25827

Participant Guide

Aircraft Wiring Practices An Interactive Training and Self-Study Course (25827)

Presented by Brett Portwood

FAA Technical Specialist, Safety and Integration

Massoud Sadeghi Aging Systems Program Manager

Federal Aviation Administration March 28 & 29, 2001

Aircraft Wiring Practices

Participant Guide Version 1.0 page ii

Table of Contents

INTRODUCTORY MATERIALS Course Orientation .......................................................................................... 2 About This Course................................................................................... 2 Who Is the Target Audience?.................................................................. 2 Who Are the Instructors? ........................................................................ 2 What Will You Learn? ............................................................................ 14 How Will This Course Help You On-the-Job? ....................................... 14 Self-Assessment ................................................................................................ 6 Pre- & Post-Course Self-Assessment Questions..................................... 6

COURSE MATERIALS Background ...................................................................................................... 10 Introduction ............................................................................................. 10 Aging Systems Program.......................................................................... 11 ASTRAC findings ................................................................................... 15 Accident service history .......................................................................... 19 Aging wiring overview..................................................................................... 25 Introduction ............................................................................................. 25 Causes of wiring degradation.................................................................. 26 Current FAA guidance.................................................................................... 28 Overview ................................................................................................. 31 Advisory Circular 43.13-1b ............................................................................ 31 Topics to be addressed ............................................................................ 31 Electrical load determination .................................................................. 31 Breaker and wire sizing/selection ........................................................... 33

Exercise 1: Circuit breaker size calculation...................................... 35 Figure 11-2 from 43.13-1b................................................................. 39 Exercise 2: Wire size calculation ...................................................... 42 Figure 11-3 from 43.13-1b................................................................. 44 Figure 11-4a from 43.13-1b ............................................................... 45 Figure 11-6 from 43.13-1b................................................................. 46


Participant Guide Version 1.0 page iii

Figure 11-5 from 43.13-1b................................................................. 47 Exercise 3: Wire harness current capacity ........................................ 50

Routing, clamping, and bend radii .......................................................... 53 Exercise 4: Circuit breaker size calculation...................................... 75

Wire replacement and splicing................................................................ 81 Wire terminals ......................................................................................... 88

Exercise 5: Terminal build up ...........................................................102 Grounding and bonding...........................................................................103 Wire marking...........................................................................................109 Connectors and conduits .........................................................................112

Exercise 6: Pin arrangement...............................................................115 Exercise 7: Bend radius......................................................................123

Wire insulation properties .......................................................................124 AC 25-16 requirements ...................................................................................129 Electrical fault and fire detection ............................................................129 Circuit protection devices........................................................................130 Wire separation................................................................................................132 Introduction .............................................................................................132 Wire separation: 25.1309(b)...................................................................133 Wire separation: 25.903(d).....................................................................135 Wire separation: 25.1353(b)...................................................................136 Wire separation: 25.631 .........................................................................137 Post-TC wire separation ..........................................................................138 Instructions for Continued Airworthiness ....................................................139 General information/overview ................................................................139 Cleaning requirements/practices .............................................................141 Wiring general visual inspections (WGVI).............................................142 Non-destructive wire testing (NDT) methods.........................................145 Preemptive wire splice repair and/or wire replacement ..........................145 Wiring installation certification .....................................................................149 Introduction .............................................................................................149 Wiring diagrams ......................................................................................150

Actual wiring diagram........................................................................152


Participant Guide Version 1.0 page iv

Wiring installation drawings ...................................................................153 Actual wire routing drawing ..............................................................156 Actual wiring installation and sub assemblies ...................................157 Actual wiring installation drawing parts list ......................................158

Questions and wrap-up ...................................................................................159 Appendices........................................................................................................160 AC 43.13-1b, Chapter 11 AC 25-16 Course Evaluation Forms


Participant Guide Version 1.0 page 1


Introductory Materials



Course Orientation

Aircraft Wiring Practices is designed to update participants about a wide variety of wiring issues. Through the two-day (four hours per day) Interactive Training format, Brett Portwood, FAA Technical Specialist, Safety and Integration, and Massoud Sadeghi, Aging Systems Program Manager, will provide you with the basic concepts of Aircraft Wiring Practices, a course that provides an overview of the aging wiring history, an update on current FAA guidance, detailed information on AC 43.13-1b, AC 25-16, wire separation, and Instructions for Continued Airworthiness, and a review of what to look for on wiring diagrams and wiring installation drawings.

This course is designed for new and experienced Systems and Propulsion Transport Aircraft engineers who require enough knowledge of wiring to be able to review data submitted by manufacturers.

Brett Portwood is the FAA Technical Specialist for Safety and Integration. Brett has 11 years experience with the FAA in certification of transport avionics systems, including fly-by-wire flight guidance systems, flight management systems, and electronic displays. As a Technical Specialist, he provides expertise in safety assessment methods and associated integration issues. Brett is active in the FAA’s Aging System Program, ATSRAC, and wiring installation and maintenance practices. He assisted with the investigation (aircraft wiring) of the MD-11 Swissair 111 accident. He worked with Boeing to develop wiring practices workshops for FAA certification engineers and inspectors. Brett also was the FAA representative on the SAE S-18 System

About This Course

Who Is the Target Audience?

Brett Portwood

Who Are the Instructors?



Safety Assessment commitee that authored ARP 4761, Guidelines and Methods of Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment. Prior to joining the FAA, Brett spent 12 years performing fault/failure analyses for industry and the Navy nuclear program. Mr. Portwood has a BS degree in Physics from San Diego State University and has published professional papers on system safety assessment methods. Massoud Sadeghi is the FAA Transport Aging Systems Program Manager responsible for implementing improvements in the requirements of design, installation, mainenance, repair, and certification processes for airplane wiring. Massoud’s previous FAA responsibilities include: SAE, ARAC, certification, validations, and policy and rulemaking in the areas of electrical systems, HIRF, and lightning. Prior to the FAA, Massoud’s industry experience included Boeing Military Airplanes (Wichita), re-engine, upgrading electrical systems, and rewiring military airplanes (KC-135s); McDonnell Douglas, designing new electrical systems for the new MD-90; and Boeing (Seattle), designing new electrical systems for the new 777s. Before college, Massoud did electrical wiring of commercial and residential buildings. Mr. Sadeghi has taught college technical classes and company classes on Modern Aircraft Electrical Systems. He has both a BS and MS in Electrical Engineering from the University of Missouri-Columbia.

Massoud Sadeghi



After completing this course you will be able to —

• Apply the concepts/aspects of aging wiring.

• Identify wiring factors used when approving wiring diagrams.

• Identify the main purpose of reviewing wiring installation drawings and the wiring factors used when approving these installation drawings.

• Describe the requirements for Instructions for Continued Airworthiness as they relate to wiring.

The purpose of this course is to deliver a detailed presentation of all aspects of aging wiring. It covers applicable 14 CFRs, policy, and industry practices in the area of wiring. It will introduce primary factors associated with wire degradation. The course will also include TC/STC data package requirements, wire selection/protection, routing, clamping, splicing, and termination practices, along with various examples, pictures, mockups, videos, etc. The course includes wiring maintenance concepts (e.g., cleans as you go), including how to perform a wiring general visual inspection. Given appropriate wiring materials to review for certification, after completing this course you should be able to —

• Describe the major factors of wiring degradation and list the characteristics of aging wiring.

• Identify and use the current FAA wiring regulations and guidance.

• Determine if the circuit breakers, conductors, and connectors are sized appropriately.

What Will You Learn?

How Will This Course Help You On-the-Job?



• Determine if the type of wiring protection is appropriate for a given environment.

• Determine if the number and type of clamps, the feed throughs/pass throughs, and conduits selected are appropriate.

• Evaluate the routing of the wire to ensure it has been done in an optimum manner to prevent damage.

• Identify what wiring information has to be in the Instructions for Continued Airworthiness.



Self-Assessment The instructor will ask you at the begining of the presentation to respond to the following questions about aircraft wiring practices. During the live broadcast, use the keypad to answer these questions.

1. What are the critical factors in addition to vibration that impact wiring degradation? a. Moisture, heat, improper installation. b. Improper installation, heat, length. c. Moisture, age, resistance. d. Heat, age, length.

2. What is the minimum bend radius for unsupported wire?

a. 3 times the largest diameter of the wire or cable in a bundle. b. 3 times the smallest diameter of the wire or cable in a

bundle. c. 10 times the largest diameter of the wire or cable in a bundle. d. 10 times the smallest diameter of the wire or cable in a

bundle.

3. AC 25-16 is about a. electrical load analysis. b. electrical fault and fire detection. c. wire routing. d. wire maintenance and repair.

Self-Assessment Questions



4. What is the primary function of the circuit breaker in an aircraft?

a. To remove power from aircraft systems. b. To protect aircraft equipment. c. To protect aircraft wiring. d. To protect electrical power sources.

5. What is a key factor used in selecting wire?

a. Marking method. b. Breaker size. c. Elasticity. d. Voltage drop.

6. Wire current-carrying capacity decreases with altitude.

a. True. b. False.

7. What is the primary purpose of conduits?

a. Facilitation of fluid drainage from wire bundles. b. Ease of wire routing. c. Protection of wire bundles against atmospheric pressure. d. Mechanical protection of wires and cables.

8. During the build up of terminal studs, a cadmium-plated washer

is a. required for high vibration areas. b. required for high temperature areas. c. required when stacking dissimilar materials. d. not required.



9. To ensure proper integrity and health of an aircraft wiring

system, the Instructions for Continued Airworthiness must be submitted for a. aircraft with extended range operation within 60 days after

certification. b. aircraft with extended range operation prior to certification. c. all aircraft within 60 days after certification. d. all aircraft prior to certification.

10. In addition to reviewing the wire installation drawings, an FAA

engineer or designee should perform a first-of-a-model general wiring compliance inspection. a. True. b. False.

11. When reviewing the wire installation drawing, ensure that

a. connector pin numbers are specified for all terminations. b. wire routing is specified end to end. c. standard practices are referenced for all wire routing. d. at least the safety-critical wire routing is clearly specified.

12. Check all items that should be submitted (as a minimum) as part

of the wiring installation data package. a. Wiring separation diagram. b. Wire installation drawing. c. Wiring diagram. d. Wiring repair manual. e. Instructions for Continued Airworthiness.




Course Materials



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Brett Portwood: [email protected]

FAA Technical Specialist, Safety and Integration

Los Angeles ACO; ANM-130L(562)627-5350

Massoud Sadeghi: [email protected]

Aging Systems Program Manager

Transport Airplane Directorate; ANM-114(425)227-2117

I. Background

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Background

Why the need for wiring practicestraining?

Aging Systems Program

Aging Transport Systems RulemakingAdvisory Committee (ATSRAC)

Accident Service History

A. Introduction 1. Historically, wiring was installed without much thought given to

the aging aspects: a) Fit and forget.



b) Unanticipated failure modes and their severity. (1) Arc tracking. (2) Arcing. (3) Insulation flashover.

2. Maintenance programs often did not address these aging aspects. Service history also indicates that Foreign Object Damage (FOD) such as drill shavings, caustic liquids, etc. does cause wiring degradation that can lead to wiring faults.

B. Aging Systems Program

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Instituted a comprehensive agingnon-structural systems program

Research to identify and prioritizeopportunities to enhance safetyA data-driven program based oninspections and service history reviewsMulti-pronged solutions developed inconjunction with aviation communityModeled after successful aging structuresprogram

1. Addresses a recommendation from the White House Commission on Aviation Safety to add non-structural systems to the aging aircraft program. a) FAA using a data-driven approach to address safety concerns. b) Data collected from research and development, various

inspections, service history review and surveys of industry. c) Analysis of the data will result in revisions to maintenance

programs, training programs and improved design solutions



for wire bundle and component installations. The goal is to preclude accidents that may result from wire degradation.

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FAA Aging Transport Non-Structural Systems Plan

Air Transport Assoc. (ATA) study team:Using lessons learned from TWA 800and Swissair 111Addressing recommendations fromGore CommissionCollecting data from– On-site evaluations– Meetings with PMIs, Airbus, and Boeing– Analysis of aging systems using NASDAC

data bases

2. Following the TWA 800 accident, the FAA initiated investigations into fuel tank wiring. These investigations revealed a need for a comprehensive review of all systems wiring. Around this same time the White House Commission on Aviation Safety and Security, or informally known as the Gore Commission, recommended that the FAA, in cooperation with airlines and manufacturers, expand the FAA’s Aging Aircraft Program to cover non-structural systems. The ongoing Swissair 111 accident investigation has provided additional focus on wiring practices. a) The FAA requested that ATA lead an effort to address aging

non-structural systems. ATA responded by forming the Aging Systems Task Force (ASTF).

b) The FAA formed the Aging Non-Structural Systems Study team. This team made detailed on-site evaluations of three representative aging aircraft.

c) Based on the on-site evaluations, meetings with industry, and analysis of data bases of service data, a plan was developed to address our aging transport airplane systems.



