Airbus

PROCESS AND MATERIAL SPECIFICATION

Printed in Germany

PROCESS SPECIFICATION

01-07-97

Manufacturing and installation of cable harnesses


AIPS07-01-001 LEP 01-07-97

Page 1 Aug 01/08

Printed in Germany

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

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AIPS07-01-001 01-07-97

Page 1 Aug 01/08

Printed in Germany

AIPS Airbus Process Specification

Manufacturing and installation of cable harnesses

Published and distributed by : AIRBUS S.A.S.

ENGINEERING DIRECTORATE 31707 BLAGNAC Cedex

FRANCE

© Copyright reserved

Ref.no. AIPS07-01-001


AIPS07-01-001 01-07-97

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AIPS07-01-001 Page 2 Issue 4

Contents

1 Scope

2 Normative references

3 Definition, applicability and limitations

4 Requirements

5 Process qualification

6 Process work and quality control instructions

7 Health and safety

8 Appendix


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1 Scope

This Airbus Process Specification defines the technical requirements for manufacturing and installation of cable harnesses. The purpose of this specification is to give design and quality requirements to manufacturers. Although the essential requirements of a process are defined, this specification does not give detailed in-house process instructions, these shall be given in the manufacturers detailed process instruction and supporting documentation (the "Process Instructions).

This specification shall not be used as an inspection document unless parts or assemblies have been manufactured according to this specification.

It shall be applied when mentioned in the relevant standard, material specification or drawing.

Refer to AIPS07-11-001 for optical cable installation.

2 Normative references

This Airbus specification incorporates by dated or undated reference provisions from other publications. All normative references cited at the appropriate places in the text are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to shall be applied.

National standards should be applied if Airbus standards are not available.

EN2997-003 Aerospace series - Connectors, electrical, circular, coupled by threaded ring, fire-resistant or non fire-resistant, operating temperatures -65° C to +175 °C continuous , +200 °C continuous, 260° C peak - Part 003: Square flange receptacle - Product standard.

EN2997-008 Aerospace series - Connectors, electrical, circular, coupled by threaded ring, fire-resistant or non fire-resistant, operating temperatures -65° C to +175 °C continuous , +200 °C continuous, 260° C peak - Part 008: Plug - Product standard.

EN3155-004 Aerospace series - Electrical contacts used in elements of connection - Part 004: Contacts, electrical, male, type A, crimp, class T - Product standard.

EN3155-008 Aerospace series - Electrical contacts used in elements of connection - Part: 008: Contacts, electrical, male, type A, crimp, class S - Product standard.

EN3545-003 Aerospace series - Connectors, electrical, rectangular, with sealed and non-sealed rear, plastic housing, locking device, operating temperatures -55 °C to +175 °C-Part 003: Connectors with female contacts - Product standard.

EN3545-004 Aerospace series - Connectors, electrical, rectangular, with sealed and non-sealed rear, plastic housing, locking device, operating temperatures -55 °C to +175 °C-Part 004: Connectors with male contacts - Product standard.

EN3646-003 Aerospace series - Connectors, electrical, circular, bayonet coupling, operating temperature +175 °C or +200 °C continuous - Part 003: Receptacle, square flange mounting - Product standard.

EN3646-004 Aerospace series - Connectors, electrical, circular, bayonet coupling, operating temperature +175 °C or +200 °C continuous - Part 004: Receptacle, jam-nut mounting - Product standard.

EN3646-008 Aerospace series - Connectors, electrical, circular, bayonet coupling, operating temperature +175 °C or +200 °C continuous - Part 008: Plug - Product standard.

EN4604-003 Aerospace series - Cable, electrical, for signal transmission - Part 003: Coaxial cable 50 Ohm, +200 °C, type WZ - Product standard.


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EN6049-003 Aerospace series - Electrical cables, installation Protection sleeve in meta-aramid fibres - Part 003: Braided tubular, expandable - Product standard (new current ref. for ASNE0389).

EN6049-006 Aerospace series - Electrical cables, installation Protection sleeve in meta-aramid fibres - Part 006:Self-wrapping protective sleeve, flexible post installation - Product standard.

EN6049-007 Aerospace series - Electrical cables, installation Protection sleeve in meta-aramid fibres - Part 007: Self-wrapping protective sleeve, flexible post installation, operating temperature from -55 °C to +260 °C - Product standard.

EN6049-008 Aerospace series - Electrical cables, installation Protection sleeve in meta-aramid fibres - Part 008: Self-wrapping protective sleeve, flexible post installation, operating tempera-ture from -55 °C to +200 °C - Product standard.

EN6049-009 Aerospace series - Electrical cables, installation protection sleeve in meta-aramid fibres - Part 009: Self-wrapping fire protective sleeve, flexible post installation, operating tem-perature from -55 °C to +260 °C - Product standard.

ABS0054 Aerospace series - Spacer bundle separation.

ABS0364 Aerospace series - Connection receptacle, plug, cable bracket, protecting cap.

ABS0375 Aerospace series - Connection 14 contacts plug and receptacle Support strain relief.

ABS0513 Aerospace series - Support, strain relief.

ABS0638 Aerospace series - Composite backshell straight 90° for EN2997 and EN3646 connectors +200 °C.

ABS0713 Aerospace series - D-SUB with crimp contacts size 20 and coaxial/power contacts size 8.

ABS0731 Aerospace series - Support, cable.

ABS0772 Aerospace series - Clips, indication for anti-push down operation of circuit breakers.

ABS0836 Aerospace series - Sleeve - heat shrinkable, dual-wall.

ABS0872 Aerospace series - Backshell, straight, non-environmental.

ABS0887 Aerospace series - Braided conduit lightweight PEEK unequipped or braided with or without mechanical protection.

ABS0916 Aerospace series - Tubing, elastomeric, heat-shrinkable, -55 °C to +150 °C.

