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Identifying Wire and Cable: Section 2
Identifying Wire and Cable: Section 2
Sect 2 Chap 2
SECTION 2
CHAPTER 2
1
AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
10. The wire size number is used to identify the size CHROM – Chromel CONS – Constantan
(AWG) of the wire. For coaxial cables and thermocouple ALML – Alumel COP – Copper
wires, a dash (-) is used in lieu of the wire size number. IRON – Iron
11. The letter “N” is used as a suffix to the wire 15. For aluminium wire, ALUMINIUM or ALUM shall
identification code to identify any wire or cable that be added as a suffix to the wire identification code.
completes the circuit to the ground network (earth). Such
wires and cables shall be capable of being connected to
the ground network of aircraft electrical systems without Spare Contact Wire Identification
causing malfunctioning of any circuit. For critical and
sensitive electronic systems that have interconnecting 16. Wires attached to spare contacts shall be
“ground” leads, but only one segment actually grounded identified by the contact designation.
to structure, only the segment actually grounded to
structure is identified with the “N” suffix. Harness Identification
12. Phase letter “A”, “B” or “C” shall be used as a 17. When required, each harness shall be identified
suffix on the wire identification code to identify the phase with the letter W and a distinct numerical suffix.
of wires that are in the three-phase power distribution Examples W-1, W-2, W-3, etc.
wiring of AC systems.
Wires Added at Modification
13. Phase letter “V” shall be used as a suffix on the
cable identification code to identify the ungrounded wire 18. When additional wires are installed in aircraft
or cable that is in a single-phase system. during modification, they should be identified by
including the letter M as a suffix to the wire
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
a. level of shielding or protection applied to the wire WIRE AND COMPONENT IDENTIFICATION
(eg. twisted pair, shielded wire etc); CODES FOR MODIFICATION
b. electromagnetic susceptibility of the coupled
Wire Numbers
victim equipment;
c. physical separation between the subject wiring 27. When additional wires and cables are installed in
and potential electromagnetic sources (including aircraft during modification they should be appropriately
other wires); and/or identified in accordance with this publication. Wire
numbers in the range 2000 to 4999 inclusive, should be
d. the type of grounding/bonding methods utilised. allocated. All wire numbers allocated to modifications
should be suffixed with the letter M (eg. L2001A20M).
23. Audio and data signals are often the most Wires installed within aircraft components and wires less
susceptible to EMI. Other typical waveforms that are than six inches long need not be numbered.
more susceptible to EMI have the following
characteristics: Electrical Component Numbers
a. low voltage,
28. Electrical components such as switches, lights,
b. low current, and/or circuit breakers etc. which are installed during
modification, should be identified on wiring diagrams
c. slow rise times. using a code letter and sequential number. As different
aircraft manufacturers use various code letters for
24. SAE AS 50881 Wiring, Aerospace Vehicle, similar components, it is recommended that the coding
requires sensitive wiring to be routed to avoid convention, used by the manufacturer on original aircraft
electromagnetic interference. SAE AS 50881 Appendix wiring diagrams, be retained.
