EWIS

MOD 7
 DESCRIPTION ABOUT VARIOUS CONDUCTORS

• WIRE: It is a single solid conductor or a stranded conductor covered with an

insulating material .
• CABLE: It is having two or three or more separately insulating wire in one
jacket. It has four types of cables i.e. Multi-conductor cable twisted cable,
shielded cable and co-axial cable.
• Multi- conductor cable : It is having two or more separately insulated wire
in one jacket.
• Twisted cable: Two or more separately insulated wire twisted together.
• Shielded cable: One or more insulated wires covered with a metallic
braided shield.
• Co-axial cable: A single insulated centre
 DIFFERENCE BETWEEN SOLID &
STRANDED
SHIELDED CONDUCTOR
CABLE
CO AXIAL CABLE
VARIOUS CABLES
 ROLE OF WIRE SIZE
The wire used for aircraft electrical installations is
sized according to the American Wire Gauge (AWG).
The wire diameters become smaller as the gauge
numbers become larger. The largest wire size number
is 0000 and the smallest wire size number is 40. The
wire ranging in size from number 0 to 36 are being
used commonly. The wire to be measured by using
standard wire gauge (Fig ) The gauge numbers are
usually stranded to increase the flexibility
STANDARD WIRE GAUGE
FACTORS TO BE CONSIDERED WHILE
SELECTION
• POWER LOSS I2R : This loss represents electrical energy converted into heat,
that is I2R loss. The use of large conductors will reduce the resistance and
therefore I2R loss will be minimum. Large conductors are more expensive and
they are heavier and required more substantial supports.
• VOLTAGE DROP ( IR Drop) : The source maintains constant voltage at the input
to the line, any variation in the IR drop in the line causes poor voltage regulation
at the load. The obvious remedy is to reduce either current or resistance . A
reduction in load current lowers the power transmitting where as a reduction in
line resistance increases the size and weight of the conductor. A compromise is
generally reached where by a oltage variation at the load is swith in the
tolerable limits and the weightof the conductor is not excessive. The maximum
allowable voltage drop between the bus and the electric components according
to the nominal voltage of the system is given below.
 PERMISSIBLE VOLTAGE DROP
NOMINAL SYSTEM ALLOWABLE VOLTAGE DROPE

VOLTAGE CONTINOUS OPERATION INTERMITTENT

OPERATION

14 0.5 1.0

28 1.0 2.0

115 4.0 8.0

200 7.0 14.0

 CURRENT CARRYING ABILITY OF THE CONDUCTOR

When current is flowing through the conductor heat is generated. The

temperatures of the wire will rise until the heat radiated or otherwise
dissipated is equal to the heat generated by the flow of current in the line. If
the conductor is insulated the heat generated in the conductor is not so
easily removed as it would be if the conductor is not insulated. So to
maintain the insulation of the conductor, the current through the conductor
must be limited to a certain value. The maximum allowable operating
temperature of insulation conductor varies with the type of insulation being
used. The following table gives few examples of safe current ratings for
various sizes and types of conductor covered with various types of
insulation.
Current Carrying Capacity Of Wire Having Different Type Of Insulator

SL.NO SIZE RUBBER THERMO IMPREGNTED ASBESTOS SLOW

OR
PLASTIC ASBESTOS BURNING
THERMO
ASBESSTO WEATHER
PLASTIC
PROOF

1 0 195 Amps 245 Amps 305 Amps 325 Amps 235 Amps

2 4 105 Amps 135 Amps 170 Amps 180 Amps 130 Amps

3 8 55 Amps 70 Amps 90 Amps 100 Amps 70 Amps

4 12 25 Amps 40 Amps 50 Amps 55 Amps 40 Amps

 IDENTIFYING WIRE AND CABLE:

To facilitate installation and maintenance, all

wiring should be indelibly marked with wire
identification numbers. Aircraft electrical system
wiring and cable may be marked with combination
of letters and numbers to identify the wire, the
circuit it belongs to the gage number and other
information necessary to relate the wire to a wiring
diagram . Such markings are called the
identification code
 LETTER FOR VARIOUS SYSTEMS
Electrical wires or cables may be identified by both numbers and letters, especially on
large aircraft. For example, on a typical airliner the following letter system is used to
identify specific circuits.

