METAL BRAIDS

FLAT - ROUND - ROPES - BONDING LEADS - POWER SHUNTS

Loo 16c
5571KR Bergeijk
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.

Cabletec is also a manufacturer of customised

multicore cables and a distributor of a wide
range high performance wire and cable, and
harness components.

For further details, please visit our website:

www.cabletec.com

Approvals: ISO 9001 • BS/EN 9100

Contents

AEROSPACE AND DEFENCE

EN4199-004 Bonding Leads 2-3
CBL150 & 260 Bonding Leads 4-5
CRL260 High Flex Bonding Leads 6
CFBA1068 Aluminium Bonding Leads 7
QBL Quick Release Bonding Leads 8-9
LN9264 Bonding Leads 10
AGS2097 Bonding Leads 11
Market Approvals 12
High Performance Materials 13

INDUSTRIAL AND ENERGY

CFBA Customised Bonding Leads 14-15
FBL Bonding Leads 16-17
RBL Bonding Leads 18-19
Power Shunts 20-21
FB Flat Braids 22
Round Braids and Ropes 23
Over Braiding 24

Tehnical Information 25

1
EN4199-004
Round Bonding Leads

• Tin & nickel-plated copper

• Choice of terminal sizes
• Designed for Aerospace and
Defence applications
• Tested and certified to EN4199
• ASD* approved
• Adopted by Airbus and
Rolls Royce

EN4199-004 bonding leads are designed

Markets specifically for Aerospace and Military
Aerospace applications. They are ASD* (formerly AECMA)
Military approved and have undergone extensive
Industrial mechanical and electrical testing, including
flex testing to 250,000 cycles, sinusoidal and
random vibration cycles and salt mist testing.
Materials Operating
Temperature EN4199-004 bonding leads are manufactured
from multi-layer round braid and are available
Tin-plated copper -65ºC to +150ºC
in tin-plated and nickel-plated copper in a
Nickel-plated copper -65ºC to +260ºC
variety of cross-sectional areas, lengths and
*Aerospace and Defence Industries Association of Europe (www.asd-europe.org) termination options.

Part Numbering System

CFBA4199 - 004 - N - 7.0 - 250 - E

Product standard
EN4199-004

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, 4.17mm terminal hole diameters.

2
 AEROSPACE AND DEFENCE
Standard Lengths (Other lengths available)
Availability for cross-sectional area (mm2)
Length (mm) 1.4mm2 3.5mm2 4.5mm2 7.0mm2 13.0mm2
63  
80     
100     
125     
160     
200     
250    
315  
400    
500  
630 
800 

Length ‘L’

Terminal end 1 W
Terminal end 2

End 1 End 2 Availability for cross-sectional area (mm2)

Code Hole size Diameter Hole size Diameter 1.4mm2 3.5mm2 4.5mm2 7.0mm2 13.0mm2
A #6 3.50mm #6 3.50mm   
B #8 4.17mm #8 3.50mm   
C #10 4.83mm #6 3.50mm   
D 1/4 6.35mm #6 3.50mm   
E #8 4.17mm #8 4.17mm    
F #10 4.83mm #8 4.17mm    
G 1/4 6.35mm #8 4.17mm    
H 10 4.83mm #10 4.83mm     
J 1/4 6.35mm #10 4.83mm     
K 1/4 6.35mm 1/4 6.35mm     
L 5/16 7.94mm #10 4.83mm   
M 5/16 7.94mm 5/16 7.94mm   
N 5/16 7.94mm 1/4 6.35mm 

Performance Testing • Sinusoidal and random vibration

EN4199-004 bonding leads are designed • Mechanical fatigue (250,000 cycles)
and tested to meet the special demands • Salt Mist (48 hours)
of Aerospace and Military applications and • Temperature endurance
environments. Adopted by some of the largest • Terminal ageing by temperature and
aerospace companies in Europe, they are fully current cycling
tested and certified to EN4199-001. • Voltage drop
• Tensile strength

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 in accordance to
EN4199-003

Markets
Cabletec’s CBL range of flat style bonding leads
Aerospace are designed for aerospace and military
Military
applications, but are also suitable for higher
Industrial
performance industrial uses.