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FAA Aging Transport Non-Structural Systems Plan, cont.

Study team, cont.

Established ATSRAC to coordinateaging systems’ initiatives with the FAA

Incorporated the Air TransportAssociation’s (ATA) aging system taskforce (ASTF) activities into ATSRAC

d) This plan called for the establishment of “an Aging Transport Systems Oversight Committee to coordinate the various aging systems initiatives within the FAA.” This task has been met with the formulation of the Aging Transport Systems Rulemaking Advisory Committee or also known as ATSRAC. ATSRAC is a formal advisory committee to the Administrator and holds public meetings every quarter.


ATSRACATSRAC•Fleet sampling inspections•Service data review•Working group outputs

FAAFAA•Study team inspections•Inspection support•Service data review•Research and development

ProductsProducts

Corrective actions

Inspection &maintenance practice

improvements

Improved design

practicesImproved

system data reporting

Improved training



3. This chart provides a conceptual look at the ATSRAC process and identifies multi-pronged solutions. The products are a result of data collection from a sampling of the fleet, review of service data, and ongoing research and development. a) The primary use of these products will be to determine

whether there are changes needed to design, manufacturing, inspection, maintenance, and modification processes for the wiring on transport airplanes to assure the continued safe operation of these airplanes.

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Aging Systems Program, cont.

Aging systems research, engineering,and development (R,E,&D)

FAA R,E,&D– Intrusive inspections– Arc fault circuit breaker development– Interconnect system testing and

assessment– Inspection and testing technology

development

4. The programs shown on the slide are some of the R, E, & D programs currently in progress.



C. ATSRAC findings

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ATSRAC Findings

Inspected 6 recently retired aircraft4 wire typesIntensive detailed visual inspectionNondestructive testing (NDT)Laboratory analysis

PurposePurpose: Determine the state of wireon aged aircraft

1. Results of detailed visual inspection, nondestructive testing, and laboratory analysis were analyzed to determine the state of wire on aged aircraft as a function of wire type and service history. In addition, the results of visual inspection were compared with the nondestructive testing and laboratory analysis to determine the efficacy of visual inspection for the detection of age-related deterioration.



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ATSRAC Findings, cont.

~1000 visual findings in the fieldMostly mis-installation or traumaticdamage

On-aircraft NDT/lab testing resultedin many additional findings

Non-negligible degradation on wire,connectors, and terminals

2. The working group choose to focus on six important categories of wire degradation: a) Degraded wire repairs or splices, b) Heat damaged or burnt wire, c) Vibration damage or chafing, d) Cracked insulation, e) Arcing, and f) Insulation delamination.



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Results:Results: Visual inspection effectivein identifying certain conditions(heat damaged/burnt wire andvibration damage or chafing)

Cannot be relied upon to find otherconditions (cracked insulation, arcing,insulation delamination, and degradedrepairs or splices)

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Risk assessment made on wiringfaults

Definite potential for long-termsafety impacts in most cases

Recommendations: Recommendations: Makechanges and additions to currentmaintenance programs for wires

3. The conclusions are not sufficiently specific to serve as mandatory design or maintenance requirements.



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Additional maintenance/designpossibilities

Periodic visual inspectionsPeriodic signal path resistance checksPreemptive splice repair or wirereplacementIn-situ NDTReduce moisture intrusion/drip shields

4. The recommendations resulting from this analysis (shown on this slide and the next ) suggest changes and additions to maintenance programs for wires subject to the conditions and influencing factors that occur in the transport aircraft operating environment. The recommendations specifically document how repairs should be effected once the condition has been observed. Current best practice is sufficient in this regard.

5. Furthermore, the working group’s recommendations should not be considered a comprehensive set of design and maintenance requirements for wire installations, nor should they be considered a substitute for specific detailed analysis. Each individual wire installation requires an analysis that considers, in addition to these recommendations, application-specific requirements.



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Additional possibilities, cont.Minimize proximate flammable materialsUse of heat shieldsMaintain separation of critical systemswiringEmphasis on clean-as-you-gophilosophyUse of arc fault circuit breakers

D. Accident service history

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TWA 800 Accident

7/17/1996, Boeing 747-131, broke upin flight and crashed in Atlantic nearNew YorkIgnition energy for center wing tankexplosion most likely enteredthrough fuel quantity indicationsystem (FQIS) wiringNeither energy release mechanismor location of ignition determined

1. On July 17, 1996, about 8:30 p.m., TWA flight 800, a Boeing 747-131, broke up in flight and crashed in the Atlantic Ocean near East Moriches, New York. TWA flight 800 was operating under part 121 as a scheduled international passenger flight from



John F. Kennedy International Airport (JFK), to Charles DeGaulle International Airport. The flight departed JFK at 8:19 p.m. All 230 people on board were killed and the airplane was destroyed. a) The Transport Airplane Directorate is currently in the

rulemaking process to address certification aspects of fuel tank design with regard to minimizing the potential for fuel vapor ignition. As part of the rulemaking focus, wiring as a source of direct and indirect arcing is addressed. (1) The next slides present some wiring lessons learned from

reviewing the TWA accident and in-service aircraft.



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Wiring Lessons Learned

Wiring to pumps located in metallicconduits

Wear of teflon sleeving and wiringinsulation has allowed arcing insideconduits, causing a potential ignitionsource in fuel tank

Fuel pump connectorsArcing at connections within electricalconnectors occurred due to bent pinsor corrosion

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Wiring Lessons Learned, cont.

FQIS wiringWire bundles with degraded andcorroded wires mixed with highvoltage wires

FQIS probesCorrosion caused reduced breakdownvoltage in FQIS wiring; fuel tankcontamination led to reduced arc pathbetween FQIS probe walls

2. FQIS probes a) Contamination in the fuel tanks (such as steel wool, lock wire,

nuts, rivets, bolts; and mechanical impact damage) caused reduced arc path resistance between FQIS probe walls.



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Bonding strapsCorrosion, inappropriately attachedconnectionsWorn static bonds on fuel systemplumbingCorroded bonding surfaces nearfuel tank access panels

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Electrostatic charge

Use of non-conductive reticulatedpolyurethane foam allowed chargebuild up

Fuel tank refueling nozzles causedincreased fuel charging

3. Electrostatic charge a) In another case, the fuel tank refueling nozzles caused spraying

of fuel into fuel tanks in such a manner that increased fuel charging, which also can lead to arcing inside the fuel tank.



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Swissair 111 Accident

Crashed off coast of Nova Scotia onSeptember 2, 1998

Smoke in cockpit

Fire in cockpit overhead area

Metalized mylar insulation blankets

23 wires found with arcing damage

Investigation on-going

4. The aircraft, enroute from JF Kennedy, NY, to Geneva Switzerland, crashed in the ocean approximately 40 miles southwest Halifax Nova Scotia following a report of “smoke” in the cockpit. There were no survivors. a) By September, 1999, the TSB had recovered approximately 98

percent of the aircraft by weight. The TSB elected to reconstruct the forward 10 meters of the MD-11 fuselage. Most of the aircraft pieces were about 6 to 12 inches in diameter and the components had to be molded and sewn together. The assembled fuselage presented a distinct footprint of fire damage in the overhead cockpit and overhead first class area.

b) Investigation into a number of in-flight/ground fires on MD-11 and MD-80 series airplanes has revealed that insulation blankets covered with film material, also know as metalized mylar film material, may contribute to the spread of a fire when ignition occurs from small ignition sources such as electrical arcing and sparking.

c) It can not be determined at this time if the arcing initiated the fire or whether the arcing was a result of the fire.



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Swissair 111 - FAA Plan of Action

AVR-1 Directive (November 1998)Minimize potential fuel sources–Replace metalized mylar insulation

blankets

Minimize potential ignition sources–Focus on wiring

5. Since results from flammability testing at the FAA Tech Center indicated that the metalized mylar insulation blankets can spread a fire from an arcing incident (the original test method was determined to be insufficient and has been updated), the FAA developed a plan to replace all metalized mylar insulation blankets.



II. Aging wiring overview

A. Introduction

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Maintenance

Age

Installation Environment

PhysicalProperties

Wiring Overview

Wire Wire DegradationDegradation

1. Wiring degradation a) Wire degradation is a process that is a function of several

variables; aging is only one of these. Other main factors that influence wire degradation are shown in the above slide.

2. Characteristics of aging wiring a) The manner in which wiring degrades is therefore dependent

upon the wire type, how it was originally installed, the overall time and environment exposed to in service, and how the wiring was maintained.

b) Service history shows that “how the wiring is installed” has a direct effect on wire degradation. In other words, wiring that is not selected or installed properly has an increased potential to degrade at an accelerated rate. Therefore, good aircraft wiring practices are a fundamental requirement for wiring to remain safely intact.



B. Causes of wiring degradation

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Causes of Wiring Degradation

Vibration

Moisture

Maintenance

1. Vibration – accelerates degradation over time, resulting in "chattering" contacts and intermittent symptoms. High vibration can also cause tie-wraps, or string-ties to damage insulation. In addition, high vibration will exacerbate any existing problem with wire insulation cracking.

2. Moisture – accelerates corrosion of terminals, pins, sockets, and conductors. Wiring installed in clean, dry areas with moderate temperatures appears to hold up well.

3. Maintenance – improperly done may contribute to long term problems and wiring degradation. Repairs that do not meet minimum airworthiness standards may have limited durability. Repairs that conform to manufacturers recommended maintenance practices are generally considered permanent and should not require rework if properly maintained. a) Care should be taken to protect wire bundles and connectors

during modification work, and to ensure all shavings and debris are cleaned up after work is completed.

b) Wiring that is undisturbed will have less degradation than wiring that is reworked. As wiring and components become more brittle with age, this effect becomes more pronounced.



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Causes of Wiring Degradation, cont.

Indirect damage

Chemical contamination

Heat

Installation

4. Indirect damage – events such as pneumatic duct ruptures can cause damage that can later cause wiring problems. When such an event has occurred, surrounding wire should be carefully inspected to ensure no damage is evident.

5. Chemical contamination – chemicals such as hydraulic fluid, battery electrolytes, fuel, corrosion inhibiting compounds, waste system chemicals, cleaning agents, deicing fluids, paint, and soft drinks can contribute to degradation of wiring. Recommended original equipment manufacturer cleaning instructions should be followed. a) Hydraulic fluid is very damaging to connector grommet and

wire bundle clamps, leading to indirect damage, such as arcing and chafing.

6. Heat – accelerates degradation, insulation dryness, and cracking. Direct contact with a high heat source can quickly damage insulation, low levels of heat can degrade wiring over long periods of time. This type of degradation is sometimes seen on engines, in galleys, and behind lights.

7. Installation – improper installation accelerates the wiring degradation process.



III. Current FAA guidance

A. Overview

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AC 43.13-1b AC 25-10

25.869

25.135325.1301/1309

Policy memo

25.1529

AC 25-16

Current FAA Guidance

Wiring Wiring PracticesPractices

1. Sections 25.1301 and 25.1309 apply in a general sense in that a system must perform its intended function in a safe manner.

2. There are some specific electrical power wiring requirements, such as 25.1353, but they do not specifically address all aircraft wiring.

3. 14 CFR 25.1529 requires that instructions for continued airworthiness are specified, which would include maintenance manuals/procedures for wiring. In support, 43.13(a) states that each person performing maintenance on an aircraft shall use the methods, techniques, and practices prescribed in the current manufacturer’s maintenance manual or Instructions for Continued Airworthiness.

4. A large body of FAA guidance for wiring practices is in Chapter 11 of AC 43.13-1b. However, this section contains methods, techniques, and practices acceptable to the Administrator for the repair of “non-pressurized areas” of civil aircraft, so it seemingly would not apply to pressurized transport aircraft. [Chapter 11 of AC 43.13-1b is an appendix of this Guide.]



5. So the question is “where do I go to find FAA guidance for acceptable wiring practices ?” The answer: 14 CFR 25.869, AC 43.13-1b, AC 25-16, and AC 25-10 all provide aspects of good wiring practices. For now, there is no one rule or AC that ties everything together, however the FAA is in the process of initiating a part 25 rulemaking activity to address wiring installations.

