Metal Braids
FLAT - ROUND - ROPES - BONDING LEADS - POWER SHUNTS
IS-Cabletec, based in Weston-super-Mare
in the UK, is a specialist manufacturer of
high performance metal braid and earth
bonding leads designed and approved for
aerospace, defence, industrial and energy
market applications.
Experts in braiding technology, we have over
20 years experience in the manufacture of
metal braid and produce a comprehensive
range of high quality metallic products
including customised and market approved
bonding leads, flat and round braids, ropes
and EMC screening braids. We also offer an
over-braiding service for cables and conduits.
IS-Cabletec is also a manufacturer of
customised multicore cables and a distributor
of a wide range of harness components, high
performance wire and cable.
For further details, please visit our website:
www.is-cabletec.com
Approvals: ISO 9001 • BS/EN 9100
Contents
AEROSPACE AND DEFENCE
CFBA4199-004 Bonding Leads
CBL150 & 260 Bonding Leads
CRL260 High Flex Bonding Leads
CFBA1068 Aluminium Bonding Leads
QBL Quick Release Bonding Leads
LN9264 Bonding Leads
AGS2097 Bonding Leads
Market Approvals
High Performance Materials
2-3
4-5
6
7
8-9
10
11
12
13
INDUSTRIAL AND ENERGY
CFBA Customised Bonding Leads
FBL Bonding Leads
RBL Bonding Leads
Power Shunts
FB Flat Braids
Round Braids and Ropes
Over Braiding
Tehnical Information
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14-15
16-17
18-19
20-21
22
23
24
25
1
CFBA4199-004
Round Bonding Leads
• Tin & nickel-plated copper
• Choice of terminal sizes
• Designed for Aerospace and
Defence applications
• Tested to EN4199
Markets
Aerospace
Military
Industrial
Materials
Operating
Temperature
Tin-plated copper
Nickel-plated copper
-65ºC to +150ºC
-65ºC to +260ºC
CFBA4199-004 bonding leads are designed
specifically for Aerospace and Military
applications. They have undergone extensive
mechanical and electrical testing, including
flex testing to 250,000 cycles, sinusoidal and
random vibration cycles, salt mist testing and
temperature cycling.
CFBA4199-004 bonding leads are manufactured
from multi-layer round braid and are available
in tin-plated and nickel-plated copper in a
variety of cross-sectional areas, lengths and
termination options.
Part Numbering System
CFBA4199 - 004 -
N - 7.0 - 250 - E
Material
T = Tin-plated copper
N = Nickel-plated copper
Cross-sectional area
1.4mm2, 3.5mm2, 4.5mm2,
7.0mm2, 13.0mm2
Length ‘L’ (mm)
Terminal code
Ordering Example
CFBA4199-004-N-7.0-250-E = Round uninsulated braid, 7.0mm2, nickel-plated copper, 250mm length
between hole centres, 4.34mm terminal hole diameters.
2
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AEROSPACE AND DEFENCE
Standard Lengths (Other lengths available)
Availability for cross-sectional area (mm2)
Length (mm)
1.4mm2
63
3
3
3
3
3
3
3
3
3
80
100
125
160
200
250
315
400
500
3.5mm2
4.5mm2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
7.0mm2
13.0mm2
3
3
3
3
3
3
3
3
3
3
3
3
630
800
3
3
3
3
3
3
Length ‘L’
Terminal end 1
Terminal end 2
End 1
Hole Diameter
Availability for cross-sectional area (mm2)
End 2
Code
Stud
Stud
Hole Diameter 1.4mm2
A
#6
3.68mm
#6
3.68mm
B
#8
4.34mm
#8
3.68mm
C
#10
5.00mm
#6
3.68mm
D
1/4
6.73mm
#6
3.68mm
E
#8
4.34mm
#8
4.34mm
F
#10
5.00mm
#8
4.34mm
G
1/4
6.73mm
#8
4.34mm
H
10
5.00mm
#10
5.00mm
J
1/4
6.73mm
#10
5.00mm
K
1/4
6.73mm
1/4
6.73mm
L
5/16
8.33mm
#10
5.00mm
M
5/16
8.33mm
5/16
8.33mm
N
5/16
8.33mm
1/4
6.73mm
3
3
3
3
3
3
3
3
3
3
3
3
3.5mm2
4.5mm2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
7.0mm2
3
3
3
3
3
3
3
3
13.0mm2
3
3
3
3
3
3
Performance Testing
•
•
•
•
•
•
•
Sinusoidal and random vibration
Mechanical fatigue (250,000 cycles)
Salt Mist (48 hours)
Temperature endurance
Terminal ageing by temperature and current cycling
Voltage drop
Tensile strength
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3
CBL
Flat Bonding Leads
• Tin-plated and nickel-plated
copper
• Choice of 6 cross-sectional areas
• Wide range of terminal sizes
• Flexible, robust and reliable
• Manufactured to EN4199-003
design
Markets
IS-Cabletec’s CBL range of flat style bonding
leads are designed for aerospace and military
applications, but are also suitable for higher
performance industrial uses.
