What is connector installation?
Fitting a primary or secondary connector to an AGL cable — cable prepared to the kit dimensions, contact crimped, insulation restored, plug and receptacle fully engaged and locked, then tested and recorded, so every connection in the series loop carries current safely.
Connector installation is fitting a connector to the end of an AGL cable and mating it to its pair. The cable is prepared to the connector kit’s dimensions, the contact is crimped on the conductor, the insulation is restored as the kit instructs, and the plug and receptacle are engaged and locked. It is done for the primary connectors at each isolating transformer and for the secondary connector on the fixture lead.
Because the lights are in series, every primary and in-line connector carries the full circuit current, and a secondary connector carries the lamp current. A poor crimp or a damp primary connector means heat, arcing, an earth fault or an open loop that puts every lamp out. Use the manufacturer’s kit, tools and instructions as a set, keep the faces clean, support the connector so the cable is not under strain, and test and record before the pit is closed. Make connectors only with the circuit isolated, locked out and proved dead, treat any cable as live until then and work to the airport’s permit-to-work.
- Isolate. Switch off, lock out and prove the circuit dead before any work.
- Prepare. Cut the cable square, strip it to the kit dimensions and clean it.
- Crimp. Fit the contact with the specified tool and die and check it.
- Insulate. Restore the insulation with the manufacturer’s kit as instructed.
- Mate. Clean the faces, engage the pair fully and lock it, with no strain on the cable.
- Test, mark and record. Check continuity and insulation resistance, discharge the circuit after the insulation test, identify the cable and log the results.
Frequently Asked Questions
Q1What is connector installation in airfield ground lighting?
Connector installation is fitting a connector to the end of an AGL cable and mating it to its pair. The cable is prepared to the connector kit’s dimensions, the contact is crimped on the conductor, the insulation is restored as the kit instructs, and the plug and receptacle are engaged and locked. It is done for primary connectors at the isolating transformer and for the secondary connector at the fixture lead.
Q2Why does one poor connector matter so much?
The lights are in a series circuit, so every primary and in-line connection carries the full circuit current, while a secondary connection carries the lamp current. A high-resistance or damp primary connector can overheat, arc or open the loop and put every lamp on the circuit out (on the secondary side the usual effect is one light), and moisture in a connector is a common cause of earth faults. Connectors are therefore made carefully and tested before the pit is closed.
Q3Why use the manufacturer’s kit, tools and instructions?
Strip lengths, crimp tool and die, insulation restoration and mating details are qualified together as one system. Mixing parts, or using a different tool, can leave a weak crimp or a gap in the insulation that does not show until the circuit is energised. Follow the connector manufacturer’s instructions and the design specification.
Q4Why must the connector be clean and fully engaged?
Dirt, grit or moisture on the mating faces can prevent a full seal and affect the contact. A half-engaged connector can open or arc under load and may work loose later. Clean the faces as the manufacturer instructs, push the pair fully home and lock it as the design requires.
Q5Where should the connector sit in the pit or base can?
At the position the design shows, where it can be reached for testing and replacement, supported rather than hanging from the cable, with the cable free of strain and a slack loop left. See Connector locations for the four places connectors sit in a layout.
Q6What should be checked before the pit is closed?
Check the connector is clean, fully engaged and locked, the cable is not under strain and keeps its minimum bending radius, and the circuit and cable are identified. Carry out continuity and insulation-resistance tests as the commissioning procedure requires, discharge the circuit after the insulation test, and record the results. Make connectors only with the circuit isolated, locked out and proved dead, and work to the permit-to-work.
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