They are available with and without insulation

Materials Operating in both tin-plated and nickel-plated copper in a
Temperature range of cross-sectional areas. They are highly
Tin-plated copper -65ºC to +150ºC flexible, robust and reliable and manufactured
Nickel-plated copper -65ºC to +260ºC in accordance to EN4199-003.
Insulated -65ºC to +150ºC

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),
4.83mm terminal hole size both ends, insulated.

4
 AEROSPACE AND DEFENCE
Terminal Availability: CBL150 (Tin-plated copper)
Terminal
Hole
Hole Cross-sectional area (mm2)
Variant Diameter
Code Size (mm) 1.5 4 6 10 16 25
A No.6 3.5 
B No.8 4.17   
C No.10 4.83      
D 1/4 6.35      
E 5/16 8.33     
F 3/8 9.91   

CBL260 (Nickel-plated copper)

Terminal
Hole
Hole Cross-sectional area (mm2)
Variant Diameter
Code Size (mm) 1.5 4 6 10 16 25
A No.6 3.5  
B No.8 4.17   
C No.10 4.83    
D 1/4 6.35     
E 5/16 8.33   
F 3/8 9.91  

Length ‘L’

Terminal end 1 W
Terminal end 2

Technical Information for Uninsulated CBL260 (Nickel-plated copper) Leads

Braid Minimum Tensile Nom Resistance Braid Nom Mass Braid
cross-section Strength 100mm Length Resistance 100mm Length Mass
(mm2) (N) (mΩ) (mΩ per 25mm) (g) (g per 25mm)
1.5 250 1.32 0.308 2.6 0.4
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

For lengths other than 100mm, nominal For maximum figures, an additional 10%
resistance and mass can be calculated by should be applied to the nominal values.
adding or subtracting multiples of the 25mm
Nominal values of mass are based on the use
braid figures as quoted above.
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.

5
CRL260
High Flex Bonding Leads

• Nickel-plated copper
• Choice of 5 cross-sectional areas
• Range of terminal sizes
Cabletec’s CRL260 bonding leads are designed
• Very high flex endurance*
to withstand exceptional levels of flexing in
• Excellent corrosion resistance combination with outstanding resistance to
*Tested in accordance with EN4199-001
corrosion and salt attack. When tested to the
flex endurance test detailed in EN4199-001, they
withstand over 5 million cycles, outperforming
Markets other existing aerospace standard leads by
Aerospace more than 5 times.
Military
CRL260 bonding leads are particularly suited for
dynamic applications in exposed areas such as
Materials Operating external aircraft doors and flaps.
Temperature
Nickel-plated copper - 65ºC to +260ºC Terminal code A B C D E
Hole size 3.5mm 4.83mm 6.35mm 8.33mm 9.91mm

Length ‘L’ 3.5mm 2

    
5.0mm 2
    
7.0mm 2
   
W 13.0mm 2
  
Terminal end 1 Terminal end 2

Part Numbering System

CRL260 - 5.0 - 200 - A

Product Reference

Cross-sectional area
3.5mm2, 5.0mm2,
7.0mm2, 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 3.5mm terminal
hole size.

6
 AEROSPACE AND DEFENCE

CFBA1068
Aluminium Bonding Leads

• Aluminium
• 5mm2 cross-sectional area
• Range of terminal sizes and lengths
Cabletec’s CFBA1068 aluminium bonding leads
• Light weight
are designed for aerospace applications
• Excellent aviation fuel resistance requiring electrical bonding in combination
with light weight. They are supplied insulated
Markets and with a protective chromate conversion
coating, making them particularly suited to
Aerospace
applications in contact with aviation fuels.
Military
CFBA1068 bonding leads are available in a
Materials Operating range of lengths and 2 sizes of specially formed
Temperature aluminium terminals.