Aerospace
Military
Industrial
Materials
Operating
Temperature
Tin-plated copper
Nickel-plated copper
Insulated
-65ºC to +150ºC
-65ºC to +260ºC
-65ºC to +150ºC
They are available with and without insulation
in both tin-plated and nickel-plated copper in a
range of cross-sectional areas. They are highly
flexible, robust and reliable.
Part Numbering System
CBL260
-
10
- CC - 200 -
S
Product Reference
CBL150 = Tin-plated copper,
CBL260 = Nickel-plated copper
Cross-sectional area
1.5mm2, 4mm2, 6mm2,
10mm2, 16mm2, 25mm2
Terminal reference
See terminal availability table
Length ‘L’ (mm)
Min. 50mm, Max. 300mm,
25mm increments
Insulated
Leave blank if insulation is not required
Ordering Example
CBL260-10-CC-200-S = Nickel-plated flat bonding lead, 10mm2, 200mm long (between hole centres),
5.00mm terminal hole size both ends, insulated.
4
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AEROSPACE AND DEFENCE
Terminal Availability: CBL150 (Tin-plated copper)
Terminal
Variant
Code
Stud
Hole
Diameter
(mm)
A
#6
3.68
B
#8
4.34
C
#10
5.00
D
1/4
6.73
E
5/16
8.33
F
3/8
9.91
Cross-sectional area (mm2)
1.5
3
3
3
3
4
6
3
3
3
3
3
3
3
3
10
16
25
3
3
3
3
3
3
3
3
3
3
3
3
16
25
3
3
3
3
CBL260 (Nickel-plated copper)
Terminal
Variant
Code
Stud
Hole
Diameter
(mm)
A
#6
3.68
B
#8
4.34
C
#10
5.00
D
1/4
6.73
E
5/16
8.33
F
3/8
9.91
Cross-sectional area (mm2)
1.5
4
3
3
3
3
3
3
3
3
6
10
3
3
3
3
3
3
3
Length ‘L’
Terminal end 1
Terminal end 2
Technical Information for Uninsulated CBL260 (Nickel-plated copper) Leads
Minimum Tensile
Strength
Nom Resistance
100mm Length
Braid
Resistance
(mm2)
(N)
(mΩ)
1.5
250
1.32
4
600
0.4
0.112
6.3
1.1
6
800
0.24
0.075
10.7
1.63
10
1200
0.14
0.046
18.4
2.9
16
1700
0.09
0.03
28.9
3.93
25
2200
0.06
0.015
43.2
7.85
Braid
cross-section
For lengths other than 100mm, nominal
resistance and mass can be calculated by
adding or subtracting multiples of the 25mm
braid figures as quoted above.
Nom Mass
100mm Length
Braid
Mass
(mΩ per 25mm)
(g)
(g per 25mm)
0.308
2.6
0.4
For maximum figures, an additional 10%
should be applied to the nominal values.
Nominal values of mass are based on the use
of typical terminals for each x-sectional area.
Example 1: resistance for a 10mm², 250mm
long strap = 0.14mΩ + (6 x 0.046 mΩ) = 0.416mΩ
total nominal resistance.
Example 2: mass for a 4mm², 50mm long strap
= 6.3g – 2.2g = 4.1g total nominal mass.
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5
CRL260
High Flex Bonding Leads
• Nickel-plated copper
• Choice of 5 cross-sectional areas
• Range of terminal sizes
• Very high flex endurance*
• Excellent corrosion resistance
*Tested in accordance with EN4199-001
Markets
Aerospace
Military
Materials
Operating
Temperature
Nickel-plated copper
-65ºC to +260ºC
IS-Cabletec’s CRL260 bonding leads are
designed to withstand exceptional levels
of flexing in combination with outstanding
resistance to corrosion and salt attack. When
tested to the flex endurance test detailed in
EN4199-001, they withstand over 5 million
cycles, outperforming other existing aerospace
standard leads by more than 5 times.
CRL260 bonding leads are particularly suited for
dynamic applications in exposed areas such as
external aircraft doors and flaps.