B allows for, but does not mandate, the identification of
EMI sensitive wires and cables with a category code
added to the significant wire number. In the past, EMI
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
Circuit Circuit
Function Circuits Function Circuits
Letter Letter
A UNASSIGNED B PHOTOGRAPHIC
Oil pressure
B PHOTOGRAPHIC Manifold pressure
Mapping camera Fuel pressure
Camera intervalometer Propeller anti-icing fluid quantity
Camera doors Engine oil quantity
Camera heaters Tachometer
Warning Synchroscope
Warning
C CONTROL SURFACE
Automatic pilot F FLIGHT INSTRUMENT
Booster Bank and turn
Control tabs Rate of climb
Diving brakes Directional gyro
Flight Air position
Horizontal stabilizer Ground position
Landing flaps Compass (including flux gate and
Water-rudder position other stabilized compasses)
Trim tabs Gyro horizon
Wing flaps Attitude gyro
Warning Driftmeter
Altimeter
D INSTRUMENT (other than flight Airspeed
or engine instruments) Accelerometer
Ammeter Pitot-static tube heater
Oil-flap position Warning
Cowl-flap position
Coolant-flap position G LANDING GEAR, WING FOLDING
Air pressure Actuator
Free air temperature Retraction
Landing gear position Wheel brakes
Hydraulic pressure Down lock
Cabin pressure Ground safety
Carbon monoxide Wheel steering
Landing-flap position Up lock
Propeller pitch position Wheel spinning
Instrument vacuum pump Warning
Horizontal-stabilizer position
Trim-tab position H HEATING, VENTILATING, AND DE-ICING
Water pressure Anti-icing (general)
Voltmeter Battery heater
Clock
Cabin heater I UNASSIGNED
Cigarette lighter
De-icing (general) J IGNITION
Heated flying suits Booster
Gallery Vibrator
Windshield defroster Distributor
Windshield defogger Electronic
Windshield de-icer Magneto ground wiring
Heater blanket Warning
Oil immersion heater
Refrigeration K ENGINE CONTROL
Cabin supercharger Carburettor air flap
Ventilation Blower ratio
Water heater Cowl flap, air shutter
Intercooler flap
E ENGINE INSTRUMENT Oil cooler shutter
Carburettor air pressure Propeller feathering
Bearing temperature Propeller synchronizer
Tailpipe temperature Propeller pitch
Carburettor anti-icing fluid quantity Supercharger regulator
Fuel mixture Starter
Torque meter Warning
Brake mean effective pressure
Fuel flow L LIGHTING
Fuel quantity Approach
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
Circuit Circuit
Function Circuits Function Circuits
Letter Letter
E ENGINE INSTRUMENTS (continued) L LIGHTING (continued)
Fuel capacity Cockpit
Cylinder head temperature Drift
Oil temperature Cabin
Interior S RADAR
Instrument SA - Altimeter
Section (fuselage) SM - Mapping
Landing SN - Navigation
Exterior SR - Recorder
Running, position, navigation SS - Search
Passing SW - Warning
Search SX – Recognition - transponder
Taxi
Anchor T SPECIAL ELECTRONIC
Warning
TB - Radar control
M MISCELLANEOUS ELECTRIC TC - Radio control
Windshield spray TD - Airborne announcing
Bilge pump TF - Repeat back
Cargo door TL - Attitude indicator
Water distillation TN - Navigation
Windshield wiper TP - Beacon (crash and locator)
Hoist TQ - Transmitters and receivers
TR - Receivers
Positioner; seat, pedal TT - Transmitters
Circuit function and circuit designation letters of electrical and electronic wires and cables should be as specified
herein. Typical circuits are listed under their respective circuit functions.
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
75mm 1m 1m 75mm
CAUTION MAX MAX
H215A20 H215A20 H215A20
Do not use metallic markers or bands for
identification. Do not use any method of marking that
may damage or deform the wire or cable insulation.
Figure 2–3 Location of Identification Sleeve
NOTE
MULTICONDUCTOR CABLE IDENTIFICATION
Use sleeves only if wire cannot be marked directly.
33. Multi-conductor cables may be identified by
marking directly onto the outer sheath using a laser
MARKING OBJECTIVES marking machine or with pre-marked sleeves (refer
Figure 2–4) installed as described in paragraph 44.
30. Which ever method of marking is used, ensure Immediately following each wire identification number,
marking is legible, and that colour of marking contrasts indicate the colour of the individual conductor as detailed
with the wire insulation or sleeve. in Figure 2–1 using the following abbreviations:
Black - BK Blue - BL
Brown - BR Violet - VT
Red - RD Grey - GY
Orange OR White - WH
Yellow - YE Pink - PK
Green - GN Purple - PR
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AC 21-99 A
Aircraft Wiring and Bondin
ng
Sect 2 Chap
p2
Figu
ure 2–4 Multicconductor Cab
ble Identificatio
on
Figure 2–6
6 Wire Identiffication at Term
minal Board
WIRE
W MARK
KING
39.
