What is connector replacement?
Taking out a damaged connector and fitting a new one in the same place, then sealing and testing it before the circuit is restored. In a series circuit, a connector left faulty can put out every light on the loop.
A connector is replaced when inspection or testing shows it can no longer be relied on: a cracked or cut moulding, corrosion, heat damage, water inside, or insulation resistance that stays low. The job is short, but it is a repair on a live-capable circuit, so the order of work matters as much as the new part.
1Make it safe first
Isolate and lock out the circuit and prove it dead, as your site procedure requires, before the can or pit is opened. Never disconnect a primary connector on a live series circuit. Work on the airfield only with the right permission and under the site’s safety rules.
2Choose the part and prepare the cable
Use the part the manufacturer or project specification calls for, with the right type and rating for that position, such as primary or secondary. Remove the old connector and look at the cable beside it. Cut back to sound, dry cable, because a fresh connector on wet or damaged cable will fail again. If this leaves the cable too short, a joint made to the kit maker’s instructions may be needed.
- Use the specified part and rating
- Cut back to sound, dry cable
- Fit and seal to the maker’s instructions
- Reuse a damaged connector or seal
- Substitute a part that only seems to fit
- Close the can before testing
3Fit, seal, test and record
Fit the new connector and seal it as the maker instructs, on clean, dry parts and over the jacket at both ends. Then test continuity and insulation resistance before the can is closed or the cable buried, discharging the circuit after each insulation test. Record the location, the part used and the readings, update the as-built records where needed, and restore the circuit only as your procedure allows.
| Stage | What to do |
|---|---|
| Reason for replacement | Defect from inspection or a failed test, noted and photographed |
| Circuit | Isolated, locked out and proved dead |
| Replacement part | Specified type and rating; primary or secondary as required |
| Cable end | Cut back to sound, dry cable; joint if cable is too short |
| Fitting and seal | Clean, dry parts; seal overlaps the jacket at both ends |
| Tests | Continuity and insulation resistance before closing the can |
| Records | Location, part, readings, date; update as-built records |
| Restore | Only as the procedure and permissions allow |
Frequently Asked Questions
Q1When should an AGL connector be replaced?
When inspection or testing shows it is damaged or no longer reliable, for example a cracked or cut moulding, corrosion, heat damage, a failed seal, water inside, or low insulation resistance that cannot be cured another way.
Q2Can a connector be replaced with the circuit live?
No. Isolate and lock out the circuit and prove it dead as the maintenance plan and site rules require. Never disconnect a primary connector on a live series circuit.
Q3Does the replacement connector have to be the same type?
Use the part the manufacturer or project specification calls for, with the right type and rating for that position, such as a primary or a secondary connector. Do not substitute a different part to make it fit.
Q4What if the cable next to the connector is damaged too?
Cut back to sound, dry cable before fitting the new connector. If that leaves the cable too short, a joint made to the kit maker's instructions may be needed, and it must be recorded.
Q5What should be done after fitting the new connector?
Seal it as the maker instructs, test continuity and insulation resistance (discharging the circuit after the insulation test) before the can is closed or the cable buried, record the location and readings, and restore the circuit only as your procedure allows.
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