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

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

  • eBook
  • PDF (Two-page spreads)
  • PDF (Single pages, print friendly)
Plug with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire, 972-101

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 performace
  • 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
Wall-Mount Receptacle with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire, 972-102

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 performace
  • 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
Jam-Nut Receptacle with Banding Platform, Compression Grommet for Tape-Wrapped or Extrusion-Insulated Wire, 972-103

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 performace
  • 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
Feed-Thru Receptacle, Jam-Nut Mount, 972-203

972-203
Feed-Thru Receptacle, Jam-Nut Mount

PowerLoad Connectors with Compression Grommet

  • Socket towers for improved creep path performace
  • 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

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

Crown Ring Crimp Contact Tooling

Pneumatic Crimp Tool for #8, #4, and #1/0 Contacts

Plug with Banding Porch, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire, 972-011

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 performace
  • 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
Wall-Mount Receptacle with Banding Platform, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire, 972-012

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 performace
  • 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
Jam-Nut Receptacle with Banding Platform, Bus Bar and Lug Contacts, Bonded Grommet for TurboFlex or Tape-Wrapped Wire, 972-013

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 performace
  • 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
Bus Bar/Lug Pin Contacts, 850-323

850-323
Bus Bar/Lug Pin Contacts

  • A = Internal thread
  • B = External thread
  • C = Lug
Bus Bar/Lug Socket Contacts, 850-324

850-324
Bus Bar/Lug Socket Contacts

  • A = Internal thread
  • B = External thread
  • C = Lug
EMI/RFI Environmental Backshell, Straight, 45°, 90° Configurations, 390PX055

390PX055
EMI/RFI Environmental Backshell

  • 390PXM055 = 45° (bent tube elbow)
  • 390PXN055 = 90° (bent tube elbow)
  • 390PXS055 = Straight
Compression Backshell with Banding Platform, 4470PXS1128

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
Environmental Heat-Shrink Boots supplied with 4470PXS1128 Backshell, 770-001S

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
PowerLoad™ Receptacle Protective Cover, 660-128

660-128
PowerLoad™ Receptacle Protective Cover

PowerLoad™ Plug Protective Cover, 660-129

660-129
PowerLoad™ Plug Protective Cover

PowerLoad™ Gasket for Flange-Mount Connectors, 930-026

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
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

Single-Wall Hookup Wire Duralectric™ Insulation, 1500 VAC, 961-106-1500

961-106-1500
Single-Wall Hookup Wire Duralectric™ Insulation, 1500 VAC

TurboFlex Hookup: Cabling with FEP and Duralectric Insulation

  • TurboFlex single-wall hookup wire
Single-Wall Hookup Wire Duralectric™ Insulation, 2000 VAC, 961-106-2000

961-106-2000
Single-Wall Hookup Wire Duralectric™ Insulation, 2000 VAC

TurboFlex Hookup: Cabling with FEP and Duralectric Insulation

  • TurboFlex single-wall hookup wire
Single-Wall Hookup Wire Duralectric™ Light Insulation, 1500 VAC, 961-108-1500

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
Single-Wall Hookup Wire Duralectric™ Light Insulation, 2000 VAC, 961-108-2000

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
Dual-Wall Interconnect Cable Duralectric Insulation, Duralectric Outer Jacket, 1500 VAC, 961-107-1500

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
Dual-Wall Interconnect Cable Duralectric Insulation, Duralectric Outer Jacket, 2000 VAC, 961-107-2000

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
Dual-Wall Interconnect Cable Duralectric Light Insulation, Duralectric Light Outer Jacket, 1500 VAC, 961-109-1500

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
Dual-Wall Interconnect Cable Duralectric Light Insulation, Duralectric Light Outer Jacket, 2000 VAC, 961-109-2000

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