ELECTRICAL WIRINGTable of Contents ELECTRICAL WIRING Subject Page Aircraft Wiring Diagrams and Wiring Harness 23 Wiring Identification Codes 24 TEFZEL Wire 26 Reference Designation 240 ‘Symbols 212 Electric Systems-General Troubleshooting 216 Review 247 “4 12EPOESMLENG 2008072100762 24 {© 2012 Bo HoleaporTentron ine. - For Tring Purposes OnyELECTRICAL WIRING Terminal Objective: At successful completion, the student will be able to troubleshoot, inspect, perform and/or supervise maintenance of the Bell 412 helicopter Electrical System up to but not including major repair and/or overhaul of the helicopter and its components. Enabling Objectives: 1. Describe the electrical wiring, tools, diagrams, and reference designators of the 412 aircraft. 2. Identify symbols of the 412 Electrical system. “S12EPO-ESMENG-20080731-00.76-2 22 (©2012 Ball Hooper Texton ne - For Taring Purposes OnlyELECTRICAL WIRING AIRCRAFT WIRING DIAGRAMS & WIRING HARNESS Wiring Diagrams The purpose of wiring diagrams is to provide maintenance personnel a means of analyzing electrical circuits by obtaining specific information as to hamess connections, individual wire identification and function as well as component and system function and requirements. Harness Routing Harness routing in the 412EP is accomplished by the most direct and unobstructed means available within the airframe structure. This usually is accomplished through lightening holes within the ship. The hamesses are attached to the airframe by use of a clamping arrangement down the length of the hamess. The size of clamp used in all cases is one that sufficiently compresses and holds the hamess in place, but does not cut into the wire insulation or physically crush the bundle. In the case of coax cables, special precautions must be taken in order not to crush the cable by too small a clamp. All primary and backup system harnesses are routed separately so that in that event of damage to the harness the other is still capable of complete function. All antenna coax cables by the very nature of their use are routed separately from all other cables, harnesses, and wiring bundles so as not to receive any electrical interference induced from other wiring. Provisions have been incorporated in the helicopter to accept alll available avionic kits. Cable assemblies and wiring have been provided with wires and connectors stowed in the helicopter at locations where units and components are installed. “s12EPO-ESM-ENG 20080731.00762 23 (©2012 Bel Heloptr Texto ne. - For Trang Purposes OryELECTRICAL WIRING WIRING IDENTIFICATION CODES WIRE IDENTIFICATION CODES CIRCUI System Nomenclature ELECTRICAL c Control Surfaces (SCAS) Engine instruments, F Flight instruments © Landing Gear Heating, Ventilation and De-icing Ground Letter J Ignition Wire size number K Engine Controls Wire segment etter Lighting Wire number M Miscellaneous Electrical ‘Gtreuit Function letter N Ground PDC Power @ — Fustand oi! VBC power and DC eontrl cables for AC W > Waming and Emergency X AC Power AVIONICS ‘ADF Automatic Direction Finder ALT Raclo Altimeter AUD Aucovintezcom 2 AUD-37 A 20 CMP Gyro Compass DME Distance Measuring Equioment Ground Letter MKR Marker Beacon ReceNver Wire size number N Ground Wire segment eter NAV Navigation Wire number VHF Very High Frequency Communication CGreutt Function letter XPDR —Transoonder ‘System number NOTE: Number preceding cicut function indicate (See Note —o-) the number of systems, Example. 24UD37A2ON. 4:26PO-E9M-ENG-20080731-007-2 24 (©2012 Bol Hetcopter Textron Ine. ~ For Tahing Purcees OnlyELECTRICAL WIRING WIRING IDENTIFICATION CODES (CONTINUED) Wiring Identification Electrical and avionic systems may be identified by means of circuit function code letters. An example of each is provided on the previous page. The method of marking of the individual wires is standard identification as is described by the wiring identification code. In addition to the individual wire identification, the wiring diagram supplies connector identification information by number and type J-901, P-403 Notes sNZEPOESMLENG 20060731-0076-2 2-5 © 2012 Be Heleopter Textron ne —For Ting Pupones OnlyELECTRICAL WIRING TEFZEL WIRE The state-of the art in electronic equipment and material has dictated many changes in the design philosophy of the Bell Helicopter Textron engineer. Operational requirements have created additional systems which enhance the mission for the operator. System miniaturization in the electrical and avionics field prevents use of larger types of wire because of the high density wiring of the attaching plugs and terminal system junctions. The addition of electrical equipment and its associated wiring and cabling to the airframe has plagued the engineer with space and weight