7.7a - Electrical Cables and Connectors

Summary of Annotations
Page 4
#1 Highlight (Shabbir)
Electrical safety practices do not replace regulations specified by manufacturers and authorities
There is a risk of electrocution if the ac or dc power stays connected to aircraft electrical circuits
Do not look into the end of a fiber-optic cable
Laser radiation is dangerous for eyes
There is a risk of laser radiation at the end of fiber optic cable, which human cannot see
Before you start work: open, safety and tag the circuit
breaker(s) related to the system/equipment to prevent the
supply of electrical power to the system/equipment during the
maintenance work
Some circuit breakers (A320 family only) have a red threaded
bush
a red threaded bush (in A320 family) prevents reset of the circuit breaker in flight (the crew cannot pull it)
The red threaded bush can be removed using a standard wrench
Page 5
Never use electric tools which deliver energy of more than 0.02 mill joule in fuel tanks or in areas where there are flammable vapors
Never use heat-generating tools in the fuel tanks or in areas where there are flammable vapors
Use only crimp-type contacts, terminals, splices, sleeves (nonheat shrinkable sleeves) in the fuel tanks or in areas where there are flammable vapors
when you use electric tools on the aircraft because
there are risks of electrocution or explosion
Some electric tools such as heat guns, soldering irons and tools without intrinsic protection are not permitted in the fuel tanks or in areas
where there are flammable vapors
Page 7
A concealed break in a cable core or at a connection may be found by using a continuity tester
A continuity tester normally consists of a low voltage battery (2.5 volts is satisfactory) and a test lamp or an ohmmeter
To prevent damage in continuity tester, the currents should be limited to 120 milliamps
Before continuity testing, the main electrical supply should be switched off or disconnected
Before continuity testing, all switches and circuit breakers, as appropriate, should be closed to complete the circuit
When carrying out a low voltage continuity check, it is essential to work progressively through the circuit, commencing from the relevant fuse or circuit
breaker and terminating at the equipment
Large circuits will probably have several parallel paths and these should be progressed systematically, breaking down as little as possible at plug and socke
or terminal block connections
While testing large circuits, it is valueless to check several low resistance paths in parallel
Excessive resistance in high-current carrying circuits can be caused by loose terminal connections, poorly swaged lead ends, etc
Faults due to loose terminal connections, poorly swaged lead ends, etc are indicated by low terminal voltage at the connections to the service load and by
heating at a conductor joint
If faults caused by loose terminal connections, poorly swaged lead ends, etc are suspected, a millivolt drop test is recommended
in case of faults caused by loose terminal connections, poorly swaged lead ends, etc, it is also acceptable to check along progressive sections of the system
accurately calibrated voltmeter
In millivolt drop test, for short-rated circuits, a suitable resistance or other dummy load should be used in lieu of the normal load and the current should
be scaled down to avoid overheating
The voltage drop across a joint, an approximate guide is 5 mV /10 amps flowing
Page 8
After installation and where specified in the Approved Maintenance Schedule or Test Schedule, aircraft circuits should be tested by means of a 250-volt ins
tester which should have its output controlled so that the testing voltage cannot
exceed 300 volts

In all systems having nominal voltages over 30 volts, cables forming circuits essential to the safety of the aircraft should be tested individually
Circuits having nominal voltage less than 30V may be connected in groups for test
Immediately after an insulation test, functioning checks should
be made on all the services subjected to the test
Prior to insulation test, the aircraft battery and any external supply should be disconnected
Prior to insulation test, all switches in the circuit concerned should be ‘ON',
dimmer-switches should be set at the minimum resistance position and micro-switches operated to the ‘ON' position
Prior to insulation test, in cases where the insulation resistance with the items concerned is not less than 2 megohms, the disconnection may be made by th
earth lead, leaving the item connected to the circuit
Page 9
The insulation resistance values are likely to vary with changes in the temperature and humidity of the local atmosphere
If the aircraft has been in damp conditions for some time before the test, low readings (insulation resistance values) can be expected
after completion of insulation tests, Results of tests and the temperature and humidity conditions at the time of the test should be recorded
Whenever possible,
functioning tests should be carried out using an external supply coupled to the ground supply connector
Where applicable, when one or more engines are
running, the power supply can be obtained from the associated
generators, due reference being made to the functioning of any
isolating relays
For certain circuits (e.g. standby lighting), functioning tests can
only be carried out using the aircraft battery system
Page 11
Bonding is the electrical interconnection of metallic aircraft parts
(normally at earth potential) for the safe distribution of electrical
charges and currents