AC power X Deicing and anti-icing -D

Engine control K Flight control -C
Engine Instrument E Flight Instruments -F
Fuel and oil Q Ground network -N
Heating and ventilating H Ignition -J
Inverter control V Lighting -L
Miscellaneous M Power -P
Radio navigation and R Warning devices -W
Communication
 WIRE IDENTIFICATION
Numbers used with the letters for identification also have a specific
purpose. In the identification number 2P28IC-20, there are two letters
and three separate numbers. The number 2 indicates that the wire is
associated with the No.2 engine, and the letter P means that the wire is
a part of the electric power system. The number 281 is the basic wire
number and remains unchanged between the electric units of any
particular system regardless of the number of junctions the wire may
have. The letter C identifies the particular section of wire in the circuit,
and the number 20 indicates the gage of the wire
WIRE IDENTIFICATION CODING
 VARIOUS METHODS OR WIRE
INSTALATION
Open wiring : Any wire , wire group, or wire bundle not enclosed in conduit. 
Wire group : Two or more wires going to the same location tied together to retain
identity of the group.
Wire bundle : Two or more wire groups tied together because they are going in the
same direction at the point where the tie is located.
Electrically protected wiring – Wire which include (in the circuit) protection against
overloading ,such s fuses, circuit breakers or other
current limiting devices.
Electrically unprotected wiring : Wires (generally from generators to main bus
distribution points) which do not have protection, such
as fuses, circuit breakers, or other current –limiting
devices.
 NECESSITY OF WIRE ROUTING
All wires and wire groups should be routed and installed to protect
them from:
1. Chafing or abrasion
2. High temperature
3. Being used as handholds, pr as support for personnel belongings
and equipment.
4. Damage by personnel moving within the aircraft.
5. Damage from cargo stowage or shifting.
6. Damage from solvents and fluids.
 WIRE ROUTING METHODS
THE VARIOUS METHODS OF ROUTING OF WIRES ARE
GIVEN BELOW

1. OPEN LOOM
2. DUCTED LOOM
3. CONDUIT LOOM
 RULES REGARDING WIRE ROUTING
SPLICED CONNECTIONS IN WIRE BUNDLES: Spliced connections in wire
groups or bundles should be locked so that they can be easily inspected.
Splices should also be staggered so that the bundle does not become
excessively enlarged. All non insulated splices should be covered with
plastic, securely tide at both ends.

BEND RADIAL : Bends in wire groups or bundles should be not less than 10
times the out side diameter of wire group or bundle. However, at the
terminal strips where wire is suitably supported at each end of the bend. A
minimum radius of three ties the outside diameter of the wire ,or wire
bundle is normally acceptable
 LACING AND TYING WIRE BUNDLES:
1. Tying is the securing together of a group or bundle of wires by individual
pieces of cord tied around the group or bundle at regular intervals.
2. Lacing is the securing together of a group or bundle of wires by a
continuous piece of cord forming loops at regular intervals around the group
or bundle.
3. A wire group is two or more wires tied or laced together to give identity to
an individual system.
4. A wire bundle is two or more wires or groups tied or laced together to
facilitate maintenance.
The material used for lacing and tying is either cotton or nylon cord. Nylon
cord is moisture and fungus resistant, but cotton cord must be waxed before
using to give it these necessary protective characteristics
 SOLDER LESS TERMINALS AND SPLICES:

Electric wires are terminated with solder less terminal lugs to

permit easy and efficient connection to and disconnection from
terminal blocks, bus bars, or other electrical equipment. Solder
less splices join electric wires to form permanent continuous
runs. Solder less terminal lugs and splices are made of copper or
Aluminum and are pre insulated or un insulated, depending on
the desired application.

If the wire gets broken it can be joined with proper splicing

procedure if the wire is made of copper. Aluminum wires can not
be spliced as per the instruction of aircraft manufactures.
TERMINAL ENDS OF CONDUCTORS
 VARIOUS TYPES OF TERMINAL
ENDS
RING TYPE LUG
WIRE SPLICER PVC
CRIMPING PLIER
TERMINAL BLOCK
THANK YOU