9200 m1f 0380 00 Issue 02

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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

REQUIREMENTS Issue: 02
FOR CABIN INTERIOR
Date: 01.07.2004
Electrical Design Requirements for Cabin

Interior (EDR)
No. 9200M1F0380 00
Aircraft A380 PAX/F
System ELECTRICAL INSTALLATION
ATA/Sub ATA ATA 92 - 00

Number
Equip. ELECTRICAL EQUIPMENT

FOR CABIN INTERIOR
Airworthiness
Criticality
Category
Development N/A
Assurance
Level
© Airbus 2004 All rights reserved. This document contains Airbus proprietary information and trade secrets. It shall at all times remain
the property of Airbus; no intellectual property right or licence is granted by Airbus in connection with any information contained in it. It is
supplied on the express condition that said information is treated as confidential, shall not be used for any purpose other than that for
which it is supplied, shall not be disclosed in whole or in part, to third parties other than the Airbus Entities, their subcontractors and suppli-
ers (to the extent of their involvement in Airbus projects), without Airbus’s prior written consent.
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RECORD OF REVISIONS
EFFECT ON REASON FOR REVISION
ISSUE DATE
PAGE PARA
FIGURE
TABLE
1 20.11.03 ALL ALL FIRST ISSUE
2 May 04 17 Table 5 System identification corrected
2 May 04 18 Table 8 Table completed
2 May 04 20 Table 9 Table simplified
2 May 04 20 Figure 2 Figure corrected
2 May 04 21 2.1.3.3.3 Text revised
2 May 04 24 Table 11 Optical Routes added, Text revised
2 May 04 25 2.1.4.1 Chapter added
2 May 04 26 2.1.4.2 Chapter “Crossing of bundles” added
2 May 04 27 2.2 Chapter revised
2 May 04 42 Figure 21 Figure added
2 May 04 45 Figure 24 Figure completed
2 May 04 46 2.4.3 Requirement 899-1 added
2 May 04 48 2.4.7 Hazardous area defined
2 May 04 49 2.4.7.2 Replacement of plastic with non-metallic
2 May 04 57 2.4.14.5 Replacement of 5 times with 6 times
2 May 04 62 Table 19 ABS1224 added
2 May 04 63 2.4.17.1.1 ABS1339 added, new standard clamp
2 May 04 65 2.4.17.1.2 No standard clamp any longer
2 May 04 67 2.4.17.1.4 ABS1224 added
2 May 04 77 Figure 48 Separator ABS1144 added
2 May 04 88 2.6.4 Description of ABS0887 added
2 May 04 96 2.7.3 Floating insert ABS1006 added
2 May 04 112 Figure 79 Figure revised
2 May 04 113 2.10.1 Text revised
2 May 04 114 2.10.2.1.1 Text an figures revised
2 May 04 116 2.10.2.1.2 Ess/ Non-Ess
2 May 04 118 2.10.6 ASNE number corrected / Requir. revised
2 May 04 127 2.11.7 Replacement of 4m with 1m
2 May 04 130 2.11.10 Requirement 649-1 deleted
2 May 04 141 Table 31 Documents added
2 May 04 143 Table 32 Documents added
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TABLE OF CONTENTS
1 GENERAL ...................................................................................................11
1.1 PURPOSE/ SCOPE/ OBJECTIVES OF THE EDR .........................................................11
1.2 TERMS, DEFINITIONS AND ABBREVIATIONS ............................................................12
1.2.1 TERMS, DEFINITIONS................................................................................................................................. 12
1.2.1.1 KEYWORD .............................................................................................................................................12
1.2.1.2 SAFETY AND RELIABILITY...................................................................................................................13
1.2.2 ABBREVIATIONS ........................................................................................................................................ 14
2 ELECTRICAL REQUIREMENTS ................................................................16

2.1 WIRING SEGREGATION................................................................................................16
2.1.1 ALLOCATION OF ELECTRICAL AND OPTICAL CABLES IN ROUTES .................................................. 16
2.1.1.1 CATEGORIES OF ROUTES .................................................................................................................. 17
2.1.2 ROUTE DESIGNATION................................................................................................................................19
2.1.3 SEGREGATION RULES .............................................................................................................................. 19
2.1.3.1 GENERAL............................................................................................................................................... 19
2.1.3.2 SEGREGATION OF SYSTEM 1 AND SYSTEM 2 ROUTES .................................................................19
2.1.3.3 SEGREGATION OF ESSENTIAL AND NON-ESSENTIAL ROUTES....................................................20
2.1.3.3.1 MIXING OF ESSENTIAL/NON-ESSENTIAL HARNESSES............................................................ 20
2.1.3.3.2 GENERAL INSTALLATION PRINCIPLE .........................................................................................20
2.1.3.3.3 PARTICULAR CASES ..................................................................................................................... 21
2.1.3.3.4 ESSENTIAL/NON ESSENTIAL CABLE SUPPORT........................................................................21
2.1.3.4 SEGREGATION OF ROUTE CATEGORIE M AND S ...........................................................................22
2.1.3.5 SEGREGATION WITHIN CONNECTOR AND TERMINAL MODULE................................................... 22
2.1.3.5.1 OPTICAL CONNECTOR..................................................................................................................22
2.1.3.6 SEGREGATION OF GROUNDING (CURRENT RETURN) AND BONDING ........................................ 23
2.1.4 SEGREGATION BETWEEN ROUTE CATEGORIES.................................................................................. 24
2.1.4.1 DISTANCES BETWEEN BUNDLE AND ELECTRICAL DEVICES........................................................ 25
2.1.4.2 CROSSING OF SEPARATING BUNDLES AND CONDUITS................................................................26

2.2 POWER SUPPLY............................................................................................................27
2.3 CABLE SELECTION.......................................................................................................28
2.3.1 SELECTION OF CABLE-TYPE....................................................................................................................28
2.3.2 SELECTION OF CONTACTS AND TERMINAL LUGS............................................................................... 29
2.3.3 CABLE SELECTION FOR GROUNDING/ BONDING.................................................................................29
2.3.4 TEMPERATURE EFFECTS ......................................................................................................................... 29
2.3.4.1 "OUT-OF-BUNDLE" UTILISATION.........................................................................................................29
2.3.4.2 "IN-BUNDLE" UTILISATION...................................................................................................................29
2.4 CABLE AND BUNDLE INSTALLATION ........................................................................35

2.4.1 DISTANCES.................................................................................................................................................. 35
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2.4.1.1 DISTANCES BETWEEN BUNDLE AND STRUCTURAL ITEMS (EXCEPT COMPOSITE

CONDUCTIVE STRUCTURE)................................................................................................................35
2.4.1.1.1 FOR INTERSECTION: CABLE, BUNDLE - STRUCTURE............................................................. 36

2.4.1.2 DISTANCES BETWEEN ELECTRIC CABLES AND CONDUCTIVE COMPOSITE
SURFACE (CARBON, GLARE…) .......................................................................................................... 37
2.4.1.3 DISTANCES BETWEEN ELECTRICAL BUNDLES/CABLES AND DIFFERENT
SYSTEMS (PIPES, MECH. CABLE…)...................................................................................................37
2.4.1.3.1 BETWEEN EL. CABLES AND MECHANICAL CABLES, MOVING PARTS ................................... 37
2.4.1.3.2 BETWEEN THE ELECTRIC CABLES AND PIPES WHICH CARRY NON-
INFLAMMABLE LIQUIDS OR GASES.............................................................................................38
2.4.1.3.3 DISTANCE TO GASEOUS OXYGEN..............................................................................................38
2.4.2 PRINCIPLE OF SUPPORT INSTALLATION ............................................................................................... 40
2.4.2.1 DISTANCES BETWEEN SUPPORTS.................................................................................................... 40
2.4.2.2 SHARP EDGES ...................................................................................................................................... 41
2.4.2.3 DISTANCES BETWEEN CONDUITS AND SHARP STRUCTURE ....................................................... 41
2.4.2.4 CLAMP.................................................................................................................................................... 42
2.4.2.5 STAND OFF (SPACER) ......................................................................................................................... 42
2.4.2.6 ATTACHMENT OF HARNESSES BENDING RADIUS.......................................................................... 43
2.4.3 DRIP LOOPS FOR FLUIDS ......................................................................................................................... 44
2.4.4 JUNCTIONS..................................................................................................................................................46
2.4.5 WIRING JOINING ON THE EQUIPMENT REMOVABLE FROM THE FORWARD FACE......................... 47
2.4.6 INTERFACE CONNECTION POSITIONING................................................................................................47
2.4.7 ELECTRICAL INSTALLATION POSITIONED IN CONTAMINATION AREAS .......................................... 48

2.4.7.1 ELECTRICAL CONNECTIONS POSITIONING .....................................................................................49
2.4.7.2 FLUID INGRESS PROTECTION OF ELECTRICAL EQUIPMENT........................................................ 49
2.4.8 INSTALLATION OF BUNDLES ON CONDUCTIVE COMPOSITE PARTS ................................................ 50
2.4.8.1 BUNDELS ON CONDUCTIVE COMPOSITE SURFACE.......................................................................50
2.4.8.1.1 INTERSECTION: BUNDLE AND COMPOSITE CONDUCTIVE STRUCTURE .............................. 52
2.4.8.2 ELECTRICAL EQUIPMENT ON COMPOSITE CONDUCTIVE STRUCTURE...................................... 53
2.4.9 OPTICAL CABLE INSTALLATION..............................................................................................................54
2.4.10 INSTALLATION ON MOVING MECHANICAL PARTS ...............................................................................54
2.4.11 COMPATIBILITY OF CONDUCTIVE MATERIALS .....................................................................................54
2.4.12 FIXATION SCREW ....................................................................................................................................... 56
2.4.13 ARRANGEMENT AND INSTALLATION OF P ROUTES............................................................................56
2.4.14 CABLE BUNDLE BENDING RADIUS ......................................................................................................... 56
2.4.14.1 26 TO 12 GAUGE COPPER................................................................................................................... 56
2.4.14.2 BENDING RADIUS OF COPPER AND ALUMINIUM CABLES (P ROUTES) ....................................... 56
2.4.14.3 BENDING RADIUS OF COAXIAL CABLE .............................................................................................56
2.4.14.4 BENDING RADIUS OF OPTICAL CABLE.............................................................................................. 57
2.4.14.5 BENDING RADIUS OF QUAD CABLE (DATABUS CABLES)............................................................... 57
2.4.14.6 BENDING RADIUS OF BUNDLES.........................................................................................................57
2.4.15 CABLE LENGTHS........................................................................................................................................57
2.4.15.1 CALCULATION OF THE BUNDLE LENGTH .........................................................................................57
2.4.15.2 ELECTRICAL CABLE OVER- LENGTH................................................................................................. 57
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2.4.15.2.1 CABLE LENGTHS FOR REPAIRS FOR COPPER CABLES.......................................................... 58

2.4.15.3 OPTICAL CABLE OVER LENGTH.........................................................................................................58
2.4.15.4 COAXIAL CABLE OVER LENGTH......................................................................................................... 58

2.4.15.5 QUAD CABLE OVER LENGTH (AFDX)................................................................................................. 58
2.4.15.6 STOWAGE AREA FOR BUNDLE LENGTH CONTROL ........................................................................58
2.4.16 PRECAUTIONS TO ENSURE CORRECT CONNECTOR MATING ........................................................... 60
2.4.16.1 BY CONNECTORS.................................................................................................................................60
2.4.16.2 BY ROUTING..........................................................................................................................................61
2.4.16.3 BY CHAINS.............................................................................................................................................61
2.4.17 FIXING ..........................................................................................................................................................62
2.4.17.1 HARNESSES FIXING PRODUCTS ....................................................................................................... 62
2.4.17.1.1 FIXING BY PLASTIC CLAMPS ABS 1339 ......................................................................................63
2.4.17.1.2 FIXING BY METALLIC CLAMPS NSA 5516 ...................................................................................65
2.4.17.1.3 FIXING BY V SUPPORT TYPE NSA 935504..................................................................................66
2.4.17.1.4 FIXING OF MODULAR CABLE SUPPORT ABS 1224....................................................................67
2.4.17.1.5 FIXING OF OPTICAL CABLES........................................................................................................ 67
2.4.17.1.6 FIXING OF OPTICAL CABLES INSTALLED INSIDE ELECTRICAL HARNESSES....................... 69
2.4.17.1.6.1 FIXING OF OPTICAL CABLES INSTALLED OUTSIDE ELECTRICAL
HARNESSES TBC......................................................................................................................69
2.4.17.1.6.2 SEPARATE ROUTING ............................................................................................................... 70
2.4.17.1.6.3 ROUTINGS ON ELECTRICAL HARNESS................................................................................. 70
2.4.17.1.6.4 OUTSIDE CLAMPS .................................................................................................................... 72
2.4.17.1.6.5 INSIDE NSA 5516 OR PLASTIC CLAMP ABS1 1339 ............................................................... 72
2.4.17.1.7 FIXING OF COAX CABLES............................................................................................................. 72
2.4.17.1.8 ADHESIVE FASTENERS ................................................................................................................ 74
2.4.17.2 FIXING OF ELECTRICAL HARNESSES WITH PROTECTION ............................................................ 74
2.4.17.2.1 ATTACHMENT OF RIGID CONVOLUTED CONDUITS ABS 0887 ................................................ 74
2.4.17.2.2 ATTACHMENT OF TEXTILE CONDUITS EN 6049-006/007..........................................................74
2.4.17.2.3 ATTACHMENT OF CONDUITS CONNECTED TO A CONNECTOR ............................................. 74
2.4.17.2.4 ACCORDANCE BETWEEN BACKSHELL ASNE 0199 (INOX/ASNE 0455 ALU) AND
CONDUIT ABS 0887........................................................................................................................75
2.4.17.3 FIXING OF ROUTES CONTAINING 1 OR 2 WIRES............................................................................. 75

2.4.18 USE OF SEPARATORS...............................................................................................................................76
2.4.18.1 ON BUNDLES.........................................................................................................................................76
2.4.18.1.1 SEPARATORS TYPE ABS 1144..................................................................................................... 77
2.4.18.1.2 SEPARATORS TYPE ABS 0054..................................................................................................... 77
2.4.18.2 ON RIGID CONVOLUTED CONDUITS/ SHIELDED CONDUITS..........................................................78
2.4.19 INSTALLATION OF NON- CODED EQUIPMENT ....................................................................................... 78
2.4.19.1 “IN LINE” NON-CODED EQUIPMENT ................................................................................................... 78
2.4.19.2 INSTALLATION OF ACTIV NON- CODED EQUIPMENT......................................................................78
2.4.19.3 INSTALLATION OF ELCETRONIC DEVICES ON MODULE ................................................................ 79
2.5 HARNESS CONSTRUCTION .........................................................................................80
2.5.1 BUNDLE DIAMETER ................................................................................................................................... 80
2.5.2 TYING ...........................................................................................................................................................82
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2.5.2.1 HARNESS TYING...................................................................................................................................82

2.5.2.2 USE OF CABLE TIES BETWEEN ESSENTIAL AND NON-ESSETIAL HARNESSES ......................... 82
2.5.2.3 TYING OF PROTECTED BUNDLES...................................................................................................... 83

2.6 PROTECTION AND INSTALLATION OF PROTECTION...............................................84
2.6.1 USE OF CONDUITS MADE OF INSULATING MATERIAL ........................................................................ 84
2.6.2 PROTECTION BY SPLIT ELASTOMERE CONDUIT ABS 0596................................................................ 85
2.6.2.1 CONDUIT OVERLAP..............................................................................................................................85
2.6.2.2 TYING .....................................................................................................................................................85
2.6.3 PROTECTION BY SPLIT CONDUIT EN 6049-006/007 (TEXTILE WOVEN CONDUIT) ............................ 86
2.6.3.1 CONDUIT OVERLAP..............................................................................................................................86
2.6.3.2 TYING .....................................................................................................................................................87
2.6.4 PROTECTION BY PEEK CONDUIT ABS0887............................................................................................ 88
2.6.4.1 CONDUITS FILLING...............................................................................................................................90
2.6.4.2 DRAINING OF RIGID CONVOLUTED CONDUITS ...............................................................................90
2.6.5 BONDING JUMPER PROTECTION.............................................................................................................90
2.6.6 PROTECTION BY HEAT- SHRINK SLEEVES............................................................................................91
2.6.7 PROTECTION OF OPTICAL CABLE .......................................................................................................... 91
2.6.8 PROTECTION BY TAPE .............................................................................................................................. 92
2.6.8.1 ASNA 5107 ............................................................................................................................................. 92
2.6.8.2 ABS 5334................................................................................................................................................ 92
2.6.9 PROTECTION OF CABLES ON BACKSHELL ...........................................................................................92
2.6.9.1 ON CLOSED METAL BACKSHELLS (CLAMPS)................................................................................... 92