penalties. Therefore, a search for a type of wire, which offers space and weight savings, low and high temperature operability, non-flammability, and high abrasion characteristics, is continuous. The wire that best meets this requirement at the present time is known as TEFZEL (Raychem registered trademark) and has been accepted by most of the major airframe manufacturers TEFZEL, as well as many other new products, requires a different concept in field maintenance and repair. Airframe wire constructions have dual-wall insulation necessary for high-durability applications. The inner extrusion is contrasting in color to the outer extrusion, or primary jacket, to provide an indicator for possible damage caused during installation or through physical wear. Bell Helicopter uses different types of TEFZEL wire/cable. Wire Type Construction M22759/41 is constructed of nickel-plated soft annealed copper with a single extrusion of ethylene tetrafluoroethylene copolymer (ETFE), also referred to as TEFZEL. 30-284 is a Bell standard and is constructed using M22759/41 wire for AWG22 thru 12 and M22759/42 wire for AWG24. The wire(s) have an overbraid of tin coated soft annealed copper with an outer jacket of ETFE insulation. Wire is available in one to seven wires per cable with individual wire colors. 30-285 is also a Bell standard and is constructed of M22759/41 wire for AWG22 thru 12, and M22759/42 wire for AWG24. The wire(s) are twisted, unjacketed, and unshielded. Wire is available in two to seven wires per cable with individual colors. Stripping Stripping of TEFZEL insulation from the wire(s) requires additional care in that the insulation is as thin as .008 - inch minimum dual-wall insulation. The standard stripper or pocketknife cannot be satisfactorily used in the stripping operation without cutting or nicking the wire strands. -s126Po.ESM-ENG-20000731-00.16-2 26 (©2012 Bel Heleptr Texton ne ~FotTahing Purposes OniELECTRICAL WIRING TEFZEL WIRE (CONTINUED) Plier-type hand strippers are the easiest and most reliable to use, but only if equipped with blades designed for TEFZEL type wire. The Ideal Industries, Inc., hand stripper frame, P/N 45-1654, with blades P/N 45-1987-1 for wire size AWG26 thru 16 blades and PIN 45-1611-1, for wire size AWG 14 thru 10, is used by Bell Helicopter. Criteria used by BHTI for inspection of damaged strands per wire size are as follows: AWG24 thru 14 0 AWG12 1 AWG10 2 AWG8 thru 4 4 AWG2 thru 00 12 Wire Marking Wire segments greater than 6" shall be marked every 3°. Soldering Tin-coated and silver-plated conductors present no problems where soldering is required. Common 60/40 or 63/37 resin solders produce acceptable solder joints. With the nickel plated conductors as in the above wire types, an active flux solder or the addition of an active flux helps in producing a reliable solder joint. Kester solder "44" and Kester liquid flux No. 185 or equivalents are products that aid in soldering nickel-plated conductors. Care should be used in soldering to prevent excessive wicking of solder under the insulation. Excessive wicking can be determined by visually examining the solder connection. If the contour of the individual strands of the conductor is not visible below the termination of the insulation, excessive wicking has occurred. «412ePO.ESMENG-20080731-00-762 27 (© 2012 Be Helcptar Teton ne. — For Training Puposos OnlyELECTRICAL WIRING Wire Support Broken wires have plagued the aerospace industry for years and in most cases, the break could easily have been prevented. After the material has been in service for a while and experience is gained in handling the wire, the problems are greatly lessened, Other than plating, the conductor used in general service airframe wiring has always been soft annealed copper. Conductor breakage can virtually be eliminated with care and attention to the area of wire termination. 1. Wire must be routed and clamped such that under vibration or maintenance conditions, any flexing of the wire does not occur at the termination of the insulation. 2. Crimp contact connectors should have either a strain relief or a rubber sealing grommet on the rear of the connector. 3. When installing crimp terminals, always be sure that the wire is installed far enough in the terminal that crimping the insulation grip of the terminal has contacted the wire insulation. 