Primary conductors are those required to carry lightning strikes
in bonding, The cross-sectional area of Primary Conductors made from copper shall be not less than ¼ inch by 26 s.w.g.
wire
where a single primary conductor used in bonding is likely to carry the whole discharge from an isolated section, the cross-sectional area shall be not
less than ½ inch by 26 s.w.g. wire
Aluminium conductors shall have a crosssectional area giving an equivalent surge carrying capacity as copper primary conductor
The cross-sectional area of secondary conductors made
from copper must not be less than 44 strands of 39
s.w.g. for braided conductors
Where a single secondary conductor wire is used for bonding, its size must be not less than 18 s.w.g
in the case of renewal or repair, if the original conductor cannot be matched exactly, a replacement manufactured of the same type of material, but of greate
crosssectional area, should be selected
Braided copper or aluminium cords fitted at each end with connecting tags or lugs (usually referred to as 'bonding jumpers'), should be used for bonding
connections between moving parts or parts subjected to vibration and these are suitable both as primary and secondary conductors
The tags or lugs on bonding jumpers are generally fitted by the 'Crimping method’
During assembly of the connections to aluminium cords, antioxidant (crimping) compound consisting of 50% by weight of zinc oxide in white petroleum
jelly and complying with DTD 5503 should be applied to the connections
Intermittent contact is worse than no contact at all
Page 12
bonding jumpers should not be excessively tight or slack
The run of all primary conductors should be as straight as possible; sharp bends must be avoided
where an engine is not in direct electrical contact with its mounting it should be bonded with at least two primary conductors, one on each side of the engine
Where applicable, bonding jumpers for control surfaces should be as flexible and as short as possible, of as low impedance as is practicable and should no
tinned.
Page 13
Flexible hose connections used for joining rigid pipes should be
bonded by fitting clips around the pipes approximately 13 mm
(0.5 inch) away from the hose and bridging with a corrugated
bonding strip or jumper
The soldering of broken ends of a fractured/broken bridging strip or bonding cord is prohibited
Not only must the flexible hose connection be bridged, but each
pipe run should be bonded to earth at each end, particularly
within a radius of 2.42 meters (8 feet) of any unscreened radio
equipment or aerial lead, where earthling bonds should not be
more than 1.5 meters (5 feet apart), or less distance apart, if
called for by the manufacturer
High-pressure flexible pipe assemblies are usually self-bonding
Metallic coatings, such as cadmium and tin, are satisfactory conductors and should not be removed for bonding purposes
If a poly sulphide compound is used for sealing the earth or bonding point, it must be ensured that the anti-oxidant to be subsequently applied will not have
detrimental effect on the sealing; e.g. DTD 5503 should not be used
When the connection has been made after bonding, any excess compound should be wiped off, using a rag damped in methyl ethyl ketone (MEK)
A corrosion washer is plated, or manufactured of a material having a potential such that when placed between materials of widely differing potentials it redu
the risk of corrosion caused by electrolytic action
Page 15
When earth terminal assemblies are also used to carry electrical supplies, a mill volt drop test, must be carried out.
Leads connected to earth terminal assemblies should be
of insulated cable with terminal tags fitted by the crimping
method
The maximum resistance values for the various conditions of bonding are summarized in the Table (CAA Requirements)
Table on page 13 of the book?

Bonding carrying the main electrical supply should be capable of carrying the full short-circuit current which can pass, without risk of fire or damage to the
bonding system
Page 16
#1 Text (Shabbir)
IMPORTANT
Page 17
A meter widely used for bond testing, consists of an ohmmeter operating on the current ratio principle and a single 1.2-volt nickel-alkaline cell housed in a w
carrying case
The associated cables for this common bonding tester are 60 feet and 6 feet in length and are fitted with a single-spike probe and a double-spike probe
respectively
Prior to carrying out a bonding test, a check should be made on
the state of the nickel-alkaline cell of the tester by observing:-
a) That a full-scale deflection of the meter is obtained when the two spikes of the 6-foot cable probe are shorted by a suitable conductor; and
b) That the meter reads zero when the two spikes of the 6- foot probe are shorted by the single spike of the 60-foot probe
The 60-foot lead of the test equipment should be connected to the main earth (also known as the bond datum point) at the terminal points, which are
usually shown diagrammatically in the relevant Aircraft Maintenance Manual.
When connecting the 60-foot lead to an earthling point,
any protective treatment (e.g. strippable lacquer) should be
removed at the point of contact
The 6-foot test lead should be used to check the resistance
between selected points
As an alternative to the common bonding tester, the four terminal method of resistance measurement may be adopted with the appropriate
miliohmmeter
With 4 terminal method type of instrument, a test current (approximately 2 amps) is supplied by the internal batteries and passed through the resistance
via cables
Page 19
Where an abrasive has been used it is

