EN 4049-003:2006

Overview

EN 4049-003:2006 is a European standard developed by CEN, specifying the product requirements for aerospace thermocouple extension cables. This standard focuses on single-core cables composed of nickel-chromium/nickel-aluminium conductors designed for operating temperatures ranging from -65 °C to 260 °C. These cables are crucial for establishing a reliable link between thermocouples and equipment in aerospace applications, ensuring precise temperature measurement and signal integrity under demanding environmental conditions.

Key Topics

• Scope and Application
  EN 4049-003:2006 details the construction, materials, and electrical characteristics of thermocouple extension cables used specifically in aerospace. It covers single core cables suitable for temperatures between -65 °C and 260 °C, protecting signal quality in critical aircraft systems.

• Materials and Construction
  The conductors comply with ISO 8056-1 standards, featuring nickel-chromium or nickel-aluminium composition with class 1 tolerances. Insulation consists of multilayer tape wrapping - including PTFE and polyimide layers with a precise minimum 51% overlap to ensure durability and thermal resistance.

• Color Coding and Designation
  Colors for cable cores follow EN 4049-002 to maintain consistency and improve identification in complex aerospace wiring harnesses. The cables are designated with a standardized type code for clear identification, facilitating streamlined procurement and maintenance.

• Required Characteristics and Testing
  The standard mandates rigorous testing per EN 3475 and ISO 8056-1 to verify electrical resistance, insulation integrity, mechanical strength, thermal endurance, and resistance to bending, cold, and environmental factors. Quality assurance aligns with EN 9133 ensuring compliance and reliability.

• Marking and Packaging
  Marking conforms to EN 4049-002 standards to facilitate traceability, with packaging and delivery lengths governed by EN 4049-001. These ensure the cables are correctly labeled and supplied in appropriate lengths for aerospace manufacturing and maintenance.

Applications

EN 4049-003 thermocouple extension cables are engineered for use in aerospace electrical systems where precise temperature monitoring is essential. Typical applications include:

• Aircraft engine and environmental control system sensors
• Flight-critical instrumentation cabling
• Thermal management systems in aerospace vehicles
• Research and development test setups for aerospace components

The standard’s high thermal tolerance, resistance to mechanical stresses, and electrical performance make these cables well-suited for harsh aerospace environments requiring robust, reliable temperature measurement connections.

Related Standards

EN 4049-003:2006 is part of a series of aerospace standards addressing thermocouple cables:

• EN 4049-001: Technical specification for thermocouple extension cables operating from -65 °C to 260 °C.
• EN 4049-002: General requirements and guidelines covering the broader thermocouple extension cable construction and insulation.
• ISO 8056-1: General requirements and testing for nickel-chromium and nickel-aluminium thermocouple extension conductors.
• EN 3475-100: Test methods for aerospace electrical cables, specifying visual, mechanical, and electrical tests applicable to these cables.
• EN 9133: Quality management system requirements specific to qualification procedures for aerospace standard parts, ensuring consistent production quality.

By adhering to EN 4049-003 and its related standards, aerospace manufacturers and maintenance organizations ensure reliable performance, safety, and compliance in critical thermocouple cabling solutions.

Keywords: aerospace thermocouple extension cable, nickel-chromium cable, nickel-aluminium cable, thermocouple cable standard, EN 4049-003, operating temperature -65 to 260 °C, aerospace electrical wiring, aerospace cable testing, thermocouple insulation, aerospace cable quality assurance