Ewis Electrical Wiring Interconnect System: Created by Air CBS / M-006 1

EWIS
Electrical Wiring Interconnect

System
Created by Air CBS / M-006 1

What is EWIS?
• All wiring related components connecting
LRU’s such as:
– Wiring
– Cannon Plugs
– Modular Blocks
– Clamps
– Terminal Strips
– Etc.
Why the concerns about EWIS?
• History
– NTSB, following the TWA 800 accident, determined
that wiring inside a fuel tank developed a short
causing an explosion which downed the aircraft.
– Vice Presidential Committee – Gore – Commissioned
detailed study be performed on the health of aircraft
wiring in regards to aging of an aircraft.

– 1998 Ageing Transport Systems Rulemaking
Advisory Committee (ATSRAC) is formed.
– Evidence of ageing effects in airplane wiring
installations accumulating in 1980’s 1990’s
Valujet
Swissair MD-11

– Fuel Tank Ignition and Flammability Reduction
initiative (SFAR-88) ran in parallel with ATSRAC.
– Wiring induced failures that are potential ignition
sources in fuel tank system installations included in
ATSRAC tasking
– First two year of ATSRAC produced five reports.
– ATSRAC commissioned for a further two years to
turn reports into rulemaking.
– The FAA in conjunction with regulatory agencies worldwide
and industry developed a focus group to study the potential
problem.
• ATSRAC (Aging Transport Systems Rulemaking Advisory
Committee)
– Originally formed to perform non-intrusive, intrusive
Inspections and develop recommendations to the FAA
for Large Transport Aircraft. (ADs, SFAR)
• After the Payne Stewart incident, NTSB recommended
that all Transport Aircraft be included in ATSRAC study -
STA

ATSRAC – HWG10 - STA
WIRING EVALUATIONS
• 39 privately owned in-service a/c
–No Safety of Flight Concern
–2256 discrepancies
–73 of them are considered as significant* items
*Significant items need to be rectified/repaired for continued airworthiness

throughout aircraft operational life

WIRING EVALUATIONS
• No aging issue specific to wire insulation and
conductor were detected
• 29 % of discrepancies are inadequate clearance with
structure, racks, equipments
• 43 % of discrepancies are bad clamp conditioning/
sizing/ spacing
• 68 % of significant items are due to inadequate
clearance or bad clamp conditioning: sizing / spacing.
WIRING EVALUATIONS
The Zonal Inspection Programme in the MPD requires
General Visual Inspection (GVI) to be applied to a
zonal volume
Let us look at some wiring installation problems

Wires improperly tied, riding on hydraulic lines, contaminated
with caustic fluid

Bundle riding on structure

Heat Discoloration

Overheated wire at the splice

Bend radii problem- Less than 3 times the diameter

EWIS degradation
 EWIS degradation attributed to
Vibration
Moisture
Maintenance standards
Indirect damage –cross coupling effects associated with
other system fault conditions
Contamination –solid and fluid

EWIS degradation
Some contaminants are combustible materials
Fuel
Hydraulic oils
Toilet fluid
Scrim –dust and lint accumulation

Dust and lint accumulation

Extensive damage to a B767 cargo hold after a fluid leak onto
an electrical module resulted in arcing which started a fire in the
cargo hold insulation blanket

General Comments - From a/c evaluations
• Aircraft in good overall condition
• Reasons of Discrepancies
– Wiring Repair
• Training Issues
• Lack of use of OAM Standard Practice Manuals
– Routing of Modification Wiring
• Training Issues
• Lack of use of Industry Standard Guidelines
(AC43.13) and OAM Standard Practice Manuals
– Clamping and Structural Contact
• Training Issues
• Instructions for Continued Airworthiness Issues
Lessons Learned
• Before April of 2002 the Majority of the Working
Group was not Aware of EWIS - Concepts
• Based on the review of:
– Aircraft Evaluations
– Service History/ADs
– Intrusive Inspection Report
– HWG-6 through HWG-9 Final Reports

Lessons Learned
• HWG-10 determined areas of need:
– Awareness and Training
– Installation Guidance (FAA driven –
Standardization Issues)
– Inspection Criteria
– Maintenance Procedures
– Enforcement of Current Regulations

HWG-10 Recommended
FAA and industry implement an “EWIS Awareness” program
to effect cultural change
Rationale
– The aircraft evaluations support the need for TC and STC
holders, approvers, designers, installers, and technicians to
become more aware of the concepts of EWIS during design,
certification, installation and maintenance. HWG-10 feels
that the current regulations with slight modifications are
adequate if properly communicated and enforced.

