A wire is - a single solid or filament of drawn metal - enclosed in a suitable insulating material and protecting cover A cable is - usually

y made up of a conductor composed of a group of single solid wires stranded together - provides greater flexibility - enclosed in a suitable insulating material and protecting cover

The names adopted for various types are derived from insulating material used NYVIN (Nylon and polyVINylchloride) TERSIL (polyesTER and SILicone) TRINYVIN (cable made up of 3 single NYVIN cables) METSHEATH (cable enclosed in a metal braided sheath)

Two metals are used for conductors ; Copper & Al Both Cu & Al has same resistance but Al has 2/3 of the weight and 2 times cross sectional area of the copper conductor.

 Toughness
Flexibility Temperature

range Resistance to fuel/hydraulic and lubricant Ease of stripping Non-flammability Minimum weight

 The

correct sequence of circuit checks

Visual inspection Bonding check Continuity check Insulation check Functional check

a)

Visual inspection

This may save damage, injury, time and money - Circuit wiring - Plugs and sockets - Terminal blocks - Damage - Deterioration - Poor routing(workmanship) - Security of attachment & connections - Corrosion check under clips & nuts

b)Bonding check
- The parts or airframe where bonding provided, bonding check need to be carried out for wear and tear or loosening. - Bonding resistance should be .05 ohm (primary bonding ; major components, engines, external surfaces) and 1 ohm (secondary bonding ; metal conduits, Junction Box, pipeline containing flammable fluids)

c)

Continuity check
The preconditions for continuity check are

All manually operated switches must be placed ON position The circuit at the time of testing must be dead except for current originating in the test equipment The portion of circuit under test must constitute a simple series circuit

c) Continuity check(cont.)
Test apparatus requires A low voltage supply A lamp A multimeter A testmeter (if necessary for special circuit) ALWAYS RECTIFY FAULTY PORTION BEFORE PROCEEDING FURTHER TEST SEQUENCE

c) Continuity check(cont.)
Methodical planning is the first step towards effective continuity testing.
-

Through study of wiring diagram(1st stage) Planned sequence of individual test that are needed to check the whole of wiring The use of low voltage supply

d)Insulation check
Two fundamental properties of insulation materials are Insulation resistance (measured with a meggar) Dielectric strength (measured raising voltage of sample until insulation breaks down)

d)Insulation check(cont.)
The steps toward effective insulation testing are - Isolate the circuit required to be tested - All switches (fuse/breaker) ON of the circuit under test - Disconnect all circuit negatives from the earthing point - Link up all isolated sections to give electrical continuity throughout the circuit or groups of circuit under test.

e) Functioning test: - Functioning test should be carried out using an external supply coupled to ground supply connector - Test must ensure proper functioning of individual and integrated sections of circuits - Test should be in accordance with schedules established by reference of MM,WDM or instruction relating to incorporation of a modification or any substantial rewiring. - After test carried out, switch OFF the circuit, fuse should be removed or breaker tripped and the circuit again switched on to check the isolation.

During flight build up of electrical energy occurs in two ways Precipitation of static charge(by surface friction) Charges due to electrostatic induction ( by cloud)
To eliminate the electrical energy bonding system is introduced which Limit potential difference between all parts Eliminate spark discharges and fire risks Reduce interference with radio and navigational aid signals

To eliminate Charges due to electrostatic induction ( created by cloud) and lightning ; a leakage path is provided by the following means
-

Making Nose wheel or tail wheel tire rubber electrical conductive

A leakage path via short flexible steel wires secured to nose wheel or main wheel axel members making physical contact with the ground.

In the literal sense earthing or grounding refers to the return of current to the conducting mass of the earth or ground. In aircraft its fuselage is considered as earthing provider as in most aircraft the structure is of metal. Earthing in aircraft is constitute of - Earth return cables & earthing bolts - Fuselage earthing strips (aircraft having nonmetallic primary structure) - Lightning strike plates

Screening provides a low resistance path for voltages producing unwanted radio frequency interference. The voltage conducted by screening system are those stray ones due o the coupling of external fields originating certain equipment & circuits. The methods adopted for screening are - suppressor(provides a low resistance path across interference source) - Metal screening(cables with metal braided sheath)

Corona discharge: - Occurs at wing tips, trailing edge, horizontal & vertical stabilizer, radio antennae ,pitot tubes. - Creates poor visibility (glow) - RF signal interference Remedy: - Static discharger can discharge static charge which consists of nichrome wires formed in the manner of brush. - Sharp tungsten needles extend at right angles to the discharger tips to keep corona voltage low.

During refueling risk of fire and explosion persists. Charge may be carried by - Aircraft - The fuel flowing the hose - The tanker The equalizing of potential is achieved by providing bonding connection between the aircraft and the tanker which themselves are bonded to the ground. The hose is bonded to aircraft special point.

Crimp tools mist be carefully inspected : Ensure that full cycle ratchet mechanism is tamperproof If the tools does not function or faults are found, reject the tool Suitable gages of the Go/No Go type are available and shall be used prior to any crimping operation to ensure crimp dimension

The terminal ends, pin and socket contacts, cable splices and tools shall be inspected for compliance with approved drawing. All crimp joints shall be visually inspected for: Correct combination of cable , tool and terminal end Correctness of form and location of crimp Freedom from fracture, rough or sharp edges Adequate insertion of all conductor strands in the barrel Absence of damage to the conductor or insulation

Fig: Installing a contact

Fig : Removing a contact

 Installing

a contact:

Select correct insertion tool Fit tool to contact/wire Push fully into connector, DO NOT ROTATE Fully seat the contact until snapping/clicking is beard/felt Remove the tool in a straight line DO NOT ROTATE

Removing a contact: Identify the connector as front or rear release Remove any back-shell or strain relief clamp Remove or loosen any compression ring Insert the tool over the contact in a straight line Push plunger forward, the contact should emerge from the rear of the connector

The cables are required to be protected from abrasion, mechanical strain and excessive heat and against harmful effects of fuel, oil and other aircraft fluids. Conduits, ducts and trunking used for carrying cables should have smooth internal surfaces The cabling must be adequately supported throughout its length by clamps to reduce vibration Bends in cable groups or bundles should not be less than eight(8) times the outside diameter of the group cable or bundle.

Cables should be so fitted and clamped that no tension will be applied in any circumstance of flight Cables should be supported independently of and with maximum practicable separation from all fluid.

Routing of wires and cables Open loom Ducted loom conduit

The composition of a cable loom is dictated by such factor as Overall diameter Temperature condition, i.e. temperature rise in cables when operating at their maximum current carrying capacity Type of current, i.e. whether alternating, direct, heavy duty or light duty. Interference resulting from inductive or magnetic effects Type of circuit with which cables are associated; cables prone to short circuit with adjoining cables must be safeguarded.