ABS1054 Aerospace series - Connectors, electrical circular bayonet locking.

ABS1057 Aerospace series - Connectors, electrical circular bayonet locking backshell.

ABS1095 Aerospace series - Bracket for covering.

ABS1144 Aerospace series - Bracket cable separator combinable

ABS1339 Aerospace series - Clamp, plastic with rubber cushion.

ABS1340 Aerospace series - Connectors, electrical, circular, plug, with backshell, coupled by threaded ring, operating temperature +200 ° C continuous, +260 ° C peak.

ABS1343 Aerospace series - Connectors, electrical, circular, plug, with backshell, coupled by threaded ring, operating temperature +175 ° C continuous.

ABS1353-003 Aerospace series - EMC protection of Airbus electrical harnesses - Part 003: Shielded overbraiding technology.

ABS1378 Aerospace series - Seal, pressure, conductive, for electrical cables, operating temperatures -55°Cto+105°C.

ABS1526 Aerospace series - Separator.

ABS1571 Aerospace series - Seal, pressure, conductive composite for electrical cables, operating temperatures -55 °C to +105 °C.


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ABS1579 Aerospace series - EMC protection requirement for electrical harnesses - Technical specification.

ABS5334 Aerospace series - Self adhering silicone tape electrical insulation high temperature.

AIPS03-06-003 Airbus Process Specification - Locking using wire.

AIPS05-05-002 Airbus Process Specification - Sealing of aircraft structures outside fuel tanks.

AIPS07-01-002 Airbus Process Specification - General requirements for the insertion and extraction of removal contacts in electrical connecting systems.

AIPS07-01-003 Airbus Process Specification - Cable tying with NSA935401 or NSA8420.

AIPS07-01-004 Airbus Process Specification - Tightening procedures for electrical equipment.

AIPS07-01-006 Airbus Process Specification - Electrical bonding.

AIPS07-01-009 Airbus Process Specification - Attachment of cables in backshell of connectors.

AIPS07-01-012 Airbus Process Specification - Shielded over braiding of electrical harnesses for A340-500/600.

AIPS07-01-013 Airbus Process Specification - Shielded over braiding of electrical harnesses developed for A380 Program.

AIPS07-01-014 Airbus Process Specification - Shielded lightweight conduits, manufacturing and production assembly instructions for electrical cable harnesses.

AIPS07-01-015 Airbus Process Specification - Modification and repair of harness protection components.

AIPS07-01-017 Airbus Process Specification -Assembly process of adhesive bonded brackets.

AIPS07-02-001 Airbus Process Specification - General requirements for the stripping of electrical cables.

AIPS07-02-005 Airbus Process Specification - Installation of coaxial connector ASNE0294.

AIPS07-02-009 Airbus Process Specification - General requirements for the stripping of electrical single conductor cables DR and AD series.

AIPS07-04-007 Airbus Process Specification - Airbus Process Specification - Installation of cap NSA936601 and NSA936604.

AIPS07-05-005 Airbus Process Specification - Assembly and connection of modules terminal and terminal blocks.

AIPS07-05-006 Airbus Process Specification - Installation of rectangular connectors ASNE0390 or EN3545

AIPS07-05-007 Airbus Process Specification - Installation of seal bundle NSA934710.

AIPS07-05-011 Airbus Process Specification - Installation of connectors EN6047-003/004 (ASNE0098 and ASN0378) and contacts EN3195-052M4A2A.

AIPS07-05-012 Airbus Process Specification - Installation of coaxial connector BNC type NSA938601.

AIPS07-05-013 Airbus Process Specification - Installation of coaxial connector TNC type NSA938621.

AIPS07-05-015 Airbus Process Specification - Installation of coaxial connector C type NSA938661.

AIPS07-05-016 Airbus Process Specification - Installation of BNC type coaxial connectors ASNE0460.

AIPS07-05-017 Airbus Process Specification - Installation of TNC type coaxial connectors ASNE0461.

AIPS07-05-018 Airbus Process Specification - Installation of N type coaxial connectors ASNE0462.

AIPS07-05-019 Airbus Process Specification - Installation of C type coaxial connectors ASNE0463.

AIPS07-05-020 Airbus Process Specification - Installation of coaxial connector ASNE0295 and grounding with terminal ASNE0296.


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AIPS07-05-026 Airbus Process Specification - Installation of connector ABS0364.

AIPS07-05-028 Airbus Process Specification - Installation of diodes and resistors on connectors NSA938361.

AIPS07-05-029 Airbus Process Specification - Installation of connector of NSA938361 and ASNE0362.

AIPS07-05-034 Airbus Process Specification - Installation of rectangular connectors ASNE0237 and ASNE0302.

AIPS07-05-035 Airbus Process Specification - Installation of coaxial connectors NSA938603, NSA938604, NSA938608.

AIPS07-05-042 Airbus Process Specification - Installation of cables brackets and supports.

AIPS07-05-046 Airbus Process Specification - Assembly process of pressure seal ABS1378.

AIPS07-05-062 Airbus Process Specification - Assembly process for pressure seals ABS1571.

AIPS07-06-002 Airbus Process Specification - Identification and marking on electrical installations.

AIPS07-07-001 Airbus Process Specification - Heat-shrink tubing and sleeves.

AIPS07-07-002 Airbus Process Specification - Flexible textile sheaths EN6049-003 to EN6049-007, ASNE0559 and ABS0596 for protection of electrical cables.

AIPS07-07-004 Airbus Process Specification - Drainage of conduits NSA935805, NSA935806 and ASNE0432.

AIPS07-11-001 Airbus Process Specification - Installation of optical fibres cables.

AIPS09-01-002 Airbus Process Specification - Cleaning with liquid non-aqueous agents.