FAA Actions
• FAR Part 147 Appendix E is revised to include the concepts
of AC 120-YY (EWIS, Detailed Inspection (DET), General
Visual Inspection (GVI), and Special Detailed Inspection
(SDI)).
Rationale
To fully effect a culture change, in the aviation industry, this
should include a “ground up” approach (e.g. future
technicians are trained from day one on EWIS concepts)

FAA Actions
• The following Advisory Circulars be revised to include EWIS concepts:
– 43.13
– 43.204
– 65-9A
– 65-11B
– 65-12A
– 65-15A
* concepts and language with standardized criteria for EWIS

Rationale
– These Advisory Circulars are the basis for certification, maintenance,
and training of industry personnel.
– “EWIS” concepts revision would generate awareness to a large group
of existing and future approvers, designers, installers, and technicians.
Installation Guidelines/Criteria
Standardization - Installation Guidelines must be FAA /
Industry driven
– Currently, Installation Guidance is based off of:
• AC43.13 – Outdated Needs to Be Revised to Latest
Technologies
– Current Non-Turbine Powered Aircraft have more
technology than AC can support
• ATA Spec 117

Inspection Criteria
Rationale
• There is a lack of Inspection Criteria for wiring and
its subcomponents.
• Development of this Criteria will ensure that
inspectors know what is to be inspected.

Maintenance Procedures
Recommendations
• Review existing manufacturer inspection/
maintenance programs and enhance for EWIS
considerations
• Manufacturer standards – wiring practices
– pass fail criteria
• Training program

Maintenance Procedures
OEMs and STC Holders to enhance the current Maintenance
Procedures
– Enhancement doesn’t necessarily drive to EZAP.
• Maintenance Program Development Philosophies of
the Various STA OEMs should be capable of enhancing
current programs incorporating concepts of EWIS
• Future Small Transport Aircraft Designs will most
likely follow the version of MSG-3 of that time period or
applicable analytical logic process of that time period.
Final Rules
FAA Final Rule issued October 22 2007
Enhanced Airworthiness Programme for Airplane

Systems/Fuel Tank Safety (EAPAS/FTS)
EASA work programme commits to 2008 issue of

harmonised requirement

FAA Final Rule
 3 FAA AC issued to accompany the EAPAS rule
AC 25.1701 –Certification of Electrical Wiring
Interconnection Systems on Transport Category Airplanes
AC25-27 –Development of Transport Category Airplane
Electrical Wiring Systems Instructions for Continued
Airworthiness Using an Enhanced Zonal Analysis
Procedure
 AC 120-94 –Aircraft Electrical Wiring Interconnection Systems
Training Programme

EAPAS Final Rule
 EAPAS Rule introduces Part 25 revised requirements for
 Design and certification of EWIS components –includes
wire
System Function
System Separation
System Safety –similar to 25.1309
Component identification
Fire protection
Electrical bonding and protection against static
 Circuit protection devices

EAPAS Final Rule
 EAPAS Rule introduces requirements for
Accessibility provisions
Protection of EWIS from environmental damage
Flammable fluid fire protection
Protection of EWIS from accidental damage
Flammable fluid fire protection
 ICAW –includes changes to Appendix H of 25.1529

EAPAS changes to FAA Part 26
 EAPAS introduces changes to FAA Part 26 to introduce
retrospective requirements on TC/STC Holders to develop
ICAW which comply with the Part 25 changes. This could
affect:
Wiring Standard Practises

Maintenance Manuals
 Maintenance Programmes –see EZAP procedure

EAPAS changes to FAA Part 121
 EAPAS introduces changes to FAA Part 121 to require
operators to incorporate
EWIS training programmes

EWIS required scheduled maintenance into maintenance
programmes
 EWIS required maintenance procedures

Enhanced Zonal Analysis Procedure”(EZAP)
EZAP analysis could result in

Cleaning tasks
Dedicated GVI –not precluded by ZIP
Detailed Inspections
These tasks would be in addition to the tasks
currently in the MPD and need to be incorporated by
the operators