Aluminium* +200ºC
Terminal code Hole size Hole size (mm)
*Insulated and available with or without Chromate conversion coating to A M3 3.61 to 3.86
MIL-C-5541 Class 3
B M4 4.90 to 5.16

Part Numbering System Ordering Example

CFBA1068 - B B - 76.2
CFBA1068-BB-76.2 = Aluminium bonding lead,
5mm², insulated, terminal hole size 4.90 - 5.16mm
Product Reference each end, 76.2mm length (between hole centres).

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

7
QBL150
Quick Release Bonding Leads

• Tin-plated copper
• BNC or TCN connector
• Fast and easy release
• Various lengths
• Choice of terminal sizes
• Rear and front mounted mating
receptacle

Cabletec’s quick release bonding leads provide

Markets an effective hand-releasable method of earth
Aerospace bonding electrical equipment. They are
Military particularly useful for applications where a
Industrial temporary connection is required or where
equipment needs to be removed quickly over
multiple times.
Materials Operating QBL bonding leads comprise of a flat tin-plated
Temperature copper braid with a crimped ring terminal
Tin-plated copper -55ºC to +120ºC at one end and a BNC or TNC connector at
Insulated -55ºC to +120ºC the other. The connector is connected to
equipment via a mating receptacle, mounted
to the equipment to be 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 = 6mm hole diameter

Insulated
Leave blank if insulation
is not required

8
 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 6mm

Length (mm)
Nominal 50 75 100 125 150 175 200
Mass (g) 5mm hole - 26.5 27.0 27.5 28.2 28.5 29.5
Mass (g) 6mm hole - 26.9 27.4 27.9 28.6 28.9 29.9
Resistance (mΩ) 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Technical details: QBL150T (TNC type)

Connector TNC, PAN6444G
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 6mm

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.

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 LN9264 is a long established aerospace and

Temperature defence specification containing a series of
Tin-plated copper - 65ºC to +150ºC uninsulated tin and nickel-plated copper
Nickel-plated copper - 65ºC to +260ºC bonding leads terminated with a range of crimp
style round terminals. They are often found
Part Number System on legacy aircraft and form the basis of more
recent bonding lead specifications such as
CFBA9264 - 4 - 160 N
JN1061 (Typhoon), EN4199-003 and Cabletec’s
CBL range.
Product Reference
They are available in 6 standard cross-sectional
Braid size
1.5mm , 4.0mm , 6.0mm ,
2 2 2 areas and a limited range of lengths.
10.0mm2, 16.0mm2, 25.0mm2

Length ‘L’ (mm)

60mm, 80mm, 100mm, 125mm, Length ‘L’
160mm, 200mm, 250mm

Material
Tin-plated copper or
N = Nickel-plated copper W
Terminal end 1 Terminal end 2

Dimensions
Braid cross-section Current Braid resistance at 20ºC Terminal Hole Diameter

(mm2) (amps) (Ω/1000m) Tin (mm) Nickel (mm)

1.5 16 14.2 4.3 4.3
4 30 5.3 5.3 5.0
6 40 3.5 6.5 6.5
10 65 2.1 6.5 6.5
16 80 1.3 8.4 8.4

25 125 0.85 8.4 8.4

Ordering Example
CFBA9264-4-160N = Flat uninsulated braid, 4mm², nickel-plated copper, 160mm length between hole
centres, 5.0mm terminal hole diameters.

10
 AEROSPACE AND DEFENCE

AGS2097
Bonding Leads

• Tin-plated copper braid

2
• 0.7mm cross-sectional area
• Choice of terminal sizes
• Multiple lengths
• Aerospace approved

Applications
Aerospace
Military

AGS2097 bonding leads are a series of

Materials Operating aerospace approved bonding leads,
Temperature generally, but not exclusively, found on
Tin-plated copper - 65ºC to +150ºC legacy aircraft such as Tornado, Hawk and
the C-130 (Hercules).