important to ensure that all traces of it are removed
Corrosion tends to form at a bonding or earth
connection and is often the cause of excessive
resistance
Where the required bond value cannot be obtained at a
structural joint the advice of the manufacturer should be
sought
The ohmmeter (used as bonding tester)is normally sealed in its case and no attempt should be made to open it; if a fault should develop, then the complete
instrument should be withdrawn from use and overhauled
Normally three standard test resistors are supplied for testing purposes regarding the accuracy of the tester and the readings obtained should be
within 10% of the standard ohmic values
Page 21
Crimping ensures electrical and mechanical connection of the
wire to an item of equipment or to a connecting system by

means of the end fitting
A properly crimped terminal provides a joint between the wire and the terminal as strong as the wire itself
The preferred crimping tool is a ratchet-type crimper that is periodically calibrated to ensure a consistent and proper crimp
Crimping tools come in different sizes indicated by the color coding on the handle
Hydraulic crimping tools are often used on wire gauge sizes 0
through 0000 because of the force required to properly crimp
the wire.
Page 23
Each crimping tool shall be submitted for gauging at(after) 1000 and 2000 crimps and only if successful, returned for use
The checking of crimping tool at (after) 3000 crimps shall be by gauging and specimen checks
All crimping tools not in regular use shall be similarly checked every 12 months to the gauging requirements
Each crimping tool or die shall be tested by the insertion of GO/NO GO gauge.
Page 25
After crimping, make sure crimping indents away from inspection hole
Page 26
The distance between the crimping barrel and the wire insulation must be less then 1mm
On completion of the crimping operation, the wire insulation must not be pushed back out of end fitting and sealing system
In specific cases where, by construction, the distance between rear face of the hard insulation is less then 3mm, this value is brought to 0.3mm max.
The maximum distance tolerated for the extension of the wire core out of the crimping barrel, connection side is 1.5mm
It is recommended that each crimp has a gentle manual pull applied in order to establish there is no movement of conductor within the crimp
Page 27
The rear-release method provides better front-end support for the contact; therefore, the contact is less likely to bend during reassembly of the connector
Page 29
Antennas are connected to most of the radio receivers and transmitters with a special type of shielded wire called “Coaxial Cable”
Coaxial cables contain two or more separate conductors
The insulation between inner and outer conductor in a coaxial cable is usually teflon or polyethylene.
The inner most conductor in a coaxial cable may be solid or stranded copper wire, and may be plain, tinned, silver plated or even gold plated
The remaining/outer conductors are in the form of tubes,

usually of fine braid
Outer coverings or jackets in a coaxial cable serve to weatherproof the cables and protect them from fluids, and mechanical and electrical damage.
Coaxial cables are shielded against electrostatic and magnetic fields

Since coaxial cables do not radiate, then likewise they will not pick up any energy or be influenced by magnetic fields
Coaxial cables have specific values of; impedance, capacitance per unit length and attenuation per unit length
while stripping a coaxial cable, The outer jacket must be cut off flat all round and at right angles to the longitudinal direction of the cable
Page 31
If the impedance of the line does not match the load impedance, not all the energy fed down the line flows into the load
To measure the VSWR (Voltage Standing-Wave Ratio),

“Time Domain Meter” (TDM) is used
In a Coaxial cable, if the line importance does not match load impedance, some of the energy is reflected back to the source, forming standing waves on
the line
The ratio of the voltage
across the line at the High V points to that at the Low V points is
known as the “Voltage Standing-Wave Ratio” (VSWR)

Measuring the VSWR on the line will
identify the position of the damage in the Coaxial cable
Page 32
Most aircraft manufacturers have adopted a method of coding wires and cables which conform to the ATA 100 specification. This method is often
referred to as ‘series coding'
Construction of the series code:
example: 3135-21B20N
digit 1-4 : wire number prefix

digit 5-6: wire number (the wire number can be upto 5 digits. explained later)
digit 7: segment letter
digit 8-9: wire gauge
digit 10: ground, phase or thermocouple suffix letter
Wire number prefix has the special job of determining in which system on the aircraft the wire or cable is located
A dash separates the ATA number prefix/wire number prefix from the wire number
A wire number consisting of a maximum of 5 digits is used to differentiate between wires, cables or co-axial cables in a particular sub system
If there was a switch or relaycontact between the two wires then the wire number would change because in this case, there would not be a permanent
connection between them
A different wire number is used for each
conductor not sharing a common connection
Page 33
Parallel or identical systems are identified with a 5 digit wire number
The first digit in a wire number indicates the specific parallel or identical system unit identification number such as Number 1 is AC generation System
A different letter is used for each segment sharing a common terminal or connection and having the same 4 digit ATA number
since the wire number didn't change where two wires were permanently connected, such as in a terminal block or a splice, we discriminate between
these two wires using a letter called wire segment letter
practicable wire segments are lettered in alphabetical sequence and the letter A identifies the first segment starting at the signal and/or power source
The letters I and 0 are not used as wire segment letters
Double letters AA, AB, AC, BA,

