Slide1:AircraftElectricalWiringInterconnectSystem(EWIS)

BestPractices JobAid Revision:2.0 [Speakernotes] Thisjobaidcoversapplicable14CFRpart25aircraft(althoughitisalsowidelyacceptablefor usewithothertypesofaircraftsuchasmilitary,smallairplanes,androtorcraft).Thisjobaid addressespolicy;industryEWISpractices;primaryfactorsassociatedwithEWISdegradation; informationonTC/STCdatapackagerequirements;EWISselectionandprotection;routing, splicingandterminationpractices;andEWISmaintenanceconcepts(includinghowtoperform aEWISgeneralvisualinspection).ThejobaidalsoincludesnumerousactualaircraftEWIS photosandexamples. [Endspeakernotes]

Slide2:AdditionalNotes
Thisslidedoesnotpertaintothisaccessibleversion: Thispresentationcontainsadditionalspeakernotesformostslides. Itsadvisabletoreadthesenoteswhileviewingtheslidepresentation

Slide3:PrintingtheAdditionalNotes
Thisslidedoesnotpertaintothisaccessibleversion: Toprinttheslidesandaccompanyingspeakernotes: NavigatebacktotheFAAAircraftCertificationjobaidswebpage OpenandprintPrintableSlidesandNotes.

Slide4:Background
1. WhytheneedforEWISbestpracticesJobAid? a. Accident/IncidentServiceHistory b. AgingTransportSystemsRulemakingAdvisoryCommittee(ATSRAC) c. EnhancedAirworthinessProgramforAirplaneSystem(EAPAS) d. EAPASRuleMaking [Speakernotes] Historically,wiringandassociatedcomponentswereinstalledwithoutmuchthoughtgivento theagingaspects: Fitandforget. Unanticipatedfailuremodesandtheirseverity.

 Arctracking. Arcing. Insulationflashover. Maintenanceprogramsoftendidnotaddresstheseagingaspects.Servicehistoryalsoindicates thatForeignObjectDamage(FOD)suchasdrillshavings,causticliquids,etc.doescauseEWIS degradationthatcanleadtoEWISfaults. [Endspeakernotes]

Slide5:Introduction
Late1980s,wiringsafetyconcernsraisedduetoaccidents&incidents Investigationsfoundcommondegradingfactorsinairplaneelectricalwiringsystems Investigationintowiring issuesdonebyindustry, civilaviationauthorities, othergovernment agencies [Speakernotes] Theagingissuesinwiringsystemsweremadeknownbythefollowing: Inthelate1980s,wiringsafetyconcernswereraisedduetoaccidents&incidents Investigationsfoundcommondegradingfactorsinairplaneelectricalwiringsystems Investigationintowiringissuesdonebyindustry,civilaviationauthorities,government agencies [Endspeakernotes]

Slide6:WiringInvestigationFindings
Design Maintenance Operation Training Repair Installation

[Speakernotes] Aslistedhere,theinvestigationoftheaircraftwiringrevealedthereareseveralfactors, togetherwithtime,thatplayaroleinwiringdegradation. [Endspeakernotes]

Slide7:AgingTransportSystemsRulemakingAdvisoryCommittee (ATSRAC)
PhaseI PhaseII Taskedtodevelopandproposerecommendationsforairworthinessenhancements totheFAA. TaskscompletedandreportsapprovedbyATSRACinJanuary2001. PhaseIII TaskedtoassistFAAwiththeimplementationoftheenhancementsdevelopedin PhaseII. [Speakernotes] AgingTransportSystemsRulemakingAdvisoryCommittee PhaseIThefollowingtaskswereundertakenbyATSRACinthisphasefordevelopingand proposingrecommendationsforairworthinessenhancementstotheFAA: Samplinginspectionofthefleet Reviewoffleetservicehistory Improvementofmaintenancecriteria Reviewandupdatestandardpracticeforwiring Reviewaircarrierandrepairstationinspectionandrepairtrainingprograms PhaseIIThefollowingtaskswereundertakenbyATSRACinthisphasetodevelopand proposeairworthinessenhancementsbasedontherecommendationsdevelopedinPhaseI: Improvingwiresystemcertificationrequirements Enhancingwiringmaintenanceproceduresandinstructions Enhancingandaugmentcurrenttrainingprograms StandardizingtheformatofStandardWiringPracticesManual Studyofagingissuesinsmalltransportairplaneselectricalwiring PhaseIIIThefollowingtasksarecurrentlyundertakenbyATSRACinthisphasetoassistFAA withtheimplementationoftheenhancementsdevelopedinPhaseII: Provideassistanceinimplementationoftheairworthinessenhancementsand,ifrequested, developalternativestorulemakingforimplementationoftrainingandmaintenance enhancements. Assistinreviewandimplementationofnewtechnologiesdevelopedformitigatingtheaging issuesinaircraftwiringsystems. Studyanddevelopenhancementsforwiringmaintenanceproceduresforsmalltransport airplanes(withapassengercapacitybetween6to30andlessthan7,500poundpayload). [Endspeakernotes] Taskedtodevelopedandproposeairworthinessenhancementsbasedonthe recommendationsdevelopedinPhaseI. TaskscompletedandreportsapprovedbyATSRACinJanuary2003.

Slide8:Routing/ChafingInServiceExamples
[Graphic] Wireschafingagainstmetalframeandchaffngagainsteachother [Endgraphic] [Speakernotes] Thesephotosshowexamplesoffindings.Theseexamplesshowthepotentialforchafingand arcing. [Endspeakernotes]

Slide9:AccumulationofDirtandLint
[Graphic] Wirescoveredindirtandlint [Endgraphic] [Speakernotes] Accumulationofdirtandlintcreateapotentialforsmokeandfire,makinginspectionofthe EWISimpossible. [Endspeakernotes]

Slide10:CoilandStowInServiceExample/Result
[Graphic] Cutwireswithendsexposedandcutantennathatisexposed [Endgraphic] [Speakernotes] Thisslideshowsanexampleofimproperterminationofunusedwires.Ontheleftside,there arenoterminationcapsanditsimproperlystowed. Ontherightsideisaphotoofanimpropermaintenanceaction.Coaxialcablewasleft attachedtoanantennainsteadofbeingremovedinitsentiretyatleastitshouldhavebeen detachedfromtheantenna.Consequently,lightningattachedtotheantenna,traveledalong theEWIS,andcausedafireinthecabin. [Endspeakernotes]

Slide11:BendRadiusProblemInServiceExample
[Graphic] Wiresbent180degreesandbundledtogether [Endgraphic] [Speakernotes]

Thisphotoshowsanimproperbendradiusinstallationofelectricalwire.Theproperbend radiusforwireonaircraftshouldbe10timestheoutsidediameterofthelargestdiameterwire inthebundleforonesidesupported(3timesfortwosidessupported.)Standardindustrial practiceandisinAC43.131bandStandardWiringPracticesManual(SWPM). [Endspeakernotes]

Slide12:ArcingEvent
[Graphic] Arcingresultswithterminalsandwires [Endgraphic] [Speakernotes] Thesephotosillustrateanimpropermaintenanceactioncausedwhentheairplanes airworthinesscertificatewasrelocated.Theattachscrewpenetratedthepowercables.The FAAmaintenanceinspectorridingonthejumpseatcaughthisclothingonfire. Thearcingevent,whichoriginatedfrominsidetheelectricalpowercenter,burnedahole throughtheleftsideofthehallway(lookingforward)betweenthecockpitandcabin. [Endspeakernotes]

Slide13:EffectofImproperMaintenance
[Graphic] Topshowschafingwirescausedconduitburnthroughongeneratedpowerfeederinconduit. Thebottomshowsthatheatfromarcingcausedholesinfuelline. [Endgraphic] [Speakernotes] Theleftsideofthisphotoshowsfailureofwireduetochafinginsideametallicconduit. Createdanarc,whichcreatedholesinthefuellinebelowtheconduit.Causedbyimproperly replacinganexistingpowerfeeder. [Endspeakernotes]

Slide14:EffectofPoorDesign
[Graphic] Burnholesonsideofairplaneandinthefloorunderapassengerseat [Endgraphic] [Speakernotes] ThisshowsarcingduetolavatoryservicinglinesleakingondamagedEWIS,creatinganarcthat causedafirethatledtoextensivedamageinsideandoutsideoftheairplane.Businessclass lavatorydripshieldnotinstalledwatershortedcannonpluginwirebundlebelowdeck. Maintenance,design,training,operationsallneedimprovement.

[Endspeakernotes]

Slide15:PreviousRegulationsInadequate
Previousregulationsfellshortofprovidingspecificwiringrelatedrequirements. Specificwiringrelatedrequirementsneededtobeincludedincertificationand operationalregulations.

Slide16:CultureShift:EAPASSafetyInitiative
RecognizingimportanceofEWISinsafeoperationofairplanesleadstobeingmore proactive;FAAis o Treatingwiringasasystem o MandatingDAHsupportoftheinitiative o IntegratingFAAlinesofbusiness; jointAFS/AIRactivity;andcooperationwith&betweenDAHsandoperators

[Speakernotes] Tocompletelyandthoroughlyaddresstheagingissuesinaircraftwiringrequiredaculturalshift comprisingof: Recognizingimportanceofelectricalwiringinsafeoperationofairplanesleadstobeingmore proactive;FAAis Treatingwiringasasystem MandatingDAHsupportoftheinitiative IntegratingFAAlinesofbusiness: jointAFS/AIRactivity;andcooperationwith&betweenDAHsandoperators [Endspeakernotes]

Slide17:GoalofEPASRule
Bannerwithmotto:Enhancesafetybyimprovingallaspectsofaircraftelectricalwiring Goalisbasedon o Industry/governmentcommitteedatadriven recommendations o Maximizingharmonization [Speakernotes] ThegoalofEAPASwastoenhancesafetybyimprovingallaspectsofaircraftelectricalwiring Goalisbasedon Industry/governmentcommitteedatadriven recommendations Maximizingharmonizationwithinternationalauthorities SonowyouhopefullyhaveabetterunderstandingofthehistorybehindtheEAPASrulemaking andhowitcameintobeing.WearenextgoingtoprovideadefinitionforanEWIS. [Endspeakernotes]

Slide18:EWIS
EElectrical WWiring IInterconnection SSystem [Speakernotes] Wiringneedstobetreatedasanimportantsystemonairplanes.Wiringisnowreferredtoas theElectricalWiringInterconnectionSystem(EWIS). [Endspeakernotes]

Slide19:EWISDefinition
AnEWISis is[pernew25.1701(a)]: Anywire,wiringdevice,orcombinationofthese,includingterminationdevices,installedin anyareaoftheairplaneforthepurposeoftransmittingelectricalenergybetweentwoormore intendedterminationpoints....

Slide20:EWISisnot[25.1701(a)] not
Electricalequipmentoravionicsqualifiedtoacceptableenvironmentalconditionsand testingprocedures Portableelectricaldevicesnotpartofairplanestypedesign Fiberoptics

Slide21:KeyPointtoRemember...
Wireandassociatedcomponentsnowtreatedasanairplanesystem

Slide22:EWISDegradationFactors
[Graphic] Inthecenter,EWISDegradationsurroundedPhysicalProperties,Age,Installation,Maintenance andEnvironmentpointingintoEWISDegradation. [Endgraphic] [Speakernotes] EWISdegradation

EWISdegradationisaprocessthatisafunctionofseveralvariables;agingisonly oneofthese.OthermainfactorsthatinfluenceEWISdegradationarethe: Environmentinwhichitisinstalled. PhysicalpropertiesoftheEWIS. ActualphysicalinstallationoftheEWIS. Maintenance(cleaningandrepair)oftheEWIS. CharacteristicsofagingEWIS ThemannerinwhichEWISdegradesisthereforedependentupontheEWIStype, howitwasoriginallyinstalled,theoveralltimeandenvironmentexposedtoin service,andhowtheEWISwasmaintained. ServicehistoryshowsthathowtheEWISisinstalledhasadirecteffectonEWIS degradation.Inotherwords,EWISthatisnotselectedorinstalledproperlyhas anincreasedpotentialtodegradeatanacceleratedrate.Therefore,good aircraftEWISpracticesarefundamentalrequirementsforEWIStoremainsafely intact. [Endspeakernotes]

Slide23:CausesofEWISDegradation
Vibration Moisture Maintenance

[Speakernotes] VibrationHighvibrationareastendtoacceleratedegradationovertime,resultingin "chattering"contactsandintermittentsymptoms.Highvibrationcanalsocausetiewraps,or stringtiestodamageinsulation.Inaddition,highvibrationwillexacerbateanyexisting problemwithwireinsulationcracking. MoistureHighmoistureareasgenerallyacceleratecorrosionofterminals,pins,sockets,and conductors.ItshouldbenotedthatEWISinstalledinclean,dryareaswithmoderate temperaturesappearstoholdupwell. MaintenanceUnscheduledmaintenanceactivities,ifdoneimproperly,maycontributetolong termproblemsandEWISdegradation.Repairsthatdonotmeetminimumairworthiness standardsmayhavelimiteddurability.Repairsthatconformtomanufacturersrecommended maintenancepracticesaregenerallyconsideredpermanentandshouldnotrequirereworkif properlymaintained. Metalshavingsanddebrishavebeendiscoveredonwirebundlesafter maintenanceorrepairshavebeenconducted.Careshouldbetakentoprotect wirebundlesandconnectorsduringmodificationwork,andtoensureall shavingsanddebrisarecleanedupafterworkiscompleted.

