Helsyn pink H30 size sleeves
Helsyn sleeves are used to provide insulation of exposed conductors/terminals, binding groups of wires, and identification marking of wires and bundles.
The material is a Chloroprene (Neoprene) based synthetic rubber, the trade name "Helsyn" is a portmanteau of "Hellermann" and "synthetic".
Asking around I have been told that aircraft manufacturers would fit Helsyn sleeves provided already marked by Hellermann, presumably marked to order with specified characters. It is however, quite unclear currently how this marking process was carried out, using what machinery and what type of ink. If anyone reading this can provide any details, please do get in touch. I would like to be able to re-produce marked sleeves similar to the originals.
This marking service appears to still be offerd by HellermannTyton, indicated by catalogue information on their South African website, see references.
Standards applicable to the manufacture and testing of binding and identification sleeves.
| Date | Standard | Title |
|---|---|---|
| 19/02/1965 | BS 3858 | Binding and Identification Sleeves for Use on Electric Cables and Wires |
| 15/10/1992 | BS 3858 | Specification for Binding and identification sleeves for use on electric cables and wires |
| 31/01/1990 | Def Stan 59-15 | Elastomeric Insulating Materials and Polytetrafluoroethylene (PTFE) Part 1: General Requirements, Tests and Test Methods for Qualification Approval Sleeving in Continuous Lengths Sleeves for Binding and/or Identification Purposes (Codification Designation - Sleeve, Insulating, Electrical) |
So far I have only found a copy of BS 3858:1992, see references.
| Stores Ref. No.: | 5K/9107066 |
| Manufacturer: | Hellermann |
| Manufacturer Size: | H30 |
New old stock, pink H30 size sleeves packed in 1982. Pack opened in 2023, sleeves were found to be perfectly serviceable.
Helsyn pink H30 size sleeves
This Tersil wiring harness connects to one of the fuel contents gauging amplifier units. Pink Helsyn sleeves are used for bundling, and are marked for cable identification purposes.
Helsyn sleeves, XS458, 09/09/2006
Unknown cable ID, but fitted with a 5C/455 2 way plug. Shows pink Helsyn sleeves used for binding the braided outer sheath loose ends, and also for insulating the soldered joints of the ring terminals.
Helsyn sleeves used as binding and insulation
Helsyn sleeves used as binding and insulation
| Stores Ref. No.: | 10HB/115304 |
Connector between muting unit and an ARC-52 junction box. These sleeves are used as cable identification markers, and have been printed with lettering.
Pink sleeves showing signs of colour degradation, to a brown-ish colour, and perishing due to age.
Helsyn sleeves used as cable markers
Helsyn sleeves used as cable markers
The first announcements of the Helsyn branded synthetic sleeve appear in 1944. (Previous mineralized rubber binding and marking sleeves had simply been branded as the Hellermann binding and marking system).
This first advert hints at developments to come, and mentions Helsyn synthetic sleeves:
Hellermann Helsyn sleeve hush hush plans
Published: Flight, 10th February 1944
Source: Aviation Ancestry
Hellermann Helsyn sleeve
Published: Aeroplane, 7th July 1944
Source: Aviation Ancestry
Hellermann Helsyn announcement
Published: Aeroplane, 29th September 1944
Source: Aviation Ancestry
Hellermann S type tool
Published: Aeroplane, 27th October 1944
Note how this advert makes a generalisation about the size female workers hands, and the need for the small size tool.
Source: Aviation Ancestry
By 1955, Hellermann had also introduced a high temperature version, the Helsyn PLUS, as seen here alongside other products.
Hellermann product range
Published: Aeroplane, 1st July 1955
Source: Aviation Ancestry
Electrical Manual:
A.P.4343C, Volume 1, Section 5, Chapter 24, A.L.39, Aug 1962 - Helsyn Cable Binding Sleeves
S.T.T.N. Aircraft cables and wiring systems
AP3275A Section 1, Chapter 2, 1967, Plessey Wiring System - Fig 22
AP3275A Section 1, Chapter 4, 1967, Cable Connections and Terminations - Paragraph 8
Hellermann Catalogues
Hellermann Leaflet HE223 May 1969 - Hellermann Sleeve Fitting Tools
Polychloroprene Markers H, ~2020s, marked Helsyn sleeves - Source: HellermannTyton South Africa ↗
British Standard
BS 3858:1992 Binding and Identification Sleeves for Electric Cables and Wires