2.6.9.2 FILLING, PROTECTING OF OPTICAL CABLES ON BACKSHELLS....................................................93
2.6.10 PROTECTION OF CONNECTION ELEMENTS...........................................................................................93
2.6.10.1 LUG INSULATION PROTECTION ......................................................................................................... 93
2.6.10.2 ANCILLARY PLUG CONNECTORS ...................................................................................................... 93
2.7 PANELS AND BOXES....................................................................................................95
2.7.1 RIVETS ON BOXES OR ELECTRICAL PANELS .......................................................................................95
2.7.2 ARRANGEMENT OF EQUIPMENT ON PANELS .......................................................................................95
2.7.3 FIXING OF PANELS AND BOXES .............................................................................................................. 96
2.7.4 FIXING INSIDE PANELS AND BOXES ....................................................................................................... 96
2.7.5 USING SPACER INSIDE PANEL.................................................................................................................96
2.7.6 FIXING OF HARNESS HINGE ..................................................................................................................... 96
2.7.7 SWITCH POSITIONS ................................................................................................................................... 98
2.7.8 ILLUMINATED PUSH- BUTTONS ............................................................................................................... 99
2.7.9 PRECAUTION TO INSURE A CORRECT RELAY MATING....................................................................... 99
2.8 CONNECTORS AND BACKSHELLS...........................................................................100
2.8.1 PINS AND SOCKETS.................................................................................................................................100
2.8.2 PROTECTION / STORAGE OF UNUSED CONNECTORS....................................................................... 100
2.8.3 INSTALLATION DIRECTION .....................................................................................................................100
2.8.4 CONNECTIONS.......................................................................................................................................... 100
2.8.5 DISTANCE BETWEEN CONNECTORS ....................................................................................................100
2.8.6 FIXING OF CONNECTORS........................................................................................................................101
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2.8.7 INSTALLATION OF CIRCULAR CONNECTORS .....................................................................................101

2.8.7.1 EN 2997 CONNECTORS ..................................................................................................................... 102
2.8.8 INSTALLATION OF RECTANGULAR CONNECTORS EN 3545 .............................................................103

2.8.9 INSTALLATION OF BACKSHELLS .......................................................................................................... 104
2.8.9.1 ELBOW BACKSHELL ORIENTATION .................................................................................................104
2.8.9.2 BACKSHELLS ON OPTICAL CONNECTORS.....................................................................................105
2.8.10 SEALING OF CONNECTORS....................................................................................................................105
2.8.10.1 SEALED CONNECTORS..................................................................................................................... 105
2.8.10.2 CONTACTS NOT IN USE AND SEALING PLUGS.............................................................................. 106
2.8.11 SEALING OF CONNECTIONS WITH TERMINAL LUGS (TR) .................................................................106
2.8.12 SEALING OF CONNECTIONS WITH TERMINAL BLOCK MODULE NSA 937901M ............................. 106
2.9 TERMINAL BLOCK AND LUG INSTALLATION..........................................................107
2.9.1 MODULE POSITIONING SEQUENCE ON TERMINAL RAIL (E.G.: NSA 937901) ................................. 107
2.9.2 INSTALLATION OF SEVERAL LUGS ON TERMINAL (E.G. NSA 937905) ............................................ 108
2.9.3 BENDING OF LUGS...................................................................................................................................108
2.9.4 INSTALLATION OF TERMINAL LUGS ..................................................................................................... 109
2.9.5 USE OF WASHER ON TERMINAL BLOCK.............................................................................................. 109
2.9.5.1 SPRING WASHER ASNA 2553 ........................................................................................................... 109
2.9.5.2 ADDITIONAL WASHER........................................................................................................................ 109
2.9.6 INSTALLATION OF LUGS ON CIRCUIT BREAKERS .............................................................................109
2.9.7 INSTALLATION OF DIFFERENT TYPES OF TERMINAL LUGS............................................................. 109
2.9.7.1.1 TERMINAL LUG INSTALLATION ORDER.................................................................................... 109

2.9.7.1.2 LUG/WASHER/NUT INSTALLATION ORDER.............................................................................. 110
2.9.8 TERMINAL BLOCK PROTECTION AND INSTALLATION....................................................................... 111
2.9.9 CONNECTION OF TWO OR THREE CABLES IN TERMINAL LUG AND SPLICE................................. 112
2.10 GROUNDING AND BONDING......................................................................................113
2.10.1 DEFINITION / WORDING ........................................................................................................................... 113
2.10.2 GROUNDING AND BONDING POINTS .................................................................................................... 114
2.10.2.1 GROUNDING AND BONDING VIA BRACKETS..................................................................................114
2.10.2.1.1 FIXED BRACKETS ........................................................................................................................ 114
2.10.2.1.2 REMOVABLE BRACKETS ............................................................................................................ 116
2.10.3 GROUNDING OF EQUIPMENT IN MONUMENTS.................................................................................... 117
2.10.4 BONDING AND GROUNDING RESISTANCE...........................................................................................117
2.10.5 TERMINAL LUGS.......................................................................................................................................118
2.10.6 BONDING JUMPERS.................................................................................................................................118
2.10.7 SURFACE PREPARATION AND PROTECTION ......................................................................................119
2.10.8 BONDING OF EQUIPMENT.......................................................................................................................119
2.10.8.1 GENERAL REQUIREMENTS............................................................................................................... 119
2.10.8.2 BONDING OF ELECTRICAL EQUIPMENT .........................................................................................120
2.10.8.2.1 BOXES, PANELS; OPERATING DEVICES ..................................................................................120
2.10.8.2.2 BONDING OF NON-ESSENTIAL MONUMENTS/ EQUIPMENT .................................................. 120

2.10.8.3 BONDING OF CONDUCTIVE PARTS EXPOSED TO CREW / PASSENGER ................................... 120
2.10.9 BONDING OF COAXIAL CONNECTORS:................................................................................................ 120
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2.11 IDENTIFICATION OF CABLES ....................................................................................122

2.11.1.1 IDENTIFICATION RULES ACCORDING TO CABLE CATEGORIES.................................................. 122
2.11.1.2 UNIDENTIFIED CABLES...................................................................................................................... 122
2.11.1.3 IDENTIFICATION BY SLEEVES.......................................................................................................... 122
2.11.1.4 PRINTABLE CABLES...........................................................................................................................122
2.11.1.5 BASIC OR SHIELDED MULTICORE CABLE....................................................................................... 123
2.11.1.6 SPECIFIC CASES ................................................................................................................................123
2.11.2 FIN IDENTIFICATION ON HARNESS ENDS ............................................................................................124
2.11.2.1 IDENTIFICATION SLEEVE/LABEL ON BUNDLES .............................................................................125
2.11.3 OPTICAL HARNESSES.............................................................................................................................126
2.11.4 PHASE IDENTIFICATION SLEEVES ........................................................................................................ 126
2.11.5 FOR MULTICORE CABLES AND TWISTED CABLES WITH OR WITHOUT SCREEN.......................... 126
2.11.6 HARNESS IDENTIFICATION MARKER....................................................................................................126
2.11.6.1 USUAL HARNESSES...........................................................................................................................126
2.11.7 ROUTE IDENTIFICATION MARKERS ...................................................................................................... 127
2.11.8 ADDITIONAL IDENTIFICATION ................................................................................................................ 127
2.11.8.1 ADDITIONAL IDENTIFICATION FOR OPTICAL CABLES AND BUNDLES ....................................... 127
2.11.9 IDENTIFICATION OF PANELS AND BOXES ...........................................................................................127
2.11.9.1 ON VE...................................................................................................................................................128
2.11.9.2 ON ARINC 600 EQUIPMENT............................................................................................................... 128
2.11.9.3 ON EQUIPMENT .................................................................................................................................. 129
2.11.9.4 IDENTIFICATION IN SMALL VE´S ...................................................................................................... 129

2.11.10 LABEL IDENTIFICATION ON STRUCTURAL PART ...............................................................................130
2.11.10.1 LABELS FOR VOLTAGE > 42 VOLTS.......................................................................................... 130
2.11.10.2 LABEL POSITIONING ................................................................................................................... 131
3 DESIGN PROCESS REQUIREMENTS.....................................................132

3.1 GENERAL .....................................................................................................................132
3.2 REQUIREMENTS AND RULES FOR MATERIAL QUALIFICATION...........................132
3.3 ENVIRONMENTAL REQUIREMENTS..........................................................................132
3.3.1 TEMPERATURE.........................................................................................................................................133
3.3.2 ALTITUDE, PRESSURE.............................................................................................................................133
3.3.3 TEMPERATURE VARIATION.................................................................................................................... 133
3.3.4 HUMIDITY ...................................................................................................................................................133
3.3.5 SHOCK AND CRASH SAFETY ................................................................................................................. 133
3.3.6 VIBRATIONS ..............................................................................................................................................134
3.3.7 WATERPROOFNESS ................................................................................................................................134
3.3.8 FLUIDS SUSCEPTIBILITY.........................................................................................................................134
3.3.9 FUNGUS RESISTANCE.............................................................................................................................134
3.3.10 SALT SPRAY..............................................................................................................................................134
3.3.11 CORROSION ..............................................................................................................................................135

3.3.12 HERMETIC..................................................................................................................................................135
3.3.13 FIRE ............................................................................................................................................................135
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3.3.14 FLAMMABILITY/ SMOKE/ TOXICITY (FIREWORTHINESS DESIGN CRITERIA) .................................. 135

3.4 ELECTRICAL REQUIREMENTS ..................................................................................135
3.4.1 CABLES......................................................................................................................................................136
3.4.2 OPTICAL CABLES.....................................................................................................................................136
3.4.3 CONNECTORS........................................................................................................................................... 136
3.4.4 OPTICAL CONNECTORS..........................................................................................................................137
3.4.5 CONTACTS ................................................................................................................................................137
3.5 QUALIFICATION TEST PLAN/ QUALTIFICATION TEST REPORD
(QTP/QTR) ....................................................................................................................138
4 APPENDIX.................................................................................................139
4.1 PURPOSE OF THE APPENDIX....................................................................................140
4.2 AIPS (AIRBUS INDUSTRIES PROCESS SPECIFICATION) .......................................141
4.2.1 GENERAL................................................................................................................................................... 141
4.3 LIST OF REFERENCED DOCUMENTS .......................................................................141
4.3.1 AIPS ............................................................................................................................................................141
4.3.2 STANDARDS.............................................................................................................................................. 142
4.3.3 ATTACHMENT OF DOCUMENTS............................................................................................................. 144
4.4 ELECTRICAL STANDARD ITEMS...............................................................................144
4.4.1 GENERAL................................................................................................................................................... 144
4.4.2 STANDARD SELECTION LIST..................................................................................................................144
4.4.3 STANDARDS.............................................................................................................................................. 144
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1 GENERAL
1.1 PURPOSE/ SCOPE/ OBJECTIVES OF THE EDR
The purpose of this document is to specify the requirements for the installation of electrical equipment
within cabin interior in passenger cabins and IFE-Racks in the electrical equipment bay for the A380
aircraft.
The established requirements are mandatory for AIRBUS installation design ATA 25/ ATA 92 and
AIRBUS-supplier.
The requirements are applicable for Buyer Furnished Equipment (BFE) and Seller Furnished Equip-
ment (SFE).
The EDR shall be used as reference document for integration of electrical installation requirements in
TN, ITS, PTS and SES.
Every application that is not mentioned in this document or every devia-

tion from the introduced applications must be explicitly approved by:
Airbus Deutschland GmbH
Kreetslag 10
21129 Hamburg
Dep. BCEGU1
Cabin Electric
Overall
Figure 1
The EDR does not cover electrical installation of equipment / bundle on A/C-structure. For electrical
installation on A/C-structure TDD, SIDP are applicable.
The scope of the EDR is limited as shown in table below:
Zones Aircraft zones in the scope of

EDR ?
crew and passenger compartment
pressurised zones cargo: inside crew rest compartment YES
(max. temperature <=85°C) IFE-Racks
cockpit, cargo, electronic bay NO
Table 1 Validity of EDR
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1.2 TERMS, DEFINITIONS AND ABBREVIATIONS
1.2.1 TERMS, DEFINITIONS
The meaning of terms, used in the EDR :
TERM MEANING
Panels boxes with control-/ service elements, accessible during flight
Boxes chassis containing electrical devices etc., not accessible
Structure structure of monuments, components,

(non-conductive or conductive material)
not: main-A/C-structure
Conductive material conductive (metal, metalized) and at least partly conductive

(conductive composite: carbon, glare..) material
Table 2 Used terms
The symbol § is used to indicate a section.
1.2.1.1 KEYWORD
The significance of each requirement is defined by a keyword.
The use of the keywords: " shall ", "shall not ”, "should ", and " may " within this document shall observe
the following rules:
KEYWORD MEANING
SHALL -Denotes a mandatory requirement.

-Departure from such a requirement is not permissible without formal agreement.
SHALL NOT -Denotes a mandatory prohibition.
-Departure from such a requirement is not permissible without formal agreement.
SHOULD -Denotes a recommendation or advice on implementing such a requirement of the
document.
-such recommendations or advice is expected to be followed unless good reasons
are stated for not doing so.
MAY -Denotes a permissible practice or action. It does not express a requirement.
Table 3 Keywords
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1.2.1.2 SAFETY AND RELIABILITY
The installation of the electrical equipment within cabin interior shall ensure a safe and reliable opera-
tion of the equipment.
The installation of the electrical equipment within cabin interior shall not create a hazard in any man-
ner for injuries to persons and shall minimize the potential of human errors that would significantly
reduce the safety.
The general safety and reliability requirements are contained in the

- GCP (General Conditions of purchase)
- ABD0100.1.3 (Equipment-Design-General Requirements for suppliers)
- ABD0200.2.3 (Requirements and Guidelines for System Designers - Safety and Reliability
Requirements) - if applicable -
- the appropriate PTS for the particular application.
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1.2.2 ABBREVIATIONS
ABBREVIATION MEANING
ABD Airbus Directives
ABS Airbus Standard
A/C Aircraft
AC Alternating Current
ACJ Advisory Circular - Joint
ACP Audio Control Panel
ADD Addition, Additional, Additive
AFDX Avionics Full Duplex Ethernet Switched
AINS Aircraft Information Network System
AIPS Airbus Industry Process Specification
AMU Audio Management Unit
ARINC Aeronautical Radio INC
ASN Aerospatiale Norme (Standard)
ATA Air Transport Association of America
ATC Air Traffic Control
APU Auxiliary Power Unit
AWG American wire gauge

CDS Control and Display System
CINS Cabin Information Network system
CoC Centre of Competence
COM Commercial
CPMS Cabin and Passenger Management System
CT Current Transformer
C/B Circuit Breaker
CWLU Cabin Wireless LAN Unit
DC Direct Current
EFCS Electrical Flight Control System
ELT Emergency Locator Transmitter
EMC Electromagnetic Compatibility
EN European Norm
ESS BUS Essential BUS
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
FEP Flour Ethylene Propylene
FIN Functional Item Number
IFE In Flight Entertainment
IMA Integrated Modular Avionics
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ABBREVIATION MEANING
ITS Internal Technical Specification
JAA Joint Airworthiness Authority (Europe)
JAR Joint Aviation Requirements
MIL Military Standard
NDT Non Destructive Test
PEEK Poly Ether Ether Keton
PTFE Poly Tetra Flour Ethylene
PTS Purchaser Technical Specification
PU Parts usage
QTP Qualification Test Plan
QTR Qualification Test Report

