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| ![](media/image1.wmf)                 | ![](media/image2.emf)        |
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| **U.S. Department**                   |                              |
|                                       |                              |
| **of Transportation**                 |                              |
|                                       |                              |
| **Federal Aviation**                  |                              |
|                                       |                              |
| **Administration**                    |                              |
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![](media/image3.wmf)

  -------------- ------------------------ ------------- --------- ------------- --------------
  **Subject:**   FAA SPECIFICATION FOR    **Date:**     9/30/08   **AC No.:**   150/5345-26D
                 L-823                                                          

                 PLUG AND RECEPTACLE,     **Initiated   AAS-100   **Change:**   
                 CABLE CONNECTORS         by:**                                 
  -------------- ------------------------ ------------- --------- ------------- --------------

**1. PURPOSE.** This advisory circular (AC) contains the specification
for plug and receptacle (cable connectors) used with underground power
cables, isolation transformer leads, and light fixture leads for airport
lighting systems.

**2. EFFECTIVE DATE.** Effective six months after the issue date of this
AC, only that equipment qualified per the specifications herein will be
listed per AC 150/5345-53, Airport Lighting Equipment Certification
Program.

**3. CANCELLATION.** AC 150/5345-26C, FAA Specification for L-823 Plug
and Receptacle, Cable Connectors, dated April 17, 2000, is canceled.

**4. APPLICATION.** The Federal Aviation Administration (FAA) recommends
the guidance and specifications in this Advisory Circular for Plug and
Receptacle, Cable Connectors. In general, use of this AC is not
mandatory. [However]{.underline}, use of this AC is mandatory for all
projects funded with federal grant monies through the Airport
Improvement Program (AIP) and with revenue from the Passenger Facility
Charges (PFC) Program. See Grant Assistance No. 34, "Policies,
Standards, and Specifications," and PFC Assurance No.9, "Standards and
Specifications."

**5. PRINCIPAL CHANGES.** The changes in this AC include the following:

> a\. Update drawings to .DWG format. All dimensions remain the same.
>
> b\. Sources for referenced documents are updated.
>
> c\. Shall statements are updated to "must" statements.
>
> d\. Paragraph 3.3.2 is updated to clarify requirements for the
> calculation of tensile strength of the conductor.
>
> e\. Paragraph 4.2.1 is reworded to clarify pass/fail criteria.
>
> f\. Paragraph 4.2.6 now references Section 1200.15 vice 1200.9 of
> UL-1581 to better address the current edition of the UL standard.
>
> g\. Paragraph 5.1 is updated to correct the insulation resistance
> value to 75,000 megohms.

**6. METRIC UNITS.** To promote an orderly transition to metric units,
this specification includes both English and metric dimensions. The
metric conversions may not be exact metric equivalents, and until there
is an official changeover to the metric system, the English dimensions
will govern.

**7. COMMENTS OR SUGGESTIONS** for improvements to this AC should be
sent to:

> Manager, Airport Engineering Division
>
> Federal Aviation Administration
>
> ATTN: AAS-100
>
> 800 Independence Avenue, S.W.
>
> Washington, DC 20591
>
> **8. COPIES OF THIS AC.** The Office of Airport Safety and Standards
> is in the process of making ACs available to the public through the
> Internet. These ACs may be accessed through the FAA website:
> www.faa.gov/airports_airtraffic/airports/resources/advisory_circulars/.
> A printed copy of this AC and other ACs can be ordered from:
>
> U.S. Department of Transportation
>
> Subsequent Distribution Office
>
> Ardmore East Business Center
>
> 3341 Q 75th Avenue
>
> Landover, MD 20785.
>
> ![](media/image4.jpeg){width="2.2527777777777778in"
> height="1.0354166666666667in"}
>
> Michael J. O'Donnell
>
> Director, Office of Airport Safety and Standards

**FAA SPECIFICATION FOR L-823 PLUG AND RECEPTACLE, CABLE CONNECTORS**

**1. SCOPE AND CLASSIFICATION.**

**1.1 Scope.** This specification contains requirements for plugs and
receptacles (cable connectors) to be used for underground cable
connections, for power cables, isolation transformer leads, and light
fixture leads for airport systems.