Terminal code
Hole size
B
C
3.68mm 5.00mm 6.73mm 8.33mm 9.91mm
3
3
3
3
5.0mm
3
3
3
3
3
3
3
3
3
10.0mm
3
3
3
13.0mm
3
3
3
7.0mm
2
2
Terminal end 2
E
3
2
Terminal end 1
D
3.5mm
2
Length ‘L’
A
2
Part Numbering System
CRL260
-
5.0
-
200
-
A
Product Reference
Cross-sectional area
3.5mm2, 5.0mm2,
7.0mm2, 10.0mm2, 13.0mm2
Length ‘L’ (mm)
Min. 50mm, Max. 250mm,
25mm increments
Terminal code
See terminal code table
Ordering Example
CRL260-5.0-200-A = High flex bonding lead, 200mm long (between hole centres) and 3.68mm
terminal hole size.
6
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AEROSPACE AND DEFENCE
CFBA1068
Aluminium Bonding Leads
• Aluminium
• 5mm2 cross-sectional area
• Range of terminal sizes and lengths
IS-Cabletec’s CFBA1068 aluminium bonding
leads are designed for aerospace applications
requiring electrical bonding in combination
with light weight. They are supplied insulated
and with a protective chromate conversion
coating, making them particularly suited to
applications in contact with aviation fuels.
• Light weight
• Excellent aviation fuel resistance
Markets
Aerospace
Military
Materials
Operating
Temperature
Aluminium*
+200ºC
CFBA1068 bonding leads are available in a
range of lengths and 2 sizes of specially formed
aluminium terminals.
*Insulated and available with or without Chromate conversion
coating to MIL-C-5541 Class 3
Part Numbering System
CFBA1068 - B
Terminal code
Hole size
Hole size (mm)
A
M3
3.61 to 3.86
B
M4
4.90 to 5.16
Ordering Example
B - 76.2
CFBA1068-BB-76.2 = Aluminium bonding lead,
5mm², insulated, terminal hole size 4.90 - 5.16mm
each end, 76.2mm length (between hole centres).
Product Reference
Terminal (End A)
Terminal (End B)
Length ‘L’ (mm)
See length availability table
Technical information (nominal values)
Bonding lead length (L)
Resistance (between terminals)
Mass (uninsulated)
(mm)
(mΩ)
(g)
76.2
2.36
4.0
101.6
2.78
4.4
127.5
3.20
4.9
152.4
3.62
5.3
177.8
4.04
5.8
203.2
4.46
6.3
228.6
4.88
6.7
254.0
5.30
7.2
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7
QBL150
Quick Release Bonding Leads
• Tin-plated copper
• BNC or TNC connector
• Fast and easy release
• Various lengths
• Choice of terminal sizes
• Rear and front mounted mating
receptacle
Markets
Aerospace
Military
Industrial
Materials
Operating
Temperature
Tin-plated copper
Insulated
-55ºC to +120ºC
-55ºC to +120ºC
IS-Cabletec’s quick release bonding leads
provide an effective hand-releasable method of
earth bonding electrical equipment. They are
particularly useful for applications where a
temporary connection is required or where
equipment needs to be removed quickly over
multiple times.
QBL bonding leads comprise of a flat tin-plated
copper braid with a crimped ring terminal
at one end and a BNC or TNC connector at
the other. Connection to equipment is via a
mating receptacle, mounted on the equipment
being earthed.
Part Numbering System
QBL150
-
B
-
50
-
A
-
S
Product Reference
Connector Reference
B = BNC, T = TNC
Length ‘L’ (mm)
Min. 50mm, Max. 200mm,
25mm increments
Terminal Code
A = 5mm hole diameter
B = 6.73mm hole diameter
Insulated
Leave blank if insulation
is not required
8
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AEROSPACE AND DEFENCE
Length ‘L’
Front mounted
receptacle
Technical details: QBL150B (BNC type)
Connector
BNC, MIL-C-39012 B (class 2, category c)
Braid
2.64mm², Tin-plated copper
Current rating
36 amps (for 60 seconds)
Operating temperature
-55ºC to +120ºC
Insulation
PAN6480K04
Front panel mounting receptacle
QBL150-BF
Rear panel mounting receptacle
QBL150-BR
Ring terminal hole diameter
5mm or 6.73mm
Length (mm)
Nominal
Mass (g) 5mm hole
Mass (g) 6mm hole
Resistance (mΩ)
50
75
100
125
150
175
200
-
26.5
27.0
27.5
28.2
28.5
29.5
-
26.9
27.4
27.9
28.6
28.9
29.9
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Technical details: QBL150T (TNC type)
Connector
TNC, PAN6444A
Braid
2.64mm², Tin-plated copper
Current rating
36 amps
Operating temperature
-55ºC to +120ºC
Insulation
PAN6480K04
Front panel mounting receptacle
QBL150-TF
Ring terminal hole diameter
5mm or 6.73mm
Length (mm)
Nominal
50
75
100
125
150
175
200
Mass (g) 5mm hole
26.0
26.5
27.0
27.5
28.2
28.8
29.5
Mass (g) 6mm hole
26.4
26.9
27.4
27.9
28.6
29.2
29.9
Resistance (mΩ)
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Ordering Example
QBL150-B-50-A-S = Quick release bonding lead, BNC type connector, 50mm long (‘L’), 5mm terminal
hole diameter, insulated.