RCCB Remote Control Circuit Breaker
SES Supplier Equipment Specification
SFAR Supplementary Federal Aviation Regulations
SIDP System Installation Design Principles
SIRD System Installation Requirement Document
SDP Supplier Development Plan
SPDB Secondary Power Distribution Box
SUB. Subsidiary
TBC To Be Confirmed
TBD To Be Defined
TDD Technical Design Directive
T/R Transmitter-Receiver
TN Technical Note
TRU Transformer Rectifier Unit
TWLU Terminal Wireless LAN Unit
VFG Variable Frequency Generator
VU/VE Electrical References
Table 4 Abbreviations
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2 ELECTRICAL REQUIREMENTS
Wording:
Bundle, Harness: A set of cables makes up a bundle, a set of bundles makes up a harness.
2.1 WIRING SEGREGATION
2.1.1 ALLOCATION OF ELECTRICAL AND OPTICAL CABLES IN ROUTES
Due
basedtoonthehighest
„Fly-by-Wire“ technology
possible quality on Airbus
standards aircraft, the
and therefore haveinstallation
to follow of electrical
certain rules components
that are not are
necessarily applicable in other industries.
For above reasons and possible electro-magnetic interference, the electrical & optical cables are in-
stalled physically separated in routes.
Route: A route is the way taken by an electric cable to go from one point to another.
Routes are classified according to main criteria:
„CATEGORY OF ROUTE“ „SYSTEM ASSIGNMENT “
CATEGORY OF ROUTE
A category of route is defined according to the nature of the cables and/ or the type of signal they
transmit. The next determination is a separation of Essential and Non-Essential routes. This classifica-
tion shows the different importance and function of the routes.
Also the routes are divided into basic and customised routes:
Wirings are installed generally in phase A or phase B:

Phase A: installed during the manufacturing of the aircraft section (basic routes)
Phase B: installed on or after Final Assembly line (customised routes)
Summing up there are the following general allocations:
- Essential basic (phase A)

- Non-Essential basic (phase A)
- Non-Essential customised (phase B)
- Essential customised (phase B)
In the scope of the EDR are only customised circuits installed in phase B.
SYSTEM ASSIGNMENT
Basically, two different electrical systems are defined for each category of routes: P, M, S …. in order
to avoid that a single failure affects simultaneously both channels of a redundant system (for definition
of routes see § 2.1.1.1) . In order to maintain homogeneity in separation of systems, systems powered
by generators 1 and 2 will use route 1 and systems powered by generators 3 and 4 will use route 2.
Routes are called respectively, e.g. “route 1” or “route 2” of a dedicated route category.
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For above mentioned reasons the design aim of wire bundle installation shall be a cable routing physi-
cally separated by distances and without any contact to other components or surrounding structure,
including sagging, vibration, swelling….
Protection means (like conduits, edge profiles etc.) shall be seen as additional help only, if it is abso-
lutely not possible to keep the minimum distances as described in this specification.
Without any chafing marks or abnormal stress on the cables, appropriate bending radii etc., the ser-
vice life of electrical installations in cabin furnishing equipment could be extended significantly.
2.1.1.1 CATEGORIES OF ROUTES
For cabin interiors, the following route categories are in the scope of EDR:
o P (Power distribution; >15A)

o M (Miscellaneous cables)
o S (Sensitive Cables)
o R (Audio and Video cables).
- Power distribution: P (Ref. Table 5: POWER DISTRIBUTION (P))

This category includes power supplies of systems with loads greater than 15 A.
- Miscellaneous cables: M (Ref. to Table 6: MISCELLANEOUS ROUTES (M))

This category includes power supply up to 15 Ampere, passive cables (i.e. cables which do not ne-
cessitate special separation requirements).
- Sensitive cables: S (Ref. to Table 7: SENSITIVE ROUTES (S))

This category includes cables, which are sensitive to interference.
- Audio and Video cables: R (Ref. to Table 8: AUDIO AND VIDEO ROUTES (R))
Specific routes are required for analogue audio lines in order to avoid interference.
CATEGORY ROUTE REMARKS SYSTEM
POWER DISTRIBU- 1P Essential System System 1

TION 2P Essential System System 2
3P Non Essential System System 1
Rating of the protection 4P Non Essential System System 2
device greater than
15 Ampere 21P Essential Customised System System 1
22P Essential Customised System System 2
23P Non Essential Customised System System 1
24P Non Essential Customised System System 2
9P Galleys power, Commercial system System 1

Table 5: POWER DISTRIBUTION (P)
Segregation between P routes is required taking into consideration:

- system 1 / system 2
- Essential system / Non Essential system
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MISCELLANEOUS 1M Essential System System 1

2M Essential System System 2
- wiring not affected 3M Non Essential System System 1
by interference or 4M Non Essential System System 2
which does not
cause interference 21M Essential Customised System System 1
22M Essential Customised System System 2
- bus ARINC 429, 23M Non Essential Customised System System 1
AFDX 24M Non Essential Customised System System 2
- low power supplies

(max C/B rating: 15
A)
Table 6: MISCELLANEOUS ROUTES (M)

Note 1: As a general rule ARINC 429 cables shall be routed in M, nevertheless when fully justified for
segregation purposes some ARINC 429 cables may be routed in route S.
Note 2: Maximum voltage permissible: 115 VAC.
SENSITIVE 1S Essential System System 1

2S Essential System System 2
- wiring susceptible to interfer-
ence
- low level circuits (AFDX..)
Table 7: SENSITIVE ROUTES (S)

Note 1: Maximum voltage permissible: 28 VDC.
CATEGORY ROUTE REMARKS
3R IFE bay- Non Essential System

TV
-AUDIO / VIDEO 4R RF coaxial route- Non Essential System
AIRFONE
9R Video and audio (Electrical support).
Non Essential System
10R Video (Optical support)
Non Essential System
11R Video (Optical support)
Essential System
Table 8: AUDIO AND VIDEO ROUTES (R)
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2.1.2 ROUTE DESIGNATION

The designation of the electrical routes comprises a number of digits allowing unambiguous identifica-
tion of the electrical routes.
Generally, this designation is related to segregation and allows the physical separation of the electrical
wiring and/or interconnections to be guaranteed and verified.
Routes R generally only comprise 2 digits. Routes P, M and S may have up to 6 digits.
st nd rd
Only the 1 ,2 and 3 digit are of interest to the EDR, digit 4-6 are used for Airbus internal designa-
tions:
st nd
1 and in some cases 2 digit: Assignment of system to route e.g.: 1, 2, 3….(a route named
with a 2 in front, shows a cus-
tomised route, e.g.: 21, 22,
23...)
nd rd
2 or 3 digit: A letter shows the Category of route e.g.: M, S...
2.1.3 SEGREGATION RULES
2.1.3.1 GENERAL
D-CGU-10-9200-726-1 No single electrical failure should affect simultaneously electrical supplies of aircraft
system 1 and system 2.
D-CGU-10-9200-727-1 Route segregation shall be maintained throughout the aircraft inclusive of production
break joints, connections and wiring.
This also applies to cabin interior equipment including sub components.
D-CGU-10-9200-728-1 Any deviation from this rule shall be dealt with as a special case and reported to
ECGU1 (Cabin Electric Overall).
2.1.3.2 SEGREGATION OF SYSTEM 1 AND SYSTEM 2 ROUTES

D-CGU-10-9200-730-1 Routes of system 1 and routes of system 2 shall not be mixed
(in all electrical & optical areas, including racks, boxes and panels).
D-CGU-10-9200-731-1 If joining of routes system 1 and 2 cannot be avoided, approval shall be obtained from
the involved system specialist and ECGU1 (Cabin Electric Overall) for each particular
case.
D-CGU-10-9200-782-1 Segregation should be ensured by physical wiring segregation, distances see §

2.1.4 segregation between route Categories.
D-CGU-10-9200-732-1 Only when segregation cannot be ensured by physical wiring segregation (distances),
this shall be ensured by approved protective elements (see § 2.6 Protection and instal-
lation of protection) which will be added to the harnesses.
D-CGU-10-9200-733-1 When electrical equipment is powered by system 1 and 2, the grounding plate shall be
allocated to System 1.
D-CGU-10-9200-878-1 A drawing which shows the route segregation should be provided by the supplier.
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2.1.3.3 SEGREGATION OF ESSENTIAL AND NON-ESSENTIAL ROUTES
2.1.3.3.1 MIXING OF ESSENTIAL/NON-ESSENTIAL HARNESSES

Table 9 shows how Essential and Non-Essential routes are allowed to fit together.
Master routing
Fitted on Essential Basic Essential Non-Essential Non-Essential
Customised Basic Customised
Essential Not acceptable
Customised Exception: same
electrical item (e.g.
galley, crew rest
Not acceptable Not acceptable
compartment...,
equipment, VU,
VE...), see
2.1.3.3.3
Non-Essential Not acceptable
Customised Exception: same
Acceptable
electrical item (e.g.
(Dedicated routing
galley, crew rest
Not acceptable and dedicated
compartment...,
connectors are
equipment, VU,
preferred)
VE...), see
2.1.3.3.3
Table 9
Note : Same system is the essential condition to fit two harnesses together!
2.1.3.3.2 GENERAL INSTALLATION PRINCIPLE
D-CGU-10-9200-862-1 Essential and Non-Essential Routes shall have a dedicated routing and dedicated
connectors, see Figure 2.
23M
21M
connectors
Cabin
Interior
Equipment
Figure 2
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2.1.3.3.3 PARTICULAR CASES
D-CGU-10-9200-865-1 For a same electrical item (e.g.: galley, crew rest compartment..., equipment, VU,
VE...), Essential and Non-Essential harnesses for a same system side may be routed
together, according to the following conditions see Figure 3.
For electrical items connected to multi-circuit harne sses:
- Essential routes shall be electrically protected (e.g. PEEK conduit)
- A pin separation within the connector for equipments designed without connectors
segregation shall be provided
For electrical items connected to single circuit harnesses:

- No protection is required if the system specialist validates the mix of the two har-
nesses. A TDD 92 deviation shall be issued.
- A pin separation within the connector for equipments designed without connectors
segregation shall be provided
EQ
Electrical items connected to

multi-circuit harnesses 21M 23M
Electrical items connected to 21M 23M

single circuit harnesses
Figure 3
Note: The preferred installation of the electrical protection is on the essential bundle. For the installa-
tion of PEEK conduit see 2.6.4.
2.1.3.3.4 ESSENTIAL/NON ESSENTIAL CABLE SUPPORT
D-CGU-10-9200-869-1 The design shall ensure that the installation of Non-Essential harnesses is possible
without action on the Essential harnesses.
D-CGU-10-9200-870-1 The design

possible shallaction
without ensureonthat the installation
the Essential of Essential Customised harnesses is
Basic harnesses.
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2.1.3.4 SEGREGATION OF ROUTE CATEGORIE M AND S
D-CGU-10-9200-783-1 Routes M panels).

boxes and and S shall not be mixed (in all electrical & optical areas, including racks,
2.1.3.5 SEGREGATION WITHIN CONNECTOR AND TERMINAL MODULE

Applicable for system 1 and 2 and route P, M & S.
D-CGU-10-9200-740-1 For connector racks, segregation of the basics routes (1M - 2M - 1S - 2S) shall be
ensured up to ARINC 600 connector inlet. This segregation shall be achieved by a re-
liable system, which will not be lost during the maintenance operations.
D-CGU-10-9200-741-1 For rectangular connectors (EN 3545 type) and terminal module (NSA937901),
segregation is ensured by dedicated cavities for 1M / 1S /2M / 2S routes.
D-CGU-10-9200-739-1 The electrical and optical route segregation aft of equipment connectors shall be the
same as that of the connector segregation except for connectors’ racks, which require
more stringent control.
2.1.3.5.1 OPTICAL CONNECTOR
D-CGU-10-9200-743-1 The mix of optical and electrical technology in the same connector is forbidden (except
for ARINC404 and ARINC 600) in order to avoid dust and contamination on optical
contacts (mating aspect).
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2.1.3.6 SEGREGATION OF GROUNDING (CURRENT RETURN) AND BONDING
GROUND POINTS
Non- Non-
ESS ESS
ESS ESS
SYST 1 SYST 2
SIGNAL SIGNAL TYPE SYST 1 SYST 2 REMARKS
& &
& &
Ess Ess
Non-Ess Non-Ess
Cust. Cust.
Cust. Cust.
Syst 1 Syst 2
Syst 1 Syst 2
28 V
DC 1 DC 2 DC3 DC 4 /
and discrete signal
6V 6 DC 1 6 DC 2 6 DC 3 6 DC 4 /
115 V 115 AC 1 115 AC 2 115 AC 3 115 AC 4 /
26 V 26 AC 1 26 AC 2 26 AC 3 26 AC 4 /
5V 5 AC 1 5 AC 2 5 AC 3 5 AC 4 /
All cable shields and

EQUIPMENT bonding General B1 B2 B3 B4 /
(except audio-com)
All low signals

and screening
Audio-com General S for audio-com
are in this
category
Table 10
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D-CGU-10-9200-884-1 In general minimum distances of 25mm between each route of the same category are
required (e.g 1P and 2P).
D-CGU-10-9200-047-1 The distances given by Table 11 Minimum distances between routes

-shall be respected on the overall length of the harness.
-shall consider slagging of cable / bundle
-shall be ensured during lifetime.
D-CGU-10-9200-886-1 For a same system side, the minimum clearance between Essential basic and
Essential customised harnesses (e.g. : 1M/21M) shall be 25mm.
Segregation distance
given in: Table above
Bundle
e.g.: M Ess Customised
Attachment point
Segregation distance
given in: Table above
e.g.: 25 mm
Bundle
e.g.: M Non-Ess Customised
Figure 4 Segregation Distances (Cross-Section-View)
2.1.4.1 DISTANCES BETWEEN BUNDLE AND ELECTRICAL DEVICES
D-CGU-10-9200-898-1 Distances between bundles and electrical devices shall be according to Table 11. For
a reduction of this distance a system specialist shall be contacted. A possible reduc-
tion depends on the electrical device.
Distance according to Table 11
Electrical Device
structure
Figure 5
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2.1.4.2 CROSSING OF SEPARATING BUNDLES AND CONDUITS
D-CGU-10-9200-900-1 Crossing bundles or conduits shall be physically separated. If this is not possible they
should be separated with a specific device (e. g. separator see 2.4.18) . Physically
separated means that only chafing aspects are necessary to take into consideration
(see Figure 6) .
Route x
NO CHAFING
ALLOWED
Route y
Figure 6
D-CGU-10-9200-901-1 For crossing of feeder cables a minimum distance of 5 mm between the cables is
required.
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2.3 CABLE SELECTION
The electrical cable selection must take the following basic operating factors into account:
-external temperature (ambient & bundle temperature)
-internal temperature (joule effect / heating temperature)
Only Airbus approved cables, items, material…, shall be used, see § 3 Design Process Requirements.
D-CGU-10-9200-848-1 The supplier shall be responsible for every wire bundle to be installed in Boxes,
Panels, Monuments, racks for internal interconnection of electronic equipment.
2.3.1 SELECTION OF CABLE-TYPE
D-CGU-10-9200-819-1 Cable type shall be selected as shown in table below:

For equipment (Boxes, Panels, Monuments, Racks) cooper-type cable shall be used.
AIRCRAFT ZONING / ROUTE CABLE TYPE GAUGE (AWG)
Boxes, Panels, Monuments, Racks

DR-Family ALL
Grounding and Bonding
P route AD-Family ALL
Table 12
D-CGU-10-9200-849-1 For Interface-Connector:

In case of different cable-types / cable gauges the matching of pins and sockets shall
be ensured.
Background: Aicraft-wiring may be defined as Aluminium-type cable.
Therefore cable-type on interface connector (between Aicraft-side connector and
equipment connector) may be of different type and - because of different electrical re-
sistances - gauges of these cables may change.
This will be defined by System Engineering and given in wiring-diagrams.
(example: A\C-side: Aluminium-type cable AWG22 / equipment-side: copper-type
cable AWG24).
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2.3.2 SELECTION OF CONTACTS AND TERMINAL LUGS

D-CGU-10-9200-821-1 Contact and terminal lugs shall be chosen according to Table 13:
Copper Cable Connection Principle Aluminium Cable Connection Principle
# 26 Contact # 10 to # 4 Contact / Terminal Lug
# 24 to # 6 Contact / Terminal Lug # 3 to # 000 Terminal Lug
# 4 to # 000 Terminal Lug
Table 13
Note: Above 23 Amps terminal blocks shall be used.
D-CGU-10-9200-822-1 The choice of type and size of contacts shall be in accordance with the cable gauge.
It shall be ensured that temperature derating effects will have no negative influence on
operating performances of all connector parts and accessories.
Type and size of contacts as well as type of connector shells and accessories shall be
selected taking into account this effect.
2.3.3 CABLE SELECTION FOR GROUNDING/ BONDING

see § 2.10 Grounding and Bonding
2.3.4 TEMPERATURE EFFECTS
2.3.4.1 "OUT-OF-BUNDLE" UTILISATION

D-CGU-10-9200-825-1 The wire temperature due to Joule effect (temperature increase, electrical heating) out
of bundle shall not exceed 25°C.
Figure 8 - Figure 12 permit to evaluate the temperature rise of a supplied electrical cable.
Example : An "out-of-bundle" gauge 24 cooper-cable supplied with 4 A will be subjected to a joule
effect temperature rise under 20°C ( Figure 8 Cable temperature with respect to its intensity Out-of-
bundle ).
2.3.4.2 "IN-BUNDLE" UTILISATION

The grouping of cables "in bundle" reduces the thermal exchanges with the environment. In any case,
these events shall not damage the bundle.
Figure 13 shows the derating coefficient with respect to the bundle load.
D-CGU-10-9200-823-1 For all categories of routes, the elevated temperature due to Joule effect (temperature
rice, electrical heating) shall not exceed 40°C.
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The temperature depends on the number of cables making up the bundle and the current intensity. As
the number of cables is fixed, the bundle temperature can only be limited by decreasing the wire
gauge to limit joule heating effect.
Example : As for the cable mentioned in the previous paragraph.