**1.2 Classification.** Cable connectors are classified by this
specification into two types, two classes, and six styles of plugs and
two types, two classes, and six styles of receptacles. Formerly, cable
connectors were classified only by a figure number. Figures in this
specification are now numbered consecutively

**1.2.1 Type.** Plugs and receptacles with the following electrical
characteristics are covered by the specification:

Type I 1 conductor, 25 ampere, 5000 volt

Type II 2 conductor, 20 ampere, 600 volt

**1.2.2 Class.** Plugs and receptacles with the following attachment
methods are covered by this specification:

Class A Factory molded to conductor(s)

Class B Field attached to conductor(s)

**1.2.3 Style**. Plugs and receptacles with following styles of housing
are covered by this specification:

Style 1 Plug, figure 1(a)

Style 2 Plug, figure 2(a)

Style 3 Plug, figures 3(a), & 3(c)

Style 4 Plug, figures 4(a), 4(b) & 4(c)

Style 5 Plug, figures 7(a), 7(b), & 7(c)

Style 6 Plug, figure 8

Style 7 Receptacle, figure 1(b)

Style 8 Receptacle, figure 1(c)

Style 9 Receptacle, figure 2(b)

Style 10 Receptacle, figures 3(b), & 3(d)

Style 11 Receptacle, figures 5(a), 5(b), & 5(c)

Style 12 Receptacle, figures 6(a), 6(b), & 6(c)

**2. REFERENCED DOCUMENTS.**

**2.1 General.** The following documents, of the issue in effect on the
date of application for qualification, are applicable to the extent
specified in this AC.

**2.2 Federal Aviation Administration (FAA) Standards.**

> AC 150/5345-53 Airport Lighting Equipment Certification Program
>
> AC-150/5345-7 L-824 Underground Electrical Cable for Airport Lighting
> Circuits, Specification for

**2.3 American Society for Testing and Materials (ASTM) Standards.**

  ---------------- ------------------------------------------------------
  B 33             Tinned Soft or Annealed Copper Wire for Electrical
                   Purposes, Specification for

  B 189            Lead-Coated and Lead Alloy Coated Soft Copper Wire for
                   Electrical Purpose, Specification for

  D 1149           Rubber Deterioration-Surface Ozone Cracking in a
                   Chamber (Flat Specimens), Test for
  ---------------- ------------------------------------------------------

**2.4 Underwriters Laboratories (UL) Publication.**

> UL 1581 Reference Standard for Electrical Wires, Cables, and Flexible
> Cords

**2.5 American National Standards**

  ---------------- ------------------------------------------------------
  ANSI/ASQC Z1.4   Sampling Procedures and Tables for Inspection by
                   Attributes

  ANSI/EIA557A     Statistical Process Control Systems
  ---------------- ------------------------------------------------------

Copies of FAA standards may be obtained from:

U.S. Department of Transportation

Subsequent Distribution Office

Ardmore East Business Center

3341 Q 75th Ave.

Landover, MD 20785

Telephone: (301) 322-4961

FAX: (301) 386-5394

Website:
www.faa.gov/airports_airtraffic/airports/resources/advisory_circulars/

Copies of ASTM Standards may be obtained from:

ASTM International

100 Barr Harbor Drive

PO Box C700

West Conshohocken, PA 19428-2959

Telephone: (610) 832-9585

FAX: (610) 832-9555

Website: www.astm.org/cgi-bin/SoftCart.exe/index.shtml?E+mystore

Copies of ANSI Standards may be obtained from:

ANSI

1819 L Street NW

(between 18th and 19th Streets)

6th Floor

Washington, DC 20036

Customer Service/Document Sales

Telephone: (212) 642-4980

Website: webstore.ansi.org/ansidocstore/default.asp

Copies of UL publications may be obtained from:

Customer Service

1285 Walt Whitman Road

Melville, NY 11747-3081

Telephone: (877) 854-3577

FAX: (631) 439-6464

Website: ulstandardsinfonet.ul.com

**3. EQUIPMENT REQUIREMENTS.**

**3.1 General.** Plugs and receptacles (cable connectors) must be
fabricated per all specification requirements.

**3.2 Environmental Requirements.** The plugs and receptacles (cable
connectors) must be designed for continuous use within a temperature
range of -67º Fahrenheit (F) (-55 Celsius (C)) to +149ºF (+65C) while
exposed to weather, submerged in water, or buried in the earth.

