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How Often Should Relay Panels Be Refurbished or Replaced?

There are 4 main types of electrical panels in an F-16: (1) Cockpit, (2) Power or Circuit Breaker, (3) Multiplex (Mux), and (4) Relay.  InterConnect refurbishes each of these types of electrical panels.  We have been doing this now for over 25 years.  Almost every day an F-16 electrical panel arrives for repair or refurbishment.  InterConnect receives F-16 electrical panels from all over the world.  Currently there are 25 countries who fly the F-16.  Each one of these countries has one thing in common: “At some point they will all need to get their F-16 electrical panels refurbished”.  Of electrical panels, the most complex one is the relay panel.  The figure below shows a typical F-16 relay panel.

Screen-Shot-2017-10-05-at-10.34.38-AM-1024x779The reason F-16 relay panels are so complex is that they have so many electrical circuits inside them.   A relay panel is made up of:  (1) relays (of course), (2) wire, (3) tons of splices, (4) sheet metal, and (5) connectors.  A typical F-16 relay panel may have 10 to 20 relays as well as over 50 splices.  When energized, each relay opens many new electrical circuits.  

Besides the fact that F-16 relay panels are difficult to manufacture, they are also the most complex to test.  A test programmer must determine each the possible circuits in a relay panel.  In some cases, there are over 70 circuits.  Thus, the test program must conduct 70 separate continuity tests.  Wow, that’s a lot of tests!

So back to the main point of this blog “How often should an F-16 user get their relay panels refurbished?”  InterConnect recommends that F-16 relay panels should be refurbished at least every 25 years.  After 25 years, relays, wires, and connectors tend to get old and start to show signs of problems, such as relays sticking.  InterConnect’s F-16 Relay Refurbishment Program fixes any problems inside a relay panel.  During our Refurbishment Program, we replace each relay, all wiring, connectors, and splices.  Typically, the sheet metal enclosure is in acceptable condition so that major cost driver need not be included in our refurbishment price.  

InterConnect is happy to provide price estimates to refurbish your F-16 relay panels.  One of our approved F-16 distributors can quickly provide you a quote.  InterConnect’s refurbishment programs will make your F-16 Fleet mission ready!

Our Licenses

We are the sole licensee of Lockheed Martin for F-16 electrical products. Through this agreement, we have access to Lockheed Martin’s F-16 engineering data, tooling and configuration control information. We also have a Technical Services agreement with Sikorsky for all of their aircraft. This agreement allows us to obtain their engineering data needed to rewire helicopters that Sikorsky manufactures.

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