A bundle constituted of 17 cables, 80% loaded would lead to a derating coefficient of 0.5.
This would ask to choose the wire for an intensity of 8 Amps (4 / 0.5 Amps).
In that case the temperature rise by the 24-gauge cable would be 61°C (> 40°C).
Thus we should take a 22 gauge wire. The joule effect heating will be then about 35°C (<40°C).
D-CGU-10-9200-820-1 Outside panels, taking into account ambient temperature, the harness temperature
should be limited to a maximum of 60°C.
This requirement recognises the disadvantage of having "hot cables" in the aircraft in respect of the
effect upon the installation, risks to servicing personnel, the increased possibility of failure and the
adverse effect upon the harness life.
Figure 8 Cable temperature with respect to its intensity Out-of-bundle
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s
le
b
t a
n d c
e f
cr e o
d r
e a e
P lo % % % % %
0
b
m
0 0 0 0 0 u
2 4 6 8 1 N
9
3
7
3
5
3
le 3
3
d
n
u 1
b 3
e
ht 9
2
to
t 7
c 2
e
p
s 5
re 2
ht
i 3
w 2
t
n 1
ie 2
ifc
f 9
e 1
o
c
g 7
1
itn
ar 5
e 1
D
3
1
1
1
7
) gnit ar e d(
5
T NEI CI FF E OC
3
1
0. 9. 8. 7. 6. 5. 4. 3.
1 0 0 0 0 0 0 0
Figure 13 Derating coefficient with respect to the bundle load
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2.4 CABLE AND BUNDLE INSTALLATION

Applicable also for optical cables.
Wording:
- Bundle, Harness: see § 2
- Secured position of cable /bundle: Distance/design of supports/fasteners shall be defined such
that in no case (slag, vibration etc.) the required distance (L) may be reduced through any kind
of relative movement (slack, acceleration, vibration..).
- Secured attachment point: clamps, carriers or some other suitable attachment systems
2.4.1 DISTANCES
The Top priority aim of wire bundle design/installation shall be a cable routing physically separated by
distances (air space, without additional protection).
Additional protection (like conduits, edge profiles, grommets etc.) shall be seen as additional help only,
if it is absolutely not possible to keep the minimum distances described in this specification.
D-CGU-10-9200-050-1 Distances shall be ensured until the end of the aircraft life.
2.4.1.1 DISTANCES BETWEEN BUNDLE AND STRUCTURAL ITEMS (EXCEPT COMPOSITE

CONDUCTIVE STRUCTURE)
D-CGU-10-9200-837-1 Any direct contact between electrical cables and metalic / non-metallic structure shall
be prohibited.
D-CGU-10-9200-045-1 The distances between cable/ bundle and metallic / non-metallic structure ( not
applicable for composite conductive structure!) shall be according to Figure 14.
for distance L ≥ 10mm
≤ 200 mm
L≥ 10 mm
metallic / non-metallic structure 2)
Figure 14
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D-CGU-10-9200-850-1 Except for P-routes:

Distance between structure and bundle protected with convoluted conduit ABS0887
may be reduced to L=0 mm if there is no relative movement between structure and
conduit
for distance L= 0mm –10mm

except for P-routes
mech. and
electrical protection
≤ 120mm (conduit ABS 0887)
support
L= 0mm
Figure 15
2.4.1.1.1 FOR INTERSECTION: CABLE, BUNDLE - STRUCTURE
≤ 120mm ≤ 120mm
L ≥ 10mm
with secured attachment point 1)
Figure 16
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≤ 200 mm
support bundle
L = 20mm
L = 25mm
Figure 17
1) Distance/ design of supports shall be defined such, that in no case (slag, vibration etc.) the re-
quired distance L can be reduced.Therefore, in confined areas, additional supports may be required.
2) Not applicable for composite conductive structure !
3) Distance/ design of supports shall be defined such, that there is no rel. movement between cable/
bundle and structure.
2.4.1.2 DISTANCES BETWEEN ELECTRIC CABLES AND CONDUCTIVE COMPOSITE SURFACE

(CARBON, GLARE…)
see § 2.4.8 INSTALLATION OF BUNDLES ON CONDUCTIVE COMPOSITE PARTs
2.4.1.3 DISTANCES BETWEEN ELECTRICAL BUNDLES/CABLES AND DIFFERENT SYSTEMS

(PIPES, MECH. CABLE…)
2.4.1.3.1 BETWEEN EL. CABLES AND MECHANICAL CABLES, MOVING PARTS
D-CGU-10-9200-838-1 Between the electrical cables and:

- Pipes carrying flammable liquids [e.g.: Fuel, hydraulic fluid, … (except gaseous
oxygen)],
- Mechanical cables,
- Moving parts,
- the distance should be 50 mm .
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D-CGU-10-9200-839-1 Only if these distances cannot be observed:

For distance 25 mm ≤ d < 50 mm, cables or bundles
-shall be protected by conduits or sleeves.
Or
-shall be secured by attachment point (Clamps, carriers or some other suitable
attachment system) to ensure a distance of 25 mm minimum.
D-CGU-10-9200-840-1 Distances less than 25 mm shall be strictly prohibited.
2.4.1.3.2 BETWEEN THE ELECTRIC CABLES AND PIPES WHICH CARRY NON-
INFLAMMABLE LIQUIDS OR GASES
D-CGU-10-9200-842-1 For P routes, the distance shall be 25 mm minimum.

A distance of less than 25 mm shall be strictly prohibited .
For other than P routes, the distance should be greater than 13 mm.
D-CGU-10-9200-841-1 Only if these distances cannot be observed:

For distance less than 13 mm and greater than 10 mm, electrical cables or bundles
shall be
-protected by conduits or sleeves.
Or
-secured by attachment point (Clamps, carriers or some other suitable attachment
system) to ensure a distance of 10 mm minimum to non-inflammable liquids or gases.
D-CGU-10-9200-843-1 Distances of less than 10 mm shall be strictly prohibited.
2.4.1.3.3 DISTANCE TO GASEOUS OXYGEN

D-CGU-10-9200-851-1 The distance should be equal or greater than 150 mm.
D-CGU-10-9200-852-1 Only if 150mm cannot be observed, for distances 50 mm ≤ d ≤ 150 mm, electrical
cables or bundles shall be
- protected by conduits or sleeves (see 2.6)
Or
- Supported by additional attachment point (Clamps, ramps…)
D-CGU-10-9200-853-1 Only for exceptional

For distances 25 mmcases:
≤ d ≤ 50 mm, electrical cables or bundles shall be
-protected by conduits or sleeves.
Or
-secured by attachment point (clamps, carriers or some other suitable attachment
system) to ensure a distance of 25 mm minimum to oxygen components.
Alternatively, in the case where cables or electrical looms are not held securely by a suitable attach-
ment or are unprotected, the oxygen pipe shall be insulated by protection made from non-corrosive
material (the identifications shall remain visible). Or, in the case of a flexible oxygen pipe, it shall be
held in such a way that it cannot come within a distance of 25 mm of electrical cables or bundles (e.g.:
vibration effects).
D-CGU-10-9200-854-1 For P routes, a distance of less than 25 mm shall be strictly prohibited.
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D-CGU-10-9200-855-1 For other routes, for distances when the distance 13 mm ≤ d < 25 mm, electrical
cables and bundles shall be:
- protected by conduits or sleeves
And
-secured by attachment point (Clamps, carriers or some other suitable attachment
system) to ensure a distance of 13 mm minimum from the oxygen components.
D-CGU-10-9200-856-1 Alternatively, in the case where cables or electrical looms are unprotected, or
additionally, the affected area of the oxygen components, such as the rigid or flexible
pipes, shall be insulated by protection made from non-corrosive material (the identifi-
cations shall remain visible).
- If the distance of P routes (unprotected) falls within these values, the affected section
of the oxygen pipe shall be insulated by protection made from non-corrosive material
(the identifications shall remain visible).
- If the distance with a coaxial cable is within these values, the affected section of the
oxygen pipe shall be insulated by non-corrosive protection material (the identifications
must remain visible).
D-CGU-10-9200-857-1 A distance of less than 13 mm shall be strictly prohibited.
D-CGU-10-9200-858-1 After installation, the protection shall be still remain in its position and location.
D-CGU-10-9200-859-1 The protection of cable / bundle shall be ensured by conduit with mechanical and
electrical resistances.
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Distance ( L / mm)
electr. Bundel, Cabel 150 < L ≤ 50 50 < L ≤ 25 25 < L ≤ 13 13 < L ≤ 10 L < 10
/ Pipes
conduits
OR
Mechanical cables,
Acceptable secured by
Moving mechanical parts
attachment
point
shall not be used
P routes Acceptable
Non-flammable
liquids or gases
(air, water, nitro- conduits
OR
gen) Other than Acceptable
secured by
shall not
P routes be used
attachment
point
conduits
P routes OR shall not be used
secured attachment point
Gaseous Oxygen
conduits conduits
AND
Other than OR
P routes secured
secured shall not be used
attachment
attachment point
point
Table 14
2.4.2 PRINCIPLE OF SUPPORT INSTALLATION

Applicable also for optical cables
Note: Glued supports are generally prohibited.
2.4.2.1 DISTANCES BETWEEN SUPPORTS
D-CGU-10-9200-829-1 Supports and distances of supports shall be defined in such a way that in no case the
cables come into contact with surrounding (metallic, non-metallic structure, equipment
structure, e.g. honeycomb-panel) or other equipment because of slack, acceleration,
vibration..).
D-CGU-10-9200-826-1 The maximum distance / pitch between two cable fixations / supports on the
equipment structure shall not exceed 200 mm.
D-CGU-10-9200-062-1 Non-metallic supports (e.g.: ramp system, composite clamp) shall not be used above
150°C continuous operation environments.
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2.4.2.2 SHARP EDGES

D-CGU-10-9200-067-1 All sharp edges or flanged edges on the cable side shall be strictly prohibited, see
Figure 18.
CORRECT WRONG
Figure 18
2.4.2.3 DISTANCES BETWEEN CONDUITS AND SHARP STRUCTURE
D-CGU-10-9200-058-1 Except for P-routes, except for conductive composite:

Distance between structure and bundle protected with convoluted conduit ABS 0887
may be reduced to 0 mm, if there is no relative movement between structure and con-
duit, see § 2.4.1.1”Distances Between bundle and structural items (except composite
conductive structure)” .
SUPPORTS CONDUITS
SHARP
STRUCTURE
Figure 19
D-CGU-10-9200-059-1 For each support the access to clamp and fitting shall be possible.
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2.4.2.4 CLAMP
D-CGU-10-9200-068-1 The increase of the bundle diameter (size of clamp) shall not reduce the segregation
distance (see § 2.1.4 segregation between route Categories) .
This is reached by selection of an adequate and adapted support to avoid sagging.
Using spacer for bundle turning or specific installation (see § 2.4.18 Use of separa-
tors) .
CLAMP OR V SUPPORT
Distance
CORRECT NOT PREFERED

Figure 20
D-CGU-10-9200-069-1 V support installation shall follow the above shown principle, wether the distance may
change with bundle diameter and size of support.
D-CGU-10-9200-070-1 The position of the clamp shall take into account the tooling (e.g.: cable tie gun).
2.4.2.5 STAND OFF (SPACER)
D-CGU-10-9200-713-1 Generally plastic stand off ABS 1423/24 type (see Figure 21) shall be used on
conductive composite surface.
Figure 21
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D-CGU-10-9200-714-1 Plastic stand off shall be fixed on metallic/carbon structure with rivet ASNA 0080 or
NAS 1919.
D-CGU-10-9200-715-1 Metallic stand off ASNA2328/27 type may be used for mechanical reason, but not on
carbon.
D-CGU-10-9200-716-1 Stand off type shall be defined in accordance with the route temperature
E.g. : Plastic stand off for M, S and R routes.
2.4.2.6 ATTACHMENT OF HARNESSES BENDING RADIUS
Respecting cable bundle bend radius rules see chapter: ”Cable Bundle Bending radius”§ 2.4.14.
D-CGU-10-9200-082-1 Attachment points shall be installed close and before the start of bend radius axis.
BEND RADIUS AXIS
ATTACHMENT POINT
BUNDLE
Figure 22
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2.4.3 DRIP LOOPS FOR FLUIDS
D-CGU-10-9200-085-1 Any cables or harnesses that may be affected by fluids shall be routed with drip loops.
Drip loops shall be designed such that the fluids cannot migrate into the rear of the
connectors or end terminations.
Only when drip loop is not possible, one of the solutions below shall be applied:
-The first attachment point is lower than the connector contacts (preferred installation)
-Cables connected to a ground point
-Cable ends are installed on a plate that is at least tilted 15° downwards.
-For optical cables.
-Connections and first attachment point are water protected by umbrella
-sealing of connectors: see § 2.8 Connectors
Clamp
LOWEST POINT ATTACHEMENT POINT
Figure 23
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see Note
prohibited
preferred
OK
(with drip loop, horizontal-axis
position of connector)
Wrong
without loop
OK
(with drip loop, vertical-axis
position of connector)
Figure 24
Note: The vertical-axis position of the connector is not preferred, additional protection shall be applied,
see § 2.8 Connectors and Backshells.
D-CGU-10-9200-087-1 All cables or harnesses shall also conform to the minimum bend radius requirements
see § 2.4.14”Cable bundle bending radius “.
D-CGU-10-9200-088-1 When the cables are installed in a rigid conduit, this conduit shall be drained (see
AIPS 07-07-004).
D-CGU-10-9200-090-1 Design of drip loop shall include an over length for aircraft repairs.
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D-CGU-10-9200-899-1 All connectors shall be visible after installation in the aircraft.
2.4.4 JUNCTIONS
A junction corresponds to a physical part of the harness used to change the direction of wires in order
to reach several end elements with branches.
D-CGU-10-9200-094-1 On rigid conduit junctions shall be single junction with one branch equipped.
Figure 25
CORRECT INCORRECT
Figure 26
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2.4.5 WIRING JOINING ON THE EQUIPMENT REMOVABLE FROM THE FOR-

WARD FACE
D-CGU-10-9200-095-1 All wiring joining on to equipment/ modular assemblies (removal from front face) fixed
by cable tie of NSA 935401 type shall be designed in such a way that individual re-
moval of each equipment is possible without opening or removing the other items.
D-CGU-10-9200-096-1 Particular care shall be taken in carrying out this wiring, so that the necessary slack is
suitably placed without risk of deterioration when the equipment is in place (see AIPS
07-01-001).
D-CGU-10-9200-097-1 Each removable bundle extremity shall have mechanical protection with textile split
conduit EN6049-006/ 007.
D-CGU-10-9200-098-1 For accessibility to the connector, sufficient harness over-length and its appropriate
stowage shall be provided to give sufficient access to the connector, typically hand
width for bayonet connectors (e.g.: control panel, equipment...).
2.4.6 INTERFACE CONNECTION POSITIONING

D-CGU-10-9200-102-1 To facilitate maintenance and tooling the interface connection shall be positioned:
-In accessible area with minimum actions required (maintenance aspect)
-No confined area (tooling)
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2.4.7 ELECTRICAL INSTALLATION POSITIONED IN CONTAMINATION AREAS

Applicable for:
-fluid projection areas
-water condensation dripping
PRESSURISED PRESSURISED
HAZARDOUS AREA* NON HAZARDOUS AREA
- SEALED CONNECTOR
- SEALED CONNECTOR
(GROMMET)
Connector (GROMMET)
- DUMMY CONTACTS
- DUMMY CONTACTS
- SEALING PLUGS
- SEALED MODULE - SEALED MODULE

Terminal
Modul
(GROMMET) (GROMMET)
- SEALING PLUGS
Terminal
Block
- UMBRELLAS - NO PROTECTION
* Hazardous Area: under passenger door sill areas, when connectors are installed vertically (not rec-
ommended)
Table 15
D-CGU-10-9200-719-1 Protection inside boxes/panels is not required.
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2.4.7.1 ELECTRICAL CONNECTIONS POSITIONING
D-CGU-10-9200-109-1 Electrical connectors shall not be positioned under pipe couplings or under fluid-
containing equipment.
D-CGU-10-9200-110-1 If it is impossible to observe the above instructions, connections shall be mechanically

protected to avoid contamination damage see Table 15.
2.4.7.2 FLUID INGRESS PROTECTION OF ELECTRICAL EQUIPMENT
D-CGU-10-9200-785-1 Sensitive electrical equipment, especially electrical components shall be protected

against water condensation dripping.
D-CGU-10-9200-111-1 In fluid exposed area (e.g.: wet galleys, lavatories), panels/boxes/connectors and
equipment shall be mechanically protected (e.g.: umbrella...).
D-CGU-10-9200-113-1 Umbrella shall be in non-metallic material to avoid affects of condensation.