AN742 Clamp, loop, plain, support, aircraft. (New current reference for MS21103.)

AN960 Washer, flat.

AS62200 Clamp loop style (snap lock) cushion reinforced (electrical harness) (for 5,00 mm & .1900 inch Fasteners).

ASNA0033 Clamp - Hose, screw, narrowband.

ASNA5107 Tape - Reinforced silicone, self adhesive.

ASNE0039 Round connectors, screw-locking plugs.

ASNE0040 Round connectors receptacle, square flange, screw locking.

ASNE0041 Round connectors receptacle, round flange, screw locking.

ASNE0052 Connector, circular, bayonet-locking, plugs.

ASNE0053 Circular, connector, square flange receptacle, bayonet-locking.

ASNE0054 Circular, connector, jam nut receptacle, bayonet-locking.

ASNE0072 Resistors fixed wire-wound axial outputs 3 to 11 watts.

ASNE0073 Pressure seals round flange.

ASNE0076 Circular connectors, bayonet-locking plug and straight backshell.

ASNE0079 Connector - MIL-C-26500, round socket.

ASNE0080 Backshell - Connector, special.

ASNE0093 Connector-square flange, MIL-C-5015, Threaded.

ASNE0094 Connector-MIL-C-5015, plug, Threaded.

ASNE0110 Connector - MIL-C-26500, square flange.


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ASNE0111 Connector - Receptacle, fire resistant.

ASNE0126 Thermoretractable sleeves, semi-rigid, polyolefine.

ASNE0150 Circular connectors, bayonet-locking plugs with cable clamp backshell and elbow cable clamp.

ASNE0163 Connectors, rectangular ARINC 600 size 2 plugs.

ASNE0165 Connectors, rectangular ARINC 600 size 3 plugs.

ASNE0186 Connector - Plug, bayonet coupling, MIL-C-83723 series III.

ASNE0187 Connector - Receptacle, bayonet coupling, square flange, MIL-C-83723 series III.

ASNE0199 Backshells with straight or 90° strain relief clamps.

ASNE0233 Connector - Plug, fire resistant.

ASNE0237 Connector - Rectangular, contact size 20.

ASNE0293 Cable, coaxial, double screening, code XF, RG 400/U (+200 °C).

ASNE0294 Connector-coaxial, SMAtype, plug.

ASNE0295 Connector-coaxial, 3 or 4 studs.

ASNE0302 Rectangular subminiature connectors, with size 20 contacts and coaxial contacts.

ASNE0354 Receptacle - Servicing.

ASNE0362 Connector - Contact, rectangular size 22, sealed series.

ASNE0374 Contacts - Crimped, male and female for rectangular connector MIL-C-81659B.

ASNE0390 Interface connector, male and female, rectangular.

ASNE0395 Male crimp contacts (pins).

ASNE0397 Dummy male contacts (dummy pins).

ASNE0406 Cable - Coaxial, double screening, WD type (+200 °C).

ASNE0432 Conduit - Electrical flexible lightened tight bend radius.

ASNE0435 Mount - Cable.

ASNE0442 Connector to prEN2997 -260 deg. C cyclic, plug, fire resistant.

ASNE0455 Backshell, simple, and with cable clamp.

ASNE0460 Connector coaxial, BNC type.

ASNE0461 Connector coaxial, TNC type.

ASNE0462 Connector coaxial, N type.

ASNE0463 Connector coaxial, C type.

ASNE0466 Terminal-Aluminium, nickel-plated.

ASNE0484 Sleeves, silicon, heat-shrinkable high flexible (-75 °C to +200 °C).

ASNE0616 Plug, filler for sealed connectors.

ASNE0663 Bracket-wiring.

ASNE0664 Bracket-wiring.

ASNE0680 Protective cover for rectangular interface connectors.


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ASNE0684 Connector, circular high density plugs, bayonet-locking.

ASNE0688 Spacers for cable bundles.

ASNE0690 Coaxial - Cables, double braid, 75 ohms, +200 °C max. WL type.

ASNE0692 Cable, coaxial code WN 50Q - +200 °C max.

ASNE0718 Sleeve, heat-shrinkable semi rigid high temperature.

ASNE0734 High density circular connectors square flange receptacles bayonet locking.

DAN269 Adhesive tape.

MS20995 Wire safety.

MS21919 Clamp, cushioned support.

NAS1599 Connectors, general purpose, electrical, miniature circular, environment resisting, 200 degrees C maximum temperature.

NAS1801 Screw, hex head, cruciform recess, full thread, alloy steel, 160 000 psi tensile.

NSA360002 Section round.

NSA5515 Clamp-nylon.

NSA5516 Clamp protected.

NSA5527 Spacer.

NSA5539 Protective sleeve.

NSA8420 Tape - Lacing, wiring and tubing.

NSA934710 Bulkhead conduct.

NSA935401 Tie - Cable.

NSA935403 Tape - Protective for elastomer silicon tape.

NSA935501 Yoke wiring.

NSA935504 Bracket-wiring.

NSA935510 Bobbin.

NSA935805 Conduit - Electrical, flexible, with normal bend radius.

NSA935806 Conduit - Electrical, flexible with tight bend radius.

NSA935807 Clamp - Loop for flexible sleeves.

NSA935809 Coil-holding.

NSA935829 Sleeves end.

NSA936507 Terminal-eye, non-insulated.

NSA936603 Cap-heat-shrinkable.

NSA937210 Sheath - Thermoretractable, high temperature.

NSA937211 Sheath - Thermoretractable, low temperature.

NSA937494 Sleeve, heat shrinkable, low temperature.

NSA937901 Module - Terminal.

NSA937905 Block-terminal, monoblock .1900-32UNF.


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NSA937910 Contact crimped, male.

NSA938003 Bush -Thread-protecting.

NSA938025 Cable clamp - Straight and right cable for connectors MIL-C-38999.