Asageneralrule,EWISthatisundisturbedwillhavelessdegradationthanEWIS thatisreworked.AsEWISbecomemorebrittlewithage,thiseffectbecomes morepronounced. [Endspeakernotes]

Slide24:CausesofEWISDegradation,cont.
Indirectdamage Chemicalcontamination Heat Installation

[Speakernotes] IndirectdamageEventssuchaspneumaticductrupturescancausedamagethat,whilenot initiallyevident,canlatercauseEWISproblems.Whensuchaneventhasoccurred, surroundingEWISshouldbecarefullyinspectedtoensurenodamageisevident. ChemicalcontaminationChemicalssuchashydraulicfluid,batteryelectrolytes,fuel, corrosioninhibitingcompounds,wastesystemchemicals,cleaningagents,deicingfluids,paint, andsoftdrinkscancontributetodegradationofEWIS.EWISinthevicinityofthesechemicals shouldbeinspectedfordamageordegradation.Recommendedoriginalequipment manufacturercleaninginstructionsshouldbefollowed. Hydraulicfluids,forexample,requirespecialconsideration.Hydraulicfluidis verydamagingtoconnectorgrommetandwirebundleclamps,leadingto indirectdamage,suchasarcingandchafing.EWIScomponentsthatmayhave beenexposedtohydraulicfluidshouldbegivenspecialattentionduringEWIS inspections. HeatEWIScomponentsexposedtohighheatcanacceleratedegradation,insulationdryness, andcracking.Directcontactwithahighheatsourcecanquicklydamageinsulation.Evenlow levelsofheatcandegradeEWISoverlongperiodsoftime.Thistypeofdegradationis sometimesseenonengines,ingalleys,andbehindlights. InstallationEWISnotinstalledproperlycanfurtheracceleratetheEWISdegradationprocess. Improperrouting,clamping,andterminatingduringinitialinstallationorduringamodifications canleadtoEWISdamage. [Endspeakernotes]

Slide25:CurrentFAAGuidance
[Graphic] Inthecenter,EWISPractices,surroundedwithPart25,Part26,AC25.17011,PolicyANM01 04,AC2510,AC2516,AC43.131bandAC25.27A [Endgraphic] [Speakernotes]

Therearedirectspecificpart25andpart26EWISpracticesrelatedto14CFR. Therearesomespecificelectricalpowerwiringrequirements,suchas25.1353,buttheydo notspecificallyaddressallaircraftEWIS. 14CFR25.1729requiresthatinstructionsforcontinuedairworthinessaredevelopedusing analyticalprocedures,whichwouldincludemaintenancetasksandintervalsforEWIS.Alarge bodyofFAAgeneralguidanceforwiringpracticesisinChapter11ofAC43.131b. [Endspeakernotes]

Slide26:Part25
Newpart25requirementsforcertificationofelectricalwiringinterconnectionsystems (EWIS) o RevisedexistingEWISrelatedcertificationrequirementsandrelocatedsomeof them o CreatednewEWIScertificationrequirements andplacedtheminanewsubpartH o NewEWISICArequirements

Slide27:Part26
Affectscontinuedairworthinessissuesand/orsafetyimprovementsfortransport airplanesaddressedviaoperationalrules Supportstheabilityofoperatorstocomplywiththeoperationalrulerequirements EAPASPart26RequiresactionsofDesignApprovalHolders(DAHs),suchas: o instructionsforcontinuedairworthiness, o distributionofinformationtoaffectedoperators

Slide28:Part26ModelApplicability
Existingairplaneswithamaximumtypecertificatedpassengercapacityof30ormore, or Existingairplaneswithamaximumpayloadcapacityof7,500poundsormore(reference 119.3) Existingairplanemodelswithatypecertificateissuedonorafter January1,1958.

Slide29:AC25.17011
ThisAdvisoryCircular(AC)providesguidanceforcertificationofelectricalwiring interconnectionsystems(EWIS)ontransportcategoryairplanes o 14CFRpart25,subpartH,sections25.1701through25.1733 o H25.4andH25.5ofAppendixHtopart25.

Slide30:AC25.27A
ProvidesguidancefordevelopingmaintenanceandinspectioninstructionsforEWIS Usesanenhancedzonalanalysisprocedure(EZAP). Forairplanemodelswhosemaintenanceprogramsalreadyincludeazonalinspection program,thelogicdescribedhereprovidesguidanceonimprovingthoseprograms.

Slide31:AC25.27A,cont.
Forairplaneswithoutazonalinspectionprogram,useofthislogicwillproducezonal inspectionsforEWISthatcanbeaddedtotheexistingmaintenanceprogram. ContainsinformationthatcanbeusedbyoperatorstoImproveEWISmaintenance practices. StressestheimportanceofinspectingEWISandpromotesaphilosophyofprotectand cleanasyougowhenperformingmaintenance,repair,oralterationsonanairplane.

Slide32:PolicyANM0104
DesigndatashouldNOTleavetheinstallationtothediscretionoftheinstaller. RoutingofEWISshouldfollowthecriteriaestablishedbytheFAAinthecertification basis,asreflectedintheholdersoriginalorsubsequentlyapprovedtypedesign. Installationdrawings/instructionsshouldcompletelydefinetherequiredroutingand installationwithsufficientdetailtoallowrepeatabilityoftheinstallation.

Slide33:Guidance:AC43.131b
AC43.131b: AC43.131b:AcceptableMethods,Techniques,andPractices AircraftInspectionandRepair o FlightStandardsAC o Chapter11AircraftElectricalSystems

NOTE:TheguidanceprovidedinAC43.131bisgeneralinnatureandisnottobereferencedor usedasasubstituteforEWISinstallationdrawingsand/orEWISdiagrams. [Speakernotes] AC43.131bcoversafairlycomprehensivewiderangeofbasicEWISpracticestopics. NOTE:TheguidanceprovidedinAC43.131bisgeneralinnatureandisnottobereferencedor usedasasubstituteforEWISinstallationdrawingsand/orEWISdiagrams. [Endspeakernotes]

Slide34:Guidance:AC2516
AC2516: AC2516:ElectricalFaultandFirePreventionandProtection(4/5/91)

o Providesacceptablemeanstoaddresselectricallycausedfaults,overheat, smoke,andfireintransportcategoryairplanes [Speakernotes] AC2516provideswiringpracticesguidanceasitrelatestoaircraftfireandsmokesafetywith emphasisonwiringflammability,circuitbreakerprotection,wiringnearflammablefluids,and associatedacceptabletestmethods. ThisACiscurrentlybeingconsideredforupdating. [Endspeakernotes]

Slide35:Guidance:AC2510
AC2510: AC2510:GuidanceforInstallationofMiscellaneous,NonrequiredElectrical Equipment(3/6/87) o Providesacceptablemeanstocomplywithapplicable14CFRsassociatedwith installationofelectricalequipmentsuchasgalleysandpassengerentertainment systems

[Speakernotes] AC2510mainlycoversnonrequiredequipmentinstallationssuchasgalleys,passenger entertainmentsystems,etc.Fromawiringstandpoint,allsystemsshouldbetreatedequally, regardlessofthefunctionscriticalitybecauseofpotentialfireandsmokehazards. ThisACcontainsminimalwiringpracticesspecifics,includinggeneralloadanalysisrequirements andcircuitbreakerprotectionrequirements,whicharemorethoroughlycoveredinAC43.13 1bandAC2516,sowearenotgoingtobecovering2510inanydetail. [Endspeakernotes]

Slide36:ElectricalLoadDetermination
Loadanalysis o Ensurethattotalelectricalloadcanbesafelycontrolledormanagedwithinrated limitsofaffectedcomponentsofaircraftselectricalsystem(25.1351) o Neworadditionalelectricaldevicesshouldnotbeinstalledwithoutanelectrical loadanalysis (AC43.131b)

[Speakernotes] Electricalloaddeterminationistoensureeachaircraftelectricalbuscansafelysupporta predeterminedamountofelectricalloadthatisbasedontheelectricalcapacityoftheaircraft generatorsandtheaircraftsoverallelectricaldistributionsystem. 25.1351requirement:Itmustbedeterminedthroughanalysisthatallelectricaldevicescan besafelycontrolledormanagedbytheaircraftselectricalsystem.

AC43.131b:Wheneveranelectricaldeviceisadded,aloadanalysisshouldbeperformedto ensurethatthenewloadonthebuscanbepoweredadequatelysuchthatthereisadequate electricalpowermargintoavoidoverloadingthebus. Wherenecessaryasdeterminedbyaloadanalysis,wire,wirebundles,andcircuitprotective deviceshavingthecorrectratingsshouldbeaddedorreplaced. [Endspeakernotes]

Slide37:CircuitBreakerDevices
Mustbesizedtoopenbeforecurrentratingofattachedwireisexceeded,orbefore cumulativeratingofallconnectedloadsisexceeded,whicheverislower(25.1357) [Speakernotes] Section25.1357requiresthatautomaticprotectivedevicesbeusedtominimizedistresstothe electricalsystemandminimizehazardtotheairplaneintheeventofwiringfaultsorserious malfunctionofthesystemorconnectedequipment. [Endspeakernotes]

Slide38:CircuitBreakerProtection
Acircuitbreakermustalwaysopenbeforeanycomponentdownstreamcanoverheat andgeneratesmoke orfire.(AC43.131b,para.1148) Circuitbreakersaredesignedascircuitprotectionforthewire,not forprotectionofblackboxesorcomponents...(AC43.131b, para.1151)

[Speakernotes] AC43.131bcontainssomeconflictingstatements.Thebulletsinthisslidearesomewhat contradictory.Thefirstbulletsaysthatthebreakermustprotectagainstanydownstream componentfailure.ThesecondbulletsaysbreakersaredesignedsuchthattheyDONOT protectcomponentsorLRUs. Inreality,breakersaresizedtoprotecttheaircraftwiringasthemaindesignconstraint.Any furtherprotectionofcomponentsorLRUsisdesirablebutnotmandatory. Ideally,circuitbreakersshouldprotectagainstanywiringfaultthatleadstoarcing,sparking, flames,orsmoke.Butaswewilllearn,thermalcircuitbreakersdonotalwaysdetectarcing events. [Endspeakernotes] Slide39:CircuitBreakerProtection,cont. Useofacircuitbreakerasaswitchisnotrecommended o Repeatedopeningandclosingofcontactscanleadtodamageandpremature failureofcircuitbreakers

o Mostcircuitbreakerfailures arelatent [Speakernotes] Mostcircuitbreakers,otherthansomeremotecontrolcircuitbreakers(RCCB),arenot designedasswitchesandshouldnotbeusedasaswitch.Repeatedopeningandclosingofthe contactscanleadtodamageandprematurefailureofthecircuitbreakers.Alsokeepinmind thatcircuitbreakerfailuresare,forthemostpart,latentinnature.Soyouwontknowthey havefaileduntilyouneedthem. [Endspeakernotes]

Slide40:WireSelection
Sizewiressothey: o Havesufficientmechanicalstrength o Donotexceedallowablevoltagedroplevels o Areprotectedbycircuitprotectiondevices o Meetcircuitcurrentcarryingrequirements

[Speakernotes] Section25.1357requiresthatautomaticprotectivedevicesbeusedtominimizedistresstothe electricalsystemandminimizehazardtotheairplaneintheeventofwiringfaultsorserious malfunctionofthesystemorconnectedequipment. [Endspeakernotes]

Slide41:WireSelection,cont.
Mechanicalstrengthofwiresizeslessthan#20 o Donotusewirewithlessthan19strands o Provideadditionalsupportatterminations o Shouldnotbeusedwhensubjecttoexcessivevibration,repeatedbending,or frequentdisconnection

(ref.para.1166(a),page1121) [Speakernotes] Wirecontaininglessthan19conductorstrandsmustnotbeused. Considerationshouldbegiventotheuseofhighstrengthalloyconductorsinsmallgaugewires toincreasemechanicalstrength. Asageneralpractice,wiressmallerthan#20shouldbeprovidedwithadditionalclampsandbe groupedwithatleastthreeotherwires. Theyalsoshouldhaveadditionalsupportatterminations,suchasconnectorgrommets,strain reliefclamps,shrinkablesleeving,ortelescopingbushings.

Theyshouldnotbeusedinapplicationswheretheywillbesubjectedtoexcessivevibration, repeatedbending,orfrequentdisconnectionfromscrewtermination. [Endspeakernotes]

Slide42:WireSelection,cont.
Conductorstranding o Minimizesfatiguebreakage Platingsforallcopperaircraftwiring o Platedbecausebarecopperdevelops surfaceoxidefilmapoorconductor Tin<150C Silver<200C Nickel<260C

[Speakernotes] Elevatedtemperaturedegradationoftinandsilverplatedcopperconductorswilloccurifthey areexposedtocontinuousoperationatelevatedlevels. Fortinplatedconductors,tincopperintermetallicswillform,resultinginan increaseinconductorresistance. Forsilverplatedconductors,degradationintheformofinterstrandbonding, silvermigration,andoxidationofthecopperstrandswilloccurwithcontinuous operationnearratedtemperature,resultinginlossofwireflexibility.Also,due topotentialfirehazard,silverplatedconductorsshallnotbeusedinareaswhere theyaresubjecttocontaminationbyethyleneglycolsolutions. Bothtinandsilverplatedcopperconductorswillexhibitdegradedsolderabilityafterexposure tocontinuouselevatedtemperature. [Endspeakernotes]

Slide43:DeterminingCurrentCarryingCapacity
Effectofheatonwireinsulation o Maximumoperatingtemperature o Singlewireorwiresinaharness o Altitude

[Speakernotes] Heatingisanimportantfactoraffectingwireinsulation.Thismustbefactoredintoproper selectionofwireforeachparticularapplication. [Endspeakernotes]

Slide44:DeterminingWireSystemDesign
AC43.131b,Section5:tablesandfiguresprovideanacceptablemethodofdeterminingwire systemdesign [Speakernotes] Theapplicantshouldensurethatthemaximumambienttemperaturethatthewirebundleswill besubjectedto,plusthetemperatureriseduetothewirecurrentloads,doesnotexceedthe maximumconductortemperaturerating. Insmallerharnesses,theallowablepercentageoftotalcurrentmaybeincreasedastheharness approachesthesinglewireconfiguration. ThecontinuouscurrentratingscontainedinthetablesandfiguresinAC43.131bwerederived onlyforwireapplication,andcannotbeapplieddirectlytoassociatedwireterminationdevices (e.g.,connectorcontacts,relays,circuitbreakers,switches).Thecurrentratingsfordevicesare limitedbythedesigncharacteristicsofthedevice.Careshouldbetakentoensurethatthe continuouscurrentvaluechosenforaparticularsystemcircuitshallnotcreatehotspotswithin anycircuitelementwhichcouldleadtoprematurefailure. [Endspeakernotes]

Slide45:WireSubstitutionforRepairsandMaintenance
Whenreplacementwireisrequired,reviewaircraftmaintenancemanualtodetermineif originalaircraftmanufacturer(OAM)hasapprovedanysubstitution o Ifnotapproved,thencontactOAMforanacceptablereplacement

[Speakernotes] MostaircraftEWISdesignsaretospecificationsthatrequiremanufacturerstopassrigorous testingofwiresbeforetheyareapprovedoraddedtoaQualifiedProductsList.Aircraft manufacturerswhomaintaintheirownwirespecificationsexerciseclosecontroloftheir approvedsources.Therefore,itisimportanttoreviewtheaircraftmaintenancemanualor contacttheoriginalaircraftmanufacturer(OAM)whenwiresubstitutionsarenecessary. TheOAMmayhavespecialconcernsregardingshielding,insulation,etc.forcertainwiringon theaircraftthatperformcriticalfunctionsorwiringthatischosenbasedonasetofunique circumstances. [Endspeakernotes]

Slide46:EWISRouting
Eliminatepotentialforchafingagainststructureorothercomponents Positiontoeliminate/minimizeuseashandholdorsupport Minimizeexposuretodamagebymaintenancecrewsorshiftingcargo Avoidbatteryelectrolytesorothercorrosivefluids

[Speakernotes] Ingeneral,EWISshouldberoutedinsuchamannertoensurereliabilityandtoofferprotection fromthepotentialhazardsshowninthisslide. Thenextseveralslidesarepicturesillustratingthesehazards. [Endspeakernotes]

Slide47:EWISRidingonStructure
Powercablesridingonstructurecancausedamagetothepowercables [Graphic] FirstshowsImproperwiringwithwirestouchingbottomofarea.SecondshowsProperwiring withwiresnottouchingbottomofarea. [EndGraphic] [Speakernotes] Exampleofwirechafing. [Endspeakernotes]

Slide48:EWISRidingonOtherEWIS
Wirebundlesthatcrossshouldbesecuredtogethertoavoidchafing. [Graphic] FirstshowsImproperbundleridingoverwires.SecondshowProperbundlewiththebundle securelytiedtotheotherbundle. [EndGraphic] [Speakernotes] Exampleofwirechafing. [Endspeakernotes]

Slide49:EWISRidingonLighteningHoleEdge
Ifthegrommetistooshort,thenthereiswirebundlechafing [Graphic] FirstshowsImpropergrommetdistancewithwiresrestingontheopening.Secondshows Propergrommetdistancewithwiresawayfromthesideoftheopening [EndGraphic] [Speakernotes] Exampleofwirechafing.