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9
LN9264
Bonding Leads
• Flat style braid
• Tin and nickel-plated copper
• Choice of terminal sizes
• Aerospace and Military approved
Applications
Aerospace
Military
Materials
Operating
Temperature
Tin-plated copper
Nickel-plated copper
-65ºC to +150ºC
-65ºC to +260ºC
LN9264 is a long established aerospace and
defence specification containing a series of
uninsulated tin and nickel-plated copper
bonding leads terminated with a range of crimp
style round terminals.
Part Number System
They are available in 6 standard cross-sectional
areas and a limited range of lengths.
CFBA9264 - 4 - 160 N
Product Reference
Braid size
1.5mm2, 4.0mm2, 6.0mm2,
10.0mm2, 16.0mm2, 25.0mm2
Length ‘L’ (mm)
Length ‘L’
60mm, 80mm, 100mm, 125mm,
160mm, 200mm, 250mm
Material
Tin-plated copper or
N = Nickel-plated copper
Terminal end 1
Terminal end 2
Dimensions
Braid cross-section
Current
Braid resistance at 20ºC
(mm )
(amps)
(Ω/1000m)
Tin (mm)
Nickel (mm)
1.5
16
14.2
4.34
4.34
4
30
5.3
5.00
5.00
6
40
3.5
6.73
6.73
10
65
2.1
6.73
6.73
16
80
1.3
8.33
8.33
25
125
0.85
9.91
9.91
2
Terminal Hole Diameter
Ordering Example
CFBA9264-4-160N = Flat uninsulated braid, 4mm², nickel-plated copper, 160mm length between hole
centres, 5.00mm terminal hole diameters.
10
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AEROSPACE AND DEFENCE
AGS2097
Bonding Leads
• Tin-plated copper braid
• 0.7mm2 cross-sectional area
• Choice of terminal sizes
• Multiple lengths
• Aerospace approved
Applications
Aerospace
Military
Materials
Operating
Temperature
Tin-plated copper
-65ºC to +150ºC
AGS2097 bonding leads are a series of
aerospace approved bonding leads,
generally, but not exclusively, found on
legacy aircraft such as Tornado, Hawk and
the C-130 (Hercules).
Part Number System
CFBA2097
B
4
B
They are available with one standard braid
size (0.7mm²) and a combination of terminal
sizes and lengths.
Length ‘L’
Standard description
Terminal variant (End 1)
Length ‘L’
1 inch increments, min. 3 inches
Terminal variant (End 2)
Terminal end 1
Terminal end 2
Terminal selection
Terminal code
Hole diameter (mm)
B
3.68
Ordering Example
C
5.00
CFBA2097-B-4-B = Flat uninsulated braid, 0.7mm²,
tin-plated copper, 101.6mm (4”) length between
hole centres, 3.68mm terminal hole diameters.
E
6.73
G
8.33
J
9.91
Smaller end quoted first
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11
AEROSPACE AND DEFENCE
Market Approvals
Defence & Aerospace
IS-Cabletec is a supplier to many of the major
aerospace and defence companies in Europe
and are proud to have been an influential
contributor to the development and promotion
of EN4199; the ASD European standard for
metal braid and bonding leads.
In addition to our standard products and
customised bonding leads, we also manufacture
to a comprehensive range of market approvals
and specifications, some of which are listed below.
Airbus
ASNE0088 to 0092 Round braid bonding leads, Tin and nickel-plated copper
Typhoon (Eurofighter)
JN1061
Flat braid bonding leads
Nickel-plated copper
JN1151
Flat & rope bonding leads
Nickel-plated copper
JN1006
Quick release bonding leads
Tin-plated copper
JN1077
Quick release bonding leads
Nickel-plated copper
JN1068
Rope bonding leads
Aluminium
Typhoon, Tornado & Hawk
PAN6619
Quick release bonding leads
Tin-plated copper
General Market Approvals
LN9264
Flat braid bonding leads
Tin and nickel-plated copper
CSP48
Flat bonding leads
Tin and nickel-plated copper
AGS2097
Flat braid bonding leads
Tin-plated copper
See page 10
See page 11
For more information on any of these specifications or others not mentioned
please call our sales team on: +44 (0)1934 424900.
