blue Jacket Color High Immunity WJC EN C Fluoropolymer Green WW F703-7 EN Fluoropolymer White F Tapes Polyimide/ PTFE White F Tapes Polyimide/ PTFE White F Tapes Polyimide/ PTFE White F Tapes Fluoropolymer Red WF ABS Polyimide Natural F (Amber) XM ASNE090XM Polyimide Natural F (Amber) Cable Family/ Reference Ø max. ethernet - usb - hdmi Very High Data-Rate Cables Operating Temperature: Max. 5 C SPC: Silver Plated Copper NPC: Fluoropolymer Silver Plated Copper Braid and Tape Fluoropolymer 6 Z (Ω) Conductor SCA SPC Shield Material (No. of Braids) Jacket High UV Laser Immunity KB ABS097 F 70- ARINC FEP KD ABS503 F 70-5 ARINC FEP F FEP F FEP F FEP F High Permeability Screen Fluoropolymer KL Inner: AL/Mylar F 70-9 EN Outer: Round FEP [Replaces KL F70-3] Inner: Flat F 70-6 AS6070/.3 00 FEP * Outer: Round * Available in markable [th digit jacket detail: U] and non- markable [no th digit on jacket] versions. Cable Family/ Reference Category Ø max. Z (Ω) Max. Weight (kg/km) ETHERNET Conductor Wire Construction Transmission Pairs SPC NPC Unshielded F e Data Patch F 709-5e Data Patch F Data Patch F Data Patch USB.0 F USB compatible with DR Wires HDMI F HDMI Data Patch data transmission

OPTICAL FIBER CABLES High-speed fiber networks are increasingly required in numerous aerospace applications, such as Avionics and Inflight-Entertainment, to transmit high volumes of data while

Responding to that demand, the Prysmian Group is producing its own optical fibers to ensure the best performance levels in these harsh and demanding environments: Interference-free solutions.

10 OPTICAL FIBER CABLES High-speed fiber networks are increasingly required in numerous aerospace applications, such as Avionics and Inflight-Entertainment, to transmit high volumes of data while gaining weight-savings. Responding to that demand, the Prysmian Group is producing its own optical fibers to ensure the best performance levels in these harsh and demanding environments: Interference-free solutions. Space-savings due to smaller size and bending radius. Easy plugging and installation. The portfolio of fibers within the Prysmian Group currently comprises: MULTI-MODE FIBERS OM- OM- OM-3 OM- (WideCap and MaxCap-BB) SINGLE-MODE FIBERS G.65 Series G.65 Series G.655-G.656 Series G.657 Series SPECIALTY FIBERS DrakaElite BendBright High-Temperature Resistant (Acrylate, Silicone) RadHard (MIL-PRF-99) For further information visit: 7 Suitable for use in harsh environments, up to 0Gbits/s, Tight and semi-loose cables, EASY TERMINATION -65 C to +50 C Fluoropolymer Color: Light Purple Cable Family/ Reference Short Designation Ø nom. Max. Weight (kg/km) Temperature Range ( C) Utilized Fiber* 8 Tight/ Semi loose Flexibility (D= Outer Diameter) Max. Attenuation (db/km 0 C) Min. Max. 850nm 300nm MULTI-MODE F µm T 3 F93- LG OM3 Bend Insensitive T 5 x D 0 F93- LF OM T 5 x D F OM Bend Insensitive S 0 x D F OM S 0 x D 3.5 F OM S 0 x D 6 3 F OM Bend Insensitive S 0 x D SINGLE-MODE F Bend Insensitive T 5 x D * Adaptation to other cores upon request. ** Depending on the length of the link the data rate can also be higher. SINGLE & MULTI-MODE FIBER CABLES 30nm 550 nm Data rate** (GBps) 0 opitcal fiber

Cable Family various designs complex designs Combining Multiple Elements -65 C to +00 C Dedicated Networks Silver Plated Copper (Gigabit Ethernet), (DR) Fluoropolymer/PTFE Fluoropolymer Silver Plated

90-65 +00 6 x MLB NPC MQD F 7-8 ECS089 6.

Conductor Temperature Range ( C) Min. Max.