They are available with one standard braid

Part Number System size (0.7mm²) and a combination of terminal
CFBA2097 B 4 B sizes and lengths.

Standard description Length ‘L’

Terminal variant (End 1)

W
Terminal end 1 Terminal end 2
Length ‘L’
1 inch increments, min. 3 inches
Terminal selection
Terminal variant (End 2)
Smaller end quoted first Terminal code Hole diameter (mm)

B 4.3
C 5.0
Ordering Example
E 6.5
CFBA2097-B-4-B = Flat uninsulated braid, 0.7mm²,
G 6.5
tin-plated copper, 101.6mm (4”) length between
J 8.4
hole centres, 4.3mm terminal hole diameters.

11
 AEROSPACE AND DEFENCE

Market Approvals
Defence & Aerospace

Cabletec is a supplier of bonding leads and metal

braid to many of the major aerospace and
defence companies of Europe and an influential
contributor to the development and promotion
of the recently launched EN4199 European
standard for metal braid and bonding leads.

In addition to EN4199, we manufacture products

to a comprehensive range of aerospace and
defence specifications, some of which are
detailed below.

Aerospace & Defence Industries of Europe (ASD)

EN4199-006 Round braid Tin and nickel-plated copper
EN4199-004 Round braid bonding leads Tin and nickel-plated copper See pages 2-3

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 See page 10
CSP48 Flat bonding leads Tin and nickel-plated copper
AGS2097 Flat braid bonding leads Tin-plated copper 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
High Performance
Materials

In addition to the standard materials used to

produce braids and bonding leads, 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 Stainless steel has outstanding Pure nickel strand can be used
excellent conductivity at corrosion resistance compared at even higher temperatures
temperatures up to 200ºC to many materials, particularly whilst still exhibiting excellent
silver-plated copper is when in contact with salt conductivity and corrosion
recommended; particularly water; perfect for off-shore resistance. Nickel is particularly
for extreme aerospace and and marine applications. suitable for applications in
space applications. extreme industrial conditions
such as welding, furnaces and
power stations.

Material Maximum Operating Temperature Properties Markets

Excellent conductivity
Silver-plated Copper 200˚C Space
High temperature

Excellent conductivity Space

Pure Nickel 649˚C Extreme temperatures Aerospace
High corrosion resistance Industrial

High temperature Marine

Stainless Steel 400˚C High corrosion resistance Offshore
High stain resistance Construction

For further details for products manufactured from these materials please contact our sales office on:
+44 (0)1934 424900.

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
In addition to our standard products, we
Markets provide a comprehensive design and build
Aerospace Military service producing fully customised bonding
Industrial Rail leads, each with its own unique part number.
Marine Energy Our bonding leads are constructed from an
extensive range of in-house manufactured
braids and ropes combined with components
Materials from a multitude of termination, insulation
Plain copper and identification options, resulting in bonding
Tin-plated copper leads specifically tailored to meet the exact
Nickel-plated copper demands of your application.
Aluminium Furthermore, we aim to keep minimum order
Stainless steel quantities low, lead times short and ensure that
Nickel our product quality and customer service levels
Silver-plated copper 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
 INDUSTRIAL AND ENERGY
Material selection
Conductivity Corrosion resistance Maximum operating Applications
temperature
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, Industrial, Military Industrial, Military, Industrial, Military, Aerospace, Military
Aerospace Aerospace Energy

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.