12
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High Performance
Materials
In addition to the standard materials used to
produce braids and bonding leads, IS-Cabletec has
braided products manufactured from even higher
performance materials such as stainless steel,
silver-plated copper and pure nickel.
These ‘specialist’ materials exhibit properties
suitable for the most demanding applications,
such as those requiring extreme temperature
and corrosion resistance. Products manufactured
from these materials find use in industrial and
energy market sectors and in more unusual
environments, such as space exploration.
Silver-plated Copper
Stainless Steel
Nickel
For applications needing
excellent conductivity at
temperatures up to 200ºC
silver-plated copper is
recommended; particularly
for extreme aerospace and
space applications.
Stainless steel has outstanding
corrosion resistance compared
to many materials, particularly
when in contact with salt
water; perfect for off-shore and
marine applications.
Pure nickel strand can be used
at even higher temperatures
whilst still exhibiting excellent
conductivity and corrosion
resistance. Nickel is particularly
suitable for applications in
extreme industrial conditions
such as welding, furnaces and
power stations.
Material
Maximum Operating Temperature
Properties
Markets
Silver-plated Copper
200˚C
Excellent conductivity
High temperature
Space
Pure Nickel
649˚C
Excellent conductivity
Extreme temperatures
High corrosion resistance
Space
Aerospace
Industrial
Stainless Steel
400˚C
High temperature
High corrosion resistance
High stain resistance
Marine
Offshore
Construction
For further details for products manufactured from these materials
please contact our sales office on: +44 (0)1934 424900.
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13
CFBA
Customised Bonding Leads
• Broad range of materials and
options
• Wide selection of terminal sizes
• Insulation and Identification
options
• Low MOQs
• Short lead times
• Designed to meet your exact
requirements
Markets
Aerospace
Industrial
Marine
Military
Rail
Energy
Materials
Plain copper
Tin-plated copper
Nickel-plated copper
Aluminium
Stainless steel
Nickel
Silver-plated copper
In addition to our standard products, we
provide a comprehensive design and build
service producing fully customised bonding
leads, each with its own unique part number.
Our bonding leads are constructed from an
extensive range of in-house manufactured
braids and ropes combined with components
from a multitude of termination, insulation
and identification options, resulting in bonding
leads specifically tailored to meet the exact
demands of your application.
Furthermore, we aim to keep minimum order
quantities low, lead times short and ensure that
our product quality and customer service levels
are consistently high.
Terminations
• Crimped terminal
• Pressed ferrules
Braid styles
•
•
•
•
Flat
Round
Rope
Layered
Cross-sectional areas
• 1.5mm2 to 100mm2
Insulation and Identification
• Various materials available
14
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INDUSTRIAL AND ENERGY
Material selection
Conductivity
Corrosion resistance
Maximum operating
temperature
Applications
Aluminium
Fair
Fair
371ºC
Industrial, Aerospace
Plain Copper
Good
Fair
150ºC
Industrial, Rail
Tin-plated Copper
Good
Good
150ºC
Industrial, Military
Stainless Steel
Fair
Excellent
400ºC
Industrial, Offshore
Nickel-plated Copper
Excellent
Excellent
260ºC
Aerospace, Marine
Nickel
Excellent
Excellent
649ºC
Aerospace, Industrial
Silver-plated Copper
Excellent
Good
200ºC
Aerospace, Space
Typical Terminal Options (Others available)
Ring
Forked
Insulated
Pressed
Quick release
Industrial, Military,
Aerospace
Industrial, Military
Industrial, Military,
Aerospace
Industrial, Military,
Energy
Aerospace, Military
Current ratings (Tin-plated copper)
Cross-sectional Area (mm2)
Current rating (amps)
1.5
28
2.5
34
6.0
69
10.0
97
16.0
132
25.0
178
50.0
282
100.0
400
Note: Above current ratings are based on a temperature rise of 50ºC above ambient.
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15
FBL
Flat Bonding Leads
• Pressed ferrule bonding leads
• Tin-plated copper
• Wide range of standard sizes
• Complete product, ready to fit
• Durable and robust design
• Low resistance terminations
FBL bonding leads are manufactured from
tin-plated copper flat braid, terminated at each
end with a pressed ferrule type connector.