E.g.: VT protection
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2.4.8 INSTALLATION OF BUNDLES ON CONDUCTIVE COMPOSITE PARTS

Due to the significant use of carbon on aircraft, precautions have to be taken for design of electrical
installation.
Minimum clearance shall be provided in order to avoid a damage of the conductive composite struc-
ture. Failures could generate fire, smoke, smell of burning and in addition for current injection, arcing
and local hot spot on conductive composite structure (temperature > 100°C).
2.4.8.1 BUNDELS ON CONDUCTIVE COMPOSITE SURFACE
D-CGU-10-9200-722-1 Direct contact between cables/ bundles and conductive composite panels shall be
strictly prohibited.
D-CGU-10-9200-692-1 The Distances between conductive composite surfaces and cable/bundles shown in
table below shall be ensured, respecting the worst position (e.g. when the bundle, the
conductive composite surface or both are in movement).
Distances
(L/ mm)
L ≥ 25 25 L ≥ 20 20 L ≥ 10 10 > L
Categorie
of route
With an electrical protection and secured
Acceptable
P routes see Figure 27 attachment point
see Figure 28
Not
With an electrical acceptable
protection and
Acceptable
M/S/R routes secured attachment
see Figure 27
point
see Figure 28
Table 16
D-CGU-10-9200-836005-1 For all categories of routes, in case of intersection between bundle and conductive
compositesecured
minimum part, (max. length:
distance of 1010mm) ( i.e.bebundle
mm shall across
ensured, see hole in carbon
Figurestructure)
27. a
D-CGU-10-9200-818-1 Installation of routes P, M, S, R shall be insured with one-level of insulation.

One-level of insulation could be achieved by a non-conductive fixed bracket.
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support ≤ 200 mm 1
bundle
L ≥ 25mm for P routes

L ≥ 20mm for other routes
composite conductive structure
Figure 27
Distance between secured position and mech. and electrical

supports <200mm 1) protection (conduit)
25 ≥ L ≥ 10mm for P routes

20 ≥ L ≥ 10mm for other routes
Figure 28
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2.4.8.1.1 INTERSECTION: BUNDLE AND COMPOSITE CONDUCTIVE STRUCTURE
secured attachment point
L ≥ 10mm

10mm max.
1) Distance/ design of supports shall be defined such, that in no case (slag, vibration etc.) the
required distance L can be reduced
Therefore, in confined areas, additional supports may be required.
Figure 29
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2.4.9 OPTICAL CABLE INSTALLATION

D-CGU-10-9200-128-1 Optical cable may be installed inside R and S routes harnesses in all areas
see § 2.4.18.
D-CGU-10-9200-130-1 The mix of electrical and optical technology in the same connector shall be forbidden,
except for ARINC 600/404 connectors, to avoid contamination (dust).
2.4.10 INSTALLATION ON MOVING MECHANICAL PARTS

D-CGU-10-9200-136-1 Harnesses should never be installed on moving mechanical parts.
D-CGU-10-9200-786-1 The bending radius of each cable shall be kept before, during, after movements, see §
2.4.14. Installed cables or bundles shall return afterwards to defined starting position.
D-CGU-10-9200-789-1 Cables or bundles shall not scrub on the edges of moving mechanical parts.
D-CGU-10-9200-788-1 Movement shall not bear any abnormal mechanical stress on cables or bundles.
D-CGU-10-9200-137-1 Prefarably the bundle shall be fixed with clamp.
2.4.11 COMPATIBILITY OF CONDUCTIVE MATERIALS

D-CGU-10-9200-140-1 The compatibility shall be according to Table 17.
Differences of electrochemical potentials between some conductive materials (in mV)

Below the line the metal of the ordinate is attacked.
Above the line the metal of the abscissa is attacked.
Between these 2 lines, the contact is practically neutral.
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Electrolysis: water with 2 % salt

l
e N N 5
ABSCISSA n
o
te
s
y
llo e
Z
%
Z
%
A e
s m
br z 1 m m
s a n 0 0 iu m e iu
m a s m G r r 3 5
0 iu n s
u C le iu H l e e o
r n e 0
3 in iu a e
itn / e p p b- s o s z ls m
m g n
dl in n - k p p s c s n d A e m d
o
r c n g
la o ta tia G ic o o lu ar lii ar o
r in
a
e S te lu a h in a a
ORDINATE P C S T A N C C A B S B B T L N S A C C Z M M
130 340 430 570 685 770 840 1000 1100 1400 1950
Platinum 0
250 350 450 600 700 800 940 1090 1200 1470
210 300 440 535 640 710 870 970 1270 1620
Gold/carbon 0
130 110 220 320 470 570 670 810 960 1070 1340
110 90 180 320 415 520 590 750 850 1150 1700
Stainless steel 0
250 100 200 350 450 550 690 840 950 1220
210 90 230 325 430 500 660 760 1050 1610
Titanium 0
340 90 10 110 260 360 460 600 750 860 1150
220 10 80 220 315 420 490 650 750 1050 1600
Silver - Mercury 0
350 100 100 250 350 450 590 740 850 1120
300 90 140 235 340 410 570 670 970 1520
Nickel 0
430 180 80 20 170 270 370 510 650 770 1040
320 110 20 120 215 320 390 530 650 950 1500
Copper alloy 0
450 200 100 150 250 350 490 640 750 1020
440 230 140 95 200 270 430 530 830 1380
Copper 0
570 320 220 120 30 130 230 370 520 630 900
Alu-bronze 470 260 170 30
0
65 170 240 400 500 800 1350
Brass 30 % ZN 600 350 250 150 100 200 340 490 600 870
535 325 235 95 105 175 335 435 735 1285
Silicon 0
665 415 315 215 65 35 135 275 425 353 805
Brass 50 % ZN 700
570
450
360
350
270
250
130
100
35 0 70
100
140
240
300
390
400
500
700
770
1250
640 430 340 200 105 70 230 330 630 1180

Bronze 0
770 520 420 320 170 70 30 170 320 435 700
670 460 370 230 135 30 40 200 300 600 1150
Tin 0
800 550 450 350 200 100 140 290 400 670
710 500 410 270 175 70 160 260 560 1110
Lead 0
840 590 490 390 240 140 40 100 250 300 630
Light alloy 810 600 510 370 275 170 100
0
60 160 460 1010
NSA 3001 940 690 590 490 340 240 140 150 260 530
870 660 570 430 335 230 160 150 400 950
Steels 0
1000 750 650 550 400 300 200 60 90 200 470
960 750 650 520 425 320 250 90 100 310 860
Aluminium A5 1090 840 740 640 490 390 290 150 0 110 380
970 760 670 530 435 330 260 150 300 850
Cadmium 0
1100 850 750 650 500 400 300 160 100 100 370
1070 860 770 630 535 430 360 200 100 200 750
Chromium 0
1200 950 850 750 600 500 400 260 110 270
1270 1050 970 830 735 630 560 400 300 550
Zinc 0
1400 1150 1050 950 800 700 600 460 310 200 70
1340 1150 1040 900 805 700 630 470 370 70 480
Manganese 0
1470 1220 1120 1020 870 770 670 530 380 270
1620 1610 1520 1380 1285 1180 1110 950 850 550
Magnesium 0
1950 1700 1600 1500 1350 1250 1150 1010 860 750 480
Table 17
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D-CGU-10-9200-158-1 6 times may be accepted in exceptional cases.
2.4.14.4 BENDING RADIUS OF OPTICAL CABLE
D-CGU-10-9200-159-1 The minimum radius shall be equal to 10 times of the outside diameter of the cable.
D-CGU-10-9200-160-1 The bending radius shall never be less than 20 mm.
2.4.14.5 BENDING RADIUS OF QUAD CABLE (DATABUS CABLES)

D-CGU-10-9200-182-1 The minimum radius shall be equal to 10 times of the outside diameter of the Quad
cable.
D-CGU-10-9200-761-1 6 times may be accepted in exceptional cases only for fixed cables which can not
move.
2.4.14.6 BENDING RADIUS OF BUNDLES
D-CGU-10-9200-161-1 The minimum bending radius of a bundle shall be equal to 6 times of the outside
diameter of the bundle when there is no optical or coaxial cable inside (bundle diame-
ter see 2.5.1) .
D-CGU-10-9200-162-1 With coaxial and optical cables inside, the minimum bend radius shall be equal to 10
times of the outside diameter of the largest coaxial or optical cable.
D-CGU-10-9200-163-1 It shall not be less than the minimum allowable radius for the largest cable in the
bundle concerned (see § 2.5) .
2.4.15 CABLE LENGTHS
2.4.15.1 CALCULATION OF THE BUNDLE LENGTH

Applicable for all electrical and optical harnesses between two attachment points when routing is
linear
D-CGU-10-9200-168-1 The length of the bundle shall take into account the shape of the bundle and the
structural tolerance. If required, at each end an over-length shall be provided for drip
loop.
2.4.15.2 ELECTRICAL CABLE OVER- LENGTH
D-CGU-10-9200-171-1 There shall be no stress on connection bars and when cables are connected to
moving parts (plugs, hinges...).
D-CGU-10-9200-172-1 Over-length more than mentioned below shall be managed by a stowage area (see §
2.4.15.6) .
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2.4.15.2.1 CABLE LENGTHS FOR REPAIRS FOR COPPER CABLES
D-CGU-10-9200-173-1 For 26 to 12 gauge cables an over-length of nominal 14mm shall be provided.

D-CGU-10-9200-174-1 For 10 to 04 and coaxial cables, this over-length nominal shall be 20 mm at each end.
D-CGU-10-9200-175-1 For 02 to 0000-cable over-length nominal shall be 30 mm at each end and stowed in a
specific area.
2.4.15.3 OPTICAL CABLE OVER LENGTH

D-CGU-10-9200-177-1 An over-length of 50mm maximum shall be located at each end.
D-CGU-10-9200-178-1 A bracket shall be installed near each end of harness to cover thus over-lengths
(+50mm maximum at each extremity).
D-CGU-10-9200-179-1 Damaged or faulty optical cables, bundles or harnesses shall be removed and
replaced.
2.4.15.4 COAXIAL CABLE OVER LENGTH
D-CGU-10-9200-180-1 An over-length of 50 mm maximum shall be located at each end during the length
definition, for each repair.
D-CGU-10-9200-181-1 The length and number of coaxial cable is fixed with system agreement and cannot be
changed.
2.4.15.5 QUAD CABLE OVER LENGTH (AFDX)

D-CGU-10-9200-184-1 Twisting effort shall be avoided on the level of extremities.
D-CGU-10-9200-186-1 Quad cable may be installed inside the electrical harness like the other cables but with
a minimum of 250mm free at the extremities.
D-CGU-10-9200-187-1 For all bundles the extremities shall be tied after plug in.
D-CGU-10-9200-188-1 Quad cables shall be installed only in M, S and R routes, network designation shall be
defined by Airbus.
D-CGU-10-9200-763-1 An overlength of 50 mm TBC shall be provided for contact repair on quad cable links.
D-CGU-10-9200-764-1 Each extremity of the Quad cable is marked (A and B), this biasing shall appear on the
electrical drawing.
2.4.15.6 STOWAGE AREA FOR BUNDLE LENGTH CONTROL

D-CGU-10-9200-680-1 For electrical and optical cable over-length management shall be provided in each
interface area.
D-CGU-10-9200-681-1 Moving attachment points (see Figure 30 and Figure 31) shall be designed in the
same attachment philosophy as used on the other part of the harness.
Applicable inside fuselage e.g. for P routes.
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Movable attachment point
Attachment points
Figure 30 Preferred solution A (stowage by moving attachment points)
overlength stowage shall ensure:

o minimum cable bending radius
o minimum distances to structure/ other routes
o defined cable shape for drip loop if necessary
shall prevent:
o mech. stress
o
crushing
Movable attachment point
Figure 31 Preferred solution B
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2.4.16.2 BY ROUTING
D-CGU-10-9200-768-1 The length of cable may only be sufficiently reduced to prevent any incorrect
connection if the use of different connectors is not possible.
D-CGU-10-9200-202-1 Routings arriving at identical connectors shall be such that permutations are
impossible.
WRONG CORRECT
Figure 33
2.4.16.3 BY CHAINS
Not recommended solution .
D-CGU-10-9200-203-1 If it is not possible to change the routing and the connector configuration to avoid a
possible permutation of connectors, small chains or leads shall be provided.
D-CGU-10-9200-204-1 The chains or leads shall be crimped on the lugs and screwed to a backshell ASNE
0199/0455.
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2.4.17 FIXING
2.4.17.1 HARNESSES FIXING PRODUCTS
D-CGU-10-9200-770-1 Electrical harnesses (protected, non protected) shall be fixed on the aircraft interior by:
categorie of route
Area M/S and others P
with strains*: ABS1339-D

ABS 1339-D
- Fuselage NSA5516 + ASNA5107
Without strains:
- Inside BOXES/ PANELS (limited use)
V- support NSA935504
for ∅≤ 45 mm
- lining materials, (Composites, ABS 1224 (preferred solu-

pre-pack, laminated) tion)
Table 19
*Bundle is considered to be strained when the bundle bending radius is > 6 and < 10 times the outside
∅ of the largest cable inside.
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2.4.17.1.1 FIXING BY PLASTIC CLAMPS ABS 1339
1: Screw
2: Cable clamp
3: Elastomer protection
4: Cable tie
Figure 34
D-CGU-10-9200-206-1 As preferred standard clamp, plastic clamp (ABS 1339) should be used:
-For P routes in pressurised areas
-In pressurised zones except hot area (temperature range: -55°C – 150°C)
-on bundle without protection
-on bundle protected by textile split conduit EN 6049-006/007 or rigid convoluted con-
duit ABS 0887
-on shielded bundles
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D-CGU-10-9200-775-1 Clamp ABS 1339 shall not be used:

-For high mechanical/ temperature strains
-When accessibility for cable tie gun is not possible.
-In those cases clamp NSA 5516 shall be used.
D-CGU-10-9200-209-1 The width of the tie rap shall be 4.8 mm.
D-CGU-10-9200-794-1 Bundles shall be preferably installed according to Figure 35
For all bundles ∅ ≤ 45mm
Figure 35
D-CGU-10-9200-795-1 Only for bundles ∅ ≤ 25 mm and if Figure 35 is not applicable, installation according to
Figure 36 should be used.
For bundles ∅ ≤ 25 mm
Figure 36
Note: For bundles ∅ ≥ 45mm NSA 5516 shall be used.
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2.4.17.1.2 FIXING BY METALLIC CLAMPS NSA 5516