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

Markets tin-plated copper flat braid, terminated at each
Military end with a pressed ferrule type connector.
Industrial The benefit of using pressed ferrules is that
Energy you achieve maximum electrical contact with
Rail minimum resistance.
FBL bonding leads are flexible, robust, durable
Materials Operating and reliable; perfect for the most demanding
Temperature industrial applications. They are available
with a wide range of standard lengths and
Tin-plated copper -65ºC to +150ºC
hole sizes, and with or without insulation.
Insulated -40ºC to +135ºC
In addition, they have low minimum order
Other non-standard materials available on request. 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
 INDUSTRIAL AND ENERGY
E

Technical Information
Cross- Strand Maximum Current
sectional C D E Allowable Hole
Size (mm) (mm) (mm) Rating
Area (mm) Size (mm) (amps)
4 0.15 10 10 2 6.5 50
6 0.15 13 15 2 8.5 65
10 0.15 15 15 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

Terminal Availability
Hole Size
Cross-
sectional M4 M5 M6 M8 M10 M12 M14 M16
Area
4.5mm 5.5mm 6.5mm 8.5mm 10.5mm 13.0mm 15.0mm 18.0mm
4   
6    
10     
16      
25       
35       
50      
For additional terminals, please contact our sales office.

17
RBL
Rope Bonding Leads

• Rope style bonding leads

• Tin-plated copper
• Multi-directional flexibility
• Durable and robust design
• Highly flexible

Markets
RBL bonding leads are stranded rope
Military construction assemblies manufactured from
Industrial
annealed copper-ETP1 manufactured to BS
Rail
EN13602. They are robust, highly flexible
and durable, making them perfectly suited
to dynamic applications and those in high
Materials Operating
vibration environments.
Temperature
Tin-plated copper -65ºC to +150ºC In addition, RBL bonding leads boast large
Insulated -40ºC to +135ºC cross-sectional areas whilst keeping overall
diameters to a minimum making them ideal
Other non-standard materials available on request. 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
 INDUSTRIAL AND ENERGY

Technical Information
Cross-sectional Strand Size ‘W’ mm Current Rating
Area (mm2) (mm) (Nominal) (amps)
4 0.15 10 50
6 0.15 11 60
10 0.15 15 80
16 0.15 16 120
25 0.15 16 150
35 0.15 18 200
50 0.15 20 240

Terminal Availability
Hole Size
Cross-
sectional M4 M5 M6 M8 M10 M12 M14 M16
Area
4.5mm 5.5mm 6.5mm 8.5mm 10.5mm 13.0mm 15.0mm 18.0mm
4     
6     
10     
16     
25     
35       
50       
For additional terminals, please contact our sales office.

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

Power shunts are large cross-sectional area

Energy and Industrial braided connectors, customised and designed
Power stations to meet the increasing demands of power
Generators distribution applications.
Switchgear
Power transmission 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 Used as an alternative to solid bus bars and power
Computer aided design is applied to each power cable assemblies, power shunts are capable
shunt proposal optimising weight, size, flexibility, of carrying very high currents yet are flexible,
performance and potential cost savings. 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
 INDUSTRIAL AND ENERGY
Braid and Termination selection

Conductivity Oxidisation Operating Applications

Resistance Temperature
Plain Copper Good Fair Medium Industrial, Rail, Power

Tin-plated Copper Good Good Medium Industrial, Rail, Power

Copper, single layer flat braid

current ratings
The current rating values are based on simple
Cross-sectional Area (mm2) Current rating (amps) flat braid configurations. The actual current
100 400 rating of a power shunt will vary accordingly
240 650 to the design and layout of the final braid
configuration. It is recommended that each
300 760
power shunt be tested and evaluated fully
500 1100
to ascertain its suitability to meet the
600 1250
requirements of its final application.
Note: Above current ratings are based on a temperature rise of
50ºC above ambient.

Nominal
Cross- Ferrule
Current A B
Sectional mm mm (End plates)
Rating
Area mm2 Finishes
(amps)

100 380 25 25
120 410 30 30 Tin
Nickel
150 450 30 30 Silver
200 600 30 30

Hole diameter to be specified by customer.