The benefit of using pressed ferrules is that
you achieve maximum electrical contact with
minimum resistance.
Markets
Military
Industrial
Energy
Rail
Materials
Operating
Temperature
Tin-plated copper
Insulated
-65ºC to +150ºC
-40ºC to +135ºC
Other non-standard materials available on request.
FBL bonding leads are flexible, robust, durable
and reliable; perfect for the most demanding
industrial applications. They are available
with a wide range of standard lengths and
hole sizes, and with or without insulation.
In addition, they have low minimum order
quantities and short manufacturing lead times.
Part Number System
FBL
-
4
- 200 - M6 -
S
Product Reference
Cross-sectional area
See table for available sizes
Length (mm)
Between holes
Hole sizes
See table for options
Insulated
Leave blank if insulation is not required
Ordering Example
FBL-4-200-M6-S = Flat braid, pressed ferrule bonding lead, tin-plated copper, 4mm², 200mm hole centres,
6.5mm hole diameters, insulated.
16
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INDUSTRIAL AND ENERGY
E
C
D
Technical Information
Crosssectional
Area
Strand
Size
(mm)
C
(mm)
D
(mm)
E
(mm)
Maximum
Allowable Hole
Size (mm)
Current
Rating
(amps)
4
0.15
10
10
2
6.5
50
6
0.15
13
15
2
8.5
65
10
0.15
14
13
3
10.5
90
16
0.2
19
20
3.5
15
125
25
0.15
25
25
4
18
160
35
0.2
25
25
4.5
18
220
50
0.2
25
25
5
18
260
Hole Size Availability
Crosssectional
Area
4
6
10
16
25
35
50
Hole Size
M4
M5
M6
M8
M10
M12
M14
M16
4.5mm
5.5mm
6.5mm
8.5mm
10.5mm
13.0mm
15.0mm
18.0mm
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
For additional terminals, please contact our sales office.
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17
RBL
Rope Bonding Leads
• Rope style bonding leads
• Tin-plated copper
• Multi-directional flexibility
• Durable and robust design
• Highly flexible
Markets
Military
Industrial
Rail
Materials
Operating
Temperature
Tin-plated copper
Insulated
-65ºC to +150ºC
-40ºC to +135ºC
Other non-standard materials available on request.
RBL bonding leads are stranded rope
construction assemblies manufactured from
annealed copper-ETP1 manufactured to BS
EN13602. They are robust, highly flexible
and durable, making them perfectly suited
to dynamic applications and those in high
vibration environments.
In addition, RBL bonding leads boast large
cross-sectional areas whilst keeping overall
diameters to a minimum making them ideal
for size restricted applications.
Part Number System
RBL
-
4
- 200 - M6 -
S
Product Reference
Cross-sectional area
See table for available sizes
Length (mm)
To be specified
Hole sizes
See table for options
Insulated
Leave blank if insulation is not required
Ordering Example
RBL-4-200-M6-S = Rope bonding lead, tin-plated copper, 4mm², 200mm hole centres, M6 holes, insulated.
18
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INDUSTRIAL AND ENERGY
Technical Information
Cross-sectional
Area (mm2)
Strand Size
(mm)
‘W’ mm
(Nominal)
Current Rating
(amps)
4
0.15
10
50
6
0.15
11
60
10
0.15
15
80
16
0.2
16
120
25
0.2
16
150
35
0.2
18
200
50
0.2
20
240
Terminal Availability
Crosssectional
Area
4
6
10
16
25
35
50
Hole Size
M4
M5
M6
M8
M10
M12
M14
M16
4.5mm
5.5mm
6.5mm
8.5mm
10.5mm
13.0mm
15.0mm
18.0mm
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
For additional terminals, please contact our sales office.
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19
Power Shunts
Large Braid Connectors
• Large cross-sectional areas
• Broad terminal and braid range
• Highly flexible
• Space and weight saving
• Fast installation
• Cost effective alternative to
power cables and solid bus bars
Energy and Industrial
Power stations
Generators
Switchgear
Power transmission
Power shunts are large cross-sectional area
braided connectors, customised and designed
to meet the increasing demands of power
distribution applications.
They are often designed with multi-layers of flat
or round braids to achieve sizes of up to 1000mm2
and to carry currents in excess of 400 amps.
Design Optimisation
Computer aided design is applied to each power
shunt proposal optimising weight, size, flexibility,
performance and potential cost savings.
Used as an alternative to solid bus bars and power
cable assemblies, power shunts are capable
of carrying very high currents yet are flexible,
robust, easy to install and cost effective.