D-CGU-10-9200-773-1 Aluminium clamp NSA 5516 shall be used only in pressurised areas.
D-CGU-10-9200-684-1 Stainless steel clamp NSA 5516C shall be used:

-in high mechanical constraint areas (i.e.: junction areas, large diameter bundle,
bending,...)
-for hinge bundles (diameter greater than 25 mm shall be attached by 2 clamps NSA
5516 on each side)
-for bundles with diameter greater than 45mm
-when bundles are in movement
D-CGU-10-9200-772-1 NSA 5516CND/J/F (T< 225° C) in pressurised, non-pressurised and high temperature
areas (with skydrol projection).
See process in AIPS 07-01-001
D-CGU-10-9200-894-1 Clamp NSA 5516 may be used :

-on single bundle without external protection (shielded or not), in this case it is neces-
sary to put additional self-vulcanising tape ASNA 5107.
-on single bundle with external protection (shielded or not), in this case it is no
protection of the bundle.
-on bundles (protected or not) attached on the came clam, in this case it is necessary
to put additional self-vulcanising tape ASNA 5107 around the outside of the combine
bundle.
D-CGU-10-9200-774-1 Clamp NSA 5516 shall be installed only on a straight bundle part, not in the curve of a
bundle.
D-CGU-10-9200-804-1 Bundles shall be preferably installed according to Figure 37.
For all ∅ bundles
Figure 37
D-CGU-10-9200-793-1 In exceptional cases only for bundles ∅ ≤ 25mm the installation principle Figure 38
shall be used.
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For bundles ∅ ≤ 25 mm
Figure 38
2.4.17.1.3 FIXING BY V SUPPORT TYPE NSA 935504

D-CGU-10-9200-212-1 V supports may be used only in pressurised areas where cable or cable bundle
temperature does not exceed 135° C.
D-CGU-10-9200-213-1 V supports should not be used for:

-Small bundles ( ∅ <5mm)
∅
-Big bundle (stressed
-temporarily >25mm)
harnesses (e.g. on moving mechanical part)
-Bundles protected by rigid conduit (ABS 0887)
D-CGU-10-9200-214-1 V- Supports shall not be used for P routes.
D-CGU-10-9200-215-1 When using open V supports, the diameter of the bundle shall not be greater than the
width of the V including 20% of the bundle diameter section for growth provision, see
Figure 39 Principle of installation for V supports.
D-CGU-10-9200-216-1 Cable ties NSA 935401 shall be used with 3.7 mm wide minimum.
D-CGU-10-9200-218-1 For small bundle diameter (Ø ≤ 5 mm) (not recommended) which can move easily
between
5107 shallthebesupport
fitted. and the cable tie, a silicone bobbin NSA 5539 S or tape ASNA
D ≤ L
L
Figure 39 Principle of installation for V supports
D-CGU-10-9200-219-1 The V - support should be installed with mouth upward (see Figure 39) .
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D-CGU-10-9200-229-1 Protections shall be made:

-By protective sleeve NSA 5539 for single optical.
-By red self-amalgamating reinforced silicon tape ASNA 5107 (3 turns minimum)
installed on each cable at each support using cable ties NSA 935401 or equivalent for
two or more optical.
-By red self-amalgamating reinforced silicon tape ASNA 5107 (3 turns minimum) when
one optical integrate a harness.
D-CGU-10-9200-230-1 The standard tying pitch shall be between 150 mm and 200 mm. The minimum
distance between fixing points shall be ≥ 20mm.
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2.4.17.1.6 FIXING OF OPTICAL CABLES INSTALLED INSIDE ELECTRICAL HARNESSES
Protection
Optical
cables PrProtection NSA 5539
S Support Tape ASNA 5107
Harness
Figure 41
D-CGU-10-9200-232-1 If optical cables are integrated within a bundle, protection (tape ASNA 5107) shall be
installed with each support.
D-CGU-10-9200-233-1 Optical cables shall be integrated in the bundle like electrical cables.
D-CGU-10-9200-234-1 The cable or harness deviation shall be attached by two points to avoid stress. Bend
radius requirements shall be ensured.
D-CGU-10-9200-776-1 Optical cables, fixed by other means than clamps, shall be protected by:
- Tape ASNA 5107 for 2 optical cables minimum
- Bobbin NSA 5539 for a single optical cable
2.4.17.1.6.1 Fixing of optical cables installed outside electrical harnesses tbc
D-CGU-10-9200-777-1 Optical cables shall be protected with:

-Tape ASNA 5107 for 2 optical cables minimum
-Bobbin NSA 5539 for a single optical cable
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2.4.17.1.6.2 Separate routing
D-CGU-10-9200-235-1 The installation shall be in accordance with Figure 42.
V support
Optical cable
Protection
Cable tie
Figure 42
2.4.17.1.6.3 Routings on electrical harness
D-CGU-10-9200-236-1 The installation of optical cable on el. harness shall be in accordance with Figure 43.
D-CGU-10-9200-778-1 Optical bundle made of 5 optical cables minimum shall be fixed with V clamps / plastic
clamps ABS 1339.
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Optical cable
Protection V support
= =
Cable tie
or
Protection V support
= =
Electrical harness
Figure 43
Optical cable
Protection
= = Cable tie
Figure 44 Optical cable not fixed in V clamp
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Following separators are used for bundles non protected or protected by conduit EN 6049
006/007.
2.4.18.1.1 SEPARATORS TYPE ABS 1144
D-CGU-10-9200-262-1 Separators type ABS 1144 shall be used if segregation distances between bundles
must be secured.
1: Head 1
2: Tube
3: Head 2
Figure 48
2.4.18.1.2 SEPARATORS TYPE ABS 0054
D-CGU-10-9200-264-1 Separators ABS 0054 (ladder type) shall be used for mechanical separation without
segregation (not preferred solution). This separator shall not be used for P routes.
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Cable tie or lacing tape
ABS 0054
Figure 49
2.4.18.2 ON RIGID CONVOLUTED CONDUITS/ SHIELDED CONDUITS
D-CGU-10-9200-266-1 Separator may be used between conduits ABS 0887, shielded conduits and over
braided bundle in exceptional cases.
D-CGU-10-9200-267-1 In all cases the location and type shall be defined in basic on relevant documentation.
D-CGU-10-9200-268-1 Rigid convoluted conduit ABS 0887 and shielded conduit shall not be crushed.
2.4.19 INSTALLATION OF NON- CODED EQUIPMENT
2.4.19.1 “IN LINE” NON-CODED EQUIPMENT
D-CGU-10-9200-269-1 The mounting of equipment “in line” on the electrical cables (passive components,
splices, diodes…) shall not be:
-Inside conduits (braided or not)
-Under clamps or other supports
-Inside connector back shell.
-In the flexible or bent portion of bundle, or cable hinge
D-CGU-10-9200-270-1 Splices shall be apparent (visible) at the periphery of the cable bundle.
D-CGU-10-9200-271-1 Splices shall be staggered along a cable bundle.
D-CGU-10-9200-272-1 Non-coded equipment crimped on electrical contacts should be adequately supported.
D-CGU-10-9200-273-1 Splices shall not be used in contamination areas (below toilets and galleys), unless
effective protection against the infiltration of liquids is provided.
2.4.19.2 INSTALLATION OF ACTIV NON- CODED EQUIPMENT

D-CGU-10-9200-274-1 Diode blocks, relays, circuit breakers, resistors shall not be installed outside noxes/
panels.
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2.5 HARNESS CONSTRUCTION
2.5.1 BUNDLE DIAMETER
D-CGU-10-9200-813-1 The maximum number of cables or bundles allowed in one routing shall be such that
its diameter does not exceed 45 mm.
45
Figure 50 max. Ø of a bundle including several harness in one attachment device= 45 mm
Table 22 shows how it is possible to calculate the bundle diameter due to the number of cables.
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6 00 0 0 0 0 0 0 0 0 0 9 8 7 6 5 4 3 6
8 7 6 5 4 3 2 1
5 1 9 5
0 0
0 0
0 0
3 , 3
S
E
L
0 B 0
0
0
A 0
C 0
2 2 2
F m
O K r m
F r
E
L O tc te to m m2 5
e la m m7
D S e
0
0 N M+
m
a
u
s 2, 8, 1. 0
0
10 U
B R
E 2 )2 ie
d in
r 21 22 )= m
m m
m 0
1
T d e d d2
9 A m v f f 8, 4 in 9
F N x a o o o 2 4 s
8 I 2 s = n 8
O D (n f le S S x
ito
7 o b E E 0 D 7
D a L L 0
M+ c
2 s c B B 1 e
6 Ø A 2 )1 m le
b e A A ( le S 6
E R d m a h
t C C + d
0
0 H G x N
A I f
c f
o 0 02) n
u
= 0
0
5 T I n1 S o 0 0 2, b K 5
D ( N r 2: 1 2 f
0 N
I r te o 0
0 A N = O e e E x r 0
4 I b L 0 4
T
B
O T m m P 0 te
D H C u ia M 2
(
e
0 O A T E n d A m 0
0 0
3 O E I S = = X = ia 3
T R W= n d E K D
0 0
20 0
2
0 0
0 0
1 1
9 0
9
8
0
7 7
6 0
6
0 0
5 5
0 0
4 4
0 0
3 3
0 0
2 2
0 Diameters in mm 0
1 0 1
0 09 0
8
0
7
0
6
0
5
0
4
0
3
0
2
0 9 8
1 7 6 5 4 3
1
Table 22 Bundle Diameter due to cable number
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2.6 PROTECTION AND INSTALLATION OF PROTECTION
2.6.1 USE OF CONDUITS MADE OF INSULATING MATERIAL

D-CGU-10-9200-317-1 Conduits made of insulating material shall be used according to Table 24.
USING -X =Level of usage PRESSURISED AREA
-1 Short circuit, arc tracking protection

segregation
PEEK RIGID CONVOLUTED CONDUIT
-2 Fluids protection
ABS 0887
-3 Modifications (spare) inaccessible with
segregation
-4 Mechanical protection (not preferred)
SPLIT ELASTOMERE CONDUIT (NOT PREFERRED)

-1 Arc tracking protection (Local)
ABS 0596
-2 Modification/punctual repair
-1 T° maxi 200° C TEXTIL WOVEN CONDUIT

-2 Mechanical protection EN 6049-006
-3 Modification/repairs
-1 T° maxi 260° C TEXTIL WOVEN CONDUIT (with PEEK protection)

-2 Mechanical protection (hinge) EN 6049-007
-3 Modification/repairs
-1 Mechanical protection SHRINK CONDUIT

ABS 0916
-2 sealing (except fuel)
TEXTIL WOVEN CONDUIT

-Mechanical protection and high density
EN 6049-006/007
area
Table 24
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2.6.2 PROTECTION BY SPLIT ELASTOMERE CONDUIT ABS 0596
D-CGU-10-9200-318-1 This product should be used for local repairs/protections without junction.
D-CGU-10-9200-319-1 Split conduit ABS 0596 should be used to protect electrical bundel against arc
tracking.
D-CGU-10-9200-320-1 Drawing shall define the size and length of the open conduit for each bundle.
2.6.2.1 CONDUIT OVERLAP

D-CGU-10-9200-321-1 The size of the split elastomer conduit ABS 0596 shall be adapted to suit the diameter
of the cable bundle so that lip overlap angle is 90° minimum.
split elastomere conduit ABS 0596
90°
0
conduit overlap Maximum diameter bundle

0°
Figure 51
2.6.2.2 TYING
D-CGU-10-9200-322-1 Split conduit ABS 0596 shall be tied by cable ties NSA 935401in accordance with
Figure 52.
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Textile woven conduit ABS 0596

(see Table 25)
90°
0
conduit overlap Maximum diameter bundle

0°
Figure 53
Conduit EN 6049-006/007 BUNDLE DIAMETER
size Max. (mm) Min. (mm)
5 5 1
8 8 5
13 13 8
19 19 13
25 25 19
32 32 25
40 40 32
Table 25
D-CGU-10-9200-328-1 An overlap of 30° may be accepted only in isolated cases (solder sleeves, branches,
etc.).
2.6.3.2 TYING
D-CGU-10-9200-330-1 Cable tie NSA 935401 shall be used for tying split conduit EN 6049-006/007 except in
confined area (choice of device depending on the local conditions) where lacing tape
NSA 8420 is used.
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2.6.4 PROTECTION BY PEEK CONDUIT ABS0887
D-CGU-10-9200-888-1 For the installation of the PEEK conduit the clamp ABS 1339 should be used.
D-CGU-10-9200-889-1 If the clamp ABS 1339 can´t be installed, a V-support on PEEK conduit may be used.
For using a V-support 2 overlapped layers of tape ASNA 5107 (see Figure 54) shall be
used. The installation of V-supports on PEEK conduit without tape leads to a crushing
at the cable tie level due to the stress. This damage is not acceptable.
Figure 54
D-CGU-10-9200-890-1 For conduit fixation on structure clamp ABS 1339 shall be used in all areas except:
- in hot temperature area, on dynamic bundles..., there a P clamp may be used
- in inaccessible pressurised areas, a V-support may be used with additional tape
ASNA5107 (2 overlapped layers) under the cable-tie in order to absorb the stress
(not preferred solution).
D-CGU-10-9200-891-1 For conduit extremity protection and fixation on backshell a compensation NSA935829
code A at the exit of the conduit shall be used to avoid chafing of cables at the conduit
extremity (see Figure 55) . Alternatively an additional clamp shall be installed near the
exit of the conduit and centred on the harness (see Figure 56) or tape shall be used
(see Figure 57) to protect the cables.
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Compensator NSA935829
ABS1339
PEEK conduit
Figure 55
10 to 15mm 20mm
ABS1339
PEEK conduit Additional clamp
Figure 56
tape
ABS1339
PEEK conduit
Figure 57
D-CGU-10-9200-892-1 On backshells, tape ASNA5107 (2 overlapped layers) shall be used between the
conduit and the cable-tie to avoid conduit damage.
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D-CGU-10-9200-902-1 When conduits are routed together, they shall be attached by lacing tape NSA8420.
When conduits are routed along a bundle, they should be attached by lacing tape
NSA8420.
2.6.4.1 CONDUITS FILLING
Conduits shall only be partially filled in such a way that the external diameter of the cable bundle
represents:
D-CGU-10-9200-339-1 For conduits with length shorter than 2 m the filling rate shall not exceed 80% of the
conduit section at the aircraft delivery.
For conduits with length greater than 2 m the filling rate shall not exceed 60% of the
conduit section at the aircraft delivery.
D-CGU-10-9200-802-1 To avoid chafing, the size of the conduit shall be determined in order to obtain the
maximum permissible fill factor.
2.6.4.2 DRAINING OF RIGID CONVOLUTED CONDUITS

D-CGU-10-9200-342-1 Non-braided conduits shall have the drain hole incorporated after installation at the
lowest point. See AIPS 07-07-004.
D-CGU-10-9200-344-1 Lengths of rigid convoluted conduit NSA ABS 0887 shall not be connected end to end
by screwing a size with another.
2.6.5 BONDING JUMPER PROTECTION
Not preferred installation.