[Endspeakernotes]

Slide50:EWISasaHandhold
[Graphic] ShowspersonshandholdingontotheEWISwithinternationalnotsymbolsuperimposed acrossit. [EndGraphic] [Speakernotes] RouteEWISsothatitisnotusedasahandholdorasasupportformaintenancepersonnel. Inaddition,routeEWISsothatitavoids: Damagebypersonnelmovingwithintheaircraft. Damagebystowageorshiftingcargo. Damagebybatteryoracidicfumesorfluids. Abrasioninwheelwellswhereexposedtorocks,ice,mud,etc. Damagefromexternalevents(zonalanalysis/particularrisksanalysisdemands). Harshenvironmentssuchasseverewindandmoistureprone(SWAMP)areas, hightemperatures,orareassusceptibletosignificantfluidorfume concentration. EWISshouldberoutedtopermitfreemovementofshockandvibrationmountedequipment, designedtopreventstrainonwires,junctions,andsupports,and,theEWISinstallationshould permitshiftingofEWISandequipmentnecessarytoperformmaintenancewithintheaircraft. Inaddition,wirelengthsshouldbechosentoallowforatleasttworeterminations. [Endspeakernotes]

Slide51:EWISRouting,cont.
ProtectEWISinwheelwellsandotherexposedareas RouteEWISabovefluidlines,ifpracticable Usedriploopstocontrolfluidsorcondensedmoisture Keepslacktoallowmaintenanceandpreventmechanicalstrain

[Speakernotes] EnsurethatEWIScomponentsareadequatelyprotectedinwheelwellsandotherareaswhere theymaybeexposedtodamagefromimpactofrocks,ice,mud,etc.(IfreroutingofEWISis notpracticable,protectivejacketingmaybeinstalled.)Thistypeofinstallationmustbeheldto aminimum. Wherepractical,routeEWISsandcablesabovefluidlines.Wiresandcablesroutedwithin6 inchesofanyflammableliquid,fuel,oroxygenlineshouldbecloselyclampedandrigidly supported.Aminimumof2inchesmustbemaintainedbetweenwiringandsuchlinesor relatedequipment,exceptwhenthewiringispositivelyclampedtomaintainatleast1/2inch separationorwhenitmustbeconnecteddirectlytothefluidcarryingequipment.

Ensurethatatrapordriploopisprovidedtopreventfluidsorcondensedmoisturefrom runningintoEWISandothercomponents.EWISinstalledinbilgesandotherlocationswhere fluidsmaybetrappedareroutedasfarfromthelowestpointaspossibleorotherwiseprovided withamoistureproofcovering. [Endspeakernotes]

Slide52:EWISAboveFluidLines
Brokenwireshallnotmakecontactwithfluidline [Graphic] Showsbrokenwireexposedendtouchingthefluidline [EndGraphic] [Speakernotes] EWISabovefluidlines.Theclampsshouldbeacompressiontypeandshouldbespacedso that,assumingawirebreak,thebrokenwirewillnotcontacthydrauliclines,oxygenlines, pneumaticlines,orotherequipmentwhosesubsequentfailurecausedbyarcingcouldcause furtherdamage. [Endspeakernotes]

Slide53:Graphic
Wiresimproperlytied,ridingonhydrauliclines,contaminatedwithcausticfluid [Graphic] Showswirestouchinghydrauliclines [EndGraphic] [Speakernotes] Thisexampleshowsanumberofproblems: Wiresinthebundlesarenottiedproperly. Thewirebundleisridinghardonthehydrauliclines. Thewirebundleappearstobecontaminatedwithhydraulicfluidresidue. [Endspeakernotes]

Slide54:YTypeWireBundleBreakouts
[Graphic] Bundleshowingfigure8loopasbundlesplitsintotwobundles.GraphicsaysFigure8loopmay
belocatedbeforeoraftertailofYandHeadofstrapshallnotbelocatedinthisareaortouching anythingtocausechafing

[Endgraphic]

 [Speakernotes] Wirebundlebreakouts.Therearethreebasicwirebundlebreakouttypesusedinrouting aircraftEWIS.TheyarecalledtheY,T,andComplextypes. TheYtypeofbreakoutisusedwhenaportionofEWISfromonedirectionofthewirebundle departsthebundletoberoutedinanotherdirection. Careshouldbetakenwhenplastictiewrapsareusedtoprovidewire containmentatthebreakoutsothatthetiewrapheaddoesnotcausechafing damagetothewirebundleatthebreakoutjunction. [Endspeakernotes]

Slide55:TTypeWireBundleBreakouts
[Graphic] BundleshowsaTtypebundlewithacrisscrosstieatjunctionaroundtheT.Gradphicsays Headofstrapshallnotbelocatedinthisareaortouchinganythingtocausechafingreferringtothe
topofthebundleandthesideoftheTgoingup.

[Endgraphic] [Speakernotes] TheTtypeofbreakout(alsocalled90breakout)isusedwhenportionsofEWISfromboth directionsinthewirebundledepartthebundletoberoutedinanotherdirection. [Endspeakernotes]

Slide56:ComplexTypeWireBundleBreakouts
[Graphic] Showsaterminalblockwiththewireconnections [Endgraphic] [Speakernotes] AComplextypeofbreakoutisgenerallyusedtoroutecertainwiresoutofawirebundletoa terminalstrip,moduleblock,orothertermination. Foralltypesofbreakouts,thereshouldbesufficientslackinthewiresthatarebeingbrokenout ofthebundletoavoidstrainonthewirebetweenthewirebundleandthetermination. [Endspeakernotes]

Slide57:Standoffs
UsestandoffstomaintainclearancebetweenEWISandstructure o Employingtapeortubingisgenerallynotacceptableasanalternative not Exception:WhereimpossibletoinstalloffangleclampstomaintainEWISseparationin Exception: holes,bulkheads,floors,etc.

 [Speakernotes] TheEWISdesignshouldprecludewirebundlesfromcontactingstructure.Standoffsshouldbe usedtomaintainclearancebetweenEWISandstructure. Employingtapeorprotectivetubingasanalternativetostandoffsshouldbeavoidedasa primarymeansofpreventingEWIScontactwithstructure. Exception:Usingtapeortubingisallowedincaseswhereitisimpossibletoinstalloffangle clampstomaintainEWISseparationinholes,bulkheads,floors,etc. [Endspeakernotes]

Slide58:UsingStandoffs
[Graphic] GraphicshowstheImpropermethodwithwiresimmediatelytouchingthebaseafterusinga standoff.Propermethodshowswiresinstandoffnottouchingbase. [Endgraphic] [Speakernotes] Whenusingstandoffsforadditionalclearance,clampsshouldnotbeinstalledinamannerthat defeatsthestandoffspurposeofprovidingadditionalclearancebetweenEWISandstructure. [Endspeakernotes]

Slide59:Bundleridingonstructure
[Graphic] showingbundletouchingaircraftstructure [Endgraphic] [Speakernotes] OneofthemorecommonaircraftEWISproblemsischafingduetowirebundlescominginto contactwithaircraftstructureorotheraircraftequipment. [Endspeakernotes]

Slide60:Graphic
[Graphic] Wirebundletooclosetocontrolcable [Endgraphic] [Speakernotes] Thispictureshowsawirebundlethatisinclosecontactwithacontrolcable.Adequate distancebetweenEWISandcontrolcablesshouldbemaintainedtoaccountformovementdue toslackandmaintenance.

[Endspeakernotes]

Slide61:Clamping
Supportwiresbysuitableclamps,grommets,orotherdevicesatintervalsofnotmore that24inches Supportingdevicesshouldbeofsuitablesizeandtypewithwireand/orcablesheld securelyinplacewithoutdamagetowireorwireinsulation

[Speakernotes] Wiresupportsandintervals.Clampsandotherprimarysupportdevicesshouldbeconstructed ofmaterialsthatarecompatiblewiththeirinstallationandenvironment,intermsof temperature,fluidresistance,exposuretoultravioletlight,andwirebundlemechanicalloads. Generally,clampsshouldnotbespacedatintervalsexceeding24inches.Inhigh vibrationareasorareasrequiringroutingaroundstructuralintrusions,the clampingintervalsmayneedtobereducedinordertoprovideadequate support. [Endspeakernotes]

Slide62:Clamps
Wirebundlesshouldbesnuginclamp(nomovement) o Cablenotabletomoveaxially RFcables:donotcrush Mountclampswithattachmenthardwareontop Tyingnotusedasalternativetoclamping

[Speakernotes] Clampsonwirebundlesshouldnotallowthebundletomovethroughtheclampwhenaslight axialpullisapplied. ClampsonRFcablesmustfitwithoutcrushingandmustbesnugenoughtopreventthecable frommovingfreelythroughtheclamp,butmayallowthecabletoslidethroughtheclamp whenalightaxialpullisapplied.Thecableorwirebundlemaybewrappedwithoneormore turnsoftapeorothermaterialsuitablefortheenvironmentwhenrequiredtoachievethisfit. Plasticclampsorcabletiesmustnotbeusedwheretheirfailurecouldresultin interferencewithmovablecontrols,wirebundlecontactwithmovable equipment,orchafingdamagetoessentialorunprotectedEWIS.Theymustnot beusedonverticalrunswhereinadvertentslackmigrationcouldresultin chafingorotherdamage. Clampsmustbeinstalledwiththeirattachmenthardwarepositionedabove them,whereverpracticable,sothattheyareunlikelytorotateastheresultof wirebundleweightorwirebundlechafing.

Clampslinedwithnonmetallicmaterialshouldbeusedtosupportthewirebundlealongthe run.Tyingmaybeusedbetweenclamps,butshouldnotbeconsideredasasubstitutefor adequateclamping.Adhesivetapesaresubjecttoagedeteriorationand,therefore,arenot acceptableasaclampingmeans. [Endspeakernotes]

Slide63:ExampleofCorrectCableSlack
[Graphic] Showsappropriateslack,lookstobeabouthalfawirethickness [Endgraphic] [Speakernotes] Thisisanexampleofanappropriateamountofcableslackbetweenclamps.Appropriateslack protectsthewiresfromstressandfromcontactwithinappropriatesurfaces. Toomuchcableslackcanallowthecabletocontactstructureorother equipmentwhichcoulddamagethewirebundle. Toolittleslackcancauseapreloadconditiononthecablewhichcouldcause damagetothewirebundleand/orclampsaswell. Also,sufficientslackshouldbeleftbetweenthelastclampandtheterminationorelectrical equipmenttopreventstrainattheterminalandtominimizeadverseeffectsofshockmounted equipment. [Endspeakernotes]

Slide64:ClampDistortion
[Graphic] Showsproperclamppositionwithnodistortionintherubberclamp.Italsoshowsimproper clamppositionwithdistortionoftherubberatthetopofoneclampandbottomofanother clamp. [Endgraphic] [Speakernotes] Asisshowninthetopgraphic,thewirebundlesareroutedperpendiculartotheclamp. Ifwirebundlesarenotroutedperpendiculartotheclamp(bottomgraphic), stresscanbecreatedagainsttheclampandclampgrommetwhichcandistort theclampand/orclampgrommet.Distortedclamps/clampgrommetscancause wirebundledamageovertime. [Endspeakernotes]

Slide65:ClampOrientation
[Graphic] Showsproperclamporientationwiththeclampbeing90degrees,plusorminus5degreesto thewire.Showsimproperclamporientationwiththeclampbeinggreaterorlessthan90 degrees(plusorminus5degrees)tothewire. [Endgraphic] [Speakernotes]Thisslidefurtherillustratescorrectandincorrectclamporientations.Incorrect clamporientationcanleadtowirebundledamage.[Endspeakernotes]

Slide66:ExampleClampDistortion
[Graphic] Showsclampdistortedfromwirebundleandnotbeingperpendiculartowire. [Endgraphic] [Speakernotes] Thisphotographisagoodexampleofclampdistortion.Notethatthewirebundleisnot perpendiculartotheclamp [Endspeakernotes]

Slide67:PlasticSnapinClamp(TieMount)
[Graphic] Showsplasticsnapinclamp(tiemount)attachedunderasupportbracket. [Endgraphic] [Speakernotes] SomeEWISdesignsutilizeplasticsnapinclampssometimesreferredtoastiemounts.These typesofclampsarenotsuitableforlargewirebundlesandshouldnotbeusedinhigh temperatureorhighvibrationareas. Anytypeofplasticclamporcabletieshouldnotbeusedwheretheirfailure couldresultininterferencewithmovablecontrols,wirebundlecontactwith movableequipment,orchafingdamagetoessentialorunprotectedEWIS. [Endspeakernotes]

Slide68:TypicalRubberClamp
[Graphic] Showsclampwitharubbercushion,wedgeandclamptab.Also,showbundleofwiresinclamp onastandoff.ItsaysthatAllwirescontainedintherubbercushionandnopinchingofthe wires. [Endgraphic]

 [Speakernotes] AcommonprobleminaircraftEWISisclamppinching.Thisoccurswhentheclampis improperlyinstalledortheclampistoosmall.Clampsonwirebundlesshouldbeselectedso thattheyhaveasnugfitwithoutpinchingwires. [Endspeakernotes]

Slide69:TypicalNylonClosedFaceClampInstallation
[Graphic] Showsbundleofwiresinclamponastandoff.Itsaysdonotpinchherereferringtothepoint wheretheclampcomestogether. [Endgraphic] [Speakernotes] Itisimportantwhenaddingwiringtoanexistingwirebundletoevaluatetheexistingclamp sizinginordertoavoidpossibleclamppinching.Insomecasesitmaybenecessarytoincrease thesizeoftheclampstoaccommodatethenewwiring. [Endspeakernotes]

Slide70:EngageClampTabinSlot
[Graphic] Showsimproperwhereclamptabshaveaseparationandproperwhereclamptabsandtight andflushtoeachother [Endgraphic] [Speakernotes] Whenusingclamptabs,makesurethatthetabsareproperlyengaged.Otherwise,thetab couldbecomelooseandcausesubsequentwiredamage. DuringEWISinstallationinspections,ensurethattheclampissnappedbefore installingandtighteningthebolt. [Endspeakernotes]

Slide71:ClampPinching
[Graphic] Showsimproperwherethewiresarepinchedatwheretheclampcomestogetherandproper wherethewiresdonotpinchintheclamp. [Endgraphic] [Speakernotes]Thisslidefurtherillustrateshowwirescanbepinchedanddamageddueto improperclampinstallation.[Endspeakernotes]

Slide72:ClampPinching,cont.
[Graphic] Showsimproperwheretherearetwowiresintheclampcausingpinchingandproperwhere therightsizedclampisusedandnotcausinganypinching. [Endgraphic] [Speakernotes] Toomuchwiringinaclamporimproperlyinstalledclampscanleadtopinchingofthewires [Endspeakernotes]

Slide73:Graphic
[Graphic] Openfacednylonclampwithcablebuildup(missinghardware) [Endgraphic] [Speakernotes] ThispicturewastakenduringageneralvisualEWISinspectionofawidebodytransportaircraft. Notethemissingclamphardware.Alsonotethattheblackcableusedatapebuildupatthe clamp.SomemanufacturersEWISspecificationsallowforwirecablebuildupundercertain circumstances. [Endspeakernotes]

Slide74:WireBendRadii
Minimumbendradius10timestheoutsidediameterofthelargestwireorcableinthe groupunsupported o Exceptions Terminations/reversingdirectioninbundle(supportedatbothendsof loop)3timesthediameter RFcables6timesthediameter Thermocouplewire20timesthediameter

[Speakernotes] Theminimumradiusofbendsinwiregroupsorbundlesmustnotbelessthan10timesthe outsidediameterofthelargestwireorcable,exceptthatattheterminalstripswherewires breakoutatterminationsorreversedirectioninabundle. Wherethewireissuitablysupported,theradiusmaybe3timesthediameterofthewireor cable. Whereitisnotpracticaltoinstallwiringorcableswithintheradiusrequirements,thebend shouldbeenclosedininsulatingtubing.