Termination
• High compaction
• Maximum conductivity
• Customised design
Braid configuration
• Flat or round
• Multi-layered
• High flexibility options
Insulation jacket options
• Fluid resistant
• High temperature
• Low smoke and toxicity
20
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INDUSTRIAL AND ENERGY
Braid and Termination selection
Conductivity
Oxidisation
Resistance
Operating
Temperature
Applications
Plain Copper
Good
Fair
Medium
Industrial, Rail, Power
Tin-plated Copper
Good
Good
Medium
Industrial, Rail, Power
Copper, single layer flat braid
current ratings
Cross-sectional Area (mm2)
Current rating (amps)
100
400
240
650
300
760
500
1100
600
1250
The current rating values are based on simple
flat braid configurations. The actual current
rating of a power shunt will vary accordingly
to the design and layout of the final braid
configuration. It is recommended that each
power shunt be tested and evaluated fully
to ascertain its suitability to meet the
requirements of its final application.
Note: Above current ratings are based on a temperature rise of
50ºC above ambient.
CrossSectional
Area mm2
Nominal
Current
Rating
(amps)
A
mm
B
mm
100
380
25
25
120
410
30
30
150
450
30
30
200
600
30
30
Ferrule
(End plates)
Finishes
Tin
Nickel
Silver
Hole diameter to be specified by customer.
CrossSectional
Area mm2
Nominal
Current
Rating
(amps)
A
mm
B
mm
C
mm
150
450
60
30
30
300
760
100
50
50
450
1000
100
50
50
600
1220
120
60
60
Ferrule
(End plates)
Finishes
Tin
Nickel
Silver
Hole diameter to be specified by customer.
CrossSectional
Area mm2
Nominal
Current
Rating
(amps)
A
mm
B
mm
C
mm
D
mm
300
940
70
70
40
40
500
1280
70
100
50
50
750
1500
70
100
50
50
1000
2000
100
100
50
50
Ferrule
(End plates)
Finishes
Tin
Nickel
Silver
Hole diameter to be specified by customer.
The current ratings indicated in the above tables are reference values for a temperature rise of 50º
above ambient. Ratings may change in accordance with the method of use and ambient conditions.
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21
FB
Flat Braids
• Wide choice of materials
• Highly flexible
• Non-standard versions available
• Optional insulation jacket
Markets
Aerospace
Military
Industrial
Rail
Marine
Energy
IS-Cabletec manufactures an extensive range
of flat braids from a wide choice of materials,
including stainless steel, aluminium, plain
copper, tin-plated copper and nickel-plated
copper.
The electrical performance of a braid is
determined by selecting the correct
cross-sectional area from the table below.
By changing the conductor strand size it is
possible to improve the braid flexibility and
vibration resistance whilst maintaining
its current rating; the smaller the strand size,
the more flexible the braid.
Materials
1. Plain copper
2. Tin-plated copper
3. Nickel-plated copper
4. Phosphor bronze
5. Stainless steel
6. Oxygen free copper
7. Silver-plated copper
8. Nickel
9. Aluminium
10. Galvanised Mild Steel
Note: replace -x with material number in part no.
Product Details: Standard Flat Braid
Part
Number
Cross-sectional
area (mm2)
Width x depth
(mm)
Current rating
(amps)
FB-02.5-X-15
2.5
6.0 x 0.8
34
FB-04.0-X-15
4.0
8.0 x 1.0
53
FB-06.0-X-15
6.0
10.0 x 1.0
69
FB-10.0-X-15
10.0
13.0 x 1.3
97
FB-16.0-X-15
16.0
19.0 x 1.5
132
FB-25.0-X-15
25.0
23.0 x 2.0
178
FB-35.0-X-15
35.0
25.0 x 3.0
223
FB-50.0-X-15
50.0
20.0 x 5.8
282
Note: Current ratings are based on temperature rise of 50˚C above ambient.
22
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INDUSTRIAL AND ENERGY
RB & RS
Round Braids and Ropes
• Choice of materials
• Wide size range
• Multi-directional flexibility
• Standard & bespoke constructions
• Insulation options
Markets
Aerospace
Energy
Military
Rail
Industrial
IS-Cabletec has an extensive range of standard
and bespoke round (hollow) braids and ropes,
available in a wide choice of constructions and
materials.
Materials
1. Plain copper
2. Tin-plated copper
3. Nickel-plated copper
4. Phosphor bronze
5. Stainless steel
6. Oxygen free copper
7. Silver-plated copper
8. Nickel
9. Aluminium
10. Galvanised Mild Steel
Bonding leads manufactured from round
braids and ropes exhibit multi-axial flexibility,
enabling them to be installed in any direction;
the principle benefit over flat braid bonding
leads. Rope braids, in particular, are strongly
recommended for applications needing
outstanding flexibility and robustness with
maximum flex performance.