D-CGU-10-9200-351-1 When bonding jumper (pigtail) are in exposed areas or in movement they shall be
protected by shrink conduit NSA 937210 when contact with bundle is possible.
D-CGU-10-9200-352-1 A bonding lead may be installed and tied directly on a non-protected electric bundle if
there is an additional protection placed between the braid and the non-protected elec-
tric bundle (textile conduit EN 6049-006/007 on electric harness or heat-shrink conduit
on bonding jumper).
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ADDITIONALPROTECTION
NSA 937210
Minimum 2 NSA 935401
BONDING JUMPER
NON-PROTECTED BUNDLE
Figure 58
2.6.6 PROTECTION BY HEAT- SHRINK SLEEVES
D-CGU-10-9200-358-1 In case a harness is in contact with water condensation it shall be sealed with heat
shrink conduits.
D-CGU-10-9200-357-1 Bundles may be locally protected mechanically by sleeve ABS 0916 in vibration zones
(see appendix 1).
D-CGU-10-9200-360-1 ABS 0916 shall not be used for high temperature (>135°C) and P routes.
D-CGU-10-9200-362-1 For segregation between harnesses in confined area only two thicknesses of conduits
are required without shrinking.
2.6.7 PROTECTION OF OPTICAL CABLE

D-CGU-10-9200-363-1 Sheaths (tape ASNA 5107 or textile EN 6049-006/ 007) shall be used for protecting an
optical cable or harness when there is a risk of mechanical wear.
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2.7 PANELS AND BOXES

Wording: panels, boxes….see § 1
D-CGU-10-9200-805-1 Non-coded equipment, e.g. diodes, transistors, relays… shall be installed in an

appropriated enclosure.
2.7.1 RIVETS ON BOXES OR ELECTRICAL PANELS

D-CGU-10-9200-399-1 Inside the boxes or on panels containing electrical wiring, all rivet-heads and riveting
shall be countersunk type, or, exceptionally, mushroom type. Cheese head type rivets
shall not be used.
CORRECT ACCEPTABLE
WRONG WRONG
Figure 62
2.7.2 ARRANGEMENT OF EQUIPMENT ON PANELS

D-CGU-10-9200-401-1 Equipment on panels shall be laid out from left to right in the order 1, 2, 3, 4, etc…, for
an operator facing the panel (whatever the built-in position of the panel).
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16 mm minimum
16mm Connectors
30 mm
minimum
16mm
Figure 67
D-CGU-10-9200-421-1 Rectangular connector EN 3545 shall be installed in accordance with the Figure 67.
Sufficient clearance must be provided near a rectangular connector in order to permit
easy access (Connection disconnection and cleaning procedures).
2.8.6 FIXING OF CONNECTORS
D-CGU-10-9200-426-1 Fixed circular connectors with square flanges - type ASNE 0053 or similar - shall be
fixed with two (minimum) diametrically opposed screws.
D-CGU-10-9200-427-1 Connectors ABS 0364 or type ASNE 0053 or equivalent mounted in the cabin for
commercial electric systems may be attached in a connector bracket with two opposite
quick release fasteners.
D-CGU-10-9200-881-1 One part of connector shall be fixed. No flying connection shall be used.
D-CGU-10-9200-882-1 Every bracket shall be fixed by screws.
2.8.7 INSTALLATION OF CIRCULAR CONNECTORS

Note: Fixed connectors shall be in the same position on the whole aircraft.
D-CGU-10-9200-423-1 Their position on the supports should be specified on drawings.
D-CGU-10-9200-428-1 No vertical axis connector should be installed.
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2.8.9 INSTALLATION OF BACKSHELLS

D-CGU-10-9200-436-1 Backshells shall be used according to table below.
Circular connector
TYPE OF BACKSHELL: type ASNE 0052/ Utilisation zones
ASNE 0053
Straight or elbow backshell type Plug and main use
ABS0638 (thermoplastic) Recaptacle except in small small boxes/panels
Straight or elbow backshell type ASNE Plug and specific use (e.g. pressure seal)
0080-01 or ASNE 0080-02 (aluminium) Recaptacle except in small VUs
Flanged straight or elbow backshell type Plug except in small small boxes/panels,
NSA 938150-01 or NSA 938150-03 (alu- used only for wire-foolproof connectors.
minium) Recaptacle NO.
Plug In small boxes/panels
Simple backshell type NSA 938150-02 NO, except in cases of risks of contami-
(aluminium) Recaptacle nation/ mechanical protection in small
small boxes/panels.
Plug NO.
YES, except risks of contamination/
Connector without backshell
Recaptacle mechanical protection in pressurised
zones and in small small boxes/panels.
Rectangular
TYPE OF BACKSHELL: connector
EN 3545 type Utilisation zones
Plug Pressurised zones
Backshell type EN 3545-007 (thermo-
Recaptacle Pressurised zones except on interface
plastic)
connectors of large small boxes/panels.
Table 26
D-CGU-10-9200-437-1 Backshells shall be used for plugs (removable and fixed connectors). Exception:
Connector inside PSU-Channel.
2.8.9.1 ELBOW BACKSHELL ORIENTATION

D-CGU-10-9200-439-1 The elbow backshell orientation (angular) shall be defined in drawing definition. The
definition shall consider:
-with view at the connector contacts side (front face)
-Connector master keyway positioned at the top
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2.9 TERMINAL BLOCK AND LUG INSTALLATION
2.9.1 MODULE POSITIONING SEQUENCE ON TERMINAL RAIL (E.G.: NSA

937901)
D-CGU-10-9200-534-1 Installation drawings shall show the direction of the module position 1.
Position 1: When the operator is opposite to the terminal block, horizontal reading shall
be performed from left to right (module 1 on the left) and vertical reading from top to
bottom (module 1 at the top).
If the operator can see the terminal block from 2 directions, priority shall be given to
the position looking forward and from the aircraft centre-line.
D-CGU-10-9200-533-1 Terminal block modules shall be aligned in numerical sequence as follows.
INCORRECT
X 1 2 3 4 X
X
1
2
CORRECT CORRECT 3
X 1 2 3 4 X 4
X
X = end clamps
Figure 74
D-CGU-10-9200-535-1 Terminal and module blocks shall be wired in groups of four (maximum) (see Figure
74)
Figure 75
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2.9.2 INSTALLATION OF SEVERAL LUGS ON TERMINAL (E.G. NSA 937905)
D-CGU-10-9200-536-1 If the connected cables are routed in opposing directions (e.g.: on a terminal block):
method shown in Figure 76 FIG. a) or b) shall be used.
D-CGU-10-9200-537-1 If the terminal is such that the connected cables are routed in the same direction:
method shown in FIG. b) shall be used. (See AIPS 07-01-001)
D-CGU-10-9200-538-1 Four lugs maximum shall be used for configurations as shown in Figure 76 a) and b),
five lugs maximum shall be used for a configuration as shown in Figure c.
NSA 937905-F material TBC
FEEDER
DISTRIBUTION
FIG. a FIG. b FIG. c

Larger contact surface
Figure 76
D-CGU-10-9200-559-1 The preferred assembly position of the copper and aluminium terminal lug shall be
considered (see also § 2.9 Terminal Block and Lug Installation) when they are in-
stalled in the same termi nal stud.
D-CGU-10-9200-539-1 The largest contact surface of the lug shall be installed first on the stud.
D-CGU-10-9200-540-1 When two different terminal lugs are superposed and are electrochemical compatible,
(terminal lug for copper cables and terminal lug for aluminium cables) the copper cable
terminal lug shall be positioned under the nut.
D-CGU-10-9200-542-1 Design shall take into account the difference in electro-chemical potential between
different materials in contact, see § 2.4.11.
2.9.3 BENDING OF LUGS
D-CGU-10-9200-543-1 The maximum allowed terminal lug bending angle shall be 30° for 10 to 0000 gauge
terminal lugs and 45° for 12 to 24 gauge terminal lugs with a minimum radius of 2 mm.
D-CGU-10-9200-544-1 In all cases, lugs shall only be bent once.

D-CGU-10-9200-545-1 Bending of aluminium lugs shall not be allowed.
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Copper lug Copper lug
Copper lug Aluminium lug
Copper/Copper lugs Copper/Aluminium lugs
Aluminium lug Copper lug
Copper lug Aluminium lug
Aluminium lug Copper lug
Aluminium/Copper/Aluminium lugs Copper/Aluminium/Copper lugs
Figure 77
2.9.7.1.2 LUG/WASHER/NUT INSTALLATION ORDER
D-CGU-10-9200-553-1 Installation with single spring washer ASNA 2553 should be used (see Figure 78) .
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Nut
Spring washer ASNA 2553
Lug
Figure 78
2.9.8 TERMINAL BLOCK PROTECTION AND INSTALLATION

D-CGU-10-9200-555-1 Terminal blocks with screw studs shall be covered by plastic cover (electrical shock
protection) outside cabin interior equipment.
D-CGU-10-9200-556-1 To avoid fluid ingress (e.g.: water proximity,...) Terminal block (VT) shall be installed
above bundles with an above additional umbrella or with cover protection, e.g. Figure
79.
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Umbrella
Terminal block plastic cover Terminal block (VT)
Bundle
Cabin
Interior
Equipment
Figure 79
2.9.9 CONNECTION OF TWO OR THREE CABLES IN TERMINAL LUG AND

SPLICE
D-CGU-10-9200-557-1 Installation of two cables in the same terminal lug barrel shall be permitted in
accordance with AIPS 07-04-003.
D-CGU-10-9200-558-1 Three cables in the same terminal lug and splice shall be avoided or with specialist
agreement.
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2.10.2 GROUNDING AND BONDING POINTS
D-CGU-10-9200-460-1 All grounding points shall be identified, see NSA 936002, ABD 0004 Part 2
D-CGU-10-9200-481-1 The thickness of the sheets to which grounding points are attached shall be consistent with
the maximum current carried, minimum thickness see table below.
Up to The light alloy structure shall have a minimum

I (A) thickness of e (mm)
20 0.6
50 0.8
100 1.2
150 2
200 2.6
Table 27
Note: These dimensions are minimum requirement for electrical installation only.
These values can be increased for mechanical reasons.
Two methods are used:to primary aircraft structure

- direct
- via an intermediate bracket
D-CGU-10-9200-897-1 Essential grounding/ bonding points shall be separated from Non-essential grounding/
bonding points
Customised grounding/ bonding points shall be separated from Basic grounding/ bonding
points
2.10.2.1 GROUNDING AND BONDING VIA BRACKETS
Brackets are fixed to A/C structure permanently by rivets or removable by screws.
2.10.2.1.1 FIXED BRACKETS
D-CGU-10-9200-463-1 The minimum number of rivets between the part to which the grounding point is attached and
the primary A/C structure shall be in accordance with Table 28.
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2.10.5 TERMINAL LUGS
Principles of lug installation – see § 2.9: Terminal Block and Lug Installation
D-CGU-10-9200-462-1 The size of the screws fixing the terminal lugs to the A/C-structure shall be in accordance
with table below:
Screw diameter (Screw type) Wire (AWG Gauge)
4.83 mm (10 - 32) 24 - to - 10

6.35 mm (1/4) 8-6
7.94 mm (5/16) 4 and less
9.52 mm (3/8) 4 and less
Table 29
D-CGU-10-9200-474-1 Gauge 26 cable shall not be used for terminal lugs.
2.10.6 BONDING JUMPERS
D-CGU-10-9200-484-1 Bonding jumpers should be as short as practicable and not longer than 220 mm, see Figure
83 (in case that a longer jumper is necessary, the acceptance of EMH specialist is required).
Electrical Intermediate Metallic

component to fixing point primary
be bonded structure
Bonding leads no
longer than 220mm
D > 220mm
NON ACCEPTABLE WITHOUT
EMH SPECIALIST APPROVAL
Figure 83
D-CGU-10-9200-475-1 Bonding jumper installation should not form loops.
D-CGU-10-9200-476-1 Jumpers shall not be less than AWG 18.
D-CGU-10-9200-477-1 The electrical bonding jumpers or leads used for bonding shall be made of nickel-plated
copper.
Types of braid:
ASNE0088: lead bonding – round bonding (for section 1.4 mm²)

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ASNE0091: lead bonding – round bonding (for section 7 mm²)
ASNE0092: lead bonding – round bonding (for section 13 mm²)
D-CGU-10-9200-502-1 The bonding lead setting shall take into consideration:

- Clearance from structure and especially sharp edge
- Relative movement of bonding parts
- The lead bonding positioning shall not interfere with access or maintenance operations
D-CGU-10-9200-812-1 Jumpers shall not be used as retainers.
2.10.7 SURFACE PREPARATION AND PROTECTION
D-CGU-10-9200-479-1 Bonding points shall be protected from corrosion and contamination. The protection shall be
done in accordance with AIPS 07-01-006 (Electrical bonding).
D-CGU-10-9200-503-1 When it has been necessary to remove the protective coating from a metallic surface, the
complete assembly should be refinished with its original finish or other suitable protective fin-
ish (ref. AIPS 07-01-006).
2.10.8 BONDING OF EQUIPMENT
2.10.8.1 GENERAL REQUIREMENTS
D-CGU-10-9200-472-1 Each bonding path shall have a current rating suitable to carry the largest fault current
expected for this equipment.
D-CGU-10-9200-473-1 The diameter of each wire used for bonding shall be at least equal to powerlines and
AWG 18 minimum.
D-CGU-10-9200-811-1 Equipment for passenger cabin interior shall be bonded according to Figure 84.
D-CGU-10-9200-832-1 In general, all equipment shall be electrically bonded to aircraft structure, via one or more
bonding connections, either by the mating face of the equipment or a bridge contact.
Exception: small, non electrical conductive parts A<400cm², which are not chafing to
electrical cables, see Figure 84.
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2.10.8.2 BONDING OF ELECTRICAL EQUIPMENT
2.10.8.2.1 BOXES, PANELS; OPERATING DEVICES
D-CGU-10-9200-846-1 Any equipment with electrical function (supplied with electrical power) shall be bonded by at
least two independent bonding pathes.
- Exception: max. power supply less / equal 28V AC or DC.
- protective insulation
D-CGU-10-9200-847-1 Boxes, Panels; operating devices shall be bonded by two wires via connector pin (inde-
pendent pathes minimum wire-diameter: equal to powerlines, minimum gauge AWG 18).
Each connector used for power supply shall provide at least one pin for protective ground
connection.
Exception:
-max. power supply less / equal 28V AC or DC.
-protective insulation....
2.10.8.2.2 BONDING OF NON-ESSENTIAL MONUMENTS/ EQUIPMENT

D-CGU-10-9200-486-1 Non-essential monuments/ equipment shall be bonded by independent bonding pathes to
the primary A/C structure, the dimension of the bonding pathes shall be confirmed by the
system specialist.
2.10.8.3 BONDING OF CONDUCTIVE PARTS EXPOSED TO CREW / PASSENGER
D-CGU-10-9200-830-1 Conductive parts exposed to crew / passenger with surface >400cm² shall be grounded
(AWG 18).
D-CGU-10-9200-496-1 Handrails with metallic surface shall be grounded in any case.
The bell cranks, pulley, rods which are essentially composed of small hinged parts, will not be fitted with
individual bonding jumpers. Trims may not need to be bonded.
2.10.9 BONDING OF COAXIAL CONNECTORS:

D-CGU-10-9200-833-1 The coaxial connectors associated with the following systems shall be insulated from the
structure:
MH system (Passenger Entertainment Video)
MK system (PES: Passenger Entertainment Music)
MM system (PVIS: Passenger Video Information System)
RD system (Phone)
RF system (CPMS: Cabin and Passenger Management System)
For all other coaxial connectors contact system specialist.
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2.11 IDENTIFICATION OF CABLES
2.11.1.1 IDENTIFICATION RULES ACCORDING TO CABLE CATEGORIES
There are three main cable categories:

-Unidentified cables
-Sleeved cables
-Printable cables
2.11.1.2 UNIDENTIFIED CABLES

D-CGU-10-9200-562-1 Unidentified cables shall be:
-very short cables (length < 75 mm)
-monitoring cables in line on adjacent circuit breakers
2.11.1.3 IDENTIFICATION BY SLEEVES
Sleeved cables are cables which cannot be directly marked on account of their physical make-up or
where marking may damage the insulation (e.g.: coaxial).
D-CGU-10-9200-564-1 This category shall include:

-Gauge cables which cannot be printed by UV laser
-Cable shorter than 75 mm located inside electrical racks
-Optical cable (OPTICAL CABLE written)
D-CGU-10-9200-565-1 Sleeved cables shall be identified using NSA 937201ME sleeves placed at each end
of the cable and bearing the cable identification characters. The sleeves shall be
white, printed in black except for sensitive cables (print code “S”) where the sleeves
are pink, printed in black.
2.11.1.4 PRINTABLE CABLES
D-CGU-10-9200-567-1 This category should mainly concern gauge 26 to gauge 6 cables, which may have
lengths greater than 75 mm.
D-CGU-10-9200-568-1 Printable cables shall be identified by directly marking identification characters on the
insulation in a repetitive manner.
AD
PRINTABLE CABLES DR
by UV laser KB
LF optical cable
Figure 85
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2.11.1.5 BASIC OR SHIELDED MULTICORE CABLE