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Guidance: AC 43.13-1b

AC 43.13-1b:AC 43.13-1b: Acceptable Methods,Techniques, and Practices -Aircraft Inspection and Repair

Flight Standards AC

Chapter 11- Aircraft ElectricalSystems

–See Appendix in Participant Guide

6. AC 43.13-1b covers a fairly comprehensive wide range of basic wiring practices topics.



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Guidance: AC 25-16

AC 25 -16:AC 25 -16: Electrical Fault and FirePrevention and Protection (4/5/91)

Provides acceptable means toaddress electrically caused faults,overheat, smoke, and fire intransport category airplanes

–See Appendix in Participant Guide

7. AC 25-16 has an emphasis on wiring flammability, circuit breaker protection, wiring near flammable fluids, and associated acceptable test methods. This AC is being considered for updating.

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Guidance: AC 25-10

AC 25 -10:AC 25 -10: Guidance for Installationof Miscellaneous, Non-requiredElectrical Equipment (3/6/87)

Provides acceptable means tocomply with applicable 14 CFRsassociated with installation ofelectrical equipment such as galleysand passenger entertainment systems

8. AC 25-10 contains minimal wiring practices specifics, including general load analysis requirements and circuit breaker protection requirements, which are more thoroughly covered in AC 43.13-1b and AC 25-16.



IV. Advisory Circular 43.13-1b A. Topics to be addressed

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AC 43.13-1b Topic Outline

Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicingWire terminalsGrounding and bondingWire markingConnectors and conduitsWire insulation properties

B. Electrical load determination

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Electrical Load Determination

Load analysis

Ensure that total electrical load can besafely controlled or managed withinrated limits of affected components ofaircraft’s electrical system (25.1351)

New or additional electrical devicesshould not be installed without anelectrical load analysis (AC 43.13-1b)

1. Each aircraft electrical bus can safely support a predetermined amount of electrical load that is based on the electrical capacity of



the aircraft generators and the aircraft’s overall electrical distribution system.

2. Where necessary as determined by a load analysis, wire, wire bundles, and circuit protective devices having the correct ratings should be added or replaced.

C. Breaker and wire sizing/selection

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AC 43.13-1b Topic Outline, cont.

Electrical load determination

Breaker and wire sizing/selection

Routing/clamping/bend radiiSplicingWire terminalsGrounding and bondingWire markingConnectors and conduitsWire insulation properties



1. Breaker and wire sizing/selection: Circuit breaker sizing and selection

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Circuit Breaker Devices

Must be sized to open beforecurrent rating of attachedwire is exceeded, or beforecumulative rating of allconnected loads are exceeded,whichever is lowest (25.1357)

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Circuit Breaker Protection

“A circuit breaker must always openbefore any component downstreamcan overheat and generate smokeor fire.” (AC 43.13-1b, para. 11-48)

“Circuit breakers are designed ascircuit protection for the wire, notfor protection of black boxes orcomponents . . .” (AC 43.13-1b,para. 11-51)

a) Breakers are sized to protect the aircraft wiring as the main design constraint. Any further protection of components or LRUs is desirable but not mandatory.



b) Ideally, circuit breakers should protect against any wiring fault that leads to arcing, sparking, flames, or smoke. But as we will learn, thermal circuit breakers do not always detect arcing events.

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Circuit Breaker Protection, cont.

Use of a circuit breaker as aswitch is not recommended

Repeated opening and closingof contacts can lead to damageand premature failure of circuitbreakers

Most circuit breaker failuresare latent

c) For the most part, you won’t know a circuit breaker has failed until you need it.



2. Exercise 1: Determining circuit breaker size

Determine appropriatesize for circuitbreakers #1-6.

Decide which circuitbreaker to size first.

Assume power factor =1,and system loads will notchange.

Bus A Bus C

R = 5Ω

#2

#1

#4#3

#5 #6

T T

T T T

T

T

Bus B

R = 10Ω

R = 10Ω R = 5Ω

TRU115Vac to 28Vdc

Exercise 190 k VA

115v, 400 Hz

T

a) The maximum continuous current through a circuit breaker must be no more than 85% of its rating.

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Determining Breaker Size

1. Determine current flowavailable voltage

load resistance of load protecting

2. Determine breaker sizebreaker current flow 85% rating factor

b) This is the formula for determining breaker size.



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Determining Breaker Size, CB #5

1. Determine current flowavailable voltage 2828

load resistance of load protecting 1010

2. Determine breaker sizebreaker current flow 2.82.8 85% rating factor .85.85

= 3.29 A= 3.29 A

c) After determining the actual breaker size, select the standard

size for circuit breaker that is the closest to the wire current without being less.

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What is the Standard CircuitBreaker Size?

CBCB11 =44.38 = 45 A

CBCB22 =13.53 = ? A

CBCB33 =27.05 = ? A

CBCB44 =11.88 = ? A

CBCB55 = 3.29 = ? A

CBCB66 = 6.59 = ? A

Ensure wire sizecompatible withcircuit breaker

rating.Dangerous to

have small wiresusing large

circuit breakers.

d) Care must be taken to ensure that wire size is compatible with the circuit breaker rating. It is dangerous to have small wires using large circuit breakers.



3. Breaker and wire sizing/selection: Wire sizing and selection

Version 1.0 40

Wire Selection

Size wires so they:Have sufficient mechanical strength

Do not exceed allowable voltage droplevels

Are protected by circuit protectiondevices

Meet circuit current-carryingrequirements

Version 1.0 41

NominalSystemVoltage

1228

115200

AllowableVoltage DropContinuous

0.5147

128

14

AllowableVoltage DropIntermittent

Table 11-6. Tabulation chart (allowablevoltage drop between bus and utilization equipment ground)

AC 43.13-1B, page 11-21

a) The voltage drop in the main power wires from the generation source or the battery to the bus should not exceed 2% of the regulated voltage when the generator is carrying rated current or the battery is being discharged.



(1) As a rule of thumb, Table 11-6 (as shown in the slide) defines the maximum acceptable voltage drop in the load circuits between the bus and the utilization equipment ground.

Version 1.0 42

Table 11-7. Examples of DeterminingRequired Wire Size Using Figure 11-2

Voltage Run Circuit Wire CheckDrop Length Current Size Calculated

Voltage Drop1 V 100 ft 20 A # 6 (.000445 ohm/ft)

(100 ft) (20 A) = 0.89 V

0.5 V 50 ft 40 A # 2 (.000183 ohm/ft)(50 ft) (40 A) = 0.366 V

4 V 100 ft 20 A ?? (.00202 ohm/ft)(100 ft) (20 A) = 4.04 V

7 V 100 ft 20 A #14 (.00304 ohm/ft)(100 ft) (20 A) = 6.08 V

b) This table is on page 11-22 of AC 43.13-1B. These calculations are based on standard conditions at 20°C. For higher temperatures, the formula shown in Figure 11-2 should be used. For calculating voltage drop, resistance of wire per unit length can be found in Table 11.9 of 43.13-1b.





Version 1.0 43

Wire Selection, cont.

Mechanical strength of wire sizes lessthan #20

Do not use wire with less than 19 strandsProvide additional support atterminationsShould not be used when subject toexcessive vibration, repeated bending, orfrequent disconnection

(ref. para. 11-66(a), page 11-21)

c) If it is desirable to select wire sizes smaller than #20, particular attention should be given to the mechanical strength and installation handling of these wires (ref. paragraph 11-66, section 5, page 21, AC 43-13.1b). (1) Consideration should be given to the use of high-strength

alloy conductors in small gauge wires to increase mechanical strength.

(2) As a general practice, wires smaller than #20 should be provided with additional clamps and be grouped with at least three other wires.



4. Breaker and wire sizing/selection: Current capacity

Version 1.0 44

Determining Current-CarryingCapacity

Effect of heat on wire insulation

Maximum operating temperature

Single wire or wires in a harness

Altitude



5. Breaker and wire sizing/selection: Exercise 2: Wire size calculation

Exercise 2: Wire Size Calculation

Wire length = 40 ft

Circuit current = 20 A

Source voltage = 28 V

Wire type = 200° C

Max ambienttemperature = 50° C

Max altitude = 20,000 ft

8 wires in a bundle

Use AC 43.13:Figure 11-3 for wire gaugeCalculate temperature riseFigure 11-4a for temperaturederating factorFigure 11-6 for altitudederating factorFigure 11.5 for bundle

Calculate estimated operatingtemperature using theformula:

T2 = T1 + (TR - T1) [(I2 / Imax)1/2]

Calculate the wire size for this example.

a) Determine if an appropriate wire size has been selected. The estimated operating temperature must be less than conductor-rated temperature. If this is not the case, then the wire size must be increased.

b) The next slide provides a larger version of the formula and an explanation of each of the formula’s components.



Version 1.0 46

Exercise 2: Wire Size Calculation

Calculate estimated operating temperatureusing the formula below (ref. page 11-26):

TT22 = T = T11 + (T + (TRR - T - T11) [(I) [(I22 / I / Imaxmax))1/21/2]]

Where : T2 = est. operating temperatureT1 = ambient temperatureTR = conductor-rated temperature I2 = circuit currentImax = calculated current

Calculating wire size

c) This formula is from AC 43.13.1b (ref. page 11-29). d) Step 1. Determine the maximum allowable temperature rise,

which is the wire-rated temperature minus the maximum ambient temperature.

e) Step 2. Use figure 11-3 for wire gauge. f) Step 3. Use figure 11-4a to determine current for #12 wire at

150°C. g) Step 4. Use figure 11-6 for altitude derating factor for 20,000

ft. h) Step 5. Use figure 11-5 for bundle of 8 wires (assuming

100% loading).











Version 1.0 47

Wire Size Calculation

Wire gauge = #12Current for #12 wire at 150° C = 60 AAltitude derating factor for 20,000 ft. = 0.92 x 60 = 55.2 ABundle of 8 wires = 0.5 x 55.2 = 27.6 A

Calculate estimated operating temperature

T2 = T1 + (TR - T1) [(I2 / Imax)1/2]

T2 =

T2 =

Compare T2 to rating for wire type to ensure T2 less

i) Step 6. Where : T2 = estimated operating temperature T1 = ambient temperature TR = conductor-rated temperature I2 = circuit current Imax = calculated current

j) Note: Estimated operating temperature must be less than conductor-rated temperature. If this is not the case, then the wire size must be increased.



6. Breaker and wire sizing/selection: Wire system design

Version 1.0 49

Determining Wire System Design

AC 43.13-1b, Section 5:AC 43.13-1b, Section 5:tables and figures providean acceptable method ofdetermining wire systemdesign

a) The applicant should ensure that the maximum ambient temperature that the wire bundles will be subjected to, plus the temperature rise due to the wire current loads, does not exceed the maximum conductor temperature rating.

b) In smaller harnesses, the allowable percentage of total current may be increased as the harness approaches the single wire configuration.

c) The continuous current ratings contained in the tables and figures in AC 43.13-1b were derived only for wire application, and cannot be applied directly to associated wire termination devices (e.g., connector contacts, relays, circuit breakers, switches). The current ratings for devices are limited by the design characteristics of the device. Care should be taken to ensure that the continuous current value chosen for a particular system circuit shall not create hot spots within any circuit element which could lead to premature failure.



7. Breaker and wire sizing/selection: Exercise 3: Wire harness current capacity

Exercise 3: Wire Harness Current Capacity

Wire harness = 10 #20 wires; 200° C25 #22 wires; 200° C

Max. ambient temperature = 60° CMax operating altitude = 60,000 ftCircuit analysis = 7 of 35 wires carryingcurrent at or near full capacity (7/35 = 20%)

Use AC 43.13Figure 11-4a for currentFigure 11-5 for bundleFigure 11-6 for altitude derating factor

Determine if wires are sized properly forbundle assembly.

a) The previous exercise looked at determining the size of a single wire. This activity looks at determining the sizes and numbers of wires in a bundle. The number of wires in a bundle reduces the overall bundle load capacity.

b) First calculate the temperature rise due to current.

c) Figure 11-4a to determine current for size 20 and 22 wires at 140° C.

d) Figure 11.5 for bundle derating for 20% curve and 35 wires.

e) Figure 11-6 to determine altitude derating factor for 60,000 ft.

f) Calculate the total harness capacity for #20 and #22 wires and for the total harness.