3 Excimer Laser marking is the reco ommended wire
marking
m meth hod. It is a rapid, non n-contact, no on-
aggressive
a priinting techniquue that relies on alteration of
F
Figure 2–5 Coaxial Cable Identification
I the
t Titanium Dioxide (TiO O2) pigment present in the
insulation matterial. This wirre marking method produces
a high contrasst, high definitiion, permanen nt mark on mo ost
THERMOCOUPLE WIRE
W IDENT
TIFICATION single
s wire and multi-ccore cables without any
degradation
d o the insulatio
of on. Laser marking should be
carried
c out ini accordancce with the manufacturer’s
36. Thermocouple wire, w which is usually du uplexed instructions.
(two insu ulated conducctors laid side e by side), may
m be
difficult to
o mark legiblyy. Where slee eves are utilissed, the
wire size in the identificcation code sh
hould be repla aced by 40.
4 Hot stam mp marking d t insulation of
directly on to the
a dash. The
T material designation sha all be as follow
ws: aircraft
a electriical wire and cable is nott recommende ed
due
d to the degradation
d th
hat may be caused to the
CHROM – Chromel CONS
S – Constantan
n insulation and because alte ernate, improvved identificatio
on
ALML – Alumel
A COP – Copper methods
m are available. WWhere hot sta amp marking is
determined
d to
o be the most appropriate marking
m metho od
IRON – Irron (eg
( large conductors and d heat shrink k sleeving) the
details
d i Table 2–2 are provided to assist in the
listed in
selection
s of the approprriate marking g foil, marking
temperature
t a dwell time.
and
WIRE ID
DENTIFICAT
TION AT TER
RMINAL BOARDS
AND ENNCLOSURESS NO
OTE
Store foils at
a approximate
ely 22°C and
d 60% relative
e
37. If possible,
p markk wires attacheed to terminal boards
humidity.
and equiipment termin nals between termination anda the
point wheere wire enterrs the wire bundle (refer Fig
gure 2–
6). Identify wires termiinating within an enclosure, inside
osure, if space
the enclo e permits. SET-UP
S OF MARKING M
MACHINE FO
OR WIRE
STAMPING
S
SELECT
TION OF IDE
ENTIFICATIO
ON SLEEVIN
NG 41.
4 After se
electing the prroper machine
e for the job, set
s
it up for the maarking procedure as follows
s:
38. For general airfrrame wiring, in i most appliccations,
heat-shrin
nkable polyetthylene tubingg should be used
u to a. From Table
T 2–3, sellect the corre
ect size type for
f
identify wire
w that cannnot be marke ed directly. Avvailable the wirre to be m marked. Make e up require ed
sizes are given in Secttion 2, Chapter 4. identificcation code aand insert intto type holde er,
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
Foil Part Number Colour Insulation Type Marking Temperature Dwell Time
c. Select wire guide into which wire will fit snugly. and tie at each end with clove hitch and square knot.
Refer to Section 2, Chapter 8 for method of tying and
d. Install wire guide and roll of marking foil on knotting. When heat shrinkable tubing is used, ties are
machine. Slide type holder into slot provided for it. not required. Before installing heat shrinkable tubing on
the wire, make sure that the wires are clean. Instructions
for installation of heat shrink sleeving are provided in
Table 2–3 Recommended Sizes of Marking Type Section 2, Chapter 4.
a. Select type size and wire guide to suit OD of IDENTIFICATION OF WIRE BUNDLES AND
tubing. HARNESSES
b. Select mandrel (metal rod) of a diameter that will 44. Identify wire bundles and harnesses (see Figure
fit snugly inside tubing. Insert mandrel into tubing, 2–8) by one of the following methods:
and both into the wire guide. If a mandrel of
proper size is not available, use a piece of a. If bundle is not too large, select sleeving of proper
insulated wire of suitable diameter and length. size to fit snugly over wire bundle. Stamp with
identification marking as described in paragraph
c. Prepare type to provide required wire number. 45 and install on bundle approximately 30cm from
each terminating end. Tie securely at both ends.
d. Select foil and install wire guide, foil, and type
holder on machine.
NOTE
Sleeving must be installed on bundle before attaching
INSTALLING IDENTIFICATION SLEEVES ON wires to connectors.
WIRING
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AC 21-99 Aircraft Wiring and Bonding
Sect 2 Chap 2
(6) Close tool handles all the way to cut off the
excess strap. Figure 2–8 Identification of Wire Bundles and
Harnesses
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AC 21-99 Aircraft Wiring and Bonding
Annex A to Sect 2 Chap 1
Blank Page
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