Theradiusforthermocouplewireis20timesthediameter.(Thisisverydelicatewire.) EnsurethatRFcables,(forexample,coaxialandtriaxial,arebentataradiusofnolessthan6 timestheoutsidediameterofthecable. [Endspeakernotes]

Slide75:MinimumBendRadii
[Graphic] Wirebundleillustrating Nosupportatendofbend o Min.bendradius10xparameterofwireorcable Supportatendofbend o Min.bendradius3xdiameterofwire Ttypebend o Min.bendradius3xdiameterofwire [Endgraphic] [Speakernotes] Thisillustrationshowstheproperbendradiiforthreedifferentscenarios. [Endspeakernotes]

Slide76:Graphic
[Graphic] BendradiiokayGreaterthan3timesdiameter(securedatbothendsofloop) [Endgraphic] [Speakernotes] Thisphotographshowsawireloopsecuredatbothendsoftheloop.Inthiscase,thebend radiusshouldbenolessthan3timesthediameterofthelargestwireinthewirebundle. [Endspeakernotes]

Slide77:Graphic
[Graphic] BendradiiproblemLessthan3timesthediameter [Endgraphic] [Speakernotes] Alsosupportedateachendoftheloop,thiswirebundledoesnotmeetbendradiusstandards duetothelargewiresinthebundle. [Endspeakernotes]

Slide78:UnusedWires
Secured o Tiedintoabundleorsecuredtoapermanentstructure Individuallycutwithstrandsevenwithinsulation Preinsulated,closedendconnectoror1inchpieceofinsulatingtubingfoldedandtied back

[Speakernotes] Ensurethatunusedwiresareindividuallydeadended,tiedintoabundle,andsecuredtoa permanentstructure. Eachwireshouldhavestrandscutevenwiththeinsulationandapreinsulated closedendconnectorora1inchpieceofinsulatingtubingplacedoverthewire withitsendfoldedbackandtied. [Endspeakernotes]

Slide79:SpareConnectorContact:PreparingSingleContact
[Graphic] Showswireandcontactintube.Thetubeistobe3timesthelengthofthecontact. [Endgraphic] [Speakernotes] Thisslideandthenexttwodepictanacceptablemethodofinsulatingandphysicallysecuringa spareconnectorcontactwithinawirebundle. [Endspeakernotes]

Slide80:SpareConnectorContact:FoldingTubeandTyingSingleContact
[Graphic] Showstyingtapebehindwireandcontactmeetwith.75inch,plusorminus.15inch,oftubing tofold [Endgraphic]

Slide81:SpareConnectorContact:SingleContactAttachmenttoWire Bundle
[Graphic] Showswire,fromabove,beingattachedtobundlewithonetyingtapewrappedaroundbundle andendoftubeonwireandanothertyingtapewrappedaroundwireandbundlebeforetube onwire. [Endgraphic]

Slide82:SpareWireTerminationUsingEndcap
[Graphic] Showing Wireandcapinpositionforcaptoslideoverwire Installendcapoverwireendandshrinkinplace Bundleusingadhesiveandfiberglasstyingtape [Endgraphic] [Speakernotes] Installingprefabricatedendcapsareaneffectivemethodofprotectingunusedwireswith exposedconductors. Thisslidedepictsatypicalexampleoftheuseofaprefabricatedendcap. [Endspeakernotes] Slide83:UnusedWires [Graphic] UnusedwiringImproperterminationwithexposedconductor(shouldbeproperlyinsulated andsecuredtobundle) [Endgraphic] [Speakernotes] FoundduringageneralEWISvisualinspection,thisexampleshowstwounusedwiresthathave beencutandtheconductorsareunprotected.Inaddition,theunusedwiresarenotsecuredto thewirebundle. [Endspeakernotes]

Slide84:CoilandStowMethods
Coilandstowshortwirebundlesinlowvibrationareas
[Graphic]

wirebundlecoiledinaloopwithaclampandwiretiestoholdittogether
[Endgraphic] [Speakernotes] Coilandstowmethodsareoftenusedtosecureexcesslengthofawirebundleortosecure wirebundlesthatarenotconnectedtoanyequipment,suchaswiringprovisioningforafuture installation. [Endspeakernotes] Slide85:CoilandStowMethods,cont. Coilandstowlongwirebundlesinlowvibrationareas

[Graphic]

excesswireloopedbackandforthtoremovetheexcess.Useswiretiesandclamp tobundletogether
[Endgraphic] [Speakernotes] Thekeyobjectivetocoilingandstowingwiringistosafelysecurethewirebundletoprevent excessivemovementorcontactwithotherequipmentthatcoulddamagetheEWIS. [Endspeakernotes]

Slide86:CoilandStowMethods,cont.
Coilandstowinmediumandhighvibrationareas
[Graphic]

wirebundle,witharadiusbetweentwobundles,tiedtoawirebundleatthetop andbottomusingTeflontape
[Endgraphic] [Speakernotes] Coilandstowinmediumandhighvibrationareasrequiresadditionaltiestraps,sleeving,and support. [Endspeakernotes]

Slide87:StowingUnusedWires
[Graphic]

Impropermethodwithbundletiedtoasinglewireaboveit.Propermethodwith bundletiedandnottiedtoanythingelse
[Endgraphic] [Speakernotes] Thesephotosshowimproperandproperstowingofunusedwires. [Endspeakernotes]

Slide88:EWISReplacement
EWIScomponentsshouldbereplacedwhen: o Chafedorfrayed o Insulationsuspectedofbeingpenetrated o Outerinsulationiscracking o Damagedbyorknowntohavebeenexposedtoelectrolyte,oil,hydraulic fluid,etc.

o Evidenceofoverheatingcanbeseen [Speakernotes] EWISneedstobereplacedunderanumberofcircumstances: Wiringthathasbeensubjectedtochafingorfraying,thathasbeendamaged,or thatprimaryinsulationissuspectedofbeingpenetrated. Wiringonwhichtheouterinsulationisbrittlewhenslightflexingcausesitto crack. Wiringthathasweathercrackedouterinsulation.NOTE:somewireinsulation typesappearstobewrinkledwhenthewireisbentandmaynotbedamaged. Wiringthatisknowntohavebeenexposedtoelectrolyteoronwhichthe insulationappearstobe,orissuspectedofbeing,inaninitialstageof deteriorationduetotheeffectsofelectrolyte. Thereisvisibleevidenceofinsulationdamageduetooverheating. [Endspeakernotes]

Slide89:HeatDiscoloration
[Speakernotes] Thisphotographshowsanexampleofheatdiscolorationonprotectivesleevingwhichispartof thewirebundle.Thelargeclampwasmovedtoseethedifferenceincolor.Inthiscase,the wiringthatisnotcoveredinsleevingshowsnosignsofheatdistress.Anadjacentlightbulb wasradiatingenoughheattocausediscolorationovertimetotheprotectivesleeving. Althoughthisconditionisnotideal,itisacceptable. [Endspeakernotes]

Slide90:WireReplacement
Wireshouldbereplacedwhen: o Wirebearsevidenceofbeingcrushedorkinked o Shieldonshieldedwireiffrayedand/orcorroded o Wireshowsevidenceofbreaks,cracks,dirt,ormoistureinplasticsleeving o Sectionsofwirehavesplicesoccurringatlessthan10ftintervals

[Speakernotes] Continuing,theseareadditionalcircumstancesthatwarrantreplacingEWIS: EWISthatbearsevidenceofhavingbeencrushedorseverelykinked. ShieldedEWISonwhichthemetallicshieldisfrayedand/orcorroded.Cleaning agents(whichcancausewiredamage)orpreservativesshouldnotbeusedto minimizetheeffectsofcorrosionordeteriorationofwireshields.

EWISshowingevidenceofbreaks,cracks,dirt,ormoistureintheplasticsleeves placedoverwiresplicesorterminallugs. Sectionsofwireinwhichsplicesoccuratlessthan10footintervals,unless specificallyauthorized,duetoparallelconnections,locations,orinaccessibility. [Endspeakernotes]

Slide91:WireReplacement,cont.
Shieldingrequirements o Replacementwiresmusthavethesameshieldingcharacteristicsastheoriginal wire,suchasshieldopticalcoverageandresistanceperunitlength o Replacementwiresshouldnotbeinstalledoutsidethebundleshield

[Speakernotes] Replacementwiresshouldhavethesameshieldingcharacteristicsastheoriginalwires,suchas shieldopticalcoverageandresistanceperunitlength. Ifanywiresaregoingtobereplacedinsideashieldedwirebundle,thereplacementwires shouldnotbeinstalledoutsidethebundleshield. Formoreinformationonshielding,theLightning/HIRFVideoandSelfstudyGuideisavailable. (Toobtain,seeyourDirectoratetrainingmanager.) [Endspeakernotes]

Slide92:AddingorReplacingWiresonaBundle
[Graphic]

Improperprocedurewithloosewiresnottieddownbetweenclamps.Proper procedurewithallwirestiedtothebundlebetweenclamps.
[Endgraphic] [Speakernotes] Whenaddingorreplacingwiresonorinawirebundle,thereplacementoraddedwireshould beroutedinthesamemannerastheotherwiresinthewirebundle. Wirebundleclampsand/ortiesmayneedtobeloosenedorremovedinorderto properlyaddorreplacewires. Whenthenewwireisinstalled,thetiesandclampsshouldbeopenedoneata timetoavoidexcessivedisassemblyofthewirebundles. [Endspeakernotes]

Slide93:AddingWiresonaBundle
[Graphic]

FirstimageshowsImproperlyroutedoutsideofthetiewrapthatsecuresthe clampandthesecondimageshowwiringroutedcorrectly
[Endgraphic]

[Speakernotes] Properandimproperlyroutedwiresinabundle [Endspeakernotes]

Slide94:WireSplicing
Keeptoaminimum Avoidinhighvibrationareas Locatetopermitinspection Staggerinbundlestominimizeincreaseinbundlesize Useselfinsulatedspliceconnector,ifpossible

[Speakernotes] SplicingispermittedonEWISaslongasitdoesnotaffectthereliabilityandtheelectro mechanicalcharacteristicsoftheEWIS.Splicingofpowerwires,coaxialcables,multiplexbus, andlargegaugewireshouldbeavoided.Ifitcantbeavoided,thenthepowerwiresplicing musthaveapproveddata. Splicingofelectricalwireshouldbekepttoaminimumandavoidedentirelyin locationssubjecttoextremevibrations.Splicingofindividualwiresinagroupor bundleshouldhaveengineeringapprovalandthesplice(s)shouldbelocatedto allowperiodicinspection. Manytypesofaircraftspliceconnectorsareavailableforusewhensplicingindividualwires. Useofaselfinsulatedspliceconnectorispreferred;however,anoninsulated spliceconnectormaybeusedprovidedthespliceiscoveredwithplasticsleeving thatissecuredatbothends. EnvironmentallysealedsplicesthatconformtoMILT7928provideareliable meansofsplicinginSWAMPareas.However,anoninsulatedspliceconnector maybeused,providedthespliceiscoveredwithdualwallshrinksleevingofa suitablematerial. [Endspeakernotes]

Slide95:StaggeredSplices
[Graphic]

Imageshowsasmallsectionwith4splicesandthewiretieplacedsothattwo splicesareononesideandtwoontheother
[Endgraphic] [Speakernotes] Splicesinbundlesshouldbestaggeredsoastominimizeanyincreaseinthesizeofthebundle thatwould: Preventbundlefromfittingintodesignatedspace. Causecongestionadverselyaffectingmaintenance.

 Causestressonthewires. [Endspeakernotes]

Slide96:Graphic
[Graphic]

Overheatedwireatthesplice [Endgraphic] [Speakernotes] Splicesthatarenotcrimpedproperly(underorover)cancauseincreasedresistanceleadingto overheatconditions. [Endspeakernotes]

Slide97:Graphic
[Graphic]

Gangedwiresplices [Endgraphic] [Speakernotes] Ifsplicesarenotstaggered,properstrainreliefshouldbeprovidedinordertoavoidstresson thewires.Inthisparticularinstallation,strainreliefwasappliedtoavoidstressonthewires. [Endspeakernotes]

Slide98:Graphic
[Graphic]

Gangedwiresplices,9spliceswith7spliceswithslackand2splicesthataretauntbetweenthe clamps. [Endgraphic] [Speakernotes] Thetoptwowiresinthisphotoareexperiencingstressduetoapreloadcondition.Alsonote thatthewirebundleisnotproperlyclamped [Endspeakernotes]

Slide99:Terminals
Tensilestrengthofthewiretoterminaljointshouldbeatleasttheequivalenttensile strengthofthewire Resistanceofthewiretoterminaljointshouldbenegligiblerelativetothenormal resistanceofthewire

 [Speakernotes] Tensilestrengthterminalsareattachedtotheendsofelectricalwirestofacilitateconnectionof thewirestoterminalstripsoritemsofequipment.Thetensilestrengthofthewiretoterminal jointshouldbeatleastequivalenttothetensilestrengthofthewireitself. Resistanceofwiretoterminaljointshouldbenegligible,relativetothenormalresistanceof thewire. Selectionofwireterminals.Thefollowingshouldbeconsideredintheselection ofwireterminals. Currentrating. Wiresize(gauge)andinsulationdiameter. Conductormaterialcompatibility. Studsize. Insulationmaterialcompatibility. Applicationenvironment. Solder/solderless. [Endspeakernotes]

Slide100:BendingofStraightCopperTerminals
[Graphic] Firstimageshowscopperterminalendbent90degreesmaxtotheleftorright.Secondimage showsterminalendbentupordown30degreesmax.Thirdimageshowscopperterminalbent upordown45degreesmax.Fourthimageshowsabrazedjointwithamax30degreeandthe tongueshouldbeevenwiththeendoftheterminal. [Endgraphic] [Speakernotes] Ifbendingofaterminalisnecessary,careshouldbetakentoavoidoverbendingtheterminal whichcancausedamagetotheterminal.Also,aterminalcanonlybebentoncesinceany additionalbendingcancausedamage. Preinsulatedcrimptyperingtongueterminalsarepreferred.Thestrength,size,and supportingmeansofstudsandbindingposts,aswellasthewiresize,shouldbeconsidered whendeterminingthenumberofterminalstobeattachedtoanyonepost. Inhightemperatureapplications,theterminaltemperatureratingmustbegreaterthanthe ambienttemperaturepluscurrentrelatedtemperaturerise.Useofnickelplatedterminalsand ofuninsulatedterminalswithhightemperatureinsulatingsleevesshouldbeconsidered. Terminalblocksshouldbeprovidedwithadequateelectricalclearanceorinsulationstrips betweenmountinghardwareandconductiveparts. Terminalsaresensitivetobendingatthejunctionbetweentheterminalringandtheterminal crimpbarrel.Bendingtheterminalmorethanonceorexceedingpredeterminedterminal bendlimitswillusuallyresultinmechanicalweakeningordamagetotheterminal.