4. The greatest care should be taken where a solder termination is required on any device mounted in the airframe. Wire breakage at solder joints is usually due to the fact that small gage wire is used and poor soldering techniques result in excessive wicking of the solder under the wire insulation. Before making the solder connection, place a suitable piece of heat shrinkable sleeving over the wire. After soldering, slide the sleeving over the soldered joint as far as practical and shrink it to its minimum recover diameter, Damaged Wire and Cable It is common that some minor damage is incurred on wire and cable during maintenance. If minor damage is detected, it is not always necessary to replace the damaged wire. To determine the acceptability of the damaged wire, inspect with a 10x magnification to determine if underlying wraps are damaged. If the outer extrusion is damaged, the wire must be replaced. “412€PO.ESM-ENG-20000731-00.16-2 28 (© 20%2 Bet Heleptr Texton ne —Fot Tring Puposes OnELECTRICAL WIRING Notes “12EPO-ESM-ENG 2000721-.00-70-2 29 (©2012 Bell Heeoper Teatro Ine ~ Fo Tring Purposes OnlyELECTRICAL WIRING REFERENCE DESIGNATION Standard Practice Manual (SPM) REFERENCE DESIGNATOR CODES 9A1P3 os sgl Bi | Item No, 4 * Unit Letter SYSTEM CODES System Propulsion Systems DC Power AC Power Pilot Instruments & Panels Copilot Instruments & Panels Lighting/Caution Warning SCASIAFCS Utiity Systems/Environmental Head-Up Display Systems Data Sensors Interface Systems ‘Communications Navigation 24 kids * Unit and Item Nunbers per USAS Y32.16. (United States of America Standards Institute) 4128POESI-ENG 20060731-0076-2 240 COMPONENT CODES Code ‘System A Box/Panel AR Adaptor B Pressure Transmitter CB Circuit Breaker CR Diode CP Control Panel DS _ Indicator (Electrical) E Antenna FL Fitter J Receptacle/Junction kK Relay L ‘Solenoid/Valve/Compensator M Mechanical indicator MP Gyro Pp PlugiConnector PS Power Supply RE Receiver s Switch sa Squibb TR Transmitter TB Terminal Board WT Wite Terminal VR Voltage Regulator Zz Sensor/Network (©2012 Ball Hlcoptr Texto ne. -FotTaning Purposes OnyELECTRICAL WIRING REFERENCE DESIGNATION Each reference designator consists or a System Number, Unit Number, and Item Number. Electrical and avionics systems may be identified by means of circuit function code letters as shown in the example above. Notes -4126Po.ESMENG-20080731-00-T62 211 ©2012 Gell Heteopter Text ne. ~ For Taring Purposes OnlyELECTRICAL WIRING SYMBOLS CONNECTORS m—l— caPACITOR ‘TRANSFORMER: [STARTER-GENERATOR “4 128POESM-ENG-20080731-00-76-2 212 ©2012 Bat Helcopter Teton Ine. For Tring Purposes OnlyELECTRICAL WIRING SYMBOLS (Continued) LIGHTS o “Ons cocker aH? a wo os SINGLE POLESINGLE THROW PUSHLON PUSH.OFF evRTCH —_— «4 12ePO-ESM-ENG-20080731-00-76-2 2:13 ©2012 Bel Heleopter Teron ne. — For Traring Purposes OnlyELECTRICAL WIRING SYMBOLS (Continued) ANTENNAS Fe conn ny ii foj =e NNT elt} ARCORE IRON CORE InoueToRs Se (am MELDED RES CABLE snr w.meurt— - apa! ONO Nona. WeuTE— + mst OPERATIONAL AMPLIFER THERMOCOUPLE HARNESS AesisTOR “4125P0.ESM-ENG-20060731-00-76-2 214 ©2012 Ber Hecopter Texton ne. For Training Purposes OnlyELECTRICAL WIRING Notes “s12EPO-ESMLENG 2008073100762 215 ©2012 Bat Heleapter Toston ne. — For Training Purposes OnlyELECTRICAL WIRING ELECTRICAL SYSTEMS GENERAL TROUBLESHOOTING The troubleshooting procedures are general in nature and may be used as a guide to find a malfunction in an electrical system. Refer to the applicable system operational check and troubleshooting chart(s) for a specific fault. Make sure that the system and component operation is understood prior to proceeding with any troubleshooting. Do the easiest or the most obvious step first. 1. Make sure that the electrical power is supplied to the electrical components that are suspected to be defective. Make sure that the ground connections are tight and properly installed. Refer to the applicable wiring diagram (Chapter 98) for the system. 2. Make sure that switches, relays, diodes, and the other miscellaneous electrical components are serviceable 3. Examine the wires, the connectors, and the terminal junctions. Make sure that they are in good condition. Make sure that the connections are properly connected and are tight. 4. Make sure that each component of a system operates correctly. “4 12¢PO-ESM-ENG-20060731-00-76.2 2:16 ©2012 Bet HetcopterTexton ne - For Traning Purposes CniyELECTRICAL WIRING Notes ‘N2EPO-ESI-ENG 20080737.00.76-2 2-17 © 2012.el HoicoperToxton ine. For Training Purposes OnlyELECTRICAL WIRING REVIEW 1. Select the location of the schematic wiring diagrams for the 412EP helicopter electrical system. Maintenance manual, chapter 96. Maintenance manual, chapter 97. Maintenance manual, chapter 98. Flight manual. aloe 2. Give the wire size number from the following wire identification: L15C20N. 15C2 15 20 15C20 aeop 3. The reference designation 9A1P3 refers to: Lighting system component value. Engine system component manufacturer. ‘Automatic Flight Control System component. Component voltage (AC or DC). goon {4 12EPO-ESMENG-20080731-00-76:2 21B © 2012.el HetcoperTexton Ine Fr Trning Purposes Oy