NSA938026 Connectors - MIL-C-38999, series 1, bayonet plug.

NSA938150 Backshell - Connector, for circular connector, type NAS1599.

NSA938155 Cable grip - for high temperature plug.

NSA938195 Pin-dummy, contact.

NSA938361 Connector-rectangular, contact size 22.

NSA938403 Contact - Crimped, male and female, for rectangular connector, ARINC B 604 A.

NSA938601 Connector coaxial BNC, sealed version.

NSA938603 Coaxial-connectors, BNC type.

NSA938604 Coaxial-connectors, MHWtype.

NSA938608 Connector - Coaxial, series HN.

NSA938621 Connector - Coaxial, type TNC.

NSA938641 Connector - Coaxial, type N.

NSA938661 Connector - Coaxial, type C.

NSA938925 Connector - Coaxial, MIL-C-5015.

TNA00710010 Sealant.

TNA00710050 Frangible paint.

TNA00710053 Structural adhesives.

TNA00710059 Non metallic materials miscellaneous.

3 Definition, applicability and limitations

3.1 Definition

A set of cables makes up a bundle; a set of bundles makes up a harness.

3.2 Applicability

This Airbus specification is applicable when invoked by the drawing directly or through another document for the purpose given in the scope. When processing to AIPS07-01-001 is required, it shall be invoked on the drawing by the words "Manufacturing and installation of cable harnesses of AIPS07-01-001".

Application paragraph contains in terms of requirements:

3.3 Limitations of the process

Not applicable.


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AIPS07 -01-001 Page 10 Issue 4

4 Requirements

4.1 Technical requirements

Manufacturing and installation of cables harnesses shall be in accordance with design office drawings.

The segregation between routes defined on the drawings must be observed along the complete route. Unless stated on the drawings, the distances between technical routes must be in compliance with those defined in annex A. When retrofitting (adding cables) on aircraft, segregation shall be observed.

The distances required between the electric bundle and the structure or the pipes are given in annexes D and E for the information, the design office drawings give these.

4.1.1 Products

There are several categories of products: - cables, - connecting item, - routing item.

4.1.1.1 Cables

All cables have to be identified in accordance with AIPS07-06-002 Identification and marking on electrical installations.

4.1.1.2 Connecting items

These are all items which are involved in the making of an electric contact or all items concerned with the connection of a conductor to this electrical contact (example: Connectors, terminal blocks, indicator lights, relay bases or other, sockets, pins, lugs, shielding terminations, etc.).

4.1.1.3 Routing item

These are all items used to attach, tie or make the wiring. Clamps, insulating extrusions, raceways, sheaths or conduits used for electrical purposes are included in these products.

4.2 Tools and tooling

The tools and tooling used for the manufacture of bundles must be suitable for the electrical standard items, and shall be in accordance with the relevant AIPS (See clause 2). The quality of the work performed is conditioned to a great extent by the choice of the tool (example: Strap wrenches and soft-jaw pliers shall be preferred to other types of pliers). Manufacturing tools shall be inspected periodically in compliance with prevailing directives. The tooling tables used for the manufacture of bundles must be free from sharp or protruding edges and must not be made from abrasive materials which may damage the electrical equipment. The transport tooling must allow the bundles to be placed flat and not suspended.

4.3 Quality requirements

The premises used in a permanent way or temporarily for the manufacture or the storage of electrical bundles must be healthy, free from of high conditions of humidity, heat, grease and dust of metallic or other origins.

5 Process qualification

For technical qualification: Refer to AIRBUS qualification procedure for Manufacturing Process.


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6 Process work and quality control instructions

The supervisory staff must make sure that all persons working on electrical equipment hold the correct qualifications so that the operations requested are performed with required level of quality.

6.1 Process work instructions

6.1.1 Utilization priority, storage and handling rules for components and bundles

6.1.1.1 Components

- All electrical standard items must be stored either in their original packaging or in a packaging provided for this purpose.

- Segregation of copper and aluminium components must be effective. - When the manufacturing date code is given, the batches must be used in the order of manufacture that is the

oldest ones must be used first. - Do not start a new batch until the previous batch has been completely used. - If several batches are placed together in the same storage location, they must be clearly identified and

separated. - If a batch is under concession, additional documents must be drawn up and conserved in order to be able to find

the electrical equipment on which the items of the batch were used. - For standard items used in high quantities (for example, contacts and lugs), it is good practice to have separate

batches at each workstation to improve traceability should a problem arise. - In case of prolonged work stoppage, the batches being used must be protected by packaging as similar as

possible to the original packaging.

6.1.1.2 Bundles

Packaging shall be such that:

- It does not modify the electrical characteristics of the bundle,

- It prevents all premature ageing and corrosion during storage,

- It does not pull on the cables at the rear of the connectors.

- It prevents damage, which may be caused by:

- Mishandling,

- Variations in temperature,

- Exposure to harsh environmental conditions.

Until their use, the bundles shall be carefully stored in racks or crates provided for this purpose, away from dust, humidity and mechanical shocks (constant cleanliness condition). During storage, it is formally prohibited to fold or suspend bundles. For those which are coiled, a minimum curvature radius shall be respected. Bundles shall be packed so that the section installed first is on the top. Bundles shall be protected by plastic sleeves along complete length taking care to separate the various branches of the bundle until delivery on the Aircraft. All end fittings (connectors, ground modules, etc...) shall be necessarily protected by a protective cap, type ASNE0680, for connectors or by a plastic bag for other items except for lugs. All these protections (plastic sleeves, bags...) shall be necessarily removed on final attachment. A desiccant product must be placed inside each transport jig to absorb condensation. The transport tooling must allow the bundles to be placed flat and not suspended.