Enhanced Zonal Analysis Procedure”(EZAP)
 Retroactive application of the “Enhanced Zonal Analysis

Procedure”(EZAP) to all turbine powered aircraft TC after 1
January 1958 with 30 seats or more, or greater than 7,500lbs
payload (cargo)
 TC and STC’sto be reviewed and EZAP applied, as

appropriate.
 Revisions to Maintenance Programmes

EASA Rulemaking
 EASA NPA 2007-1

 Similar to FAA rule
 Vehicle for retroactive application different
 EASA rules to be amended:
 Amendments to EASA 2042/2003 Part M, to revise:
AMC.M.A.302 for maintenance programmes, and
M.A.706 for training requirements
 Amendment to Part 66 syllabus module 7.7 to reflect EWIS
training recommendation

EASA Rulemaking
Introduction of three new AMC 20 leaflets:

AMC 20-21 EZAP - Programme to enhance airplane
Electrical Wiring Interconnection System (EWIS)
maintenance
AMC 20-22 EWIS Training Programme
AMC 20-23 Electrical Standard Wiring Practices
Manual

CS-25 Subpart H
Electrical wiring interconnection system (EWIS)
 New CS-25 Subpart H containing all wiring related requirements in one
place, titled Electrical Wiring Interconnect System (EWIS).
New subpart to contain new and revised wire related certification
requirements some taken from existing subparts of CS-25
 Amendment to appendix “H” of CS-25 Instructions for Continued

Airworthiness with associated AMC
 Creation of new Advisory Material in CS-25 book 2 to support the new

Subpart H and CS 25.1357(f)

CS-25 Special Condition H-01
Statement of Issue
To enhance the safety of large aeroplanes wiring systems, EASA has
developed in cooperation with FAA a regulatory package including new
and revised certification and maintenance requirements to address
shortcoming of current wiring systems design, installation and maintenance
practices. New certification requirements are contained in CS-25.
By letter EASA D (2008) CEXP/PME/84328 dated October 31st, 2008,

EASA has requested applicant for an EASA STC to conduct analyses and,
when required, develop Instructions for Continued Airworthiness (ICA) on
Electrical Wiring Interconnection System (EWIS) by 7th of June 2010 or
the date of issuance of the certificate whichever occur later.

Enhanced Airworthiness Programme for Airplane
Systems – ICA on EWIS
EASA AMC 20-21 (programme to enhance airplane EWIS maintenance)
and FAA AC25-27 (Development of transport category airplanes EWIS
ICA using an EZAP) provide additional guidance on whether the design
change necessitates a revision of the EWIS ICA.
The compliance plan for the STC must address whether the design change
for which approval is sought does necessitate a revision of the EWIS ICA
developed for that particular airplane model.

This Special Condition lists the requirements applicable to
Supplemental Type Certificate (STC) installed on Type Certified
aeroplane, where the development of basic EWIS ICA derived
from an Enhanced Zonal Analysis Procedure (EZAP) has been
enforced, having:
a- a maximum type-certificated passenger capacity of 30 or more ; or

b- a maximum payload capacity of 3402 kg (7500 pounds) or more

Following these criteria, each applicant for a STC must
develop and submit for approval by the Agency,
Instructions for Continued Airworthiness (ICA) derived
from the ENHANCED ZONAL ANALYSIS
PROCEDURE (EZAP), for the representative aeroplane’s
Electronic Wiring Interconnection System (EWIS) as defined in
CS 25.1701 in accordance with CS-25 Appendix H paragraph
H25.5 and AMC appendix H 25.5 paragraphs 1 and 6 when the
Design change for which approval is sought does necessitate a
revision of the EWIS ICA.
Requirements
1. The applicant must conduct analyses if the STC requires a revision of
the Instructions for Continued Airworthiness (ICA) applicable to
Electrical Wiring Interconnection System (EWIS) as defined below
that include the following:
 Maintenance and inspection requirements for the EWIS developed
with the use of an enhanced zonal analysis procedure (EZAP)
that includes:
a. Identification of each zone of the airplane.
b. Identification of each zone that contains EWIS.
c. Identification of each zone containing EWIS that also contains
combustible materials.
d. Identification of each zone in which EWIS is in close proximity
to both primary and back-up hydraulic, mechanical, or
electrical flight controls and lines.
Requirements
e. Identification of :
Tasks, and the intervals for performing those tasks, that will reduce the
likelihood of ignition sources and accumulation of combustible material, and
Procedures, and the intervals for performing those procedures, that will
effectively clean the EWIS components of combustible material if there is
not an effective task to reduce the likelihood of combustible material
accumulation.
f. Instructions for protections and caution information that will minimize

