Example: Terminal Stacking

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To prevent corrosion from dissimilar metals, put a cadmium washer between aluminum and copper terminals.

Example: Lock Washers, cont.

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AC 43.13-1b Topics Covered

4 Electrical load determination 4 Breaker and wire sizing/selection 4 Routing/clamping/bend radii 4 Splicing 4 Wire terminals

4Grounding and bonding

4 Wire marking 4 Connectors and conduits 4 Wire insulation properties
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Grounding Definition
4Grounding is the process of

electrically connecting conductive objects to either a conductive structure or some other conductive return path for the purpose of safely completing either a normal or fault circuit.
4

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Grounding
4Types of grounding
AC returns DC returns Others

4Avoid mixing return currents from

various sources

Noise will be coupled from one source to another and can be a major problem for digital systems
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Grounding, cont.
4Design of ground path should be

given as much attention as other leads in the system

4Grounding should provide a

constant impedance
4Ground equipment items externally

even when internally grounded

Avoid direct connections to magnesium structure for ground return

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Grounding, cont.
4Heavy current grounds

Attach to individual grounding brackets attached to aircraft structure with a proper metal-to-metal bond Accommodate normal and fault currents of system without creating excessive voltage drop or damage to structure Give special attention to composite aircraft
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Bonding
4Equipment bonding

Low impedance paths to aircraft structure required for electronic equipment to provide radio frequency return circuits Facilitates reduction in EMI for most electrical equipment
4

Cases of components that produce EMI should be grounded to structure

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Bonding, cont.
4 Metallic surface bonding

Electrically connecting conductive exterior airframe components through mechanical joints, conductive hinges, or bond straps
4

Protects against static charges and lightning strikes

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AC 43.13-1b Topics Covered

4 Electrical load determination 4 Breaker and wire sizing/selection 4 Routing/clamping/bend radii 4 Splicing 4 Wire terminals 4 Grounding and bonding

4Wire marking
4 Connectors and conduits 4 Wire insulation properties
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Wire Marking
4Necessary for:
Safety of operation Safety to maintenance personnel Ease of maintenance/troubleshooting

4To identify performance capability,

use wire material part number and five digit/letter code identifying manufacturer
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Wire Marking, cont.

4Wire identification ID should identify

wire type, circuit, and gauge size

4Markings should be legible in size,

type, and color at 15-inch maximum intervals along the wire [directly on wire or indirect (sleeve/tag)]

4<3 inches needs no marking

Readable without removing clamps, ties, or supporting devices
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Example: Marking a Wire Bundle A B

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AC 43.13-1b Topics Covered

4 Electrical load determination 4 Breaker and wire sizing/selection 4 Routing/clamping/bend radii 4 Splicing 4 Wire terminals 4 Grounding and bonding 4 Wire marking

4Connectors and conduits

4 Wire insulation properties
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Connectors
4 Many types of connectors, however crimped contacts generally used

Circular type Rectangular Module blocks

4 Selected to provide max. degree of safety and reliability given electrical and environmental requirements

Use environmentally-sealed connectors to prevent moisture penetration

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Circular Connectors

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Example: Lock Wire Installation

Wired in Counter Clock wise direction

incorrect

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Example: Lock Wire Installation, cont.

Clock wise direction

correct

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Rectangular Connectors

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Module Blocks (Terminal Blocks)

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Terminal Block Grommet Distortion

wire

View A Acceptable

grommet
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View B Unacceptable

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Exercise: Grommet Distortion

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Conduits
4Purpose

Mechanical protection of wires and cables Grouping and routing wires

4Standards

Absence of abrasion at end fittings Proper clamping Adequate drain holes free of obstructions Minimized damage from moving objects Proper bend radii
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Review Exercise 7: Bend Radius

Calculate the minimum bend radius for this wire bundle (assume it is supported at
one end only).

.2"
Select an answer: a. 1 inch b. 5 inches c. 7 inches d. 8 inches e. 7.4 inches
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.7" .4" .2" .8"

.2" .5" .2"

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AC 43.13-1b Topics Covered

4 Electrical load determination 4 Breaker and wire sizing/selection 4 Routing/clamping/bend radii 4 Splicing 4 Wire terminals 4 Grounding and bonding 4 Wire marking 4 Connectors and conduits

4Wire insulation properties

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Wire Insulation Selection

4Chose characteristics based on environment
Abrasion Arc

resistance resistance strength strength

Flame resistant Mechanical strength Smoke emission Fluid resistance Heat distortion

resistance

Corrosion

Cut-through Dielectric

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Flame Resistant Insulating Materials

Polymer
PTFE ETFE

Mil Spec
22759/12 22759/16

Aromatic polyamide 81381 Composite

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22759/80-92
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How to Choose Wire Insulation

4Seek the best balance of properties:

Electrical Mechanical Chemical Thermal

Plus

Nonflammability and low smoke

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Conclusion on Insulation
4Aircraft designer can choose among

many polymeric materials

4Physical and chemical properties

are equally important

4Safest system combines balance

of properties with inherent flame and/or smoke resistance

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AC 25-16: Electrical Fault and Fire Detection

4Supplements existing guidance

provided in AC 43.13-1b
4Should apply to new airplanes,

as well as modifications
4Not intended to take the place of

instructions or precautions provided by aircraft/equipment manufacturers

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Arc Tracking and Insulation Flashover

(Caused by multiple circuit breaker resets)

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Wire Separation
4Regulatory requirements

Sections 25.1309(b), 25.903(d), 25.1353(b), 25.631

4Manufacturers standards

Power/signal wire separation

4

EMI concerns

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Clean-as-you-go Philosophy
4Keep wiring clean throughout

life of aircraft
Protect

wiring during routine maintenance wiring periodically (vacuum, light brushing, etc.) during heavy maintenance when hidden areas exposed
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Clean

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Focus Areas
4Clamping 4Connectors

points

Worn seals Loose connectors Lack of strain relief Drip loops Tight wire bends
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Improper installation Clamp/wire damage Clamp cushion migration

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Focus Areas, cont.

4Terminations

4Grounding

Lugs/splices

points
Tightness Cleanliness Corrosion

4Backshells
Improper build-up Lack of strain relief

4Damaged sleeving

and conduits
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Wiring Inspection Locations

4Wings

Exposed wiring on leading/trailing edges during flap/slat operation

4Engine/APUs/pylon/nacelle

Heat/vibration/chemical contamination High maintenance area

4Landing gear/wheel wells

Environmental/vibration/chemical
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Wiring Inspection Locations, cont.

4 Electrical panels/line replacement units (LRU)

High density areas High maintenance activity Prone to broken/damaged wires Chemical contamination/corrosion Feeder terminations Signs of heat distress

4 Batteries

4 Power feeders

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Wiring Inspection Locations, cont.

4 Under galleys and lavatories Susceptible to fluid contamination Fluid drainage provisions 4 Cargo bay/underfloor area High maintenance activity 4 Surfaces, controls, doors Moving and bending wire harnesses 4 Near access panels Prone to accidental damage
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Questions ??

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Thank You

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