8. Breaker and wire sizing/selection: Wire selection

Version 1.0 52

Wire Selection

Conductor strandingMinimizes fatigue breakage

Platings for all copper aircraft wiringPlated because bare copper developssurface oxide film — a poor conductor– Tin < 150° C– Silver < 200° C– Nickel < 260° C

a) Elevated temperature degradation of tin- and silver-plated copper conductors will occur if they are exposed to continuous operation at elevated levels. (1) For tin-plated conductors, tin-copper intermetallics will

form, resulting in an increase in conductor resistance. (2) For silver-plated conductors, degradation in the form of

interstrand bonding, silver migration, and oxidation of the copper strands will occur with continuous operation near rated temperature, resulting in loss of wire flexibility. Also, due to potential fire hazard, silver-plated conductors shall not be used in areas where they are subject to contamination by ethylene glycol solutions.

(3) Both tin- and silver-plated copper conductors will exhibit degraded solderability after exposure to continuous elevated temperature.



9. Breaker and wire sizing/selection: Wire substitution

Version 1.0 53

Wire Substitution for Repairsand Maintenance

When replacement wire is required,review aircraft maintenance manualto determine if original aircraftmanufacturer (OAM) has approvedany substitution

If not approved, then contact OAMfor an acceptable replacement

a) Most aircraft wire designs are to specifications that require manufacturers to pass rigorous testing of wires before they are approved or added to a Qualified Products List. Aircraft manufacturers who maintain their own wire specifications exercise close control of their approved sources.

b) The original aircraft manufacturer (OAM) may have special concerns regarding shielding, insulation, etc. for certain wiring on the aircraft that perform critical functions or wiring that is chosen based on a set of unique circumstances.



D. Routing, clamping, and bend radii

Version 1.0 54


Electrical load determinationBreaker and wire sizing/selection

Routing/clamping/bend radii

SplicingWire terminalsGrounding and bondingWire markingConnectors and conduitsWire insulation properties

1. Routing, clamping, and bend radii: Routing

Version 1.0 55

Wiring Routing

Eliminate potential for chafing againststructure or other components

Position to eliminate/minimize use ashandhold or support

Minimize exposure to damage bymaintenance crews or shifting cargo

Avoid battery electrolytes or othercorrosive fluids

a) In general, wiring should be routed in such a manner to ensure reliability and to offer protection from the following potential hazards:



(1) Wire chafing

Wire Riding on Structure

Power cables ridingon structure can

cause damage to thepower cables

A

B

Wires Riding on Other Wires

Wire bundles thatcross should be

secured together toavoid chafing

A

B



Wires Riding on Lightening Hole

If the grommet is tooshort, then there iswire bundle chafing

A

B

(2) Use as a handhold or as a support for maintenance personnel.

Wiring as a Handhold



(3) Damage by personnel moving within the aircraft. (4) Damage by stowage or shifting cargo. (5) Damage by battery or acidic fumes or fluids. (6) Abrasion in wheel wells where exposed to rocks, ice,

mud, etc. (7) Damage from external events (zonal analysis/particular

risks analysis demands). (8) Harsh environments such as severe wind and moisture-

prone (SWAMP) areas, high temperatures, or areas susceptible to significant fluid or fume concentration.

b) In addition, wiring should be routed to permit free movement

of shock and vibration mounted equipment, designed to prevent strain on wires, junctions, and supports, and, the wiring installation should permit shifting of wiring and equipment necessary to perform maintenance within the aircraft. In addition, wire lengths should be chosen to allow for at least two reterminations.



Version 1.0 60

Wiring Routing, cont.

Protect wires in wheel wells and otherexposed areas

Route wires above fluid lines, ifpracticable

Use drip loops to control fluids orcondensed moisture

Keep slack to allow maintenance andprevent mechanical strain

c) Ensure that wires and cables are adequately protected in wheel wells and other areas where they may be exposed to damage from impact of rocks, ice, mud, etc. This type of installation must be held to a minimum. (1) Wires and cables routed within 6 inches of any

flammable liquid, fuel, or oxygen line should be closely clamped and rigidly supported. A minimum of 2 inches must be maintained between wiring and such lines or related equipment, except when the wiring is positively clamped to maintain at least 1/2-inch separation or when it must be connected directly to the fluid-carrying equipment.

(2) Ensure that a trap or drip loop is provided to prevent fluids or condensed moisture from running into wires and cables dressed downward to a connector, terminal block, panel, or junction box.

(3) Wires and cables installed in bilges and other locations where fluids may be trapped are routed as far from the lowest point as possible or otherwise provided with a moisture-proof covering.



Path of exposed end

Broken wire shall not makecontact with fluid line

Wire Bundles Above Fluid Lines

2. Wire bundles above fluid lines. The clamps should be a compression type and should be spaced so that, assuming a wire break, the broken wire will not contact hydraulic lines, oxygen lines, pneumatic lines, or other equipment whose subsequent failure caused by arcing could cause further damage.

Wires improperly tied,riding on hydraulic lines,

contaminated withcaustic fluid

a) This slide shows a number of problems:



(1) Wires in the bundles are not tied properly. (2) The wire bundle is riding hard on the hydraulic lines. (3) The wire bundles appears to be contaminated with

hydraulic fluid residue.

b) Wire bundle breakouts. There are three basic wire bundle breakout types used in routing aircraft wiring. They are called the “Y,” “T,” and Complex types.

Wire bundlebreakout

Figure 8 loop maybe located beforeor aftertail of Y

Plastic mechanical strapping

Wirebundles

BeforeAfter

Y Type Wire Bundle Breakouts

Head of strap shall notbe located in this areaor touching anythingto cause chafing

(1) The “Y” type of breakout is used when a portion of wiring from one direction of the wire bundle departs the bundle to be routed in another direction.

• Care should be taken when plastic tie wraps are used to provide wire containment at the breakout so that the tie wrap head does not cause chafing damage to the wire bundle at the breakout junction.



Plastic mechanical strapping

Wire bundle breakout

Wirebundle

Head of strap shallnot be located in

this area ortouching anything

to cause chafing

T Type Wire Bundle Breakouts

(2) The “T” type of breakout (also called 90° breakout) is used when portions of wiring from both directions in the wire bundle depart the bundle to be routed in another direction.

Complex TypeWire Bundle Breakouts

(3) A Complex type of breakout is generally used to route certain wires out of a wire bundle to a terminal strip, module block, or other termination.



c) For all types of breakouts, there should be sufficient slack in the wires that are being broken out of the bundle to avoid strain on the wire between the wire bundle and the termination.

d) Use of stand-offs

Version 1.0 66

Stand-offs

Use stand-offs to maintain clearancebetween wires and structure

Employing tape or tubing is generallynotnot acceptable as an alternative

Exception:Exception: Where impossible toinstall off-angle clamps to maintainwiring separation in holes,bulkheads, floors, etc.

(1) The wiring design should preclude wire bundles from contacting structure.



Exercise: Using Stand-offs

A

B

e) Examples of bundle problems

Bundle riding on structure

(1) One of the more common aircraft wiring problems is chafing due to wire bundles coming into contact with aircraft structure or other aircraft equipment.



Wire bundle ridingon control cable

(2) This picture shows a wire bundle that is in close contact with a control cable. Adequate distance between wire bundles and control cables should be maintained to account for movement due to slack and maintenance.



3. Routing, clamping, and bend radii: Clamping

Version 1.0 70

Clamping

Support wires by suitable clamps,grommets, or other devices atintervals of not more that 24 inches

Supporting devices should be ofsuitable size and type with wire and/orcables held securely in place withoutdamage to wire or wire insulation

a) Wire supports and intervals. Clamps and other primary support devices should be constructed of materials that are compatible with their installation and environment, in terms of temperature, fluid resistance, exposure to ultraviolet light, and wire bundle mechanical loads.



Version 1.0 71

Clamps

Wire bundles should be snug inclamp (no movement)

Cable not able to move axially

RF cables: do not crush

Mount clamps with attachmenthardware on top

Tying NOT used as alternative toclamping

b) Clamps on wire bundles should not allow the bundle to move through the clamp when a slight axial pull is applied.

c) Clamps on RF cables must fit without crushing and must be snug enough to prevent the cable from moving freely through the clamp, but may allow the cable to slide through the clamp when a light axial pull is applied. The cable or wire bundle may be wrapped with one or more turns of tape or other material suitable for the environment when required to achieve this fit. (1) Plastic clamps or cable ties must not be used where their

failure could result in interference with movable controls, wire bundle contact with movable equipment, or chafing damage to essential or unprotected wiring. They must not be used on vertical runs where inadvertent slack migration could result in chafing or other damage.

(2) Clamps must be installed with their attachment hardware positioned above them, wherever practicable, so that they are unlikely to rotate as the result of wire bundle weight or wire bundle chafing.

d) Clamps lined with nonmetallic material should be used to support the wire bundle along the run.



Example of Correct Cable Slack

Appropriate slack

e) Appropriate slack protects the wires from stress and from contact with inappropriate surfaces. (1) Too much cable slack can allow the cable to contact

structure or other equipment which could damage the wire bundle.

(2) Too little slack can cause a pre-load condition on the cable which could cause damage to the wire bundle and/or clamps as well.

(3) Also, sufficient slack should be left between the last clamp and the termination or electrical equipment to prevent strain at the terminal and to minimize adverse effects of shock-mounted equipment.



Clamp Distortion

Incorrect clamp position

Distortion of rubber onclamp is NOT acceptable

Correct clamp position

f) As is shown in the top graphic, the wire bundles are routed perpendicular to the clamp. (1) If wire bundles are not routed perpendicular to the clamp

(bottom graphic), stress can be created against the clamp and clamp grommet which can distort the clamp and/or clamp grommet. Distorted clamps/clamp grommets can cause wire bundle damage over time.



Correct

Correct Incorrect

Incorrect

90±5°

Clamp Orientation

90±5°

g) This slide further illustrates correct and incorrect clamp orientations. Incorrect clamp orientation can lead to wire bundle damage.

Example - Clamp Distortion

h) Note that the wire bundle is not perpendicular to the clamp.



releasetab

supportbracket

tail

snap-in tiemount

Plastic Snap-in Clamp (Tie Mount)

i) These types of clamps are not suitable for large wire bundles and should not be used in high temperature or high vibration areas. (1) Any type of plastic clamp or cable tie should not be used

where their failure could result in interference with movable controls, wire bundle contact with movable equipment, or chafing damage to essential or unprotected wiring.



Stand offNo

pinching

Clamptabs

Rubber cushion

Wedge

Typical Rubber Clamp

All wires containedin rubber cushion

j) Clamps on wire bundles should be selected so that they have a snug fit without pinching wires.

Typical Nylon Closed-FaceClamp Installation

Do not pinchwire here

k) It is important when adding wiring to an existing wire bundle to evaluate the existing clamp sizing in order to avoid possible clamp pinching. In some cases it may be necessary to increase the size of the clamps to accommodate the new wiring.



Engage Clamp Tab in Slot

Incorrect

Clampslot

Clamptab

Correct

l) When using clamp tabs, make sure that the tabs are properly engaged. Otherwise, the tab could become loose and cause subsequent wire damage. (1) Ensure that the clamp is snapped before installing and

tightening the bolt.



Do not pinchwires here

Correct

Incorrect

Clamp Pinching

m) This slide further illustrates how wires can be pinched and damaged due to improper clamp installation.

Open-faced nylon clamp with cablebuild-up (missing hardware)

n) Note the missing clamp hardware. Also note that the black cable was using a tape build-up at the clamp. Some manufacturer’s wiring specifications allow for wire cable build-up under certain circumstances.



Exercise: Clamping

A

B

4. Routing, clamping, and bend radii: Wire bend radii

Version 1.0 83

Wire Bend Radii

Minimum bend radius - 10 times theoutside diameter of the largest wireor cable in the group — unsupported

Exceptions– Terminations/reversing direction in bundle

(supported at both ends of loop) -3 times the diameter

– RF cables - 6 times the diameter– Thermocouple wire - 20 times the diameter

a) Where it is not practical to install wiring or cables within the radius requirements, the bend should be enclosed in insulating tubing.



No support atend of bend

Min. bend radius - 10 xparameter of wire or cable

Support at bothends of wire bend

Diameter ofwire or cable

Min. bend radius3 x diameter of wire

Minimum Bend Radii

b) This illustration shows the proper bend radii for three different scenarios.

Bend radii okay-Greater than 3 times diameter(secured at both ends of loop)



Bend radii problem-Less than 3 times the diameter

c) Although supported, this wire bundle does not meet bend radius standards due to the large wires in the bundle.

A

Exercise 4: Wiring Problems

B

Passenger Seat

Find the wiringproblems illustratedin these photos.