**3.3 Performance Requirements.**

**3.3.1 Electrical Connection**. The electrical rating of each connector
must not be less than 5000 Volts (V) for type I connectors, or 600 V for
type II connectors. The voltage drop across the contacts of a connected
plug and receptacle must not exceed 7.5 millivolts (mV) for the Type I
connectors and must not exceed 6.0 mV for the Type II connectors.

**3.3.2 Bonding Strength.** The completed Class A connector assembly
must withstand a longitudinal pull of at least 30,000 pounds per square
inch (psi) (207 Megapascals (MPa)), 75 percent of an average tensile
strength of 40,000 psi, (276 MPa) for all wire sizes. Calculation of
tensile strength should be done by considering the cross-sectional area
of the conductor only. Separation between the molded on connector and
the cable must not exceed 0.03 inches (0.8 mm). The wires must be per
with ASTM Specification B 33 and B 189.

**3.3.3 Mechanical Connection.** Each connected plug and receptacle must
withstand a static pull load of 10 pounds (44 N) without showing
evidence of separation. No damage must occur to the mating components
when the connected plug and receptacle are separated by a greater static
pull load.

**3.3.4 Seal.** A watertight seal must be provided between the mated
plug and receptacle and between the rubber and metal parts of the plug
and receptacle.

**3.4 Fabrication and Materials.**

**3.4.1 General**. Each plug and receptacle (cable connector), type,
class, and style must be per the dimensions and construction
requirements shown on the applicable figures in Appendix I of this
specification.

**3.4.2 Housing.** The connector housing must be molded from natural
and/or synthetic elastomeric materials serving both as insulation and
sheath to fully enclose the pins of the plug and sockets of the
receptacle. The housing material must be suitable for direct earth
burial, submergence in water, and capable of withstanding limited attack
from chemicals, typically present on the airfield, including but not
limited to, oil, de-icing fluids and/or gasoline. Material compounds
used in connector housings must not contain more than 25 pounds (11
kilograms (kg)) of carbon black per 100 pounds (45 kg) of elastomer.
Housings for Class A connectors must be fabricated from materials
capable of bonding to cable sheaths or conductor insulation, during the
manufacturing process, to provide a watertight bond.

**3.4.3 Pins and Sockets.** The pins and sockets must conform to all
dimensions and construction requirements per the applicable figures in
Appendix I of this specification. Pins and sockets must be made of
materials that contain at least 98 percent copper, or free cutting brass
alloy 360 (AMS C36000) and in either case must be made of material at
least \"half hard\". The contact portion of the pin and socket must be
left \"stock hard\" and the crimping section, when necessary, fully
annealed. The hardness transition must be limited to the locking section
of the pin and socket. The pin and socket must be electroplated with tin
or other suitable material to provide good electrical contact per
paragraph 3.3.1. The sockets must be spring loaded or slotted and spring
loaded to insure good electrical contact per paragraph 3.3.1, and Class
A sockets must have a means that protects the sockets slots from filling
with insulating compound during molding. The pin for the Style 3
connector must be provided with a visual indication that verifies proper
assembly position. Pins and sockets provided for Class B connectors must
have provisions for crimping to the cable conductor(s), and must not
exhibit damage after crimping.