D-CGU-10-9200-570-1 Multicore cables are, according to the aircraft concerned, identified:
-Either by a number, characterising all the conductors, located at each end
-By individual numbers, for each constituent conductor, located at each end
D-CGU-10-9200-571-1 These numbers may be on one or more sleeves.
2.11.1.6 SPECIFIC CASES
D-CGU-10-9200-573-1 Twisted cables which will be partially untwisted over a length of ≥ 20 cm shall be
identified by as many additional individual sleeves as there are untwisted cables.
Additional sleeves
Original slee-
ves
Figure 86
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2.11.2 FIN IDENTIFICATION ON HARNESS ENDS
N
V
T L
V A K
IN C
ML
R O
E B
T
T
V
. er
G s
V le tu
d c
n u
b
u tr
s
F
O 's Y n n
T U
L o o
U V N
O r r
O e e
b b
m m
u u
n n
m m
te te
lia lia
n n
ito ito
c c
n n
u u
F F
-
A
S
S
E
C
E
N
Y
IF R
C
V
L - Y
A A R
N
IC A
IO F
I IF S
T T L S
C N N E E
N E O B C
U D I A E
F I T L N
+
T
N
E
M
P
I
U
Q
E
Figure 87
A) Connectors (VC)
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Installation of a label on fix and movable plug side (VC/VCA).
B) Terminal blocks (VT power)
Installation of a label.
C) Grounding modules (VG) and ground point (VN)
Installation of a label .
D) Non-dismantled splices (VS)
Installation of a label near the junction.
E) Arinc 600/404 connectors
Installation of a label.
F) Module bars (signal)
No label needed
D-CGU-10-9200-666-1 For normal bundle the following colour principle shall be applied:
- on bundle the lettering should be black on a white background
- on structure the lettering should be black on white background or reverse
2.11.2.1 IDENTIFICATION SLEEVE/LABEL ON BUNDLES
D-CGU-10-9200-574-1 Plates ASNE 0248 or sleeve shall be installed at all the extremity FIN (Functional
Identification Number) connectors, bulkhead, grounding module or components fitted
in the bundle except for terminal module type.
D-CGU-10-9200-575-1 The following items will be installed:

- Sleeves NSA 937201 (Type MR, MT).
Inside bundles labels ASNE 0248 tied by NSA 935401 or NSA 8420 cable tie NSA
935401 shall be forbidden.
D-CGU-10-9200-576-1 Marking and installation of these parts are defined AIPS 07-06-002.
D-CGU-10-9200-577-1 In panels and boxes identification of cable shall be made by ASNE 0646 and
identification of extremities (switches, connectors, …) by ASNE 0248.
D-CGU-10-9200-578-1 These labels shall be white and printed in black.
ASNE 0248A14HP identification plates (4 holes) bearing the identification of the extremities.
D-CGU-10-9200-580-1 The identification shall be composed of the FIN (Functional Item Number) of the
extremities with, in certain cases, the abbreviated functional designation.
D-CGU-10-9200-581-1 The plate shall be located 130 mm max from the end.
D-CGU-10-9200-582-1 The bundle manufacturer shall verify the label positioning on bundle to permit correct
reading (not opposite reading) when the harness extremities are connected.
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2.11.7 ROUTE IDENTIFICATION MARKERS

D-CGU-10-9200-600-1 Route identification markers shall indicate the routes inside harnesses and how to
position them.
D-CGU-10-9200-601-1 They shall mainly be placed in zones of high wiring density in accordance with the
production line, and density where knowledge of routes is necessary: at each harness
extremities and every 1 meters maximum.
D-CGU-10-9200-602-1 Route identification marker may be installed directly on the cable or on a protected
harness.
D-CGU-10-9200-604-1 For routes yellow markers ASNE 0248 secured with cable ties or lacing tape shall be
used.
2.11.8 ADDITIONAL IDENTIFICATION
2.11.8.1 ADDITIONAL IDENTIFICATION FOR OPTICAL CABLES AND BUNDLES

D-CGU-10-9200-608-1 For single optical cable or optical cable bundles a specific identification along the route
harness should be fitted.
D-CGU-10-9200-609-1 Sleeve NSA 937201 ME shall be used, text shall be black on white background.
OPTICAL CABLE
Figure 88
D-CGU-10-9200-610-1 Letter shall have the height 2.5 following NSA 937201.
D-CGU-10-9200-611-1 This label shall be installed:

- Along the harness every 2 meter (maximum pitch) in straight line harness
-- Close
Close to
to extremity
the point where harness becomes not visible for maintenance purposes
components
- Close to the optical cable exit (when the optical cable is routing inside a standard
bundle)
- Sleeves shall not be shrinked
2.11.9 IDENTIFICATION OF PANELS AND BOXES
D-CGU-10-9200-631-1 All panels or boxes with identification shall have their references in a place, which is
visible after installation on the aircraft, except for passenger cabin panels, for which
identification is inside the panels.
D-CGU-10-9200-632-1 All panels or boxes shall have their identification label following NSA 9117.
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2.11.9.3 ON EQUIPMENT
1PU1 2RN4
TR-1
2RN4.A
1PU1.A
ACP-AYNCS
COMPTS
GENERAL EXCEPTIONAL
(If structural label not easy to read)
Figure 91
2.11.9.4 IDENTIFICATION IN SMALL VE´S
D-CGU-10-9200-639-1 One sleeve, showing the identification reference of the non-coded equipment for the
bundle of cables which ends at this equipment shall be mounted on the whole bundle.
D-CGU-10-9200-640-1 Terminations on a given connecting item are identified by a portion of ASNE 0248A
labels (2 holes) where the Functional Item Number is written.
5 HA
Figure 92
D-CGU-10-9200-816-1 In confined areas where label ASNE 0248 cannot be installed sleeve NSA 937201
shall be used.
D-CGU-10-9200-817-1 When bundles diameter ≤ 5 mm NSA 937201 shall be used.
D-CGU-10-9200-642-1 An ASNE 0248 label is used to identify all equipment and electrical standard items
except for the following items:
-Cut-off connectors (VC)
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-Module-type terminal blocks

-Grounding connections (VN)
-Illuminated panels(LF) connectors
-Diodes and diode blocks
-Relays
-Circuit-breakers
-Selector (connected by soldering)
IDENTIFICATION SLEEVES
FOR CONNECTION 1
5 HA LABEL ASN E0248 OR EQUIVALENT 1
(ASNE 0646 OR EQUIVALENT)
1 1
2 2
EQUIPMENT 5 5 5 HA
10 10
1
4 SX
2
VN VC VT
VC
Figure 93
2.11.10 LABEL IDENTIFICATION ON STRUCTURAL PART
2.11.10.1 LABELS FOR VOLTAGE > 42 VOLTS
D-CGU-10-9200-647-1 Boxes or panels containing parts with voltages exceeding 42 V which are liable to
expose maintenance personnel to hazardous operations should be fitted with a label
reading: Caution High Voltage inside.
D-CGU-10-9200-648-1 This label shall have 6 mm white letters on red background, according to AIPS 07-06-
005 and NSA 931031 requirements.
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CAUTION
HIGH VOLTAGE INSIDE
Figure 94
2.11.10.2 LABEL POSITIONING
D-CGU-10-9200-660-1 As a general rule, these plastic labels shall be positioned at the top or left hand side of
the item of equipment when looking at the front face.
D-CGU-10-9200-661-1 They shall always be visible when the equipment is installed.
D-CGU-10-9200-662-1 Other positions, i.e.: bottom or right hand side, are allowed only when the top and the
left-hand positions cannot be used.
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3 DESIGN PROCESS REQUIREMENTS
3.1 GENERAL
Electrical components to be installed in the A380 aircraft have to accomplish the Airbus standard.
Items, which fulfil these conditions are registered in the Airbus electrical component Standard Selec-
tion List. Sections of this document, which include the relevant parts for the EDR are listed in the Ap-
pendix.
For searching a particular Airbus qualified electrical component, it is possible to take it directly from
this list. This procedure ensures that the selected item is approved.
In the case of special items, which are not listed in this document, it is necessary to qualify them. This
procedure includes a variety of tests, depending on the function of the component. Common tests for
standard components are listed in 3.4. The full test description is published by the “European Associa-
tion of Aerospace Industries – Standardization” (AECMA-STAN). Due to proprietary issues the test
procedures can’t be provided by Airbus, but it is possible to get the tests under www.aecma-stan.org.
For the qualification a complete Qualification Test Plan and Report (see 3.4) is essential. The QTP
shall be approved by the responsible Airbus system specialist. After the approval the QTR can be
created.
Generally all requirements for parts and components which are not listed in this document and which
shall be meet are in responsibility of the Airbus system specialist.
3.2 REQUIREMENTS AND RULES FOR MATERIAL QUALIFICA-

TION
Basis for the qualification of electrical components, intended for installation in civil aircraft, forms the
ABD 0100, which has replaced the ABD 0007, as well as appropriate technical specifications of stan-
dard parts (ABS, EN, etc.).
ABD 0100 section 1.2 describes the site conditions and test requirements in connection with a qualifi-
cation of the components. The components are tested regarding the following site conditions. The test
extent and the used regulations (e.g. DO 160, ABD 0031) are specified by the PTS (purchaser techni-
cal specification).
The supplier is responsible for ensuring that the components used originate from a source having valid
company/quality approvals and are qulified for the intended application.
If thereapproved
report, is a reason
by of usingisnot
Airbus, qulified components, a qualification test plan and a qualification test
necessary.
3.3 ENVIRONMENTAL REQUIREMENTS

For the equipment, which is used inside the cabin the following test parts are relevant:
- temperature
- altitude, pressure
- temperature variation
- humidity
- shock and crash safety
- vibration
- waterproofness
- fluids susceptibility
- fungus resistance
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3.3.6 VIBRATIONS
This definition is according to DO160.

Category S or S2 – Standard Vibration Test.
The standard vibration tests ensure that components will meet their functional performance require-
ments during normal operating conditions. For components located in the fuselage and Category S or
S2 the test curve is specified as type C. The test level for this type C is shown in Figure 8-1 “Standard
Random Vibration Test Curves for Components Installed in Fixed-Wing Aircraft with Turbojet or Turbo-
fan Engines”.
3.3.7 WATERPROOFNESS
This
This definition is according
test specifies to DO160. can withstand water, which is sprayed or fallen on the equip-
how the components
ment. Components which are installed in locations where they subject to falling water are identified as
Category W. For components intended for installation in such locations, the drip proof test procedure
is necessary and the components are identified as Category W.
3.3.8 FLUIDS SUSCEPTIBILITY

This test specifies how the components can withstand water, which is sprayed or fallen on the equip-
ment. Fluids susceptibility tests should only be performed if the components are installed in areas
where fluid contamination (fuels, hydraulic fluids, oils, cleaning fluids, de-icing fluids, insecticides, sul-
lage) could be commonly encountered. Components that passed the test are identified as Category F.
3.3.9 FUNGUS RESISTANCE

This test defines how fungi affects component material (reasons are e.g. high humidity, warm atmos-
phere and inorganic salts). A typical problem is that microorganism produces living bridges across
components that may produce electrical failures. In this case components are identified as Category F.
3.3.10 SALT SPRAY

This test shows the consequences of a salt atmosphere or salt spray for the components. The main
effects are: corrosion of metals, blocking of moving parts as a result of salt deposits, insulation fault,
damage of contacts and uncoated wiring. Components that have passed the test are identified as
Category S.
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3.3.11 CORROSION
The Supplier has to demonstrate that the materials, which he used for the design of the component,
are adequately protected against corrosion. He has to use only qualified methods.
3.3.12 HERMETIC
The PTS defines if EN 60068-2-17 is applicable. In case of electrical components EN 60068-2-17 Test
of “Dive into liquids” is not applicable. It shall determine a degree of protection provided by enclosures
(IP-Code) according to IEC 60529.
3.3.13 FIRE
The PTS will define if ISO2685 is applicable.

Not applicable are no fire zones in accordance to ISO2685 (Resistance to fire in designated fire
zones).
3.3.14 FLAMMABILITY/ SMOKE/ TOXICITY (FIREWORTHINESS DESIGN CRITE-

RIA)
The supplier has to demonstrate in accordance with the procurement procedure that this item com-
plies with the FST-requirements. The use of a BFE-item, which complies with the applicable certifica-
tion requirements but fails to meet the Airbus FST-requirements, may be permitted, as long as national
airworthiness requirements are not concerned. In this case, it is the responsibility of the supplier to
inform the costumer, that there is a deviation to the ABD0031. The deviation has to be reverenced in
the respective test documentation and DDP for Airbus monitoring purposes only.
3.4 ELECTRICAL REQUIREMENTS
The values of electrical parameters during the qualification test are provided in ABD0100.1.8 “Electri-
cal and Installation Requirements”.
These regulations are very general and correspond to the well-known relevant regulations of electrical
technology.
During a component qualification test, it shall be shown that the electrical components are in compli-
ance with the electrical requirements.
Generally, all electrical requirements for parts and components are in the responsibility of the Airbus
system specialist.
The required tests for the main components are available, e.g.
- EN3475 for cables
- EN3745 for optical cables
- EN2591 for connectors and contacts
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FOR CABIN INTERIOR
Date: 01.07.2004
317 Flammability
402 Shock
403 Sinusoidal and random vibration
406 Mechanical endurance
3.4.4 OPTICAL CONNECTORS
EN2591 Designation of the test

301 Endurance at temperature
305 Rapid change of temperature
307 Salt mist
308 Sand and dust
317 Flammability
402 Shock
403 Sinusoidal and random vibration
div. Special optical tests on request
3.4.5 CONTACTS
EN2591 Designation of the test

201 Contact resistance low level
202
301 Contact resistance
Endurance at at rated current
temperature
305 Rapid change of temperature
307 Salt mist
315 Fluid resistance
417 Tensile strength
508 Measurement of thickness of coating on contacts
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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

Electrical Design Requirements for Cabin

Aircraft A380 PAX/F

System ELECTRICAL INSTALLATION

ATA/Sub ATA ATA 92 - 00

Equip. ELECTRICAL EQUIPMENT

EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

Airbus 2004 All rights reserved Page 2/144 Issue 02

EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

2 ELECTRICAL REQUIREMENTS ................................................................16

2.1.4.2 CROSSING OF SEPARATING BUNDLES AND CONDUITS................................................................26

2.4 CABLE AND BUNDLE INSTALLATION ........................................................................35

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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

2.4.1.1 DISTANCES BETWEEN BUNDLE AND STRUCTURAL ITEMS (EXCEPT COMPOSITE

2.4.1.1.1 FOR INTERSECTION: CABLE, BUNDLE - STRUCTURE............................................................. 36

2.4.7 ELECTRICAL INSTALLATION POSITIONED IN CONTAMINATION AREAS .......................................... 48

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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

2.4.15.2.1 CABLE LENGTHS FOR REPAIRS FOR COPPER CABLES.......................................................... 58

2.4.15.4 COAXIAL CABLE OVER LENGTH......................................................................................................... 58

2.4.17.3 FIXING OF ROUTES CONTAINING 1 OR 2 WIRES............................................................................. 75

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EDR - ELECTRICAL DESIGN Ref: 9200M1F0380 00

2.5.2.1 HARNESS TYING...................................................................................................................................82

2.5.2.3 TYING OF PROTECTED BUNDLES...................................................................................................... 83

2.6.9.1 ON CLOSED METAL BACKSHELLS (CLAMPS)................................................................................... 92

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2.8.7 INSTALLATION OF CIRCULAR CONNECTORS .....................................................................................101

2.8.8 INSTALLATION OF RECTANGULAR CONNECTORS EN 3545 .............................................................103

2.9.7.1.1 TERMINAL LUG INSTALLATION ORDER.................................................................................... 109

2.10.8.2.2 BONDING OF NON-ESSENTIAL MONUMENTS/ EQUIPMENT .................................................. 120

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2.11 IDENTIFICATION OF CABLES ....................................................................................122

2.11.9.4 IDENTIFICATION IN SMALL VE´S ...................................................................................................... 129

3 DESIGN PROCESS REQUIREMENTS.....................................................132

3.3.11 CORROSION ..............................................................................................................................................135

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3.3.14 FLAMMABILITY/ SMOKE/ TOXICITY (FIREWORTHINESS DESIGN CRITERIA) .................................. 135

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1.1 PURPOSE/ SCOPE/ OBJECTIVES OF THE EDR

Every application that is not mentioned in this document or every devia-

The scope of the EDR is limited as shown in table below:

Zones Aircraft zones in the scope of

Table 1 Validity of EDR

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1.2 TERMS, DEFINITIONS AND ABBREVIATIONS

1.2.1 TERMS, DEFINITIONS

The meaning of terms, used in the EDR :

Panels boxes with control-/ service elements, accessible during flight

Boxes chassis containing electrical devices etc., not accessible