5. Routing, clamping, and bend radii: Spare wire and connector contacts

Version 1.0 88

Unused Wires

SecuredTied into a bundle or secured to apermanent structure

Individually cut with strands evenwith insulation

Pre-insulated, closed-end connectoror 1-inch piece of insulating tubingfolded and tied back

a) The following three slides depict an acceptable method of

insulating and physically securing a spare connector contact within a wire bundle.

3 times length of contact

WireContact

Tubing

Spare Connector Contact:Preparing Single Contact



Tying tape 0.75 ± 0.15 in.

Fold

Spare Connector Contact: FoldingTube and Tying Single Contact

Tying tapeWirebundle

Spare Connector Contact: SingleContact Attachment to Wire Bundle



b) Spare wire termination using an endcap. This is another way to protect unused wiring.

Wire and end capin position

Install end cap over wireend. Shrink in place.

Fiberglasstying tape

Wire bundle

End caps

Adhesive tape

Spare Wire Termination Using Endcap

(1) Installing prefabricated end caps are an effective method of protecting unused wires with exposed conductors.

Unused wiring -Improper termination with exposed conductor

(should be properly insulated andsecured to bundle)



c) Coil and stow methods

Wirebundle

ties

Coil and stow short wire bundlesin low vibration areas

Clamp

Coil and Stow Methods

Wirebundle

(1) Coil and stow methods are often used to secure excess length of a wire bundle or to secure wire bundles that are not connected to any equipment, such as wiring provisioning for a future installation.

(2) The key objective to coiling and stowing wiring is to safely secure the wire bundle to prevent excessive movement or contact with other equipment that could damage the wiring.



Coil and Stow Methods, cont.

Wire bundle

Wire bundle ties

Coil and stow long wire bundlesin low vibration areas

Clamp

Excess wire

Coil and stow in mediumand high vibration areas

Adjacent wire bundle

Wirebundle Wire

bundleties

Teflontape

Coil and Stow Methods, cont.

(3) Coil and stow in medium and high vibration areas requires additional tie straps, sleeving, and support.



Exercise: Stowing Unused Wires

A

B

E. Wire replacement and splicing 1. Wire replacement and splicing: Wire replacement

Version 1.0 98

Wire Replacement

Wires should be replaced when:Chafed or frayedInsulation suspected of beingpenetratedOuter insulation is crackingDamaged by or known to have beenexposed to electrolyte, oil, hydraulicfluid, etc.Evidence of overheating can be seen



Heat Discoloration

a) This picture shows an example of heat discoloration on protective sleeving which is part of the wire bundle. The large clamp was moved to see the difference in color. In this case, the wiring that is not covered in sleeving shows no signs of heat distress. An adjacent light bulb was radiating enough heat to cause discoloration over time to the protective sleeving. Although this condition is not ideal, it is acceptable.



Version 1.0 100

Wire Replacement, cont.

Wire should be replaced when:Wire bears evidence of being crushedor kinkedShield on shielded wire if frayedand/or corrodedWire shows evidence of breaks, cracks,dirt, or moisture in plastic sleevingSections of wire have splices occurringat less than 10-ft intervals

b) Continuing, this slide shows additional circumstances that warrant replacing wiring.

c) Shielding requirements

Version 1.0 101

Wire Replacement, cont.

Shielding requirementsReplacement wires must have thesame shielding characteristics as theoriginal wire, such as shield opticalcoverage and resistance per unitlength

Replacement wires should not beinstalled outside the bundle shield

(1) For more information on shielding, the Lightning/HIRF Video and Self-study Guide is available. (To obtain, see your Directorate training manager.)



d) Adding or replacing wires on a bundle

Correctprocedure

Incorrectprocedure

Chafing

Adding or Replacing Wireson a Bundle

(1) When adding or replacing wires on a wire bundle, the replacement or added wire should be routed in the same manner as the other wires in the wire bundle.

• When the new wire is installed, the ties and clamps should be opened one at a time to avoid excessive disassembly of the wire bundles.

Example: Adding Wires on aBundle

A

B



2. Wire replacement and splicing: Splicing

Version 1.0 104


Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radii

Splicing

Wire terminalsGrounding and bondingWire markingConnectors and conduitsWire insulation properties

Version 1.0 105

Wire Splicing

Keep to a minimum

Avoid in high vibration areas

Locate to permit inspection

Stagger in bundles to minimizeincrease in bundle size

Use self-insulated spliceconnector, if possible

a) Splicing is permitted on wiring as long as it does not affect the reliability and the electro-mechanical characteristics of the wiring. Splicing of power wires, co-axial cables, multiplex bus, and large gauge wire should be avoided. If it can’t be



avoided, then the power wire splicing must have approved data.

b) Many types of aircraft splice connectors are available for use when splicing individual wires. (1) A non-insulated splice connector may be used provided

the splice is covered with plastic sleeving that is secured at both ends.

(2) Environmentally-sealed splices that conform to MIL-T-7928 provide a reliable means of splicing in SWAMP areas. However, a non-insulated splice connector may be used, provided the splice is covered with dual wall shrink sleeving of a suitable material.

Staggered Splices

c) Splices in bundles should be staggered so as to minimize any increase in the size of the bundle that would: (1) Prevent bundle from fitting into designated space. (2) Cause congestion adversely affecting maintenance. (3) Cause stress on the wires.



Overheated wire at the splice

d) Splices that are not crimped properly (under or over) can cause increased resistance leading to overheat conditions.

Gangedwire

splices

e) If splices are not staggered, proper strain relief should be provided in order to avoid stress on the wires. In this particular installation, strain relief was applied to avoid stress on the wires.



Ganged wire splices

f) The top two wires in this photo are experiencing stress due to a preload condition. Also note that the wire bundle is not properly clamped.

F. Wire terminals

Version 1.0 110


Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicing

Wire terminals

Grounding and bondingWire markingConnectors and conduitsWire insulation properties



Version 1.0 111

Terminals

Tensile strength of the wire-to-terminal joint should be at leastthe equivalent tensile strength ofthe wire

Resistance of the wire-to-terminaljoint should be negligible relative tothe normal resistance of the wire

1. Tensile strength – terminals are attached to the ends of electrical wires to facilitate connection of the wires to terminal strips or items of equipment. a) Selection of wire terminals. The following should be

considered in the selection of wire terminals: (1) Current rating. (2) Wire size (gauge) and insulation diameter. (3) Conductor material compatibility. (4) Stud size. (5) Insulation material compatibility. (6) Application environment. (7) Solder/solderless.

2. Bending straight copper terminals

a) If bending of a terminal is necessary, care should be taken to avoid over bending the terminal which can cause damage to the terminal. Also, a terminal can only be bent once since any additional bending can cause damage.



b) Pre-insulated crimp-type ring-tongue terminals are preferred. The strength, size, and supporting means of studs and binding posts, as well as the wire size, should be considered when determining the number of terminals to be attached to any one post.

c) In high-temperature applications, the terminal temperature rating must be greater than the ambient temperature plus current related temperature rise. Use of nickel-plated terminals and of uninsulated terminals with high-temperature insulating sleeves should be considered. Terminal blocks should be provided with adequate electrical clearance or insulation strips between mounting hardware and conductive parts.

d) Terminals are sensitive to bending at the junction between the terminal ring and the terminal crimp barrel. Bending the terminal more than once or exceeding pre-determined terminal bend limits will usually result in mechanical weakening or damage to the terminal.

e) This slide is an example of limits established by the OAM with regard to bending the terminal prior to installation.

Brazedjoint

Position of tonguebefore bending

Bending of Straight CopperTerminals



3. Terminal strips

Version 1.0 113

Terminal Strips

Barriers to prevent adjacent studsfrom contacting each other

Current should be carried by terminalcontact surface and not by stud

Studs anchored against rotation

Replace defective studs with studsof same size and material, mountsecurely, tighten terminal securing nut

a) Wires are usually joined at terminal strips fitted with barriers. (1) When more than four terminals are to be connected

together, a small metal bus should be mounted across two or more adjacent studs.

Version 1.0 114

Terminal Strips, cont.

Mount strips so loose metallic objectscannot fall across terminal

Provide spare stud for breaks andfuture expansion

Inspect terminal periodically for looseconnections, metallic objects, dirt, andgrease accumulation–Can cause arcing, resulting in fire

or systems failure



Terminals on circuit breakers

b) Every possibility of terminals not being torqued properly, due to misinstallation, poor maintenance, and service life, should be addressed in the design. (1) Electrical equipment malfunction has frequently been

traced to poor terminal connections at terminal boards. (2) Loose contact surfaces can produce localized heating that

may ignite nearby combustible materials or overheat adjacent wire insulation.

(3) The green torque stripes painted on the terminal fasteners in this picture. This is an excellent method to quickly determine if a terminal fastener is still torqued to its original value.



Power feeder terminals

c) High current terminals are more sensitive to increased resistance due to a improperly torqued terminal. (1) The power feeder cables should not be touching each

other without being suitably tied with spacers or other securing device.



4. Terminal lugs

Version 1.0 117

Terminal Lugs

Connect wiring to terminal block studsNo more than 4 lugs, or 3 lugs anda bus bar, per studLug hole size should match studdiameter

Greatest diameter on bottom,smallest on topTightening terminal connectionsshould not deform lugs

a) Wire terminal lugs should be used to connect wiring to terminal block studs or equipment terminal studs.

b) When the terminal lugs attached to a stud vary in diameter, the greatest diameter should be placed on the bottom and the smallest diameter on top.

c) Terminal lugs should be so positioned that bending of the terminal lug is not required to remove the fastening screw or nut, and movement of the terminal lugs will tend to tighten the connection.



Version 1.0 118

Terminal Lugs, cont.

Aluminum lugsCrimped to aluminum wire only–Special attention needed to guard

against excessive voltage drop atterminal junction• Inadequate terminal contact area• Stacking errors• Improper torquing

Use calibrated crimp tools

d) The tongue of the aluminum terminal lugs or the total number of tongues of aluminum terminal lugs when stacked, should be sandwiched between two flat washers (cadmium plated) when terminated on terminal studs. Spacers or washers should not be used between the tongues of like material terminal lugs. (1) Examples of such conditions are improper installation of

terminals and washers, improper torsion (“torquing” of nuts), and inadequate terminal contact areas.

e) Aluminum wire is normally used in sizes of 10 gauge and larger to carry electrical power in large transport category aircraft in order to save weight. Although not as good a conductor as copper, aluminum is lighter when compared to copper and the weight savings can be significant for a large aircraft that may have several hundred feet of power feeder cable.

f) Because aluminum is used primarily for high current power applications, the terminal junctions are more sensitive to conditions leading to increased junction resistance which can cause arcing and localized heat distress.



5. Terminal stacking materials and methods a) Multiple wires often terminate onto a single terminal stud.

Care should be taken to install the terminal properly. The materials that the terminals are constructed of will impact the type of stacking methods used. Dissimilar metals, when in contact, can produce electrolysis that can cause corrosion, thus degrading the terminal junction resistance and causing arcing or hot spots.

Copper terminallugs

Flat washer

Lock washer

NutTerminalStacking

(like materials)

Terminal stud

b) For stacking terminals that are made of like materials, the terminals can be stacked directly on top of each other.



Terminal Stacking(unlike materials)

Copper terminal

Flat washerLock washer

Terminal stud

Nut

AluminumterminalsFlat

washers

c) When stacking unlike materials together, use a cadmium-plated flat washer to isolate the dissimilar metals.

TerminalStackingMethods

One-Sided Entry With Two Terminals

Flat washer

Lock washer

Nut

Crimp barrel(belly up) Crimp barrel

(belly down)

d) When two terminals are installed on one side of the terminal strip, ensure that the terminal crimp barrels do not interfere with one another. One method to avoid this problem is to install the terminals with the barrels “back to back.”



One-Sided Entry With 3 Terminals

Flat washer

Lock washer

Crimp barrel(belly down)in “V” split

Crimp barrel(belly up) incenter of “V”

TerminalStackingMethods, cont.

Nut

One-Sided Entry With 4 Terminals

TerminalStacking

Methods, cont.

Nut

Flat washerLock washer

Crimp barrel(belly up) in“V” split

Crimp barrel(belly down)in “V” split

e) The stacking method used to connect terminals to terminal strips should cause no interference between terminals that could compromise the integrity of the terminal junction.



6. Terminal tightening hardware

Nut

Flatwasher

Lockwasher

IncorrectCorrect

Lock washernot compressed

Lock washer compressed

Space

Terminal Tightening Hardware

a) Service history has shown that hardware stack up at terminals is prone to human error.

b) It is important to use the correct tightening hardware and install it correctly for a given installation. It is important to ensure the locking washer is fully compressed and is adjacent to the nut.

c) There should be a minimum of two to three threads showing on the stud when the nut is properly torqued.



