PowerLoad™ High-Power Aircraft Connectors and Cables

The Aircraft Industry's most Advanced Power Distribution Interconnect with High-Current Carrying Capacity Crown Ring Contacts and Flexible TurboFlex® Cabling

Series 972

Electrical power generation technology in aircraft has evolved to meet modern requirements for higher power and lighter weight systems. Growing electrical power needs on commercial aircraft — and emerging eVTOL platforms — have caused major changes in power system architectures to accommodate peakload stress factors in electrical wire interconnect (EWIS) cabling.

PowerLoad™
High-vibration, high-temperature interconnect optimized for higher-voltage, higher-altitude, and higher-frequency.
TurboFlex®
Glenair signature high-flexibility power cable solution.
Crown Ring
Crimp, bus bar, and lug style contacts, optimized for high current carrying, high temperature performance.

When specifying interconnect technology for aircraft power distribution, three main performance variables must be considered: voltage, current, and frequency. Higher voltage applications demand premium-quality insulation, careful design for partial discharge, and quality manufacturing to ensure reliable operation. Higher-current applications require detailed, peak-load analysis, accurate wire gauge selection, and high-temperature materials. Higher-frequency systems must be designed for accurate skin/proximity effect derating, incorporate comprehensive operating and peak voltage/current analyses, and perform in accordance with aircraft power generation and distribution electronics. Cable-to-contact termination must be exactingly performed to eliminate voids that can potentially initiate partial discharge events. The Glenair PowerLoad ecosystem, with its highly engineered connectors, cables, and Crown Ring contacts ensures peak performance for every specification requirement in high-current, high-voltage, and high-frequency applications.

Reference

TurboFlex® Cable Insulation Stripping Procedure

Related Catalogs

PowerLoad™ - High-Power Aircraft Connectors and Cables

PowerLoad™ High-Power Aircraft Connectors and Cables

The Aircraft Industry's most Advanced Power Distribution Interconnect with High-Current Carrying Capacity Crown Ring Contacts and Flexible TurboFlex® Cabling

Series 972

eBook
PDF (Single pages, print friendly)

	972-101 Plug with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire PowerLoad Connectors with Compression Grommet Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-vibration self-locking coupler High-temperature Crown Ring contact technology Patented wire sealing grommet Heavy-duty accessory interface
	972-102 Wall-Mount Receptacle with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire PowerLoad Connectors with Compression Grommet Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-temperature Crown Ring contact technology Patented wire sealing grommet Heavy-duty accessory interface
	972-103 Jam-Nut Receptacle with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire PowerLoad Connectors with Compression Grommet Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-temperature Crown Ring contact technology Patented wire sealing grommet Heavy-duty accessory interface
	972-203 Feed-Thru Receptacle, Jam-Nut Mount PowerLoad Connectors with Compression Grommet Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-temperature Crown Ring contact technology
	850-150 Crown Ring Crimp Pin Contact 850-151 Crown Ring Crimp Socket Contact Temperature rating: 260°C Contact resistance 40% of typical AS39029 contacts when mated to PowerLoad socket contacts Double-thick gold-plated on contact mating surfaces versus AS39029 Passivated Stainless steel spring member on socket contact provides contact spring force and is resistant to stress relaxation up to 260°
	Crown Ring Crimp Contact Tooling Pneumatic Crimp Tool for #8, #4, and #1/0 Contacts
	972-011 Plug with Banding Porch, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-vibration self-locking coupler High-temperature bus bar and lug type Crown Ring contacts Heavy-duty accessory interface
	972-012 Wall-Mount Receptacle with Banding Platform, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-vibration self-locking coupler High-temperature bus bar and lug type Crown Ring contacts Heavy-duty accessory interface
	972-013 Jam-Nut Receptacle with Banding Platform, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire Socket towers for improved creep path performance Single-piece insulator eliminates bond lines that can lead to electrical failure High-vibration self-locking coupler High-temperature bus bar and lug type Crown Ring contacts Heavy-duty accessory interface
	850-323 Bus Bar/Lug Pin Contacts A = Internal thread C = Lug
	850-324 Bus Bar/Lug Socket Contacts A = Internal thread C = Lug
	390PX055 EMI/RFI Environmental Backshell 390PXM055 = 45° (bent tube elbow) 390PXN055 = 90° (bent tube elbow) 390PXS055 = Straight
	4470PXS1128 Compression Backshell with Banding Platform Backshell is supplied standard with PowerLoad connectors unless otherwise specified Choose Band Option "K" for backshell supplied with BandMaster ATS precoiled band (P/N 601-050) Choose option P for polysulfide barrier stripes on NF and ZR finished backshells (see drawing detail A) Band - CRES / passivated Anti-decoupling device - corrosion-resistant material
	770-001S Environmental Heat-Shrink Boots supplied with 4470PXS1128 Backshell Lipped, straight shrink boots provide mechanical and environmental protection from damage and debris Shrink boots are water-tight when equipped with factory installed or user-installed adhesive Lipped boots lock into the boot groove on PowerLoad compression backshells Boots come standard with eylelet for attachment of protective covers
	660-128 PowerLoad™ Receptacle Protective Cover
	660-129 PowerLoad™ Plug Protective Cover
	930-026 PowerLoad™ Gasket for Flange-Mount Connectors Fluorosilicone and Viton versions provide environmental protection to panel-mounted PowerLoad connectors Conductive silver-plated aluminum-filled fluorosilicone versions provide additional EMI protection
	600-289 Connector Holding Tools 600-286 / 600-288 "Crow's Foot" Torquing Wrenches 600-289 Connector Holding Tools Heat-treaded steel alloy / nickel finish Use with 3/8" drive torque wrench or proper adapter 600-286 / 600-288 "Crow's Foot" Torquing Wrenches Passivated 300 series stainless steel Connector wrench for use with PowerLoad plug connectors Backshell wrench for use with standard PowerLoad backshell (P/N 4470PXS1128) Use with 3/8" drive torque wrench or proper adapter For proper hex clearance, torque wrench head must not exceed Ø 1.50"