Technical Information: Standard Round (Hollow) Braids
Part Number
Cross-sectional area (mm2)
Nominal Diameter (mm)
Current rating (amps)
RB-02.5-X-15
2.5
3.0
34
RB-04.0-X-15
4.0
4.0
53
RB-06.0-X-15
6.0
5.0
69
RB-10.0-X-15
10.0
7.0
97
RB-16.0-X-15
16.0
8.0
132
RB-25.0-X-15
25.0
10.0
178
RB-35.0-X-15
35.0
12.0
223
RB-50.0-X-15
50.0
15.0
282
Part Number
Cross-sectional area (mm2)
Nominal Diameter (mm)
Current rating (amps)
RS-02.5-X-15
2.5
2.10
30
RS-04.0-X-15
4.0
3.2
50
RS-06.0-X-15
6.0
4.40
60
RS-10.0-X-15
10.0
5.4
80
RS-16.0-X-15
16.0
6.80
110
Standard Ropes
RS-25.0-X-15
25.0
8.30
130
RS-35.0-X-15
35.0
10.05
180
RS-50.0-X-15
50.0
11.70
230
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23
INDUSTRIAL AND ENERGY
Over Braiding
• Wide choice of materials
• Bespoke & standard constructions
• Up to 99% coverage
• Diameters of up to 60mm
• Fast and reliable service
• Customer issued substrates option
• Design service
Applications
IS-Cabletec’s over-braiding service is designed
to offer you a comprehensive range of materials
and constructions to provide an effective braid
protection suited to your application. The
cable or conduit can be supplied by you or,
alternatively, supplied by us from our own fully
manufactured over-braided cable or conduit
product range. The choice is yours.
Cables
Conduits
Hoses
Mechanical protection
Armouring
EMI Screening
Markets
Whether your need is for mechanical protection
or EMI screening, our design engineers are on
hand to offer you a product that will perfectly
meet your application.
Aerospace
Military
Industrial
Energy
Materials
1. Plain copper
2. Tin-plated copper
3. Nickel-plated copper
4. Phosphor bronze
5. Stainless steel
6. Oxygen free copper
7. Silver-plated copper
8. Nickel
9. Aluminium
10. Galvanised Mild Steel
24
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Technical
Information
Metal braids, whether they are tubular or flattened follow the same basic principles of braid construction. The construction of
a braid is usually written as shown below:
48 / 30 / 0.15
Diameter of conductor strands
Number of conductor strands or ends
Number of carriers
Braid (Cross-sectional area)
The size of a braid is most often quoted using its ‘cross-sectional area’, although its width, length and thickness may also be
given. The cross-sectional area of a braid is crucial to predicting its current rating, its resistance and its temperature rise due to
it carrying a given current. The cross-sectional area of a braid is calculated using the following equation:
Cross-sectional area = C x E x
πx
D2
4
Example:
A braid manufactured using a 48-carrier
machine, comprising 30 ends of a 0.15mm
diameter conductor strand, using the equation
above, has a cross-sectional area of 25mm2
C = Number of carriers
E = Number of conductor strands or ends
= 3.142
D = Diameter of conductor strands
π
Bonding Leads - Critical Dimensions
Bonding Leads are typically designed and manufactured for a specific application or to a detailed customer specification. In addition to the
cross-sectional area of a braid the dimensions shown below are required to ensure the correct finished product.
D2
D1
W
L2
L1
D1
D2
L1
=
=
=
Left terminal hole diameter
Right terminal hole diameter
Overall length of connector
L2
W
=
=
Length between terminal hole centres
Braid width
Disclaimer
Whilst every effort has been made to ensure that the information contained in this publication is correct. IS-Cabletec and its agents will not accept any liability or
responsibility for any costs or damages whatsoever arising directly or indirectly from the use or misuse of the products or information contained in this publication. Users
must independently ascertain the suitability of the product to meet their requirements. IS-Cabletec reserve the right to change the product specification without notice.
IS-Cabletec’s obligations are limited to those indicated in our standard terms and conditions of sale, available on our website.
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25
IS-Cabletec Sunnyside Road Weston-super-Mare North Somerset BS23 3PZ UK
Tel: +44 (0) 1934 424900 Fax: +44 (0) 1934 636632 Email: sales@is-cabletec.com Web: www.is-cabletec.com
CAB 0214/1