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6.1.2 Cutting cables to length

The cutting tool shall in no case modify the initial characteristics of the cable. Suitable tools reserved for this purpose such as cable cutting pliers with rounded and profiled jaws shall be used. The cut shall be clean, without burrs and perpendicular to the axis of the cable, the geometrical distortion of the diameter must be kept to a minimum in order not to penalize the other installation operations.

6.1.3 Cable lengths

6.1.3.1 Over length at the end of the wiring (including drip loops and repairs)

From the long range family the harness length (included over lengths, drip loops...) are defined by the design office (drawings).

For optical cable: Refer to AIPS07-11-001 "Installation of optical harnesses".

An over length shall be provided at the end of the wiring for the following reasons:

- To facilitate installation and removal of connectors and the locking and unlocking of contacts.

- To allow the possibility of end fitting replacements (contact).

- To suppress the effects of vibrations on devices and loads on cables, mounts and junctions.

- To avoid the contacts in the connecting items being contaminated by liquid, drip loops must be provided when

installing the bundle.

- Make the buckle of wiring called ‘’Droplet ‘’.

This over length shall be distributed at each end of the harness and taken into account during installation of this harness. Drip loops must be made when routing the cables. It is forbidden to make complete loops to reduce the over length of cables and bundles (this prohibition also applies to the coaxial cables). Exceptionally, for commercial furnishing harnesses, a loop outside the loom may be accepted (specific of bundles with set length the connection point of which changes according to the commercial furnishings).

Figure 1


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The over length for a repair shall be included in the drip loop. Over lengths at each ends of the wires are given in the chart 1 below:

Table 1 - Examples of over length

There is no-repair possibility on optical cable installations, therefore damaged optical cable, looms or harnesses shall be removed and replaced.

The length and number of repair of coaxial cable is given by system specialist and cannot be changed (see TN462.0015/95A).

For the O.B.B (Over Braiding Bundles) same rules are applicable.

For equipment removing (e.g.: small VU) an over length of 100 mm + VU length shall be applied on the bundle connected on the equipment in order to allow an external disconnection.

Figure 2 - Over length for equipment removing

6.1.3.2 Harness length measuring reference

6.1.3.2.1 Straight backshell connectors

According to figures 3 and 4.

Figure 3 - Reference for connectors type ASNE0052/53


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Figure 4 - Reference for rectangular connectors type EN3545

6.1.3.2.2 Elbow backshell connectors

According to figure 5.

Figure 5 - Connector centerline

6.1.3.2.3 Straight coaxial connectors


Figure 6 - Front face of connector

6.1.3.2.4 Elbow coaxial connectors


Figure 7 - Connector centerline


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6.1.3.2.5 Rack connectors


Figure 8 - Rear face of connector

6.1.3.2.6 Terminal block module

Contact insertion face (centre point per block of 5 modules maximum).

Figure 9

6.1.3.2.7 Terminal lug


Figure 10 -Terminal lug hole centerline


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6.1.3.2.8 Contacts (for C connections)


Figure 11 - Rear face of male contact

Figure 12 - Rear face of female contact

6.1.3.2.9 Branch


Figure 13 - Centre point of branch


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6.1.3.3 Dimension tolerances of harnesses

According to table 2.

Table 2

These rules are not applicable for coaxial cables (see chapter 6.1.3.3.1 below). When a repair shortens the length below the minimum tolerance the cable must be entirely replaced. From programs A340/A380 close lengths "of manufacture" are taken into account by the design (3Ddrawings/tools)

6.1.3.3.1 Specificity of coaxial cables

Certain coaxial cables may have a strictly defined length. This length is specified on the drawing. If a repair shortens the cable length to below the minimum tolerance, it must be replaced in full. This rule applies to all coaxial cables of the ASNE0406/WD and ASNE0293/XF types.

6.1.4 Bend radius

6.1.4.1 Bend radii for 26 to 12-size copper or aluminium cables


Table 3


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6.1.4.2 10 to 0000 size copper and aluminium (P and G routes)

The minimum bend radii shall be equal 10 times of the outside diameter of the cable. In exceptional cases, when 10 times cannot be applied it can be reduced to 6 times of the outside diameter of the cable. For G feeders, fixed by bobbin, the internal minimum radius shall be equal to 10 times of the cable diameter.

6.1.4.3 Coaxial cable

The minimum radius shall be equal to 10 times the outside diameter of the cable in general and for movable parts. In exceptional cases, when 10 times cannot be applied it can be reduced to 6 times of the outside diameter of the cable.

6.1.4.4 Data bus cable (AFDX)

The minimum radius shall be equal to 10 times of the outside diameter of the Data bus cable. In exceptional cases, when 10 times cannot be applied it can be reduced to 6 times of the outside diameter of the cable.

6.1.4.5 Optical cables

The minimum bend radius shall be equal to 10 times of the outside diameter of the cable and it shall never be less than 20 mm (see AIPS07-11 -001).

6.1.4.6 Bundles

The minimum bend radius for bundles shall be equal 6 times of the outside diameter of the largest loom when there are no optical or coaxial cables inside. 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. It must in no case be lower than the minimum allowable radius for the largest cable in the bundle concerned.

6.1.4.7 Flexible cables type BF

The bend radius can be 3 times the outside diameter. These cables are used only inside small VU's.

6.1.5 Stripping and connections

Cable ends shall only be stripped immediately prior to their connection. The rules relevant to stripping are given in AIPS07-02-001and AIPS07-02-009. The stripping dimensions are defined by the characteristics of the end fittings and are specified in the documents relevant to the use of each end fitting. WD cable ends (coaxial) shall be insulated by a heat shrink sleeve on coaxial connector.