ThisslideisanexampleoflimitsestablishedbytheOAMwithregardtobendingtheterminal priortoinstallation. [Endspeakernotes]

Slide101:TerminalStrips
Barrierstopreventadjacentstudsfromcontactingeachother Currentshouldbecarriedbyterminalcontactsurfaceandnotbystud Studsanchoredagainstrotation Replacedefectivestudswithstudsofsamesizeandmaterial,mountsecurely,tighten terminalsecuringnut

[Speakernotes] Wiresareusuallyjoinedatterminalstrips.Aterminalstripfittedwithbarriersshouldbeused topreventtheterminalsonadjacentstudsfromcontactingeachother. Studsshouldbeanchoredagainstrotation.Whenmorethanfourterminalsare tobeconnectedtogether,asmallmetalbusshouldbemountedacrosstwoor moreadjacentstuds.Inallcases,thecurrentshouldbecarriedbytheterminal contactsurfacesandnotbythestuditself. Defectivestudsshouldbereplacedwithstudsofthesamesizeandmaterial sinceterminalstripstudsofthesmallersizesmayshearduetoovertightening thenut.Thereplacementstudshouldbesecurelymountedintheterminalstrip andtheterminalsecuringnutshouldbetight. [Endspeakernotes]

Slide102:TerminalStrips,cont.
Mountstripssoloosemetallicobjectscannotfallacrossterminal Providesparestudforbreaksandfutureexpansion Inspectterminalperiodicallyforlooseconnections,metallicobjects,dirt,andgrease accumulation Cancausearcing,resultinginfireorsystemsfailure [Speakernotes] [Endspeakernotes]

Slide103:Terminalsoncircuitbreakers
[Graphic] terminalwiresconnectedtocircuitbreakerswithseparatescrews [Endgraphic]

 [Speakernotes] Connectorsandterminalsinaircraftrequirespecialattentiontoensureasafeandsatisfactory installation.Everypossibilityofterminalsnotbeingtorquedproperly,duetomisinstallation, poormaintenance,andservicelife,shouldbeaddressedinthedesign. Electricalequipmentmalfunctionhasfrequentlybeentracedtopoorterminal connectionsatterminalboards. Loosecontactsurfacescanproducelocalizedheatingthatmayignitenearby combustiblematerialsoroverheatadjacentwireinsulation. Notethegreentorquestripespaintedontheterminalfastenersinthispicture.Thisisan excellentmethodtoquicklydetermineifaterminalfastenerisstilltorquedtoitsoriginalvalue. [Endspeakernotes]

Slide104:Graphic
[Graphic] Powerfeederterminals [Endgraphic] [Speakernotes] Again,youcanseetheredcoloredtorquestripesappliedtothesehighcurrentpowerfeeder terminations.Highcurrentterminalsaremoresensitivetoincreasedresistanceduetoa improperlytorquedterminal. Asasidenote,thepowerfeedercablesshouldnotbetouchingeachother withoutbeingsuitablytiedwithspacersorothersecuringdevice. [Endspeakernotes]

Slide105:TerminalLugs
Connectwiringtoterminalblockstuds Nomorethan4lugs,or3lugsand abusbar,perstud Lugholesizeshouldmatchstuddiameter o Greatestdiameteronbottom, smallestontop o Tighteningterminalconnections shouldnotdeformlugs

[Speakernotes]

Wireterminallugsshouldbeusedtoconnectwiringtoterminalblockstudsorequipment terminalstuds.Nomorethanfourterminallugsorthreeterminallugsandabusshouldbe connectedtoanyonestud. Totalnumberofterminallugsperstudincludesacommonbusbarjoining adjacentstuds.Fourterminallugsplusacommonbusbarthusarenot permittedononestud. Terminallugsshouldbeselectedwithastudholediameterthatmatchesthediameterofthe stud.However,whentheterminallugsattachedtoastudvaryindiameter,thegreatest diametershouldbeplacedonthebottomandthesmallestdiameterontop. Tighteningterminalconnectionsshouldnotdeformtheterminallugsorthestuds.Terminal lugsshouldbesopositionedthatbendingoftheterminallugisnotrequiredtoremovethe fasteningscrewornut,andmovementoftheterminallugswilltendtotightentheconnection. [Endspeakernotes]

Slide106:TerminalLugs,cont.
Aluminumlugs o Crimpedtoaluminumwireonly Specialattentionneededtoguardagainstexcessivevoltagedropat terminaljunction Inadequateterminalcontactarea Stackingerrors Impropertorquing o Usecalibratedcrimptools

[Speakernotes] Aluminumterminallugsshouldbecrimpedtoaluminumwireonly. Thetongueofthealuminumterminallugsorthetotalnumberoftonguesofaluminumterminal lugswhenstacked,shouldbesandwichedbetweentwoflatwashers(cadmiumplated)when terminatedonterminalstuds.Spacersorwashersshouldnotbeusedbetweenthetonguesof likematerialterminallugs. Specialattentionshouldbegiventoaluminumwireandcableinstallationstoguardagainst conditionsthatwouldresultinexcessivevoltagedropandhighresistanceatjunctionsthatmay ultimatelyleadtofailureofthejunction. Examplesofsuchconditionsareimproperinstallationofterminalsandwashers, impropertorsion(torquingofnuts),andinadequateterminalcontactareas. Notethataluminumwireisnormallyusedinsizesof10gaugeandlargertocarryelectrical powerinlargetransportcategoryaircraftinordertosaveweight.Althoughnotasgooda conductorascopper,aluminumislighterwhencomparedtocopperandtheweightsavingscan besignificantforalargeaircraftthatmayhaveseveralhundredfeetofpowerfeedercable. Becausealuminumisusedprimarilyforhighcurrentpowerapplications,theterminaljunctions aremoresensitivetoconditionsleadingtoincreasedjunctionresistancewhichcancausearcing andlocalizedheatdistress.

[Endspeakernotes]

Slide107:TerminalStacking(likematerials)
[Graphic] ExplodediagramofTerminalstacking.Frombottomtotop:terminalstud,copperterminallugs, flatwasher,lockwasherandnut. [Endgraphic] [Speakernotes] Terminalstackingmaterialsandmethods Multiplewiresoftenterminateontoasingleterminalstud.Careshouldbetaken toinstalltheterminalproperly.Thematerialsthattheterminalsareconstructed ofwillimpactthetypeofstackingmethodsused.Dissimilarmetals,whenin contact,canproduceelectrolysisthatcancausecorrosion,thusdegradingthe terminaljunctionresistanceandcausingarcingorhotspots. Forstackingterminalsthataremadeoflikematerials,theterminalscanbe stackeddirectlyontopofeachother. [Endspeakernotes] Slide108:TerminalStacking(unlikematerials) [Graphic] ExplodediagramofTerminalstacking.Frombottomtotop:terminalstud,flatwasher, aluminumterminal,flatwasher,copperterminal,flatwasher,aluminumterminal,flatwasher, lockwasherandnut [Endgraphic] [Speakernotes] Whenstackingunlikematerialstogether(forexample,aluminumandcopper),acadmium platedflatwasherisusuallyneededtoisolatethedissimilarmetals. [Endspeakernotes]

Slide109:TerminalStackingMethods
[Graphic] Explodediagramof"onesidedentrywithtwoterminals.".Frombottomtotop:terminalstud, crimpbarrel(bellydown),crimpbarrel(bellyup),flatwasher,lockwasherandnut [Endgraphic] [Speakernotes] Whentwoterminalsareinstalledononesideoftheterminalstrip,careshouldbetakento ensurethattheterminalcrimpbarrelsdonotinterferewithoneanother.Onemethodtoavoid thisproblemistoinstalltheterminalswiththebarrelsbacktoback.

[Endspeakernotes]

Slide110:TerminalStackingMethods,cont.
[Graphic] Explodediagramof"onesidedentrywith3terminals."Frombottomtotop:terminalstud, crimpbarrel(bellydown)in"V"split,crimpbarrel(bellydown)in"V"split,crimpbarrel(belly up))incenterof"V"split,flatwasher,lockwasherandnut [Endgraphic] [Speakernotes] Thisillustrationdepictsaterminalinstallationwiththreeterminalsenteringononeside. [Endspeakernotes]

Slide111:TerminalStackingMethods,cont.
[Graphic] Explodediagramof"onesidedentrywith4terminals"..Frombottomtotop:terminalstud, crimpbarrel(bellydown)in"V"split,crimpbarrel(bellydown)in"V"split,crimpbarrel(belly up))incenterof"V"split,crimpbarrel(bellyup))incenterof"V"split,flatwasher,lock washerandnut [Endgraphic] [Speakernotes] Thisillustrationdepictsaterminalinstallationwithfourterminalsenteringononeside. Thestackingmethodusedtoconnectterminalstoterminalstripsshouldcausenointerference betweenterminalsthatcouldcompromisetheintegrityoftheterminaljunction. [Endspeakernotes]

Slide112:TerminalTighteningHardware
[Graphic] Impropertightening:terminalstud,flatwasher,terminals,flatwasher,lockwashernot compressed,space,andnut.Propertightening:terminalstud,flatwasher,terminals,flat washer,lockwashercompressed,andnut. [Endgraphic] [Speakernotes] Servicehistoryhasshownthathardwarestackupatterminalsispronetohumanerror. Omissionoflockwashers,incorrectwashers,impropersizingofwashers,etc.hasbeena definiteproblem.

Itisimportanttousethecorrecttighteninghardwareandinstallitcorrectlyforagiven installation.Thisillustrationshowsatypicalflatwasher/lockwasher/nutinstallation.Itis importanttoensurethelockingwasherisfullycompressedandisadjacenttothenut. Aftertheterminaliscompletelyassembled,thereshouldbeaminimumoftwotothree threadsshowingonthestudwhenthenutisproperlytorqued. [Endspeakernotes]

Slide113:WasherSizeSelection
[Graphic] Impropersizeshowswasherraisedonportionofterminal.Propersizeshowswasherswithout anyraisedportionsonterminalandallthewashersarethesamesize. [Endgraphic] [Speakernotes] Itisimportanttoselectandusethecorrectsizewashersinanytermination.Undersizedor oversizedwasherscanleadtoincreasedjunctionresistanceandlocalizedheatorarcing. Thisillustrationshowshowanimproperlysizedwashercanleadtoinsufficientcontactbetween theterminalandterminallug. [Endspeakernotes]

Slide114:LockWashers
[Speakernotes] Inthisphotograph,thelockwasherismissingfromtheterminalontheleft. [Endspeakernotes]

Slide115:Grounding:Definition
Groundingistheprocessofelectricallyconnectingconductiveobjectstoeitheraconductive structureorsomeotherconductivereturnpathforthepurposeofsafelycompletingeithera normalorfaultcircuit. [Speakernotes] Grounding.Oneofthemoreimportantfactorsinthedesignandmaintenanceofaircraft electricalsystemsisproperbondingandgrounding.Inadequatebondingorgroundingcanlead tounreliableoperationofsystems,suchasEMI,electrostaticdischargedamagetosensitive electronics,personnelshockhazard,ordamagefromlightningstrike. [Endspeakernotes]

Slide116:Grounding
Typesofgrounding o ACreturns o DCreturns o Others Avoidmixingreturncurrentsfromvarioussources o Noisewillbecoupledfromonesourcetoanotherandcanbeamajorproblem fordigitalsystems

[Speakernotes] Groundingtypes:ACreturns,DCreturns,andothers. Mixingreturncurrents.Ifwirescarryingreturncurrentsfromdifferenttypesofsources,such assignalsorDCandACgenerators,areconnectedtothesamegroundpointorhavea commonconnectioninthereturnpaths,aninteractionofthecurrentswilloccur.This interactionmaynotbeaproblem,oritcouldbeamajornonrepeatableanomaly. Tominimizetheinteractionbetweenvariousreturncurrents,differenttypesof groundsshouldbeidentifiedandused.Asaminimum,thedesignshoulduse threegroundtypes:(1)ACreturns,(2)DCreturns,and(3)allothers. Fordistributedpowersystems,thepowerreturnpointforanalternative powersourcewouldbeseparated. Forexample,inatwoACgeneratorsystem(oneontherightsideand theotherontheleftside),iftherightACgeneratorweresupplying backuppowertoequipmentlocatedintheleftside,(leftequipment rack)thebackupACgroundreturnshouldbelabeledACRight.The returncurrentsfortheleftgeneratorshouldbeconnectedtoaground pointlabeledACLeft. [Endspeakernotes]

Slide117:Grounding,cont.
Designofgroundpathshouldbegivenasmuchattentionasotherleadsinthesystem Groundingshouldprovideaconstantimpedance Groundequipmentitemsexternallyevenwheninternallygrounded o Avoiddirectconnectionstomagnesiumstructureforgroundreturn

[Speakernotes] Designofgroundpaths.Thedesignofthegroundreturncircuitshouldbegivenasmuch attentionastheotherleadsofacircuit. Constantimpedance.Arequirementforpropergroundconnectionsisthattheymaintainan impedancethatisessentiallyconstant. Groundreturncircuitsshouldhaveacurrentratingandvoltagedropadequate forsatisfactoryoperationoftheconnectedelectricalandelectronicequipment.