BB, BC, etc., are used when more than 24 segments are required
Segments joined by a permanent splice have different segment letters assigned to them
Page 34
The wire or cable size number is used to identify the American wire gauge (AWG) size of the wire or cable
For
thermocouple wires a dash is used instead of the wire size
number
The wire size
number is not normally included for co-axial cables
The letter N (ground or earth) is used as a suffix to the wire
identification code to identify a segment of a wire or cable that is
a part of the ground network

The phase letter 'V' is used as a suffix to the
identification code to identify all segments of the high voltage
side of a single phase power circuit
The phase letters 'A', 'B' and 'c' are
used as suffixes to the wire or cable identification code on all
wire segments carrying three phase a.c. power
Page 35
The quantity of wires and cables required for a distribution
system depends on the size and complexity of the systems.
Wiring protection methods may be grouped under three principal headings:
 Open loom
 Ducted loom
 Conduit
In cable loom method, wires or cables to be routed to and from
consumer equipment in the specific zones of the aircraft are
grouped parallel to each other in a bundle and bound together
with waxed cording or p.v.c. strapping
Page 36
Magnetic Field cancellation is achieved by routing the positive and earth return cables together and connecting the earth-return cable at an earthing point
located at a specific safe distance from the magnetic detector element of a compass system
When wires or wire bundles are routed through the aircraft
without the mechanical protection of conduit, it is called open
wiring
Most aircraft use the open wiring system
Open wiring is more vulnerable to wear, abrasion, and damage
from liquids than wiring installed in conduits

Shielded cable, ignition cable, and wire that is not
protected by a circuit breaker or fuse should be routed
separately
The bending radius of a wire bundle should not be
less than 10 times the outer diameter of the bundle
Page 37
Ducted loom method is basically the same as that of the open loom except that the bundles are supported in ducts, which are routed through the aircraft an
secured to the aircraft structure
In Ducted loom method, for identification purposes, each loom is bound with appropriately colored waxed cording.
Ducts used in Ducted loom method may be of aluminium alloy resin impregnated asbestos or molded fiber-glass-reinforced plastic
Page 38
Electrical conduit consists of thin-walled aluminium tubing,

braided metal tubing called flexible conduit, and non-metallic tubing
The purpose of conduit is to provide mechanical protection, and metal conduit is often used as a means of shielding electric wiring to prevent radio interfere
Approved flexible conduit is covered by specification MIL-C-6136 for aluminium and specification MIL-C-7931 for brass
The aluminium conduit is made in two types. Type I is bare, and type II is rubber-covered
The size of conduit should be such that the inside diameter is about 25 percent larger than the largest diameter of the cable bundle
To obtain the correct inside diameter of a conduit,