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6.1.6 Protection, insulation, sealing of connections

Heat-shrink tubing shall be used according to AIPS07-07-001. The type of tubing to be used shall be specified each time in the end fitting utilisation documents. On cables where the insulation diameter is too small or smaller than the connecting hole, heat-shrink tubing will also be used to make up for the difference in diameters and to ensure sealing and sometimes mechanical retention. Tubing shall also be used to stop bending and improve cable sturdiness at the rear of and on tin solders. Sleeves will also be used to prevent folds and perfect the solidity of cables behind and on brazing.

6.1.6.1 Insulation and protecting connections

On end fittings without specific protection (terminals not preinstalled for example), additional protection of the connection will be ensured by adding heat shrink tubing ASNE0484 and NSA937494 or ABS0916 according to drawings in order to improve the electrical insulation. When crimping extremities are not connected a temporary sleeve shall be installed on each extremity to avoid short circuit.

6.1.6.2 Insulation terminals lugs

Terminals reference NSA936507TG and ASNE0466TS also require, after crimping, the installation of two tubings (ASNE0484 + ASNE0718) or equivalent or a single tubing (ABS0916 to ensure electrical and mechanical protection). ABS0916 single tubing will be used on A340 and following programs.

6.1.6.3 Insulation of contacts

a)ARINC600 To prevent cables from breaking at outlets of contacts with reduced barrels (example: ARINC600 #12 contact with # 24 to # 18 cables), two heat-shrink sleeves shall be installed to improve the mechanical strength (ASNE0718-01-20 + ASNE0718-02-10). b) Sub-D connector (ABS0713) # 8 contacts protruding behind the rear of hard insulation must be protected by heat-shrink tubing (ASNE0718-03-30 for # 12 and # 14 cables and ASNE0718-02-30 for # 16 cables). Note: Electric contacts protruding beyond insulation must be protected (example: heat-shrink tubing ABS0916). c) Specific procedure associated with extraction of contacts To enable a contact to be extracted when the outer diameter of the insulation of each cable does not allow the extraction tool to pass, it is necessary:

To strip the cable (the stripping length must be limited to the strict minimum required),

To protect the conductor with a shrink sleeve (10 mm partial overlap of the cable insulator is necessary, see figure 15).

Figure 15


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6.1.6.4 Servicing connectors

6.1.6.4.1 ASNE0354-204 (28 VDC)

Protect the connector with heat-shrink tubing ASNE0126 or NSA937211 or equivalent from base flange over a length of 50 ± 5 mm after shrinking.

Figure 16 - ASNE0354-204 (28 VDC)

6.1.6.4.2 ASNE0354-301 (115 VAC)

Protect the connector with heat-shrink tubing ASNE0126 or NSA937211 or equivalent from base flange to flush with rear part of connector.

Figure 17 - ASNE0354-301 -(115 VAC)

6.1.6.4.3 ASNE0354-302

Protect screw heads as per PQ10010-103-01 (CAF4).

Figure 18 - ASNE0354-302

6.1.6.5 Coaxial connectors/stowage connectors

To create a stowage connector for coaxial connectors E0460, E0461 and E0462 (with square flange bases), use the heat-shrink tubing delivered with this type of connector. Position this tubing on the rear part of the socket, shrink it then pinch the rear of the connector with flat-nose pliers after having removed the contact, the insulation, the sleeve, the plug, the ferrule and the plastic protective cap (see figure 18). If the heat-shrink conduit is not delivered with the connector, use conduit ABS0836 or equivalent with a maximum length of 40 mm after shrinking and of size adapted to suit diameter of connector to be protected.

Note: This procedure for sealing stowage connectors can be generalised to all types of coaxial connectors.


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Figure 19 - Stowage for coaxial connectors

6.1.6.6 In line items

This applies when system requirements specify protection of the wiring as near as possible to the connectors (example: thrust reverser 3rd line of defence). Inserting 20 mm heat-shrink conduit inside the spiral conduit can provide the protection. A route can be protected close to its end (connector, terminal block, etc.) by screwing a spiral conduit on the main one to leave room for the insertion / extraction of contacts as defined below (for example).

Figure 20

Note: when bonding is not directly performed through the connector but on an adjacent structural part by a pigtail connection on VN or VG, it is not required to add a protection (sleeve or a conduit) on the pigtail wiring. (see note 1 of chapter 6.1.11.1.4)

6.1.6.7 Protection of connector unused cavities

6.1.6.7.1 By pins

Certain circular connectors must be equipped with all their male contacts. Unwired male contacts may be standard connecting contacts or dummy contacts. For NAS1599 connectors, preferably install dummy pin NSA938195FE01 in size 20 holes. If applicable, this dummy contact can be replaced by pin PA2000. For connectors ASNE0390 / EN3545, pins ASNE0395FV... can be replaced by dummy pins ASNE0397FY. These dummy pins are preferred to pins ASNE0395FV....


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6.1.6.7.2 Sealing plug installation

Sealing plugs shall be necessarily installed in non-pressurised areas in all unused cavities of electrical standard items equipped with grommets (rubber seals). According to specific instructions given on the installation drawing or in the hole protection table (fluid hazard zones, example: in sensitive under floor areas, cargo compartment, under insulating blankets, see table 5 below).

Figure 21

6.1.6.7.3 Sealing plug and dummy contact installation

In size 22 connector holes (example: connectors ASNE0734 and NSA938361 equipped with dummy contacts), blanking plugs will be installed with the head inside the grommet to improve hold.

Figure 22

6.1.6.7.4 Dummy contact installation


Figure 23


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6.1.6.7.5 Use of dummy contacts / sealing plugs


Table 4


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Table 5 - Hazardous areas

6.1.7 Protection of harnesses

6.1.7.1 Protection by convoluted conduit

When installing electric cables inside closed conduits flexible or rigid (defined in NSA935805), the following rules must be obeyed:

-There must be no cable ties inside the conduit.