EMIproblems,thatcanbecausedbyasystemspowerwire,canbereduced substantiallybylocatingtheassociatedgroundreturnneartheoriginofthe powerwiring(e.g.,circuitbreakerpanel)androutingthepowerwireandits groundreturninatwistedpair. Specialcareshouldbeexercisedtoensurereplacementongroundreturnleads. Theuseofnumberedinsulatedwireleadsinsteadofbaregroundingjumpers mayaidinthisrespect. Externalgroundingofequipmentitems.Ingeneral,equipmentitemsshouldhaveanexternal groundconnection,evenwheninternallygrounded.Directconnectionstoamagnesium structure(whichmaycreateafirehazard)mustnotbeusedforgroundreturn. [Endspeakernotes] Slide118:Grounding,cont. Heavycurrentgrounds o Attachtoindividualgroundingbracketsattachedtoaircraftstructurewitha propermetaltometalbond o Accommodatenormalandfaultcurrentsofsystemwithoutcreatingexcessive voltagedropordamagetostructure o Givespecialattentiontocompositeaircraft [Speakernotes] Heavycurrentgrounds.Powergroundconnectionsforgenerators,transformerrectifiers, batteries,externalpowerreceptacles,andotherheavycurrentloadsmustbeattachedto individualgroundingbracketsthatareattachedtoaircraftstructurewithapropermetalto metalbondingattachment. Thisattachmentandthesurroundingstructuremustprovideadequate conductivitytoaccommodatenormalandfaultcurrentsofthesystemwithout creatingexcessivevoltagedropordamagetothestructure. Atleastthreefasteners,locatedinatriangularorrectangularpattern,mustbe usedtosecuresuchbracketsinordertominimizesusceptibilitytoloosening undervibration. Ifthestructureisfabricatedofamaterialsuchascarbonfibercomposite(CFC), whichhasahigherresistivitythanaluminumorcopper,itwillbenecessaryto provideanalternativegroundpath(s)forpowerreturncurrent. [Endspeakernotes]

Slide119:Bonding
Equipmentbonding o Lowimpedancepathstoaircraftstructurerequiredforelectronicequipmentto provideradiofrequencyreturncircuits o FacilitatesreductioninEMIformostelectricalequipment

CasesofcomponentsthatproduceEMIshouldbegroundedtostructure

[Speakernotes] Equipmentbonding.Lowimpedancepathstoaircraftstructurearenormallyrequiredfor electronicequipmenttoprovideradiofrequencyreturncircuitsandformostelectrical equipmenttofacilitatereductioninEMI.Thecasesofcomponentsthatproduce electromagneticenergyshouldbegroundedtostructure. Toensureproperoperationofelectronicequipment,itisparticularlyimportant toconformthesystemsinstallationspecificationwheninterconnections, bonding,andgroundingarebeingaccomplished. [Endspeakernotes]

Slide120:Bonding,cont.
Metallicsurfacebonding o Electricallyconnectingconductiveexteriorairframecomponentsthrough mechanicaljoints,conductivehinges,orbondstraps Protectsagainststaticchargesandlightningstrikes

[Speakernotes] Metallicsurfacebonding.Allconductingobjectsontheexterioroftheairframemustbe electricallyconnectedtotheairframethroughmechanicaljoints,conductivehinges,orbond strapscapableofconductingstaticchargesandlightningstrikes. Exceptionsmaybenecessaryforsomeobjectssuchasantennaelements,whose functionrequiresthemtobeelectricallyisolatedfromtheairframe.Suchitems shouldbeprovidedwithanalternativemeanstoconductstaticchargesand/or lightningcurrents,asappropriate. [Endspeakernotes] Slide121:Bonding,cont. Staticbonds o Requiredforallisolatedconductingpartswithareagreaterthan3in2anda lineardimensionover3"subjectedtoappreciableelectrostaticchargingdueto precipitation,fluid,orairinmotion Resistanceoflessthan1ohmwhencleananddryusuallyensuresstatic dissipationonlargerobjects [Speakernotes] Staticbonds.Allisolatedconductingpartsinsideandoutsidetheaircraft,havinganarea greaterthan3in2andalineardimensionover3inches,thataresubjectedtoappreciable electrostaticchargingduetoprecipitation,fluid,orairinmotion,shouldhaveamechanically secureelectricalconnectiontotheaircraftstructureofsufficientconductivitytodissipate possiblestaticcharges.

Aresistanceoflessthan1ohmwhencleananddrywillgenerallyensuresuch dissipationonlargerobjects.Higherresistancesarepermissibleinconnecting smallerobjectstoairframestructure. [Endspeakernotes]

Slide122:EWISIdentification
Necessaryfor: o Safetyofoperation o Safetytomaintenancepersonnel o Easeofmaintenance Toidentifyperformancecapability,usewirematerialpartnumberandfivedigit/letter codeidentifyingmanufacturer

[Speakernotes] Purpose.TheproperidentificationofEWIScomponentswiththeircircuitsandvoltagesis necessarytoprovidesafetyofoperation,safetytomaintenancepersonnel,andeaseof maintenance. Commonmanufacturermarkingprocess.Eachwireandcableshouldbemarkedwithapart number.Itiscommonpracticeforwiremanufacturerstofollowthewirematerialpartnumber withthefivedigit/letterC.A.G.E.codeidentifyingthewiremanufacturer.Usingthiscode, existinginstalledwirethatneedsreplacementcanbeidentifiedastoitsperformance capabilities.Thishelpstopreventtheinadvertentuseoflowerperformanceandunsuitable replacementwire. NOTE:Specialcareshouldbetakenwhenhotstampingwire.Servicehistoryhas shownproblemsassociatedwithhotstampingduetoinsulationdamagecaused duringtheprocess. ThemethodofidentificationshouldnotimpairthecharacteristicsoftheEWIS. Originalwireidentification.Tofacilitateinstallationandmaintenance,retain theoriginalwiremarkingidentification.Thewireidentificationmarksshould consistofacombinationoflettersandnumbersthatidentifythewire,thecircuit itbelongsto,itsgaugesize,andanyotherinformationtorelatethewiretoa EWISdiagram.Allmarkingsshouldbelegibleinsize,type,andcolor. IdentificationandinformationrelatedtotheEWISdiagrams.Thewire identificationmarkingshouldconsistofsimilarinformationtorelatethewireto aEWISdiagram. [Endspeakernotes] Slide123:EWISIdentification,cont. Wireidentificationmarksidentifywire,circuit,andgaugesize Markingsshouldbelegibleinsize,type,andcolorat15inchmaximumintervalsalong thewire(directlyonwireorindirect[sleeve/tag])

Lessthan3inchesneedsnomarking o Readablewithoutremovingclamps,ties,orsupportingdevices

[Speakernotes] MarkingEWISinaircraft.Identificationmarkingsgenerallyareplacedateachendofthewire andat15inchmaximumintervalsalongthelengthofthewire. Wireslessthan3incheslongneednotbeidentified. Wires3to7inchesinlengthshouldbeidentifiedapproximatelyatthecenter. Addedidentificationmarkersleevesshouldbelocatedsothatties,clamps,or supportingdevicesneednotberemovedinordertoreadtheidentification. Thewireidentificationcodemustbeprintedtoreadhorizontally(fromleftto right)orvertically(fromtoptobottom).Thetwomethodsofmarkingwireor cableareasfollows: (1) Directmarkingisaccomplishedbyprintingthecablesouter covering. (2) Indirectmarkingisaccomplishedbyprintingaheatshrinkable sleeveandinstallingtheprintedsleeveonthewireorcablesouter covering.Indirectmarkedwireorcableshouldbeidentifiedwithprinted sleevesateachendandatintervalsnotlongerthan6feet.Theindividual wiresinsideacableshouldbeidentifiedwithin3inchesoftheir termination. Themarkingshouldbepermanentsuchthatenvironmentalstressesduring operationandmaintenancedonotadverselyaffectlegibility. [Endspeakernotes]

Slide124:MarkingaWireBundle
[Graphic] Firstimageshowsbundlewithnomarkingandthesecondimageshowsbundlemarkedwith identificationnumberonatag. [Endgraphic] [Speakernotes] Therecanbeseriousrepercussionswhenthereisasituationinwhichanumberofunmarked cablesaredisconnected.Whenthecablesreconnected,thechancesarehighthattheywillbe connectedincorrectly,thuscausingnumerousproblems. [Endspeakernotes]

Slide125:Connectors
Manytypes,howevercrimpedcontactsgenerallyused

o Circulartype o Rectangular o Moduleblocks Selectedtoprovidemaximumdegreeofsafetyandreliabilitygivenelectricaland environmentalrequirements o Useenvironmentallysealedconnectorstopreventmoisturepenetration

[Speakernotes] Connectors.ThenumberandcomplexityofEWIShaveresultedinanincreaseduseofelectrical connectors.Theproperchoiceandapplicationofconnectorsisasignificantpartoftheaircraft EWISsystem.Connectorsshouldbekepttoaminimum,selected,andinstalledtoprovidethe maximumdegreeofsafetyandreliabilitytotheaircraft.Fortheinstallationofanyparticular connectorassembly,thespecificationofthemanufacturershouldbefollowed. Purposeandtypes.Theconnectorusedforeachapplicationshouldbeselectedonlyaftera carefuldeterminationoftheelectricalandenvironmentalrequirements.Considerthesize, weight,tooling,logistic,maintenancesupport,andcompatibilitywithstandardization programs. Foreaseofassemblyandmaintenance,connectorsusingcrimpedcontactsare generallychosenforallapplicationsexceptthoserequiringahermeticseal. Areplacementconnectorofthesamebasictypeanddesignastheconnectorit replacesshouldbeused. Withacrimptypeconnectorforanyelectricalconnection,theproperinsertion, orextractiontoolshouldbeusedtoinstallorremovewiresfromsucha connector.Refertomanufactureroraircraftinstructionmanual. Aftertheconnectorisdisconnected,inspectitforloosesolderedconnectionsto preventunintentionalgrounding. Connectorsthataresusceptibletocorrosiondifficultiesmaybetreatedwitha chemicallyinertwaterproofjellyoranenvironmentallysealedconnectormaybe used. NOTE:AlthoughnotrequiredbyAC43.131b,moistureproofconnectorsshould beusedinallareasoftheaircraft,includingthecabin.Servicehistoryindicates thatmostconnectorfailuresoccurduetosomeformofmoisturepenetration. Eveninthepressurized,environmentallycontrolledareasofthecockpitand cabin,moisturecanoccurduetorainintheplanetypeofcondensationthat generallyisaprobleminallmoderntransportcategoryaircraft. [Endspeakernotes]

Slide126:CircularConnectors
[graphic] Threeimagesshowing6differenttypesofcircularconnectors [Endgraphic]

[Speakernotes] AlthoughAC43.131bdoesnotaddresspinlayoutdesignaspects,considerationshouldbe giventothedesignofthepinarrangementtoavoidsituationswherepintopinshortscould resultinmultiplelossoffunctionsand/orpowersupplies.Forexample,youwouldavoid115 Vac,400Hzbeinglocatedadjacenttolowpowerwires,suchas28and5Vdc. Awidevarietyofcircularenvironmentresistantconnectorsareusedinapplicationswhere theywillprobablybesubjectedtofluids,vibration,thermal,mechanicalshock,corrosive elements,etc.Inaddition,firewallclassconnectorsincorporatingthesesamefeaturesshould beabletopreventthepenetrationofthefirethroughtheaircraftfirewallconnectoropening andcontinuetofunctionwithoutfailureforaspecifiedperiodoftimewhenexposedtofire. Hermeticconnectorsprovideapressuresealformaintainingpressurizedareas. WhenEMI/RFIprotectionisrequired,specialattentionshouldbegiventothe terminationofindividualandoverallshields.Backshelladaptersdesignedfor shieldtermination,connectorswithconductivefinishes,andEMIgrounding fingersareavailableforthispurpose. [Endspeakernotes] Slide127:CircularConnectors,cont. [graphic] Imagesshows3differentlockingdevices [Endgraphic] [Speakernotes] Inmediumorhighvibrationareasitmaybenecessarytoprovidealockingdevicetokeepthe connectorsfromloosening. [Endspeakernotes]

Slide128:ImproperLockWireInstallation
[Speakernotes] Thisslideshowsalockwireimproperlyinstalled.Thelockwireisinstalledonthe"loosening sideoftheconnector;itshouldbeonthelighteningside. [Endspeakernotes]

Slide129:ProperLockWireInstallation
[Speakernotes]

Thisisanexampleofaproperlyinstalledlockwireonthelighteningside. [Endspeakernotes]

Slide130:RectangularConnectors
[graphic] Imageshowsfourtypesofrectangularconnectors [Endgraphic] [Speakernotes] Rectangularconnectorsaretypicallyusedinapplicationswhereaverylargenumberofcircuits areaccommodatedinasinglematedpair.Theyareavailablewithagreatvarietyofcontacts, whichcanincludeamixofstandard,coaxial,andlargepowertypes.Couplingisaccomplished byvariousmeans. Smallertypesaresecuredwithscrewsthatholdtheirflangetogether. Largeroneshaveintegralguidepinsthatensurecorrectalignment,orjackscrews thatbothalignandlocktheconnectors. Rackandpanelconnectorsuseintegralorrackmountedpinsforalignmentandboxmounting hardwareforcouplings. [Endspeakernotes]

Slide131:ModuleBlocks(TerminalBlocks)
[Graphic] Showstwotypesofmodularblocks [Endgraphic] [Speakernotes] Moduleblocksacceptcrimpedcontactssimilartothoseonconnectors.Someuseinternal busingtoprovideavarietyofcircuitarrangements. Moduleblocks(orterminalblocks)areusefulwhereanumberofwiresare connectedforpowerorsignaldistribution.Whenusedasgroundingmodules, theysaveandreducehardwareinstallationontheaircraft. Standardizedmodulesareavailablewithwireendgrommetsealsfor environmentalapplicationsandaretrackmounted. [Endspeakernotes]

Slide132:TerminalBlockGrommetDistortion
[Speakernotes]

Forcomplexwirebreakoutsthatareterminatedintoterminalblocks,caremustbetakento allowenoughslacktopreventexcessiveforcesfrompullingtheterminatedwiresthatare insertedintotheterminalblock. Thisconditioncanleadtoterminalblockgrommetdistortion,whichcanleadto wiredamageorawirethatwillbepulledfreefromtheterminalblock. [Endspeakernotes]

Slide133:GrommetDistortion
[Graphic] FirstimageshowsImproper:grommetdistortionduetotightwires;notenoughslack.Second imageshowsProper:noexcessivetensiononwires;enoughslacktoavoidgrommetdistortion [Endgraphic]

Slide134:Conduits
Purpose o Mechanicalprotectionofwiresandcables o Groupingandroutingwires Standards o Absenceofabrasionatendfittings o Properclamping o Adequatedrainholesfreeofobstructions o Minimizeddamagefrommovingobjects o Properbendradii

[Speakernotes] Purpose.Primarilythepurposeofconduitsisformechanicalprotectionofcablesorwires. Secondarily,conduitsareusedforenvironmentalprotectionandgroupingofwiresbysignal type. Standards Conduitshouldbeinspectedfor:properendfittings;absenceofabrasionatthe endfittings;properclamping;distortion;adequatedrainholesthatarefreeof dirt,grease,orotherobstructions;andfreedomfromabrasionordamagedueto movingobjects,suchasaircraftcontrolcablesorshiftingcargo. Sizeofconduit.Conduitsizeshouldbeselectedforaspecificwirebundle applicationtoallowforeaseinmaintenance,andpossiblefuturecircuit expansion,byspecifyingtheconduitinnerdiameter(I.D.)about25percent largerthanthemaximumdiameterofthewirebundle. Conduitfittings.Wireisvulnerabletoabrasionatconduitends.Suitablefittingsshouldbe affixedtoconduitendsinsuchamannerthatasmoothsurfacecomesincontactwiththewire. Whenfittingsarenotused,theendoftheconduitshouldbeflaredtopreventwireinsulation damage.Conduitshouldbesupportedbyuseofclampsalongtheconduitrun.