contamination and accidental damage to EWIS, as applicable, during the
performance of maintenance, alteration, or repairs.
The ICA must be in the form of a document appropriate for the

information to be provided, and they must be easily recognizable as EWIS
ICA. Created by Air CBS / M-006 61
Requirements
2. For the purpose of this SC, the following EWIS definition applies:
(a) Electrical wiring interconnection system (EWIS) means any wire, wiring device,
or combination of these, including termination devices, installed in any area of the
airplane for the purpose of transmitting electrical energy, including data and
signals between two or more intended termination points. Except as provided for
in subparagraph (c) of this paragraph, this includes:
(1) Wires and cables.
(2) Bus bars.
(3) The termination point on electrical devices, including those on relays,
interrupters, switches, contactors, terminal blocks, and circuit breakers and
other circuit protection devices.
(4) Connectors, including feed-through connectors.
(5) Connector accessories.
(6) Electrical grounding and bonding devices and their associated
connections.

Requirements
(7) Electrical splices.
(8) Materials used to provide additional protection for wires, including wire
insulation, wire sleeving, and conduits that have electrical termination for
the purpose of bonding.
(9) Shields or braids.
(10) Clamps and other devices used to route and support the wire bundle.
(11) Cable tie devices.
(12) Labels or other means of identification.
(13) Pressure seals.
(b) The definition in subparagraph (a) of this paragraph covers EWIS

components inside shelves, panels, racks, junction boxes, distribution
panels, and back-planes of equipment racks, including, but not limited
to, circuit board back-planes, wire integration units and external wiring
of equipment.
Requirements
(c) Except for the equipment indicated in subparagraph (b) of this paragraph, EWIS
components inside the following equipment, and the external connectors that are part of
that equipment, are excluded from the definition in subparagraph (a) of this paragraph:
(1) Electrical equipment or avionics that is qualified to environmental conditions and
testing procedures when those conditions and procedures are :
(i) Appropriate for the intended function and operating environment, and
(ii) Acceptable to the Agency.
(2) Portable electrical devices that are not part of the type design of the airplane. This
includes personal entertainment devices and laptop computers.
(3) Fibre optics.

Requirements
3. The following can be used as a guide to assess the impact of the STC on
the EWIS ICA EZAP and re-application of EZAP to STC affected
zone:
Step 1: Does the STC:
- Affect or modify wiring or its environment,
- Install or result in wiring being located within 5 cm (2 inches) of
both primary and back-up hydraulic, mechanical, or electrical
flight controls,
- Change the density of the zone or
- Change the potential effects of fire in the zone?
Step 2: If answer to step 1 is “NO”, no further action required
Step 3: If answer to step 1 is “YES”, perform EZAP analysis

Requirements
Step 4: Determine if there is an existing (MRBR) EZAP
task(s) that is applicable and effective
Step 5: If answer to step 4 is “YES”, no further action

required because the existing EZAP derived maintenance
task(s) are adequate
Step 6: If answer to step 4 is “NO”, develop appropriate

task(s) and incorporate them into existing maintenance
program
Requirements
In case the initial assessment shows that no revision is necessary for the
EWIS ICA in accordance with AMC 20-21, this shall be substantiated as
part of the certification package for the approval of the STC.
In case the initial assessment shows that a revision to the EWIS ICA may
be necessary, the applicant for the STC of the affected airplane types
identified above must perform an EZAP analysis and must accordingly, if
necessary, submit final EWIS ICA to the Agency by 7 June 2010 or the
date of issuance of the certificate whichever occurs later.