-After installation on aircraft, drain holes shall be provided in conduits with low points in accordance with (AIPS07-07-004 - Drainage of conduit NSA935805, NSA935806 and ASNE0432.) Small diameter conduits (02, 03 and 04 in standard) are not drained, including conduits, which are part of a pressurized compartment, a sealed harness, or a moving conduit.

- Sheaths must be one-piece. Connection of two sheaths to make up a conduit is unacceptable.

- Conduits must never be filled above 80% of their inside section.

When the length of the conduit exceeds 2 meters, filling percentage must not exceed 60% of inside section.

Caution: for "xxG" routings (sensible systems protection) the use of convoluted conduit ensures electrical protection. The section of the convoluted conduit can be adapted to the inside diameter routing while being as close as possible to the cables Consequently the above rule (80% of inside section) is not mandatory in this case.

Figure 24


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- In all conduits, except those shorter than 500 mm and those where all the cables have a disconnected end (connectors, terminal blocks, etc...), an electrical conductor (size 18) shall be placed inside to be used as a draw wire.

- Each end of the draw wire shall be insulated with an insulating cap as described in AIPS07-04-007 and identified by a sleeve marked "DRAW WIRE".

- The draw wire shall protrude at least 100 mm from both ends of the conduit.

Figure 25

Note: Non-metallic electrical protective conduits must be attached by means of cable ties NSA935401 with the gun set so that the ties when tightened do not excessively crush the conduit. However, make sure that conduit attachment is correct. Rigid conduits shall have the drain hole incorporated after installation at the lowest point (see AIPS07-07-004). For braided conduits drain it's forbidden to have additional hole.

6.1.7.1.1 Installation on a bundle

6.1.7.1.1.1 Conduits NSA935805 / ABS0887 on a bundle

The conduit shall be held without crushing:

- Cable tie NSA935401 can be used to hold convoluted conduits and can be crossed. The NSA935401 cable tie gun must be set according to AIPS07-01-003.

- Lacing tape NSA8420 can be used .

When conduit is integrated in the bundle, it shall be visible. The head of the cable tie shall be positioned to avoid contact on the bundle.

6.1.7.1.1.2 Branches protected by tubing


Figure 26


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Figure 27

Note: The bend radius must be at least equal to 6 times the outside diameter of the cable. However, this rule does not apply to draw wires installed inside the conduits, they can be bent to below the cable radius of curvature.

6.1.7.1.2 Attachment of rigid convoluted conduits

Convoluted conduit shall be attached by:

- Clamp NSA935807 for PTFE conduit NSA935805 only.

- Clamp AN742 (old reference: MS21103) with bobbin NSA935809 for PTFE conduit NSA935805 only.

- Clamp ABS1339.

- ClampNSA5516.

- V support (example: NSA935504) + cable tie NSA935401, in this case conduit ABS0887 shall be protected by two layers of tape ASNA5107 to avoid crushing (see figure 28).

Figure 28

Note: Use of tape ASNA5107 is also required when a peek conduit is a part of a harness installed in a V-support.

6.1.7.1.3 Conduit end / Diameter

At each end, a min. length between attachment and the conduit end shall be provided:

Figure 29


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Figure 30

For Peek conduit ABS0887, end cap NSA935829 shall used. See the corresponding tables number 6 and 7 below.

Table 6 - For harnesses with length lower than 2 meters:


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Table 7 - For harnesses with length greater than 2 meters

6.1.7.2 Conduit end on backshell

The end of the conduit must in no case bear against the end fitting insulation (this may lead to a loss of insulation by liquid accumulating in the tubing). The PTFE NSA935805 conduit can be crushed but only at connector backshell to ensure a good tightening. For PEEK conduit ABS0887, end cap NSA935829 shall be used.

Figure 31 - Straight backshell or elbow backshell


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6.1.7.3 Protection by flexible sheaths

These flexible sheaths are installed according to the drawing and the corresponding AIPS07-07-002 Flexible textile sheaths for protection of electrical cables.

6.1.7.4 Mechanical protection of cables at ends of shielded conduits NSA935806 or rigid tubes

Electric cables of shielded conduits shall mandatory be protected at outlet by NSA937210 type tubing or equivalent. Take a length from 60 to 70 mm length of tubing NSA937210; insert by at least 30 mm into the conduit end fitting and the other end secured by a cable tie. This tubing shall have a sufficient diameter so that it can wrapped at least twice the bundle, once it has been split longitudinally (see figures 31 and 32). In this application it is not necessary to heat shrink NSA934210. Note: Attach outgoing bundle by the device provided for this purpose. This device may be of the NSA5516 clamp

or ABS0513 type or a cable tie NSA935401 picked up on an NSA935504 type mount or equivalent defined by the Design Office.

Figure 32

Figure 33

6.1.8 Insertion/extraction of removable contacts

The use of insertion and extraction tools will be given in the documents relevant to each connecting item. However, it is standard practice for the operator to check that, whenever a contact is inserted, it is locked in its cavity. Note: Check the good locking of the contact is mandatory (see AIPS07-01-002 General requirements for the

insertion and extraction of removable contacts in electrical connecting system).


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6.1.8.1 Twisted cables

To facilitate the insertion of the contacts in the modules and to improve the check made on the locking of each contact, twisted cables must be untwisted over a length of 60 + 10 mm before connecting to connectors or modules. Note: The locking check must be made on each cable individually by pulling on the cable after inserting the contact.

Figure 34

6.1.9 Tightening torque's, attachment and locking of electrical components

6.1.9.1 Tightening torque's

The torque's to be applied are those given in the specifications or data sheets of the product or the component. AIPS07-01-004 gives the methods for applying torques and gives the torque values for the most currently used equipment.

Note 1: All modification in torque values must be covered by a concession granted by the design. Note 2: On primary generation electrical connections and up to, but not including the secondary circuit breakers, a

red paint mark (frangible paint PQ10050-182-00) shall be made on screws and nuts, self-locking or not, as shown below, once torque has been applied.