[Endspeakernotes]

Slide135:ConduitInstallationGuidelines
Donotlocateconduitwhereserviceormaintenancepersonnelmightuseashandhold orfootstep Provideinspectabledrainholesatthelowestpointinconduitrunremovedrilling burrscarefully Supportconduittopreventchafingagainststructureandavoidstressingendfittings

[Speakernotes] Conduitinstallation.Conduitproblemscanbeavoidedbyfollowingtheseguidelines: Donotlocateconduitwhereserviceormaintenancepersonnelmightuseitasa handholdorfootstep. Provideinspectabledrainholesatthelowestpointinaconduitrun.Drilling burrsshouldbecarefullyremoved. Supportconduittopreventchafingagainststructureandtoavoidstressingits endfittings. [Endspeakernotes]

Slide136:ConduitCovering
[Graphic] Firstimageshowsdamagedconduitcovering.Secondimageshowsanacceptableconduit coveringwithnodamage [Endgraphic] [Speakernotes] FODisabigproblemwithdamagedconduitcovering. [Endspeakernotes]

Slide137:WireInsulationSelection
Chosecharacteristicsbasedonenvironment o Abrasionresistance o Arcresistance o Corrosionresistance o Cutthroughstrength o Dielectricstrength o Flameresistant o Mechanicalstrength

o Smokeemission o Fluidresistance o Heatdistortion [Speakernotes] Environmentalcharacteristics.Asshowninthisslide,therearemanyinsulationmaterialsand combinationsusedinaircraftwiring.Wireinsulationcharacteristicshouldbechosenbasedon meetingFAAflameresistanceandsmokeemissionrequirements(25.869)andtheenvironment inwhichthewireistobeinstalled. [Endspeakernotes]

Slide138:FlameResistantInsulatingMaterials
Polymer PTFE ETFE Aromaticpolyamide Composite [Speakernotes] Thesearethefourmostcommontypesofinsulationmaterialsusedinaircrafttoday.Allofthe wireinsulatingmaterialsinthisslidemeettheminimumFAAsmokeandflammability standards. [Endspeakernotes] MilSpec 22759/12 22759/16 81381 22759/8092

Slide139:SelectingInsulatingMaterials
FACT:Thereisnoperfectinsulationsystemforaerospacewireandcable n Thedesignerstask: Considertradeoffstosecurebestbalanceofproperties Considerinfluenceofdesign, installationandmaintenance .....foreachapplication!

Slide140:HowtoChooseWireInsulation
Seekthebestbalanceofproperties: o Electrical o Mechanical o Chemical o Thermal Nonflammabilityandlowsmoke

Plus

Slide141:ComparativePropertiesofWireInsulationSystems
Ranking1ismostdesirableand4istheleastdesirable RelativeRanking 1 2 3 4 Weight PIE TFE COMP PTFE Temperature PTFE COMP PI ETFE Abrasionresistance PI ETFE COMP PTFE Cutthroughresistance PI COMP ETFE PTFE Chemicalresistance PTFE ETFE COMP PI Flammability PTFE COMP PI ETFE Smokegeneration PI COMP PTFE ETFE Flexibility PTFE ETFE COMP PI Creep(attemperature) PI COMP PTFE ETFE Arcpropagation PTFE ETFE COMP PI resistance [Speakernotes] PI[AromaticPolyimide(KAPTON)](milspec81381) Desirableproperties:abrasion/cutthrough,lowsmoke/nonflame, weight/space Limitations:arctrackresistance,flexibility ETFE(TEFZEL)(milspec22759/16) Desirableproperties:chemicalresistance,abrasionresistance,easeofuse Limitations:hightemperature,cutthrough,thermalrating(150C) Composite(TKT)(milspec22759/8092) Desirableproperties:hightemperaturerating(260C),cutthroughresistance, arctrackresistance Limitations:outerlayerscuffing PTFE(TEFLON)(milspec22759/12) Desirableproperties:260Cthermalrating,lowsmoke/nonflame,high flexibility Limitations:Cutthroughresistance,creepattemperature

[Endspeakernotes]

Slide142:ConclusiononInsulation
Aircraftdesignercanchooseamongmanypolymericmaterials Physicalandchemicalpropertiesareequallyimportant Safestsystemcombinesbalanceofpropertieswithinherentflameand/orsmoke resistance

Slide143:AC2516:ElectricalFaultandFireDetection
SupplementsexistingguidanceprovidedinAC43.131b Shouldapplytonewairplanes,aswellasmodifications Notintendedtotaketheplaceofinstructionsorprecautionsprovidedby aircraft/equipmentmanufacturers

[Speakernotes] ThepurposeofAC2516,ElectricalFaultAndFirePrevention,istoprovideinformationon electricallycausedfaults,overheat,smoke,andfireintransportcategoryairplanes.Acceptable meansareprovidedtominimizethepotentialfortheseconditionstooccur,andtominimizeor containtheireffectswhentheydooccur.Anapplicantmayelecttouseanyothermeansfound tobeacceptablebytheFAA. ThisACiscurrentlybeingreviewedandwillberevisedbasedonrecentservicehistoryand ATSRACrecommendations. [Endspeakernotes]

Slide144:AC2516:CircuitProtectionDevices(CPDs)
Circuitbreakerresets o Cansignificantlyworsenanarcingevent o Crewshouldonlyattempttoresetatrippedbreakeriffunctionisabsolutely required InformationshouldbeprovidedinAFMsorAFMrevisionsor supplements

[Speakernotes] InformationshouldbeprovidedinFAAapprovedAirplaneFlightManuals(AFM)orAFM revisionsorsupplementsthatthecrewshouldonlyattempttorestoreanautomatically disconnectedpowersourceorresetorreplaceanautomaticallydisconnectedcircuitprotection device(CPD)thataffectsflightoperationsorsafety. NOTE:Itisstronglyrecommendedthatcircuitbreakersfornonessential systemsnotberesetinflight.

MosttransportOAMsandoperatorsarerevisingtheirprocedurestonotallowcircuitbreaker resetsinflightfollowingacircuitbreakertripevent.Servicehistoryhasshownthatresettinga circuitbreakercangreatlyinfluencethedegreeofarcingdamagetotheEWIS.Eachsuccessive attempttorestoreanautomaticallydisconnectedCPD,canresultinprogressivelyworsening effectsfromarcing. [Endspeakernotes]

Slide145:ArcTrackingandInsulationFlashover (Causedbymultiplecircuitbreakerresets)
[Graphic] showswiringburnedandbrokenfromarcing [Endgraphic] [Speakernotes] Thispictureshowstheeffectsofmultiplecircuitbreakerresets.Inthiscase,theoriginalarcing eventwasnotabletobedeterminedduetotheseveresecondarydamagefollowingthecircuit breakerresets. [Endspeakernotes]

Slide146:EWISSeparation
Regulatoryrequirements o Sections25.1707,25.1709,25.903(d),25.631 Manufacturersstandards o Power/signalwireseparation EMIconcerns

[Speakernotes] EWISseparation/segregationisafundamentaldesigntechniqueusedtoisolatefailureeffects suchthatcertainsinglefailuresthatcancompromiseredundancyareminimized.EWIS separationisalsousedtocontroltheeffectsofEMIinaircraftEWIS. Fromaregulatorystandpoint,wehaveregulationsinplacethatmayinfluence EWISdesignwithrespecttoseparation/segregation. Inaddition,manufacturersmayhavecompanydesignstandardswhichestablish EWISseparationrequirementswithrespecttopowerandsignalroutingwhich areusuallydrivenfromaEMIstandpoint. ThenextfewslidesbrieflypresenttheprimaryregulationsassociatedwithEWIS separation/segregation. [Endspeakernotes]

Slide147:SystemSeparation:EWIS25.1707
AppliestoeachEWISonairplane

RequiresadequatephysicalseparationbetweenEWISandcertainairplanesystems knowntohavepotentialforcreatingahazardouscondition,forexample: o Fuelsystems o Hydraulicsystems o Oxygensystems o Water/wastesystems

Slide148:SystemSeparation:EWIS25.1707,cont.
Adequatephysicalseparationmustbeachievedbyseparationdistanceorbyabarrier thatprovidesprotectionequivalenttothatseparationdistance HazardousmustperformaqualitativedesignassessmentofinstalledEWIS o Useengineering&manufacturingjudgment o EvaluaterelevantservicehistorytodecidewhetheranEWIS,anyothertypeof system,oranystructuralcomponentcouldfailsothataconditionaffectingthe airplanesabilitytocontinuesafeoperationcouldresult

Slide149:SystemSafety:EWIS25.1709
EWISbedesignedandinstalledsoeach o catastrophicfailureconditionisextremelyimprobable,anddoesnotresultfromasingle failure,and

o eachhazardousfailureconditionisextremelyremote BothfunctionalandphysicalfailuresofEWISmustbeassessedwhendemonstrating ompliancewiththisruletofullyassesseffectofEWISfailures

Slide150:EWISSeparationfroma25.903(d)Standpoint
Turbineengineinstallations:Minimizehazardsincaseofrotorfailure o Projectdebrispaththroughaircraft Determinevulnerableareaswhereredundancycanbeviolated Mayneedtoseparatecertaincriticalsystemscomponents includingEWIS, e.g.,electricalpowerfeeders,flybywirecontrolpaths

[Speakernotes] Recently,theJAArequirementswithrespecttouncontainedenginefailureassessmentwere harmonizedwiththeFAAandwereissuedasAC20128A.AC20128Aprovidesspecific methodsfordemonstratingcompliancewith25.903(d). Theprimaryrequirementrelativetouncontainedenginefailureistouse practicaldesignprecautionstominimizetheriskofcatastrophicdamagedueto noncontainedenginerotordebris.

Anelementofdifficultyisintroducedwhenthefuselagediameteris exposedtotherelativelylargediameterfanrotorsofmodernhigh bypassratioturbofanengines. SeparationofcriticalsystemsEWISmaybeaprimaryfactorin establishingcompliance. [Endspeakernotes]

Slide151:EWISSeparationfroma25.631Standpoint
Continuedsafeflightandlandingafterimpactwith8lb.bird o Considerprotectedlocationofcontrolsystemelements IfimpactcaneffectredundantsystemEWIS,mayneedadditional physicalprotectionofEWISorwiringseparation E.g.:Impactbrowareaabovewindshieldcouldaffectelectrical powerredundancyinsomeaircraft

[Speakernotes] Thebirdstrikeimpactareasoftheaircraftshouldbeassessedfortheirstructuralstrengthby testand/orapprovedanalysismethods.Anypenetrationsordeformationsoftheaircraft structureshouldbefurtheranalyzedfortheeffectofsystemsinstallation. Forexample,ifabirdstriketestonthecockpitoverheadeyebrowareaindicates anelasticdeformationof2inches,thenthedeformationshouldbeanalyzedor superimposedonwhateversystemsmaybeinstalledintheoverheadcockpit areaatthatparticulardeformationlocation.Inmanyaircraft,electricaland/or hydrauliccontrolpanelsandassociatedEWISareinstalledintheoverhead cockpitarea(thisisarelativelysmallarea). Theeffectofthebirdstrikecanbeanalyzedwithrespecttoacommoncause failurestandpoint.EWISseparationaspectsofthedesignmaybeanelementin compliancetothisrule. [Endspeakernotes]

Slide152:PostTCEWISSeparation
MaintainEWISseparationrequirementsthroughoutlifeofaircraft o STCapplicantsmaynotbeawareofseparationorotherEWISrequirements(i.e., donothaveneededdesigndata) o EWISaddedormovedaspartoftheSTCshouldsatisfyoriginalseparation requirementsandEWISstandards o FAApolicyletterANM0104

[Speakernotes] ApotentialproblemwithSTCsandothermodificationstotransportaircraftisthatthe applicantsmaynotanalyzetheirproposedEWISinstallationwithrespecttotheOAMsEWIS

separationrequirementsandotherOAMEWISdesignstandards.AddedormodifiedEWIS couldpossiblydefeattheOAMEWISphilosophyandcreateunsafeconditions. TheFAAiscurrentlyintheprocessofdraftingpolicy.ThedraftpolicyletterwillclarifyFAAs policytorequirethattypedesigndatapackagesformultipleapprovalsincludethefollowing: Adrawingpackagethatcompletelydefinestheconfiguration,material,and productionprocessesnecessarytoproduceeachpartinaccordancewiththe certificationbasisoftheproduct. Anyspecificationsreferencedbytherequireddrawings. Drawingsthatcompletelydefinethelocation,installation,androuting,asappropriate,ofall equipmentinaccordancewiththecertificationbasisoftheproduct. Examplesofsuchequipmentarewirebundles,plumbing,controlcables,and othersysteminterconnectinghardware. Ifthemodificationbeingapprovedisachangetoatypecertificatedproduct,the modificationmustbeequivalenttoandcompatiblewiththeoriginaltypedesign standards. InstructionsforContinuedAirworthiness(ICA)preparedinaccordancewiththerequirementsof 21.50(Instructionsforcontinuedairworthinessandmanufacturersmaintenancemanuals havingairworthinesslimitationssections). [Endspeakernotes]

Slide153:InstructionsforContinuedAirworthiness(ICAs)
EWISICAsaredevelopedusingEnhancedZonalAnalysisProcedure(EZAP): Eachzoneofairplane EachzonewithEWIS EachEWISzonewithcombustiblematerials EachEWISzoneclosetobothprimary andbackupflightcontrolsandlines Tasks,intervals,andprocedures toreducecombustibles(i.e.cleanasyougo) Instructionsforprotections&cautioninformation [Speakernotes] 14CFR25.1729requiresapplicantstosubmitInstructionsforContinuedAirworthiness, otherwiseknownasthemaintenancerequirements,fortheproposedEWISinstallationaspart ofthecompliancedatapackage.Historically,EWIShasbeenthoughtofasfitandforgetand typicallyhasnotbeenproperlyaddressedintheICAdatapackagesubmittedtotheFAAfor approval. InlightofATSRACrecommendations,theFAArequiresapplicantstosubmitEWISrelated maintenancerequirementstotheFAAACOandAEGofficesforapprovaltosatisfytheintentof 25.1729.Thisslideshowssomeoftheissuesthatneedtobeaddressedforwirereplacements instructions. [Endspeakernotes]

Slide154:WhyEZAP?
EZAPusedtodevelopICAtopreventthepossibilityofsmokeandfireby o MinimizingaccumulationofcombustiblesonandaroundEWIS o DetectingEWISdegradations ThisleadstofewerEWISandotherairplanesystemsfailuresandtosaferoperation

Slide155:3EWISInspectionTypes
DetailedInspection(DET) StandAloneGVI GeneralVisualInspection(GVI)

Slide156:GeneralVisualInspection(GVI)
Avisualexaminationofaninteriororexteriorarea,installation,orassemblytodetect obviousdamage,failure,orirregularity.Thislevelofinspectionismadefromwithin touchingdistanceunlessotherwisespecified.