7. Washer size selection

Steelwashers

Non-selflocking nut

Split lockwasher

Aluminumterminal

Improperly-sized washer

Raised portion ofterminal

Correct

Washer Size Selection

a) Select and use the correct size washers in any termination. Undersized or oversized washers can lead to increased junction resistance and localized heat or arcing.

b) An improperly sized washer can lead to insufficient contact between the terminal and terminal lug.

Example: Terminal Stacking

To prevent corrosionfrom dissimilar metals,put a cadmium washerbetween aluminum andcopper terminals.

A

B



Example: Lock Washers

Example: Lock Washers, cont.



8. Exercise 5: Terminal build up

Exercise 5: Terminal Build UpWhich of the terminal assemblies below is correct?

copper lug

A

nut

flat washer

lock washer

aluminumlug

nut

aluminum lug

flat washerlock washer

cadmium-platedwashers

copperlug

C

nut

aluminumlug

B

flat washerlock

washer

cadmiumwashers



G. Grounding and bonding

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AC 43.13-1b Topics Covered

Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicingWire terminals

Grounding and bonding

Wire markingConnectors and conduitsWire insulation properties

1. This is a high-level overview of grounding. For more detailed information, the Lightning/HIRF Video and Self-study Guide is available through your training manager.

Version 1.0 131

Grounding Definition

Grounding is the process ofelectrically connectingconductive objects to eithera conductive structure orsome other conductivereturn path for the purposeof safely completing either anormal or fault circuit.

2. Grounding. One of the more important factors in the design and maintenance of aircraft electrical systems is proper bonding and grounding. Inadequate bonding or grounding can lead to



unreliable operation of systems, such as EMI, electrostatic discharge damage to sensitive electronics, personnel shock hazard, or damage from lightning strike.

Version 1.0 132

Grounding

Types of groundingAC returnsDC returnsOthers

Avoid mixing return currents fromvarious sources

Noise will be coupled from one sourceto another and can be a major problemfor digital systems

a) Mixing return currents. This interaction may not be a problem or it could be a major non-repeatable anomaly. (1) To minimize the interaction between various return

currents, different types of grounds should be identified and used. As a minimum, the design should use three ground types: (1) AC returns, (2) DC returns, and (3) all others.

(2) For distributed power systems, the power return point for an alternative power source would be separated.

• For example, in a two-AC generator system (one on the right side and the other on the left side), if the right AC generator were supplying backup power to equipment located in the left side, (left equipment rack) the backup AC ground return should be labeled “AC Right.” The return currents for the left generator should be connected to a ground point labeled “AC Left.”



Version 1.0 133

Grounding, cont.

Design of ground path should begiven as much attention as otherleads in the system

Grounding should provide aconstant impedance

Ground equipment items externallyeven when internally grounded

Avoid direct connections to magnesiumstructure for ground return

b) Constant impedance. A requirement for proper ground connections is that they maintain an impedance that is essentially constant. (1) Ground return circuits should have a current rating and

voltage drop adequate for satisfactory operation of the connected electrical and electronic equipment.

(2) EMI problems, that can be caused by a system’s power wire, can be reduced substantially by locating the associated ground return near the origin of the power wiring (e.g., circuit breaker panel) and routing the power wire and its ground return in a twisted pair.

(3) Special care should be exercised to ensure replacement on ground return leads. The use of numbered insulated wire leads instead of bare grounding jumpers may aid in this respect.

c) External grounding of equipment items. Direct connections to a magnesium structure (which may create a fire hazard) must not be used for ground return.



Version 1.0 134

Grounding, cont.

Heavy current groundsAttach to individual grounding bracketsattached to aircraft structure with aproper metal-to-metal bond

Accommodate normal and fault currentsof system without creating excessivevoltage drop or damage to structure

Give special attention to compositeaircraft

d) Heavy-current grounds. Examples include power ground connections for generators, transformer rectifiers, batteries, and external power receptacles. (1) Use at least three fasteners, located in a triangular or

rectangular pattern, must be used to secure such brackets in order to minimize susceptibility to loosening under vibration.

(2) When using a material such as carbon fiber composite (CFC), which has a higher resistivity than aluminum or copper, provide an alternative ground path(s) for power return current.



3. Bonding

Version 1.0 135

Bonding

Equipment bondingLow impedance paths to aircraftstructure required for electronicequipment to provide radiofrequency return circuits

Facilitates reduction in EMI for mostelectrical equipment– Cases of components that produce EMI

should be grounded to structure

a) Equipment bonding. To ensure proper operation of electronic equipment, it is particularly important to conform the system’s installation specification when inter-connections, bonding, and grounding are being accomplished.

Version 1.0 136

Bonding, cont.

Metallic surface bondingElectrically connecting conductiveexterior airframe componentsthrough mechanical joints,conductive hinges, or bond straps

–Protects against static charges andlightning strikes

b) Metallic surface bonding. Exceptions may be necessary for some objects such as antenna elements, whose function



requires them to be electrically isolated from the airframe. Such items should be provided with an alternative means to conduct static charges and/or lightning currents, as appropriate.

Version 1.0 137

Bonding, cont.

Static bondsRequired for all isolated conductingparts with area greater than 3 in2 anda linear dimension over 3" subjectedto appreciable electrostatic chargingdue to precipitation, fluid, or air inmotion– Resistance of less than 1 ohm when

clean and dry usually ensures staticdissipation on larger objects

c) Static bonds. All isolated conducting parts inside and outside the aircraft, having an area greater than 3 in2 and a linear dimension over 3 inches, that are subjected to appreciable electrostatic charging due to precipitation, fluid, or air in motion, should have a mechanically secure electrical connection to the aircraft structure of sufficient conductivity to dissipate possible static charges. (1) A resistance of less than 1 ohm when clean and dry will

generally ensure such dissipation on larger objects. Higher resistances are permissible in connecting smaller objects to airframe structure.



H. Wire marking

Version 1.0 138


Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicingWire terminalsGrounding and bonding

Wire marking

Connectors and conduitsWire insulation properties

1. Purpose

Version 1.0 139

Wire Marking

Necessary for:Safety of operationSafety to maintenance personnelEase of maintenance

To identify performance capability,use wire material part number andfive digit/letter code identifyingmanufacturer

2. Common manufacturer marking process. Each wire and cable should be marked with a part number. It is common practice for wire manufacturers to follow the wire material part number with the five digit/letter C.A.G.E. code identifying the wire



manufacturer. Using this code, existing installed wire that needs replacement can be identified as to its performance capabilities. This helps to prevent the inadvertent use of lower performance and unsuitable replacement wire. a) NOTE: Be careful when hot stamping wire. Service history

has shown problems associated with hot stamping due to insulation damage caused during the process.

b) The method of identification should not impair the characteristics of the wiring.

c) Original wire identification. To facilitate installation and maintenance, retain the original wire-marking identification. The wire identification marks should consist of a combination of letters and numbers that identify the wire, the circuit it belongs to, its gauge size, and any other information to relate the wire to a wiring diagram. All markings should be legible in size, type, and color.

d) Identification and information related to the wire and wiring diagrams. The wire identification marking should consist of similar information to relate the wire to a wiring diagram.



Version 1.0 140

Wire Marking, cont.

Wire identification marks identify wire,circuit, and gauge sizeMarkings should be legible in size,type, and color at 15-inch maximumintervals along the wire [directly onwire or indirect (sleeve/tag)]<3 inches needs no marking

Readable without removing clamps, ties,or supporting devices

3. Marking wires in aircraft. a) Wires less than 3 inches long need not be identified. b) Wires 3 to 7 inches in length should be identified

approximately at the center. c) Added identification marker sleeves should be located so that

ties, clamps, or supporting devices need not be re-moved in order to read the identification.

d) Wire identification code must be printed to read horizontally (from left to right) or vertically (from top to bottom). The two methods of marking wire or cable are as follows: (1) Direct marking – print on the cable’s outer covering. (2) Indirect marking – print on a heat-shrinkable sleeve and

install on the wire or cables outer covering. Indirect-marked wire or cable should be identified with printed sleeves at each end and at intervals not longer than 6 feet. The individual wires inside a cable should be identified within 3 inches of their termination.

e) The marking should be permanent such that environmental stresses during operation and maintenance do not adversely affect legibility.



Example: Marking a Wire Bundle

A

B

I. Connectors and conduits

Version 1.0 142


Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicingWire terminalsGrounding and bondingWire marking

Connectors and conduits

Wire insulation properties

1. Connectors. The number and complexity of wiring systems have resulted in an increased use of electrical connectors. The proper choice and application of connectors is a significant part of the aircraft wiring system. Connectors should be kept to a minimum, selected, and installed to provide the maximum degree of safety



and reliability to the aircraft. For the installation of any particular connector assembly, the specification of the manufacturer should be followed.

Version 1.0 143

Connectors

Many types, however crimpedcontacts generally used

Circular typeRectangularModule blocks

Selected to provide max. degree ofsafety and reliability given electricaland environmental requirements

Use environmentally-sealed connectorsto prevent moisture penetration

a) Purpose and types. The connector used for each application should be selected only after a careful determination of the electrical and environmental requirements. Consider the size, weight, tooling, logistic, maintenance support, and compatibility with standardization programs. (1) Connectors using crimped contacts are generally chosen

for all applications except those requiring a hermetic seal. (2) A replacement connector of the same basic type and

design as the connector it replaces should be used. (3) With a crimp type connector for any electrical

connection, the proper insertion, or extraction tool should be used to install or remove wires from such a connector. Refer to manufacturer or aircraft instruction manual.

(4) After the connector is disconnected, inspect it for loose soldered connections to prevent unintentional grounding.



(5) Connectors that are susceptible to corrosion difficulties may be treated with a chemically inert waterproof jelly or an environmentally-sealed connector may be used.

• NOTE: Although not required by AC 43.13-1b, moisture-proof connectors should be used in all areas of the aircraft, including the cabin. Service history indicates that most connector failures occur due to some form of moisture penetration. Even in the pressurized, environmentally-controlled areas of the cockpit and cabin, moisture can occur due to “rain in the plane” type of condensation that generally is a problem in all modern transport category aircraft.

Circular Connectors

b) Although AC 43.13-1b does not address pin layout design aspects, consideration should be given to the design of the pin arrangement to avoid situations where pin-to-pin shorts could result in multiple loss of functions and/or power supplies. For example, you would avoid 115 Vac, 400Hz being located adjacent to low power wires, such as 28 and 5 Vdc.



2. Exercise 6: Pin Arrangement

Exercise 6: Pin Arrangement

a, b: 115 Vac, 400 Hz, galley powerc, d: 5 Vdc, discrete weight on wheels signale, f: 28 Vdc, backup power

A B C

a

e

dc

bab

f

ed c

ba f

edc

f

a) A wide variety of circular environment-resistant connectors are used in applications where they will probably be subjected to fluids, vibration, thermal, mechanical shock, corrosive elements, etc. In addition, firewall class connectors incorporating these same features should be able to prevent the penetration of the fire through the aircraft firewall connector opening and continue to function without failure for a specified period of time when exposed to fire. Hermetic connectors provide a pressure seal for maintaining pressurized areas. (1) When EMI/RFI protection is required, special attention

should be given to the termination of individual and overall shields. Backshell adapters designed for shield termination, connectors with conductive finishes, and EMI grounding fingers are available for this purpose.



Circular Connectors

(2) In medium or high vibration areas it may be necessary to provide a locking device to keep the connectors from loosening.



Example: Lock Wire Installation

Example: Lock Wire Installation, cont.



Rectangular Connectors

b) Rectangular connectors are typically used in applications where a very large number of circuits are accommodated in a single mated pair. They are available with a great variety of contacts, which can include a mix of standard, coaxial, and large power types. Coupling is accomplished by various means. (1) Smaller types are secured with screws that hold their

flange together. (2) Larger ones have integral guide pins that ensure correct

alignment, or jackscrews that both align and lock the connectors.

(3) Rack and panel connectors use integral or rack-mounted pins for alignment and box mounting hardware for couplings.



Module Blocks (Terminal Blocks)

c) Module blocks accept crimped contacts similar to those on connectors. Some use internal busing to provide a variety of circuit arrangements. (1) Module blocks (or terminal blocks) are useful where a

number of wires are connected for power or signal distribution. When used as grounding modules, they save and reduce hardware installation on the aircraft.

(2) Standardized modules are available with wire-end grommet seals for environmental applications and are track-mounted.