High-Flexibility Airframe Wires BF ASNE060 8 Nickel + Silver Plated Copper -55 00 600 Equipment Interconnect Cables 600 V BN ASNE079 6 Silver Plated Copper Alloy ( ), Tin Plated Copper ( 6 to ) NEMA

11 Cable Family various designs complex designs Combining Multiple Elements -65 C to +00 C Dedicated Networks Silver Plated Copper (Gigabit Ethernet), (DR) Fluoropolymer/PTFE Fluoropolymer Silver Plated Copper Braid (SPC), Braid (NPC) Ø max. Temperature Range ( C) Min. Max. Max. Mass (kg/km) F Conductor Gigabit Ethernet S-STP Cat. 7+ DR MQB F 7-7 ECS x MLB NPC MQD F 7-8 ECS x MLB NPC Shield SPC + Tape Cable Family various designs other designs Diverse Applications -90 C to +00 C Refer to Table PTFE (BF & NEMA HP3 Wires), ETFE (BN) Silver Plated Copper Braid Conductor Temperature Range ( C) Min. Max. Min. Max. High-Flexibility Airframe Wires BF ASNE060 8 Nickel + Silver Plated Copper Equipment Interconnect Cables 600 V BN ASNE079 6 Silver Plated Copper Alloy ( ), Tin Plated Copper ( 6 to ) NEMA HP3 Wires (former MIL W 6878) Silver Plated Copper ET 3 0 Optional: (up to 60 C) Silver Plated Copper E 3 Optional: (up to 60 C) Silver Plated Copper EE 3 Optional: (up to 60 C) Operating Shield Voltage F870-6 MQB F 7-7 MQD F 7-8 thermocouples Temperature Sensoring and Measurements -95 C to +60 C Nickel-Chrome (NiCr), Nickel-Aluminum (NiAl), (NPC), Copper (CU), Constantan (Ctt; Copper-Nickel Alloy) (NPC), Copper-Tin Alloy (SnCU) ET 30 0 E 30 0 EE 30 0 ET, E, or EE Series exists with,, or 3 conductors ET, E, or EE Series exists with,, or 3 conductors ET, E, or EE Series exists with,, or 3 conductors Cable Family Ø max. Temperature Range ( C) Min. Max. Nom. Mass (kg/km) Cores EMF* (mv at 00 C) Jacket Shield F ASNE (Elements recognition) NiCr/NiAl.0 NPC F793- NSA (Elements recognition) NiCr/NiAl.0 NPC F NiCr/NiAl.0 SnCu or NPC F NiCr/NPC 6.3 NPC F Cu/Ctt.7 * EMF: Electromotive Force 9 Our expertise with and passion for cables does not end here. Contact us for our complete portfolio or discuss customization possibilities with our experienced team. 0 various designs

THE FUTURE STARTS NOW - DRAKA FILECA AS PART OF CLEAN TECHNOLOGIES Draka Fileca is proud to be Specialized Partner of Clean-Tech Projects such as : With our innovative and light-weight cabling we

12 THE FUTURE STARTS NOW - DRAKA FILECA AS PART OF CLEAN TECHNOLOGIES Draka Fileca is proud to be Specialized Partner of Clean-Tech Projects such as : With our innovative and light-weight cabling we pave the way for future technologies whether high up in the air or throughout the oceans of the world. If you want to learn more about our involvement in one these projects, scan the following QR-Code: Energy Observer Energy Observer Kadeg Boucher

13 Linking the Future Distributed by : Draka Fileca 07. All Rights Reserved. The information contained within this document must not be copied, reprinted or reproduced in any form, either wholly or in part, without the written consent of Draka Fileca. The information is believed correct at the time of issue. Draka Fileca reserves the right to amend the specifications without notice. The specifications are not contractually valid unless specifically authorized. Draka Fileca D Sainte Geneviève France Tel.: Fax: fileca-office@prysmiangroup.com Imp. Barré 8900 Collemiers - Tél

W I R E S a n d C A B L E S

A E R O S P A C E W I R E S a n d C A B L E S Edition N 7 - June 2015 HOOK UP WIRES-AIRFRAME WIRING Arc Tracking & Moisture Resistant Light weight Rating Temperature 260 C Cable Code EN Range DR EN 2267-010A