[Speakernotes] ForGeneralVisualInspection,amirrormaybenecessarytoenhancevisualaccesstoall exposedsurfacesintheinspectionarea.Thislevelofinspectionismadeundernormally availablelightingconditionssuchasdaylight,hangarlighting,flashlight,ordroplightandmay requireremovaloropeningofaccesspanelsordoors.Stands,ladders,orplatformsmaybe requiredtogainproximitytotheareabeingchecked. [Endspeakernotes]

Slide157:StandAloneGVI
Ageneralvisualinspectionthatisnotperformedaspartofazonalinspection.Evenin caseswheretheintervalcoincideswiththezonalinspection,thestandaloneGVI remainsanindependentstepontheworkcard.

Slide158:DetailedInspection(DET)
Anintensiveexaminationofaspecificitem,installation,orassemblytodetectdamage, failure,orirregularity.DETisdiscussedingreaterdetailinsection14b(1)ofAC25.27A.

Slide159:EWISInspectionFocusAreas
Clampingpoints o Improperinstallation o Clamp/wiredamage o Clampcushionmigration Connectors o Wornseals o Looseconnectors o Lackofstrainrelief o Driploops o Tightwirebends

[Speakernotes] ClampingpointsWirechafingisaggravatedbylooseclamps,damagedclamps,clampcushion migration,orimproperclampinstallations. ConnectorsWornenvironmentalseals,looseconnectors,excessivecorrosion,missingseal plugs,missingdummycontacts,orlackofstrainreliefonconnectorgrommetscancompromise connectorintegrityandallowcontaminationtoentertheconnector,leadingtocorrosionor grommetdegradation.Driploopsshouldbemaintainedwhenconnectorsarebelowthelevel oftheharnessandtightbendsatconnectorsshouldbeavoidedorcorrected. [Endspeakernotes]

Slide160:EWISInspectionFocusAreas,cont.
Terminations o Lugs/splices Backshells o Improperbuildup o Lackofstrainrelief Damagedsleevingandconduits Groundingpoints o Tightness o Cleanliness o Corrosion

[Speakernotes] TerminationsTerminallugsandsplicesaresusceptibletomechanicaldamage,corrosion,heat damageandchemicalcontamination.Also,thebuildupandnuttorqueonlargegaugewire studsiscriticaltotheirperformance. BackshellsWiresmaybreakatbackshells,duetoexcessiveflexing,lackofstrainrelief,or improperbuildup.Lossofbackshellbondingmayalsooccurduetotheseandotherfactors. DamagedsleevingandconduitsDamagetosleevingandconduits,ifnotcorrected,willoften leadtowiredamage.

GroundingpointsGroundingpointsshouldbecheckedforsecurity(i.e.tightness),condition ofthetermination,cleanliness,andcorrosion.Anygroundingpointsthatarecorrodedorhave losttheirprotectivecoatingshouldberepaired. [Endspeakernotes]

Slide161:EWISInspectionLocations:Examples
Wings o ExposedEWISonleading/trailingedgesduringflap/slatoperation Engine/APUs/pylon/nacelle o Heat/vibration/chemicalcontamination o Highmaintenancearea Landinggear/wheelwells o Environmental/vibration/chemical

[Speakernotes] EWISinspectionlocations.Availabledataindicatethatthelocationsshownontheslideshould receivespecialattentioninanoperatorsEWISinspectionprogram. WingsThewingleadingandtrailingedgesareareasthatexperiencedifficultenvironmentsfor EWISinstallations.ThewingleadingandtrailingedgeEWISisexposedonsomeaircraftmodels whenevertheflapsorslatsareextended.Otherpotentialdamagesourcesincludeslattorque shaftsandbleedairducts. Engine,pylon,andnacelleareaTheseareasexperiencehighvibration,heat,frequent maintenance,andaresusceptibletochemicalcontamination. APULiketheengine/nacellearea,theAPUissusceptibletohighvibration,heat,frequent maintenance,andchemicalcontamination. LandinggearandwheelwellsThisareaisexposedtosevereexternalenvironmental conditionsinadditiontovibrationandchemicalcontamination. [Endspeakernotes]

Slide162:EWISInspectionLocations,cont.
Electricalpanels/linereplacementunits(LRU) o Highdensityareas o Highmaintenanceactivity o Pronetobroken/damagedEWIS Batteries o Chemicalcontamination/corrosion Powerfeeders o Feederterminations o Signsofheatdistress

[Speakernotes]

Electricalpanelsandlinereplaceableunits(LRUs)PanelEWISisparticularlypronetobroken wiresanddamagedinsulationwhenthesehighdensityareasaredisturbedduring troubleshootingactivities,majormodifications,andrefurbishment.Onerepairfacilityhas foundthatwiredamagewasminimizedbytyingEWIStowoodendowels.Thisreducedwire disturbanceduringmodification.Itisalsorecommendedtoremoveentiredisconnectbrackets, whenpossible,insteadofremovingindividualreceptacles. BatteriesWiresandEWIShardwareinthevicinityofallaircraftbatteriesshouldbeinspected forcorrosionanddiscoloration.Discoloredwiresshouldbeinspectedforserviceability. Corrodedwiresand/orEWIShardwareshouldbereplaced. PowerfeedersOperatorsmayfinditadvantageoustoinspectsplicesandterminationsfor signsofoverheatingandsecurity.Ifanysignsofoverheatingareseen,thespliceortermination shouldbereplaced.Thisappliestogalleypowerfeeders,inadditiontothemainandAPU generatorpowerfeeders.Thedesirabilityofperiodicallyretorquingpowerfeederterminations shouldbeevaluated. [Endspeakernotes]

Slide163:EWISInspectionLocations,cont.
Undergalleysandlavatories o Susceptibletofluidcontamination o Fluiddrainageprovisions Cargobay/underfloorarea o Highmaintenanceactivity Surfaces,controls,doors o Movingandbendingwireharnesses Nearaccesspanels o Pronetoaccidentaldamage

[Speakernotes] UndergalleysandlavatoriesAreasunderthegalleys,lavatoriesandotherliquidcontainers areparticularlysusceptibletocontaminationfromcoffee,food,water,softdrinksandlavatory fluids,etc.Fluiddrainprovisionsshouldbeperiodicallyinspectedandrepairedasnecessary. Cargobay/underfloorCargocandamageEWIS.DamagetoEWISinthecargobayunderfloor canoccurduetomaintenanceactivitiesinthearea. Surfaces,controls,anddoorsMovingorbendingharnessesshouldbeinspectedatthese locations. AccesspanelsHarnessesnearaccesspanelsmayreceiveaccidentaldamageandshouldhave specialemphasisinspections. [Endspeakernotes]

Slide164:25.1703Requirementsforpreemptivemaintenance
NewruleassuresEWIScomponentsselectioncarriedoutsafely,consistently,& standardized Whatdoesitrequire? a. EWISComponentsmustfunctionproperlywheninstalled b. EWIScomponentsmustbequalifiedforairborneuse i. Householdwireorwireusedonconsumerelectronicsnotacceptable unlessshowntomeetallpart25certificationrequirements c. Expectedservicelifemustbeaddressed i. LimitationsmustbepartoftheICA(H25.4) d. Mustconsiderknowncharacteristicsinrelationtoeachspecificapplication i. Includeswiresinsulationsusceptibilitytoarctracking

Slide165:UseofGrommets
[Graphic] Firstimageshowsimpropergrommetusebyleavingaspace.Secondimageshowsproper grommetusebyleavingnospace [Endgraphic] [Speakernotes] Thegrommetshouldcovertheentireedgeandcometogetheratthetopofthehole. [Endspeakernotes]

Slide166:PotentialForeignObjectDamage
[Graphic] Firstimageshowsmetallicshavingsonwires.Secondimageshowswashersandscrapwiresin area. [Endgraphic] [Speakernotes] Thesephotographsshowforeignobjectdamage(FOD)thatcancausedamagetoEWIS components.Metallicshavingposeaseriousthreatwhichcandamagewireinsulationand causesubsequentarcingandfiredamage.Thisisoneofthereasonsforthecleanasyougo maintenancephilosophy. [Endspeakernotes]

Slide167:TieWrapEnds
[Speakernotes]

Itisimportanttocutthetiewrapendsaftersecuringthewiresinordertoavoidpossible interferencewithotherEWIScomponents. [Endspeakernotes]

Slide168:ClampCushion
[Speakernotes] DamagedclampcushionscancauseEWISdamagethatcanleadtoarcing. [Endspeakernotes]

Slide169:SleevingInstallation
[Graphic] Firstimageshowssleevingnotcompletelyaroundwirebundle.Secondimageshowssleeving overlappingwirebundle. [Endgraphic] [Speakernotes] Protectivesleevingshouldoverlapatleast30%toensure100%coverageofthewirebundle. [Endspeakernotes]

Slide170:Part25and26RequiredComplianceDocumentation
ProjectSpecificCertificationPlan(PSCP)(EWIS/EZAPaspects) o Loadanalysis o EWISInstallationDrawingsandEWISDiagrams(25.1701,includingidentification ofEWIScomponentsper25.1711) o EWISseparationrequirements(25.1707) o SystemsSafetyAnalysis(25.1709) o ICAforEWISincludinganyairworthinesslimitations(25.1729and25.1703, respectively)

Slide171:EWISDiagrams
Wireselection o Gauge/breakersize o Insulation o EWISIdentification o Environmentalconsiderations Connectors o Pin/socketratings o Pinarrangement(bestpractices)

o Environmentalconsiderations Grounding

[Speakernotes] TheengineerordesigneeshouldreviewtheEWISdiagramsandverifythefollowingpoints.This informationshouldbeavailableontheEWISdiagramsorreferencedtothesource. WireselectionThewiresmustbesizedproperlyandthecircuitbreakersizedtoadequately protectthewireconsideringtheambienttemperatureoftheenvironment.Thecircuitbreaker protectingthewireshouldopenbeforethecircuitbreakerprotectingtheupstreambus. Thewireinsulationandconductorplatingmustbesuitablefortheenvironment plusanyfurthertemperatureriseduetodissipatedpower. ConnectorsEnsurethattheconnectorsaresuitablefortheenvironmentandthepinsand socketsareproperlyratedtohandlethepowerdemandsofthecircuit. Aswediscussedearlier,pinarrangementsshouldminimizethepossibilityof shortsbetweenpower,ground,and/orsignals.Verifythatseparation requirementsfromthesafetyassessmentprocessareaddressed.Also,ensure unusedpinsareproperlyprotected. GroundingEnsurecircuitshavepropergrounding. [Endspeakernotes]

Slide172:EWISInstallationDrawings
Clamps o Propersize,type,andmaterial o Spacedappropriatelyforenvironment o Mountedcorrectly Feedthroughs/passthroughs o Grommetsusedwhennecessary o Wirebundlesproperlysupported

[Speakernotes] Itisimportanttonotethatinstallationdrawingsgenerallydonotprovidethenecessarydetail toensureproperclamping,routing,andterminationofEWISforagiveninstallation. Itisadvisablefortheengineerordesigneetoperformafirstofamodelorfirstofadesign generalEWIScomplianceinspectioninadditiontoreviewingtheEWISdiagramsandEWIS installationdrawings.ConsiderationshouldbegiventothecomplexityoftheEWISin determiningtheappropriatedepthofthecomplianceinspection. Theengineerordesigneeshouldensurethatadequateinstallationdrawingsexistandreview thedrawingsandperformthecomplianceinspectiontoverifytheitemsnotedonthefollowing slides(whichwediscussedindetailearlier). Clampsmustbesuitablewithrespecttosize,type,andmaterial.Alsoensurethatanadequate numberofclampsareusedtoproperlysupportthewirebundle.Clampsshouldbemounted correctlywithproperorientation.

Feedthroughs/passthroughsGrommetssuitablefortheenvironmentmustbeusedwhenthe wirebundlepassesthroughpressurebulkhead,firewall,andotheropeningsinthestructure. [Endspeakernotes]

Slide173:EWISInstallationDrawings,cont.
Routing o Chafing o Locationwithrespecttofluidlines,lavs,andgalleys o EWISIdentification(componentmarking) o Driploops o Bendradius o Coil,cap,andstowmethods o Humanfactors(hand/stepholds) o Protectedagainstcargo/maintenance

[Speakernotes] EWISroutingshouldbereviewedtoensureproperclearancefromaircraftstructure,fluidlines, andotherequipment. ConsiderationshouldbegiventotheeffectsonEWISfrommaintenance,shifting cargo,andpassengers.Properbendradius,useofdriploops,andpropercoil andstowmethodsshouldbeverified.EWISthatcouldbeusedashandorstep holdsshouldbeminimizedorplacarded. [Endspeakernotes]

Slide174:EWISInstallationDrawings,cont.
Routing,cont. o Accessibleformaintenance,repairs, andinspection o Properslack o Segregationandseparation CompatiblewithOAMstandards Doesnotviolateanyregulatorysafetyrequirements

[Speakernotes] Connectors,clamps,splices,andterminationsshouldbeaccessibleformaintenance,repairs, andinspection.EnsurethattheEWISissecureyetnotpreloadedandthatenoughslackexists toaccountforshockmountedequipment,maintenance,andbreakoutstoterminals,as appropriate. ForEWISmodificationstoexistingaircraft,theroutingshouldbecompatiblewithsafety requirementsandtheOAMEWISphilosophywithrespecttoexistingseparationand segregationstandards.

[Endspeakernotes]

Slide175:EWISInstallationDrawings,cont.
Conduits o Sizedproperly o Appropriateforenvironment o Conduitendsareterminated o Bendradius o Drainholes o MetallicAreEWIScomponentsproperlyprotectedinside? o AircraftEWISPractices [Speakernotes] Conduits.Ensurethatconduitsaresizedproperlyandappropriatefortheenvironment. Payparticularattentiontotheconduitendpointstoensurepropertermination. Conduitbendradiishouldbesuitableforboththeconduitandwirebundle insidetheconduit. Ensurethatlowspotsintheconduithavedrainholesthatcanbemaintainedand inspected. Also,ensurethatEWISinmetallicconduitisprotectedinasuitablemanner. [Endspeakernotes]

Slide176:PointsofContact:
BrettPortwood:brett.portwood@faa.gov o FAATechnicalSpecialist,SafetyandIntegration o LosAngelesACO;ANM130L o (562)6275350 MassoudSadeghi:massoud.sadeghi@faa.gov o AgingSystemsProgramManager o TransportAirplaneDirectorate;ANM114 o (425)2272117