**3.4.4 Connector Assemblies.**

**3.4.4.1 Class A**. Pins and sockets must be held perpendicular to the
face of the block. Suitable electrical conductors must be mechanically
and electrically connected to the pin(s) or socket(s). The connector
housing must be molded per paragraph 3.4.2. Primary connectors must be
molded to an electrical conductor having a voltage rating equal to or
less than the specified voltage rating of the connector. Secondary
connectors must be molded to an electrical conductor having a voltage
rating equal to or less than the specified voltage rating of the
connector with the preferred being equal to the connector rating. A
connector must never be molded to an electrical conductor or cable
having a higher voltage rating than the specification requirements for
the connector. After molding, the space between the pins of Type II
plugs must not be less than 1/8 inch (3 mm) when the pins are pinched
together with a force of 6 pounds (27 N) applied 1/2 inch (12.7
millimeters (mm)) out from the face of the plug. Also, the space between
the ends of the pin of the Type II plugs must not be greater than 9/16
inch (14.3 mm) when the pins are pulled apart with a force of 6 pounds
(27 N) applied 1/2 inch (12.7 mm) out from the face of the plug. The
force is applied to the pins only. During testing for the above
mentioned requirements, the plug is to be held only to keep it from
turning.

**3.4.4.2** **Class B**.

**3.4.4.2.1 Type I.** Each receptacle must be equipped with a disposable
sleeve fitted into the receptacle's water seal to catch surplus silicone
compound upon assembly. Each socket must be equipped with a disposable
pin fitted tightly into the pin end of the socket to prevent entry of
silicone compound on assembly and to provide a visual indication of
proper socket position after assembly. The pin design must be such that
proper internal dispersion of silicone compound in the assembly is
assured. An adequate amount of silicone insulating compound must be
furnished with each connector to insure filling all internal voids when
the connector is assembled. Each housing must be capped with a
disposable shipping cap on the cable entrance end.

**3.4.4.2.2 Type II**. Connector assemblies must be composed of two
parts, an insert assembly and a housing. Pins or sockets must be held
perpendicular to the face of each end of the molded insert assembly and
fastened. After proper assembly, the space between the pins of the plug
must not be less than 1/8 inch (3 mm) when the pins are pinched together
with a force of 6 pounds (27 N) applied 1/2 inch (12.7 mm) out from the
face of the plug. Also, the space between the ends of the pin must not
be greater than 9/16 inch (14.3 mm) when the pins are pulled apart with
a force of 6 pounds applied 1/2 inch (12.7 mm) out from the face of the
plug. Inserts and housing must be molded as specified in paragraph
3.4.2, and must comply with the dimensions and styles per the applicable
figures in Appendix I of this AC. When assembled the plug and receptacle
assemblies must provide a watertight seal to prevent moisture from
entering the housing.

**3.4.5 Marking.** Each plug and receptacle must be marked with
manufacturer's identification and L-823 designation with style number,
e.g., L-823, Style 3.

**3.4.6 Caps*. ***Caps must be supplied with Class A connectors (unless
requested otherwise by the buyer) to protect plugs and receptacles prior
to final connection. Caps must be made of a plastic material compatible
with the housing materials per paragraph 3.4.2. When a series short
circuiting plug type cap with internal jumpers is required for Type II
receptacles, jumpers must be connected to the proper pins. The mating
dimensions must be the same as the corresponding plug. The short
circuiting cap must be permanently marked with an \"S\".

**3.4.7 Instructions.** Installation instructions must be furnished by
the manufacturer with each Class B connector.

**4. EQUIPMENT QUALIFICATION REQUIREMENTS.**

**4.1 Qualification Procedures**. Procedures for qualifying equipment to
be furnished under the Federal grant assistance program for airports are
contained in Advisory Circular 150/5345-53, Airport Lighting Equipment
Certification Program.

**4.2 Qualification Tests.** The following tests must be performed on
each unit submitted for qualification to demonstrate compliance with all
specifications in this AC. Should a conflict exist between this AC and
referenced documents, the specification in this AC must apply.

**4.2.1 General.** Assembled connectors, with conductors attached, must
be subjected to electrical and physical tests. Class B connectors must
be assembled per the manufacturer's instructions to lengths of wire or
cable, as appropriate, of at least 24 inches (0.6 m) for all tests. Six
pairs of mated connectors must be selected at random from a production
run for each type of connector to be tested for approval. Each tested
connector must pass all qualification tests. Failure of any one of the
connectors in any one of the qualification tests causes rejection and
indicates failure to comply with this specification.