Nominal
Cross- Ferrule
Current A B C
Sectional mm mm mm (End plates)
Rating
Area mm2 Finishes
(amps)

150 450 60 30 30
300 760 100 50 50 Tin
Nickel
450 1000 100 50 50 Silver
600 1220 120 60 60

Hole diameter to be specified by customer.

Nominal
Cross- Ferrule
Current A B C D
Sectional mm mm mm mm (End plates)
Rating
Area mm2 Finishes
(amps)

300 940 70 70 40 40
500 1280 70 100 50 50 Tin
Nickel
750 1500 70 100 50 50 Silver
1000 2000 100 100 50 50

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.

21
FB
Flat Braids

• Wide choice of materials

• Highly flexible
• Non-standard versions available
• Optional insulation jacket

Markets
Aerospace
Military
Cabletec manufactures an extensive range
Industrial
of flat braids from a wide choice of materials,
Rail
including stainless steel, aluminium, plain
Marine
copper, tin-plated copper and nickel-plated
Energy
copper.

The electrical performance of a braid is

Materials
determined by selecting the correct
1. Plain copper
cross-sectional area from the table below.
2. Tin-plated copper
By changing the conductor strand size it is
3. Nickel-plated copper
4. Phosphor bronze possible to improve the braid flexibility and
5. Stainless steel vibration resistance whilst maintaining
6. Oxygen free copper its current rating; the smaller the strand size,
7. Silver-plated copper the more flexible the braid.
8. Nickel
9. Aluminium
10. Galvanised Mild Steel
Note: replace -x with material number in part no.

Product Details: Standard Flat Braid

Part Cross-sectional Width x depth Current rating
Number area (mm2) (mm) (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
 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 Military Industrial
Energy Rail
Cabletec has an extensive range of standard
and bespoke round (hollow) braids and ropes,
Materials available in a wide choice of constructions and
1. Plain copper materials.
2. Tin-plated copper
Bounding leads manufactured from round
3. Nickel-plated copper
braids and ropes exhibit multi-axial flexibility,
4. Phosphor bronze
5. Stainless steel enabling them to be installed in any direction;
6. Oxygen free copper the principle benefit over flat braid bonding
7. Silver-plated copper leads. Rope braids, in particular, are strongly
8. Nickel recommended for applications needing
9. Aluminium outstanding flexibility and robustness with
10. Galvanised Mild Steel 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

Standard Ropes
Part Number Cross-sectional area (mm2) Nominal Diameter (mm) Current rating (amps)

RS-02.5-X-15 2.0 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
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

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 Cabletec’s over-braiding service is designed to

Cables offer you a comprehensive range of materials
Conduits and constructions to provide an effective braid
Hoses
protection suited to your application. The
Mechanical protection
cable or conduit can be supplied by you or,
Armouring
alternatively, supplied by us from our own fully
EMI Screening
manufactured over-braided cable or conduit
product range. The choice is yours.
Markets
Whether your need is for mechanical protection
Aerospace
or EMI screening, our design engineers are on
Military
hand to offer you a product that will perfectly
Industrial
Energy meet your application.

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
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 π x D2
4
Example:
A braid manufactured using a 48-carrier C = Number of carriers
machine, comprising 30 ends of a 0.15mm E = Number of conductor strands or ends
diameter conductor strand, using the equation π = 3.142
above, has a cross-sectional area of 25mm2 D = Diameter of conductor strands

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.

D1 D2

W
W

L2

L1

D1 = Left terminal hole diameter L2 = Length between terminal hole centres

D2 = Right terminal hole diameter W = Braid width
L1 = Overall length of connector T = Braid thickness

Disclaimer
Whilst every effort has been made to ensure that the information contained in this publication is correct. 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. Cabletec reserve the right to change the product specification without notice. Cabletec’s obligations are limited to those
indicated in our standard terms and conditions of sale, available on our website.

25
CAB 0710/1