Part 66 Training Syllabus Module 7.7
Annex III (Part66) to Commission Regulation (EC) 2042/2003 is hereby amended as
follows:
In Appendix I, “Basic knowledge requirements”, amend paragraph 7.7 of module 7 to
read:
7.7 Electrical Wiring Interconnection System (EWIS) Level
A B1 B2
1) Continuity, insulation and bonding techniques and testing; 1 3 3
2) Use of crimp tools: hand and hydraulic operated;
3) Testing of crimp joints;
4) Connector pin removal and insertion;
5) Coaxial cables: testing and installation precautions;
6) Identification of wire types, their inspection criteria and damage tolerance.
7) Wiring protection techniques: Cable looming and loom support, cable clamps,
protective sleeving
8) Techniques including heat shrink wrapping, shielding.
9) EWIS installations, inspection, repair, maintenance and cleanliness
standards

Differences from FAA / CS-25
Main differences with FAA text

FAA incorporates proposals from Electrical Systems
HWG and Wiring Systems HWG whilst EASA only uses
WSHWG product (ESHWG part already in CS-25)
Subpart H EWIS architecture and collector requirement
depth (25.1705) slightly different from the FAA version.
EASA has more in collector list.
Editorial differences due to different codes structure. No
technical difference

Differences from FAA / Appendix H
 Main differences with FAA text
 CS-25 Appendix H25.5 EWIS ICA (ED Decision 2009/013/R)
 Text is minimal to conform with philosophy of Appendix H
(Request for the applicant to provide EWIS ICA)
 ICA Content/Form moved to AMC
 No mention of approval in EASA text
 Technically equivalent to FAA text

Differences from FAA / FAR 26
EASA has no CS-26 like tool
Implementation through AD indicated in NPA
2007/01
Only TC holders identified in the original NPA
Original compliance dates:
16 December 2008 TC holders
16 December 2009 Operators

EASA Implementation Plan
 Objectives :
 Final rule June 2008
 Implementation tool for EWIS ICA in the form of EZAP will be
separate from rulemaking package
 See Yves Morier’s presentation on long term options and EAPAS
specifics
 Both TC holders and STC applications after final rule date will be
addressed
 Dates will be aligned with FAA:
TC holder to gain approval of enhanced ICAs by 10 Dec. 2009
(7 June 2010 for future STCs)
Operator implementation by 10 Dec. 2010 according to
M.A.302 (7 June 2011)
Rulemaking time frames
EASA timeline to be similar to that planned by FAA
EASA development could affect this timeframe

So now we know…
• Installation of wiring (EWIS) has not had the
awareness of the Approvers & Maintainers it
requires
• Concerns for installation & functionality of
equipment was the priority – not wiring
• Current practices will not be allowed to continue as is

Future - demands an EWIS
priority…
• Communicate through existing industry venues and
forums available and through FAA /EASA
• Enhance Maintenance Procedures – Instructions for
Continuous Airworthiness – both TC and STC
Holders
• Enhancement of Advisory Material both Current and
Future Development of EWIS Installation Guidance
• Inspection Criteria – Pass/Fail Inspection Criteria
for go/no-go decisions
Thank You!

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EWIS

Electrical Wiring Interconnect

Created by Air CBS / M-006 1

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*Significant items need to be rectified/repaired for continued airworthiness

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Let us look at some wiring installation problems

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* concepts and language with standardized criteria for EWIS

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Enhanced Airworthiness Programme for Airplane

EASA work programme commits to 2008 issue of

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Wiring Standard Practises

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EWIS training programmes

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EZAP analysis could result in

Created by Air CBS / M-006 51

 Retroactive application of the “Enhanced Zonal Analysis

 TC and STC’sto be reviewed and EZAP applied, as

 Revisions to Maintenance Programmes

 EASA NPA 2007-1

Created by Air CBS / M-006 53

Introduction of three new AMC 20 leaflets:

Created by Air CBS / M-006 54

 Amendment to appendix “H” of CS-25 Instructions for Continued

 Creation of new Advisory Material in CS-25 book 2 to support the new

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By letter EASA D (2008) CEXP/PME/84328 dated October 31st, 2008,

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a- a maximum type-certificated passenger capacity of 30 or more ; or

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f. Instructions for protections and caution information that will minimize

The ICA must be in the form of a document appropriate for the

Created by Air CBS / M-006 62

(b) The definition in subparagraph (a) of this paragraph covers EWIS

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Step 5: If answer to step 4 is “YES”, no further action

Step 6: If answer to step 4 is “NO”, develop appropriate

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