**4.2.2 Dielectric Tests.**

**4.2.2.1 Plugs and Receptacles.** Six test insert plugs made of nylon
or equal material of suitable dielectric strength must be provided for
the test. The test plugs must meet the mating dimensions of the
corresponding standard plug intended for use with the receptacle being
tested. Each plug must be checked with \"go\" and \"no go\" ring gauges
to insure compliance with specified dimensions. Each connector
receptacle under test must be mated with one of the test plugs and
allowed to soak for 24 hours in a tap water bath at room temperature,
(68 - 77 F (20-25 C)). At the end of the soaking period, with the
receptacle still immersed, apply a test voltage of 4.7 kilovolts (kV) dc
for 5 minutes to Type II connectors and 15 kV dc to Type I connectors.
One minute after the test voltage has been applied the minimum
insulation resistance between the conductors and water, and between
conductors measured with a 500-volt source must be 25,000 megohms
minimum. Receptacles that have passed this test will then be used for
testing the corresponding plugs in a like test.

**4.2.2.2 Connector Assembly.** After the conclusion of the test in
paragraph 4.2.2.1, each plug and receptacle being tested must be mated
and immersed in a tap water bath at room temperature, (68 - 77 F (20-25
C)). Immerse not more than 2 feet (0.6 m) of cable, 1 foot (0.3 m) of
the plug, and 1 foot (0.3 m) of the receptacle. While immersed, each
connector assembly must be manually flexed for 2 minutes and then left
immersed for a minimum of 24 hours with its cable leads flexed and
maintained 180 from its longitudinal axis. Measure the insulation
resistance between conductors of each connected assembly after the 24
hour soaking period. The resistance measurements must be taken 1 minute
after a test voltage of 4.7 kV dc has been applied for 5 minutes to Type
II connectors and 15 kV dc to Type I connectors. The minimum resistance
between conductors must be 25,000 megohms. Heat the tap water to 149 F
(65 C ) without removing the assemblies and maintain this temperature
for at least 1 hour. Again measure the resistance between the
conductor(s) and water, and between conductors with a 500-volt
source***.*** The minimum acceptable resistance after the heated soaking
period must be 10,000 megohms.

**4.2.3 Bond Test.** The molded bond between cable and Class A connector
must be subjected to a static longitudinal pull load of the magnitude
per paragraph 3.3.2. When testing Class A, Type II, connectors of any
Style the two conductors must be pulled as a single cable, not as
individual conductors. The connector must be held in a manner that does
not impart a crimping or clamping action to the connector that would
affect the pull test. The connector molding cavity, or a similarly
shaped fixture, is acceptable for holding the connector. Separation
between the molded on connector and the cable jacket or conductor
insulation exceeding .03 inches must be cause for rejection.

**4.2.4 Mechanical Connection Test.** Each plug and receptacle intended
for mating must be connected together and subjected to the static pull
load per paragraph 3.3.3. Any evidence of separation of the connection
must be cause for rejection. An increasing load must be applied to the
connector assembly until separation occurs. No damage must occur to the
mating components when the connected plug and receptacle are separated
by the greater static pull load. Any evidence of damage to plugs,
receptacles, conductors, and/or the connector bond will be cause for
rejection.

**4.2.5 Electrical Connection Test.** Voltage drop measurements must be
made across mated connectors while conducting their rated current.
Voltage drops in excess of those in paragraph 3.3.1 must be cause for
rejection. This test may be performed using unmolded contacts conducting
rated current. This would permit the measurement to be made without
damaging the molded connectors. This test must be performed on the
equivalent of six connectors (six contact pairs for Type I connectors
and twelve contact pairs for Type II connectors).