subtract twice the wall thickness from the outside diameter
Typically, conduits are specified according to their outside diameter.
If a fitting is not installed on the end of a conduit section, the end should be flared to prevent the edge of the tubing from rubbing and wearing the insulation
cable
A clean metal-to-metal contact will assure good bonding to aid in shielding
Drain holes must be provided at the lowest point in any conduit run
Bends in the conduit must not be wrinkled and must not be flattened to the extent that the minor diameter is less than 75 percent of the nominal tubing diam
Flexible conduit cannot be bent as sharply as rigid conduit
Before a wire or cable bundle is placed in a conduit, the bundles should be liberally sprinkled with tale
Page 40
Approved lacing cord complying with specification MIL-C-5649 or twine specification JAN-T-713 may be used for wire lacing
If wire bundles will not be exposed to temperatures greater than 248°F [120°C], cable tie straps complying with specificationMS-17821 or MS-17822 can
be used
Single-cord lacing is used for cable bundles 1 in. [2.5 cm] in diameter or less
In open areas, the bundles should be laced or tied if supports for the cable are more than 12 in. [30.5 cm] apart
When it is desired to use single ties to secure a wire bundle, the locked clove hitch is used
When the continuous lacing is applied, the first loop is a clove hitch locked with a double overhand knot
These loops are continued at suitable intervals, and the series is then terminated with another clove hitch
The terminating ends of the cord are trimmed to provide a minimum length of 3/8 in [0.95 cm]
When double-cord lacing is required for large cable bundles, the
first loop is made with a special type of slipknot similar to the
bowline-on-a-bight
Page 42
Specification MS-21919 cable clamp meets the requirement for civil aircraft use.
The cables are a tight fit in the holes of the bung
The anti-friction washer prevents damage to the face of the bung when the clamping nut is turned
On assembly, holes not occupied by cables are plunged with plastic plugs
Page 44
Where wire bundles pass through bulkheads or other structural members, a grommet or suitable clamping device should be provided to prevent abrasion
lf a wire bundle is held by a clamp in the center of a hole through a bulkhead, and the clearance between the edge of the hole and the bundle is more than
64 cm), a grommet is not required
At points in an installation where electric wire may be exposed to oil, hydraulic fluid, battery acid, or some other liquid, the cable should be enclosed in a
plastic sleeve
At the lowest point in the sleeve, a hole 1/8 in. [0.32 cm] in diameter should be cut to provide for drainage
When separation between electrical wire and fluid lines is impractical, the electric wire should be placed above the flammable-fluid line and securely
clamped to the structure
Electric wiring is insulated and protected with various types of materials, some of which can withstand temperatures as high as 392°F [200°C)
In areas where a wire must be subjected to high temperatures, it is necessary to use wiring with insulation made of asbestos or some other heat-resistant m
Page 46
When it is impossible to prevent cable loom contact with the
aircraft structure, then wrapping is the recommended method of
protection
Page 47
When a loom has to pass through a bulkhead, cable clamps and grommets are used to keep the cables clear of the bulkhead structure
The slack or droop of a loom between loom supports should be not more than 1/2 inch when moderate hand pressure is applied at the mid point between
clamps
Page 48
The selection of a cable as an alternative is most readily achieved by obtaining a Declaration of Design and Performance (DPP) from the manufacturer if
that manufacturer is suitably CAA Approved

7.7a - Electrical Cables and Connectors

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Summary of Annotations

Do not look into the end of a fiber-optic cable

Laser radiation is dangerous for eyes

breaker(s) related to the system/equipment to prevent the

supply of electrical power to the system/equipment during the

Some circuit breakers (A320 family only) have a red threaded

The red threaded bush can be removed using a standard wrench

when you use electric tools on the aircraft because

there are risks of electrocution or explosion

#10 Highlight (Shabbir)

#11 Highlight (Shabbir)

#12 Highlight (Shabbir)

#13 Highlight (Shabbir)

#14 Highlight (Shabbir)

exceed 300 volts

Immediately after an insulation test, functioning checks should

be made on all the services subjected to the test

Where applicable, when one or more engines are

running, the power supply can be obtained from the associated

generators, due reference being made to the functioning of any

For certain circuits (e.g. standby lighting), functioning tests can

only be carried out using the aircraft battery system

Bonding is the electrical interconnection of metallic aircraft parts

(normally at earth potential) for the safe distribution of electrical

charges and currents

Primary conductors are those required to carry lightning strikes

The cross-sectional area of secondary conductors made

from copper must not be less than 44 strands of 39

s.w.g. for braided conductors

#11 Highlight (Shabbir)

#12 Highlight (Shabbir)

Intermittent contact is worse than no contact at all

bonding jumpers should not be excessively tight or slack

Flexible hose connections used for joining rigid pipes should be

bonded by fitting clips around the pipes approximately 13 mm

bonding strip or jumper

pipe run should be bonded to earth at each end, particularly

within a radius of 2.42 meters (8 feet) of any unscreened radio

equipment or aerial lead, where earthling bonds should not be

more than 1.5 meters (5 feet apart), or less distance apart, if

called for by the manufacturer

High-pressure flexible pipe assemblies are usually self-bonding

Leads connected to earth terminal assemblies should be

of insulated cable with terminal tags fitted by the crimping

Table on page 13 of the book?

Prior to carrying out a bonding test, a check should be made on

the state of the nickel-alkaline cell of the tester by observing:-

When connecting the 60-foot lead to an earthling point,

any protective treatment (e.g. strippable lacquer) should be

removed at the point of contact

The 6-foot test lead should be used to check the resistance

between selected points

Where an abrasive has been used it is

Corrosion tends to form at a bonding or earth

connection and is often the cause of excessive

Where the required bond value cannot be obtained at a

structural joint the advice of the manufacturer should be

Crimping ensures electrical and mechanical connection of the