TurboFlex® Interconnect: Cabling with FEP and Duralectric Insulation

Power distribution cables present a unique challenge to electrical wire interconnect system engineers. Typically fabricated from stiff, non-flexible conductors with extremely large bend radii, such cables are heavy, hard to route, and prone to jacket damage from weathering and abrasion. TurboFlex® power distribution cables are constructed from high strand-count rope-lay inner conductors made with tin-, nickel-, and silver-plated copper. These highly-flexible conductors, insulated with FEP or Glenair signature Duralectric jacketing result in cables ideally suited for applications where flexibility, durability, and weight reduction are required.

Amazingly durable — especially in cold weather — TurboFlex cable with Duralectric insulation provides outstanding resistance to temperature extremes, ozone exposure, caustic chemicals including jet fuel, gamma radiation, and other forms of environmental and mechanical damage. Long life and performance are critical in power distribution applications. TurboFlex, with its flexible conductors and durable insulation delivers both. Consult factory for lightweight aluminum version.

About TurboFlex with Duralectric™ D Jacketing

Duralectric™ D is a Glenair Signature elastomeric material used in wire insulation, cable and conduit jacketing, overmolding, and shrink boots. Glenair TurboFlex high-flexibility power distribution cables are supplied with Duralectric jacketing in different wall thicknesses, as well as "tell-tale" dual-layering.

TurboFlex core conductors are available in three aerospace-grade material and temperature configurations:

-T = Tin/Copper (-60° – 150°C)
-S = Silver/Copper (-60° – 200°C)
-N = Nickel/Copper (-60° – 260°C)

A signature configuration of TurboFlex is available with high-temperature shielding and lightweight aluminum conductors.

Reference

	961-106-1500 Single-Wall Hookup Wire Duralectric™ Insulation, 1500 VAC TurboFlex Hookup: Cabling with FEP and Duralectric Insulation TurboFlex single-wall hookup wire
	961-106-2000 Single-Wall Hookup Wire Duralectric™ Insulation, 2000 VAC TurboFlex Hookup: Cabling with FEP and Duralectric Insulation TurboFlex single-wall hookup wire
	961-108-1500 Single-Wall Hookup Wire Duralectric™ Light Insulation, 1500 VAC TurboFlex Hookup: Cabling with FEP and Duralectric Insulation TurboFlex single-wall hookup wire
	961-108-2000 Single-Wall Hookup Wire Duralectric™ Light Insulation, 2000 VAC TurboFlex Hookup: Cabling with FEP and Duralectric Insulation TurboFlex single-wall hookup wire
	961-107-1500 Dual-Wall Interconnect Cable Duralectric Insulation, Duralectric Outer Jacket, 1500 VAC TurboFlex Interconnect: Cabling with FEP and Duralectric Insulation TurboFlex dual-wall interconnect cable
	961-107-2000 Dual-Wall Interconnect Cable Duralectric Insulation, Duralectric Outer Jacket, 2000 VAC TurboFlex Interconnect: Cabling with FEP and Duralectric Insulation TurboFlex dual-wall interconnect cable
	961-109-1500 Dual-Wall Interconnect Cable Duralectric Light Insulation, Duralectric Light Outer Jacket, 1500 VAC TurboFlex Interconnect: Cabling with FEP and Duralectric Insulation TurboFlex dual-wall interconnect cable
	961-109-2000 Dual-Wall Interconnect Cable Duralectric Light Insulation, Duralectric Light Outer Jacket, 2000 VAC TurboFlex Interconnect: Cabling with FEP and Duralectric Insulation TurboFlex dual-wall interconnect cable
	851-005 Crimp Terminal Lugs for TurboFlex® Cable Aircraft Power Interconnect Technology Glenair 851 Series crimp terminal lugs are constructed from precision-machined high-conductivity copper alloy, purpose-built to fit TurboFlex high-flexibility power distribution cable Improved performance versus stamped and formed mil-spec lugs