View AUnacceptable

wire

grommet

Terminal Block Grommet Distortion

A

View AAcceptable

(3) For complex wire breakouts that are terminated into terminal blocks, care must be taken to allow enough slack to prevent excessive forces from pulling the terminated wires that are inserted into the terminal block.

• This condition can lead to terminal block grommet distortion, which can lead to wire damage or a wire that will be pulled free from the terminal block.



Exercise: Grommet Distortion

A

B

3. Conduits. Conduits are manufactured in metallic and nonmetallic materials and in both rigid and flexible forms.

Version 1.0 153

Conduits

PurposeMechanical protection of wires and cablesGrouping and routing wires

StandardsAbsence of abrasion at end fittingsProper clampingAdequate drain holes free of obstructionsMinimized damage from moving objectsProper bend radii

a) Standards (1) Size of conduit. Conduit size should be selected for a

specific wire bundle application to allow for ease in maintenance, and possible future circuit expansion, by



specifying the conduit inner diameter (I.D.) about 25 percent larger than the maximum diameter of the wire bundle.

(2) Conduit fittings. Wire is vulnerable to abrasion at conduit ends. Suitable fittings should be affixed to conduit ends in such a manner that a smooth surface comes in contact with the wire. When fittings are not used, the end of the conduit should be flared to prevent wire insulation damage. Conduit should be supported by use of clamps along the conduit run.

Version 1.0 154

Conduit Installation Guidelines

Do not locate conduit where serviceor maintenance personnel might useas handhold or footstepProvide inspectable drain holes at thelowest point in conduit run — removedrilling burrs carefullySupport conduit to prevent chafingagainst structure and avoid stressingend fittings



Example: Conduit CoveringDamagedconduit covering

Acceptable conduitcovering

4. Review exercise 7: Bend radius

.2"

.4"

.5"

.7".2"

.2".8"

.2"

Review Exercise 7: Bend Radius

Calculate the minimum bend radius forthis wire bundle (assume it is supported atone end only).

Select an answer:a. 1 inchb. 5 inchesc. 7 inchesd. 8 inchese. 7.4 inches



J. Wire insulation properties

Version 1.0 157


Electrical load determinationBreaker and wire sizing/selectionRouting/clamping/bend radiiSplicingWire terminalsGrounding and bondingWire markingConnectors and conduits

Wire insulation properties

1. Environmental characteristics

Version 1.0 158

Flame resistantMechanical strengthSmoke emissionFluid resistanceHeat distortion

Wire Insulation Selection

Chose characteristics based onenvironment

Abrasion resistanceArc resistanceCorrosion resistanceCut-through strengthDielectric strength

a) As shown in this slide, there are many insulation materials and combinations used in aircraft wiring. Wire insulation characteristic should be chosen based on meeting FAA flame



resistance and smoke emission requirements (25.869) and the environment in which the wire is to be installed.

2. Flame resistant insulating materials

Version 1.0 159

Flame Resistant InsulatingMaterials

Polymer Mil SpecPTFE 22759/12

ETFE 22759/16

Aromatic polyamide 81381

Composite 22759/80-92

a) These are the four most common types of insulation materials used in aircraft today. All of the wire insulating materials in this slide meet the minimum FAA smoke and flammability standards.



3. Balancing properties

Version 1.0 160

Selecting Insulating Materials

FACT:FACT: There is nono “perfect” “perfect” insulation systeminsulation system for aerospace wire and cable

The designer’s task:The designer’s task:Consider trade-offs to secure bestbalance of propertiesConsider influence of design,installation and maintenance

.....for each application!.....for each application!

Version 1.0 161

How to Choose Wire Insulation

Seek the best balance of properties:ElectricalMechanicalChemicalThermal

PlusPlusNonflammability and low smoke



4. Comparative properties

Comparative Properties of Wire Insulation SystemsComparative Properties of Wire Insulation Systems

Relative Ranking 1 2 3 4Weight PI ETFE COMP PTFETemperature PTFE COMP PI ETFEAbrasion resistance PI ETFE COMP PTFECut-through resistance PI COMP ETFE PTFEChemical resistance PTFE ETFE COMP PIFlammability PTFE COMP PI ETFESmoke generation PI COMP PTFE ETFEFlexibility PTFE ETFE COMP PICreep (at temperature) PI COMP PTFE ETFEArc propagation resistance PTFE ETFE COMP PI

Most desirable Least

a) PI [Aromatic Polyimide (KAPTON)] - (mil spec 81381) (1) Desirable properties: abrasion/cut-through, low-

smoke/non-flame, weight/space (2) Limitations: arc-track resistance, flexibility

b) ETFE (TEFZEL) - (mil spec 22759/16) (1) Desirable properties: chemical resistance, abrasion

resistance, ease of use (2) Limitations: high temperature, cut-through, thermal

rating (150°C) c) Composite (TKT) - (mil spec 22759/80-92)

(1) Desirable properties: high temperature rating (260°C), cut-through resistance, arc-track resistance

(2) Limitations: outer layer scuffing



d) PTFE (TEFLON) - (mil spec 22759/12)

(1) Desirable properties: 260°C thermal rating, low-smoke/non-flame, high flexibility

(2) Limitations: Cut-through resistance, “creep” at temperature

5. Insulation selection

Version 1.0 163

Conclusion on Insulation

Aircraft designer can choose amongmany polymeric materials

Physical and chemical propertiesare equally important

Safest system combines “balanceof properties” with inherent flameand/or smoke resistance



V. AC 25-16 requirements (a high-level overview)

A. Electrical fault and fire detection

Version 1.0 164

AC 25-16: Electrical Fault andFire Detection

Supplements existing guidanceprovided in AC 43.13-1b

Should apply to new airplanes,as well as modifications

Not intended to take the place ofinstructions or precautions providedby aircraft/equipment manufacturers

1. AC 25-16 provides information on electrically caused faults, overheat, smoke, and fire in transport category airplanes. Acceptable means are provided to minimize the potential for these conditions to occur, and to minimize or contain their effects when they do occur. An applicant may elect to use any other means found to be acceptable by the FAA.

2. This AC, in your appendix, is currently being reviewed and will be revised based on recent service history and ATSRAC recommendations.



B. Circuit protection devices

Version 1.0 165

AC 25-16: Circuit ProtectionDevices (CPDs)

Circuit breaker resetsCan significantly worsen an arcingevent

Crew should only attempt to reset atripped breaker if function is absolutelyrequired– Information should be provided in AFMs

or AFM revisions or supplements

1. It is strongly recommended that circuit breakers for non-essential systems not be reset in flight.

2. Most transport OAMs and operators are revising their procedures to not allow circuit breaker resets in flight following a circuit breaker trip event. Service history has shown that resetting a circuit breaker can greatly influence the degree of arcing damage to the wiring. Each successive attempt to restore an automatically-disconnected CPD, can result in progressively worsening effects from arcing.



Arc Tracking and Insulation Flashover(Caused by multiple circuit breaker resets)

3. This picture shows the effects of multiple circuit breaker resets. In this case, the original arcing event was not able to be determined due to the severe secondary damage following the circuit breaker resets.

VI. Wire separation

A. Introduction

Version 1.0 167

Wire Separation

Regulatory requirementsSections 25.1309(b), 25.903(d),25.1353(b), 25.631

Manufacturers’ standardsPower/signal wire separation–EMI concerns



1. Wire separation/segregation is a fundamental design technique used to isolate failure effects such that certain single failures that can compromise redundancy are minimized. Wire separation is also used to control the effects of EMI in aircraft wiring. a) From a regulatory standpoint, we have regulations in place

that may influence wiring design with respect to separation and segregation.

b) In addition, manufacturers may have company design standards which establish wiring separation requirements with respect to power and signal routing which are usually driven from a EMI standpoint.

B. Wire separation: 25.1309(b)

Version 1.0 168

Wire Separation from a25.1309(b) Standpoint

No single failure shall preventcontinued safe flight and landing

Consider possible modes of failureincluding external events, e.g. wirebundle failure or damage–– Common Cause AnalysisCommon Cause Analysis may indicate

need for separation requirements–– Zonal AnalysisZonal Analysis will verify requirements

• E.g.: auto-land wiring, inertial referenceunit (IRU) wiring

1. A single failure includes any set of failures that cannot be shown to be independent from each other. Failure-containment techniques available to establish independence may include partitioning, separation, and isolation.

2. Common cause failure considerations. An analysis should consider the application of the fail-safe design concept and give special attention to ensure the effective use of design techniques that would prevent single failures or other events from damaging



or otherwise adversely affecting more than one redundant system channel, more than one system performing operationally similar functions, or any system and an associated safeguard. a) When considering such common-cause failures or other

events, consequential or cascading effects should be taken into account. Some examples of such potential common cause failures or other events would include: (1) Rapid release of energy from concentrated sources such

as uncontained failures of rotating parts (other than engines and propellers) or pressure vessels.

(2) Pressure differentials. (3) Non-catastrophic structural failures. (4) Loss of environmental conditioning. (5) Disconnection of more than one subsystem or component

by overtemperature protection devices. (6) Contamination by fluids. (7) Damage from localized fires. (8) Loss of power supply or return (e.g. mechanical damage

or deterioration of connections). (9) Excessive voltage. (10) Physical or environmental interactions among parts,

errors, or events external to the system or to the airplane. b) ARP 4761 contains industry accepted methods of conducting

Common Cause Analysis. If you want to know more about ARP 4761, there is a System Safety Assessment Video and Self-study Guide available through your Directorate training manager.



C. Wire separation: 25.903(d)

Version 1.0 169

Wire Separation from a25.903(d) Standpoint

Turbine engine installations: Minimizehazards in case of rotor failure

Project debris path through aircraft–Determine vulnerable areas where

redundancy can be violated• May need to separate certain critical

systems components including wiring,e.g., electrical power feeders, fly-by-wirecontrol paths

1. Recently, the JAA requirements with respect to uncontained engine failure assessment were harmonized with the FAA and were issued as AC 20-128A. AC 20-128A provides specific methods for demonstrating compliance with 25.903(d). a) The primary requirement relative to uncontained engine

failure is to use practical design precautions to minimize the risk of catastrophic damage due to non-contained engine rotor debris. (1) An element of difficulty is introduced when the fuselage

diameter is exposed to the relatively large diameter fan rotors of modern high-bypass-ratio turbofan engines.

(2) Separation of critical systems wiring may be a primary factor in establishing compliance.



D. Wire separation: 25.1353(b)

Version 1.0 170

Wire Separation from a25.1353(b) Standpoint

Group, route, and space cables tominimize damage to essentialcircuits if faults in heavy current-carrying cables

If fault can damage other essentialcircuit wires in same bundle, mayneed to segregate or separate wiring,as practicable, to minimize damage

1. Paragraph 25.1353(b) is a direct carryover from Civil Air Regulations (CAR) 4b.625(c). It was promulgated in the early 1950s at a time when aircraft electrical systems were becoming more complex. The preamble to the original rule indicates that the rule is considered an objective provision sufficiently flexible so as not to hinder the detail design. Also, the word “minimize” in the rule implies that it may not be practicable to completely eliminate the potential for collateral damage to essential circuits. Therefore, a degree of engineering judgement is required to interpret compliance with this regulation.



E. Wire separation: 25.631

Version 1.0 171

Wire Separation from a25.631 Standpoint

Continued safe flight and landingafter impact with 8-lb. bird

Consider protected location of controlsystem elements– If impact can effect redundant system

wiring, may need additional physicalprotection of wiring or wiring separation• E.g.: Impact brow area above windshield

could affect electrical power redundancyin some aircraft

1. The birdstrike impact areas of the aircraft should be assessed for their structural strength by test and/or approved analysis methods. Any penetrations or deformations of the aircraft structure should be further analyzed for the effect of systems installation.



F. Post-TC wire separation

Version 1.0 172

Post-TC Wire Separation

Maintain wire separation requirementsthroughout life of aircraft

STC applicants may not be aware ofseparation or other wiring requirements(i.e., do not have needed design data)Wiring added or moved as part of theSTC should satisfy original separationrequirements and wiring standardsFAA draft policy letter in development

1. A potential problem with STCs and other modifications to transport aircraft is that the applicants may not analyze their proposed wiring installation with respect to the OAM’s wiring separation requirements and other OAM wiring design standards. Added or modified wiring could possibly defeat the OAM wiring philosophy and create unsafe conditions.