**4.2.6 Weathering Test**. A slab of connector housing material and
sample pairs of connectors must be subjected to simulated sunlight by
conditioning with carbon-arc or xenon-arc radiation for 720 hours as
described in Section 1200.15 of UL-1581. The conditioned and
unconditioned slabs of connector housing material must then be evaluated
to Section 1200.9 of UL-1581. Failure of the test slab samples and/or
the connectors to meet the ratio requirements of Section 1200.9 of
UL-1581 must be cause for rejection.

Additionally, a slab of connector housing material and sample pairs of
connectors must be exposed to ozone per ASTM D1149, with 50 parts per
million (ppm) ozone, 100.4 F (38 C), 20 percent sample extension, and
100 hours exposure. Cracking of the connectors, or test slab, as a
result of weathering test will be cause for rejection.

**4.2.7 Metal Bond Test**. Class A assemblies must have their connector
plug and receptacle placed in water, with 20 psi air pressure applied
from the free end of the cable, for 10 minutes. There must be no air
bubbles emanating from the assembly observed in the water.

**5. PRODUCTION TEST REQUIREMENTS.**

**5.1 Production Tests.** Each connector must be visually inspected and
interface dimensions checked per the process control below. Each plug
and receptacle, cable connector (Class A) must be subjected to a
dielectric and continuity test during the validation of a production
run. The test voltage must be 4.7 kV dc for Type II connectors and 15 kV
dc for Type I connectors. The minimum insulation resistance between the
conductors must be 23,500 megohms for Type II connectors and 75,000
megohms for Type I connectors (0.2 micro amps leakage current). The
application of the test voltage may be reduced to 1 second. For
conventional testing, sampling is defined by ANSI/ASQC Z1.4-1993,
Inspection Level II, AQL 2.5. For SPC systems, sampling shall be per
ANSI/EIA557A 1995 and shall show statistical capability with a Cpk1.0
and 3.0.

**APPENDIX I**

Cable Connector Figures

![](media/image5.wmf){width="6.272222222222222in"
height="8.115972222222222in"}

**Figure 1 Class A, Type II, Plugs and Receptacles** -- Two Conductor,
20 Ampere,

600 Volts Between Contacts, 1500 Volts to ground

![](media/image6.wmf){width="7.3805555555555555in"
height="5.8069444444444445in"}

**FIGURE 1A. Class A and B, Plugs and Receptacles** -- Dimensions

![](media/image7.wmf){width="6.4743055555555555in"
height="8.311805555555555in"}

**FIGURE 2. Class A, Type I, Plugs and Receptacles --** Single
Conductor, 25 Ampere, 5000 Volts to Ground

![](media/image8.wmf){width="6.64375in" height="8.427083333333334in"}

**FIGURE 3. Class B. Type I, Style 3, Plugs and Class B, Style 10,
Receptacle** --

Single Conductor, 5000 Volts, 25 Ampere

![](media/image9.wmf){width="6.905555555555556in" height="8.49375in"}

**Figure 4. Class B, Type II, Style 4 Plug --**

Two Conductor, 20 Ampere, 600 Volts Between Contacts, 1500 Volts to
Ground

![](media/image10.wmf){width="6.6in" height="8.309722222222222in"}

**Figure 5. Class B, Type II, Style 11, Receptacle --**

Two Conductor, 20 Ampere, 600 Volts Between Contacts, 1500 Volts to
Ground

![](media/image11.wmf){width="6.498611111111111in" height="8.44375in"}

**Figure 6. Class B, Type II, Style 12, Receptacle --**

Single Conductor, 20 Ampere, 600 Volts Between Contacts, 1500 Volts to
Ground

![](media/image12.wmf){width="6.920138888888889in"
height="8.218055555555555in"}

**Figure 7. Class B, Type II, Style 5, Plug --**

Single Conductor, 20 Ampere, 600 Volts Between Contacts, 1500 Volts to
Ground

![](media/image13.wmf){width="7.064583333333333in"
height="8.243055555555555in"}

**Figure 8. Class A, Type II, Style 6, Plug --**

Two Conductor, 20 Ampere, 600 Volts Between Contacts, 1500 Volts to
Ground