2. The FAA is currently in the process of drafting policy. The draft policy letter will clarify FAA’s policy to require that type design data packages for multiple approvals include the following: a) A drawing package that completely defines the configuration,

material, and production processes necessary to produce each part in accordance with the certification basis of the product.

b) Any specifications referenced by the required drawings. c) Drawings that completely define the location, installation, and

routing, as appropriate, of all equipment in accordance with the certification basis of the product. (1) Examples of such equipment are wire bundles, plumbing,

control cables, and other system interconnecting hardware.



(2) If the modification being approved is a change to a type certificated product, the modification must be equivalent to and compatible with the original type design standards.

d) Instructions for Continued Airworthiness (ICA) prepared in accordance with the requirements of 21.50 (“Instructions for continued airworthiness and manufacturer’s maintenance manuals having airworthiness limitations sections”).

VII. Instructions for Continued Airworthiness

A. General information/overview 1. 14 CFR 25.1529 requires applicants to submit Instructions for

Continued Airworthiness, otherwise known as the maintenance requirements, for the proposed installation as part of the compliance data package. Historically, wiring has been thought of as “fit and forget” and typically has not been properly addressed in the ICA data package submitted to the FAA for approval.

Version 1.0 173

Instructions for ContinuedAirworthiness

Wire replacement instructionsinclude information on how to:

Repair or replace a failed wire–Splicing instructions–Compatible replacement wire types–Pertinent clamping and routing aspects–Shielding, grounding aspects, if

applicable

2. In light of recent ATSRAC recommendations, the FAA will now be requiring applicants to submit wiring-related maintenance



requirements to satisfy the intent of 25.1529. This slide shows some of the issues that need to be addressed for wire replacements instructions.

Version 1.0 174

ICA, cont.

ATSRAC recommendationsClean-as-you-go philosophy

Wiring general visual inspections (WGVI)

Non-destructive testing (NDT)equipment

Preemptive repair of splices and/orreplacement of wire



B. Cleaning requirements/practices 1. Clean-as-you-go philosophy

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Clean-as-you-go Philosophy

Keep wiring clean throughoutlife of aircraft

Protect wiring during routinemaintenance

Clean wiring periodically (vacuum,light brushing, etc.) during heavymaintenance when hidden areasexposed

a) CAUTION! For wiring with extremely heavy accumulation of dirt, lint, and other FOD where cleaning cannot be safely accomplished, judgement must be used since more damage may occur during a vigorous cleaning process than if the dirt were allowed to accumulate. Wire replacement should be considered in these cases.



C. Wiring general visual inspections (WGVI) 1. What to look for:

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WGVI Focus Areas

Clampingpoints

Improperinstallation

Clamp/wiredamage

Clamp cushionmigration

ConnectorsWorn sealsLooseconnectorsLack of strainreliefDrip loopsTight wire bends

Version 1.0 177

WGVI Focus Areas, cont.

TerminationsLugs/splices

BackshellsImproper build-upLack of strain relief

Damaged sleevingand conduits

Groundingpoints

TightnessCleanlinessCorrosion



2. Wiring inspection locations. Available data indicate that the following are locations that should receive special attention in an operator’s wiring inspection program:

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Wiring Inspection Locations

WingsExposed wiring on leading/trailingedges during flap/slat operation

Engine/APUs/pylon/nacelleHeat/vibration/chemical contaminationHigh maintenance area

Landing gear/wheel wellsEnvironmental/vibration/chemical

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Wiring Inspection Locations, cont.

Electrical panels/line replacementunits (LRU)

High density areasHigh maintenance activityProne to broken/damaged wires

BatteriesChemical contamination/corrosion

Power feedersFeeder terminationsSigns of heat distress

a) Electrical panels and line replaceable units (LRUs) - One repair facility has found that wire damage was minimized by tying wiring to wooden dowels. This reduced wire



disturbance during modification. It is also recommended to remove entire disconnect brackets, when possible, instead of removing individual receptacles.

b) Power feeders - If any signs of overheating are seen, the splice or termination should be replaced. This applies to galley power feeders, in addition to the main and APU generator power feeders. The desirability of periodically retorquing power feeder terminations should be evaluated.

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Wiring Inspection Locations, cont.

Under galleys and lavatoriesSusceptible to fluid contaminationFluid drainage provisions

Cargo bay/underfloor areaHigh maintenance activity

Surfaces, controls, doorsMoving and bending wire harnesses

Near access panelsProne to accidental damage



D. Non-destructive wire testing (NDT) methods

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Non Destructive Wire TestingMethods

Still in the R & D phase

Can detect wiring faults “in-situ”i.e., with wiring still installed

Can aid in isolating wiring faultsduring the maintenance process

E. Preemptive wire splice repair and/or wire replacement

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Pre-emptive wire splice repairand/or wire replacement

Certain wire types and splice typesmay need periodic repair orreplacement depending oninstallation environment

Maintenance procedures shouldaddress this aspect, as required



Exercise: Use of Grommets

A

B

Exercise: Tie Clamp

A

B



Exercise: Foreign ObjectDamage

Exercise: Tie Wrap Ends

A

B



Exercise: Clamp Cushion

A

B

Exercise: Sleeving Installation

A

B



VIII. Wiring installation certification

A. Introduction

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Wiring Installation Certification

What does anapplicant needto provide for

FAA orDesigneereview?

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Compliance Documentation

Project Specific Certification Plan(PSCP) (wiring aspects)

Load analysis

Wiring diagrams

Wiring installation drawings

Wire separation requirements (e.g.,25.1309, 25.1353 completed data)



B. Wiring diagrams 1. The engineer or designee should review the wiring diagrams and

verify the points shown on this slide. This information should be available on the wiring diagrams or referenced to the source.

1/20/01 187

Wiring Diagrams

Wire selectionGauge/breaker sizeInsulationEnvironmental considerations

ConnectorsPin/socket ratingsPin arrangement (best practices)Environmental considerations

Grounding

2. Wire selection - The wire insulation and conductor plating must be suitable for the environment plus any further temperature rise due to dissipated power.

3. Connectors - As we discussed earlier, pin arrangements should minimize the possibility of shorts between power, ground, and/or signals. Verify that separation requirements from the safety assessment process are addressed. Also, ensure unused pins are properly protected.





C. Wire installation drawings: 1. Installation drawings generally do not provide the necessary

detail to ensure proper clamping, routing, and termination of wiring for a given installation.

2. It is advisable for the engineer or designee to perform a first-of-a-model or first-of-a-design general wiring compliance inspection in addition to reviewing the wiring diagrams and wiring installation drawings. Consideration should be given to the complexity of the wiring system in determining the appropriate depth of the compliance inspection.

3. The engineer or designee should ensure that adequate installation drawings exist and review the drawings and perform the compliance inspection to verify the items noted on the following slides (which we discussed in detail earlier).

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Wiring Installation Drawings

ClampsProper size, type, and materialSpaced appropriately for environmentMounted correctly

Feed throughs/pass throughsGrommets used when necessaryWire bundles properly supported

4. Clamps - Ensure that an adequate number of clamps are used to properly support the wire bundle.

5. Feed throughs/pass throughs - Grommets suitable for the environment must be used when the wire bundle passes through pressure bulkhead, firewall, and other openings in the structure.



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Wiring Installation Drawings, cont.

RoutingChafingLocation with respect to fluid lines, lavs,and galleysDrip loopsBend radiusCoil, cap, and stow methodsHuman factors (hand/step holds)Protected against cargo/maintenance

6. Wire routing should be reviewed to ensure proper clearance from aircraft structure, fluid lines, and other equipment.

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Routing, cont.

Accessible for maintenance, repairs,and inspection

Proper slack

Segregation and separation–Compatible with OAM standards–Does not violate any regulatory safety

requirements



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ConduitsSized properlyAppropriate for environmentConduit ends are terminatedBend radiusDrain holesMetallic - Are wires properlyprotected inside?







Drawing Parts List Contract Number ________________________ DWG Size J DWG No PL TRA7015 Rev NEW

WIRE INSTALLATION Title: LOWER CARGO____________ SHEET 1 OF 4

Engineer Draftsman L. Macintosh

Date 03/27/97

1 2 3 4 5 6 7 8 9 Design Group

Elect – Wire Instal

Part or Identifying

No Nomenclature or

Description Cage No

CC Stock Size Parts :ost Code or Material Description

Material Specification

and/or Supplier

NOTES

Item Find No

Zone

1 1 -3 CONDUIT .75 I.D. x .010 x 14 IN

TUBE 2024-2

DMS 2024 TYPE 2

28

2

2 3 MS21919WDG-12 CLAMP 28 4 4 S426-14-3 CLAMP UM PCD INC

645 SHADE AVE ORANGE, CA

35

6 5 S7934111-6SA CLAMP 29 3 6 MS25281-R4 CLAMP 28 3 7 9DO166-15 CLAMP 28 10 8 NMC1001-1 CLAMP NYLON MOLDING

716 ORANGE ST. SHADE, CA

31

3 9 5D0061-2 TIE MOUNT 35 1 10 CSCS-M SPACER 35 15 11 9D0254-1-1-9 STRAP TIE

DOWN

31

6 12 MS21266-2N GROMMET 35



IX. Questions and wrap-up

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Questions ??

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Thank You



Appendices

Appendix A: AC 43.13-1b, Chapter 11

Appendix B: AC 25-16

Appendix C: Course Evaluation Forms


Participant Guide Version 1.0 Course Evaluation page 1

Appendix C

Course Evaluation Forms

There are two course evaluation forms in this Appendix. Please select the one appropriate for your method of study.

• Live broadcast

• Self-study video course

If you are taking this course via live broadcast and you are logged on to a keypad, you will be asked to complete the course evaluation by using the Viewer Response System keypad. Your IVT instructor will provide directions on how to complete the course evaluation. If you do not have access to a keypad, circle your responses and fax the form to the IVT studio. If you have completed this by watching the video, please complete the Self-Study Evaluation Form and return to your directorate/division training manager (ATM).



Aircraft Certification’s Aircraft Wiring Practices

March 28 & 29, 2001

Please give us your candid opinions concerning the training you’ve just completed. Your evaluation of the IVT course is important to us, and will help us provide the best possible products and services to you. NOTE: Your keypad responses are not identifiable by name; only average item responses are provided to the instructor and to others responsible for the training.

Use your Viewer Response keypad to answer the following questions.

Very Very Good Good Average Poor Poor

1. Length of course A B C D E

2. Depth of information A B C D E

3. Pace of training A B C D E

4. Clarity of objectives A B C D E

5. Sequence of content A B C D E

6. Quality of course materials A B C D E

7. Quality of graphics/visual aids A B C D E

8. Readability of text on monitor A B C D E



Very Very Good Good Average Poor Poor

9. Effectiveness of instructors A B C D E

10. Communication between student and instructors A B C D E

11. Applicability of material to your job A B C D E

12. Overall quality of the course A B C D E

13. Overall effectiveness of the interactive training format A B C D E

14. Would you like to take other interactive training courses? A. YES B. NO C. UNDECIDED

15. On the keypad, enter your number of years of FAA experience. ________ (number/enter )

When finished, press the “Next Quest” key on your keypad and answer YES, then ENTER. Your responses will be sent electronically. Individual responses are not tabulated; only item averages for each question are presented to the instructor(s) and to AIR-510.

Additional Comments may be faxed to the broadcast studio in Oklahoma City:

405-954-0317 / 9507



SELF-STUDY VIDEO EVALUATION

Please give us your candid opinions concerning the training you’ve just completed. Your evaluation of the self-study video course is important to us, and will help us provide the best possible products and services to you.

Course title: _____________________________________________________________

Date:

Number of years of FAA experience:

(Optional)Name: Office phone: ( )

For the following, please darken the circle appropriate to your response.

Very Very Good Good Average Poor Poor N/A

1. Length of course

2. Depth of information

3. Pace of training

4. Clarity of objectives

5. Sequence of content

6. Amount of activities/practice

7. Quality of course materials

8. Effectiveness of instructors

9. Overall quality of the course

10. Overall effectiveness of the self-study video format

11. Rate your level of knowledge of the topic before and after taking this self-study course.



Very Very Low Low Moderate High High

BEFORE THE COURSE:

AFTER THE COURSE:

12. What did you like best about the course?

13. What would you improve in the course?

14. What previous experience, if any, have you had with self-study courses?

None Moderate Considerable

15. Were you comfortable with the self-study video format? Yes No Undecided If not, why not?

16. Would you like to take other self-study video courses? Yes No Undecided If not, why not?

17. Additional comments:

PLEASE SEND THIS COMPLETED FORM TO YOUR DIRECTORATE/DIVISION TRAINING MANAGER (ATM). THANK YOU.

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