Figure 35

If the connection is unscrewed, the torque value must be reapplied when tightening again and paint mark removed and remade (it is not sufficient to simply bring the colour mark opposite the fixed mark). Note: In no case the lines (features) of location have to be of use as replacing to the tightening of the nut.

Self-locking nuts or damaged nuts must not be reused.

6.1.9.2 Locking (indication)

Certain products, such as circular or rectangular connectors, are equipped with a locking indication (line or spot of white or red paint), which must be checked after coupling.


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6.1.9.3 Connection of rectangular and circular connectors

For modifying wiring on aircraft, a visual check locking of a connector must be done. Make sure that the connectors are correctly / connect by pushing in contact axis. After connection of the various connectors, refer to annex B check that locking has been correctly achieved. For rectangular connectors, the tightening/torque of the two fixation screws must be checked following AIPS07-05-006 Installation of rectangular connectors.

6.1.9.4 Locking / Safetying procedure

Locking / Safetying is made with AIPS07-01-004 Tightening procedures for electrical equipment and PQ10053-056-00 adhesive and red paint PQ10050-182-00 or with lockwire according to the instructions given on the drawing. The adhesive in accordance with PQ10053-056-00 shall permit screw removal. Safetying with adhesive shall be carried out in accordance with the following specific procedures:

- clean in accordance with AIPS09-01-002,

- apply the activator (PQ10053-064-00) to the threads inside the coupling or nut,

- leave to dry for a minimum of 10 minutes,

- apply adhesive (PQ10053-056-00) onto the threads of the connector and backshell,

- remove any excess adhesive with a soft cloth,

- identify component locked with a painted red line (PQ10050-182-00).

If a modification requires removal of the component, loosen using rubber-jaw pliers (UTICA 529-10) or equivalent and remove particles of adhesive with a soft cloth, in accordance with AIPS09-01-002. Reinstall as previously specified. Securing with lockwire shall be performed using pliers Ref.: BELZER 2855 or FACOM 455, or equivalent. Once the item to be insured has been tightened and positioned, the lockwire must be installed to prevent the item from coming loose (See AIPS03-06-003 Locking using wire). The methods for safetying various connectors are defined on annex C.

6.1.9.4.1 Locking of shielded bundles

6.1.9.4.1.1 On pressure seal or connector

Figure 36 -A on B/C Tightening and locking by lock wire or self-locking device


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6.1.9.4.1.2 On metallic plate

Figure 37 - Bulkhead

Screw of bulkhead shall be locked by lock wire.

6.1.9.4.2 Terminal blocks and module retainers locking (VT)

Terminal blocks shall be covered outside Vu's by screwed covers. These terminal block screwed covers shall be locked by lock-wire throughout the A/C. Module retainers in vibration areas shall be locked by lock-wire . Module retainers dedicated to wirings of Electrical Flight Control Systems (EFCS) are to be locked by lock-wire except when these modules are located inside VU's in all areas. In pressurized areas it is not necessary to lock-wire the module retainers except for modules dedicated to wirings of E.F.C.S (see pink labels). When terminal blocks are located above mechanical flight control system (A300/310 programs) screwed covers and module retainers shall be locked by lock-wire.

The locking process is also described in AIPS07-05-005 "Assembly and connection of modules terminal and terminal blocks".

6.1.9.4.3 Circuit breaker clips

Circuit breakers shall be de-activated using ABS0772 indication clips (to prevent operation). In case of full provision during flight operations white safety clip ABS0772A on circuit breakers shall be used. In case of flight operation under MMEL (Master Minimum Equipment List) or ground operating conditions red safety clip ABS0772B on circuit breakers shall be used. Clips preventing non-push down operation of circuit breakers ABS0772 shall be secured by lock wire type MS20995C32 (Ø 0,63). (See figures bellow)

Figure 39 - Incorrect installation


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6.1.9.4.4 Coaxial connector

All the coaxial plug, type of looking by screw, shall be locked with lockwire.

6.1.9.4.5 Battery connector

The battery connector NSA938915 or equivalent shall be locked with lockwire.

6.1.9.4.6 Visual check of locking

Valid for bolts other than quick-release fasteners type NSA55110-1 and quick-attach with cruciform recess.

So that it shall only be necessary to perform visual inspection of the bolts to check them on boxes and panels, a white line shall be painted in the extension of the bolt slot for the bolted closed position (this slot shall also be painted).

6.1.10 Installation of electrical standard items

6.1.10.1 Electrical standard items installed in-line on cables

Electrical Standard items installed in line on cables (splices, diodes, butt or parallel connectors, resistors, etc.) shall be positioned on the outside of the bundle so that they can be easily accessible, visible, identified, inspected or replaced. They shall be staggered along a cable loom to avoid contact between them. They shall not be located:

- Inside rigid convoluted conduits

- Under clamps or other supports

- Inside connector back shell

- In the dynamic or curved portion of bundle

There shall be no splices in zones below toilets and galleys, unless a special device affords effective protection against the infiltration of liquids. A minimum distance of 10 mm between each standard items of the same family or different family shall be provided. When cable section adapters are used, they shall be located in an area 100 to 300 mm behind the item of equipment (see figure 40) Note: In areas where splices cannot be individually staggered a grouping by family is authorized -see clause

6.1.10.2 below.


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Figure 40

Figure 41

6.1.10.2 Repair by splices in service

Only temporary repair is allowed on EFCS routes and safety wires, with specialist agreement Splices shall be staggered along a cable loom with maximum 4 splices arranged in parallel to avoid contact between family as shown on the diagrams below and be correctly held.

When installation of splice is to be performed for a repair INSIDE an open flexible textile sheath (e.g. EN6049-006) a placard with the indication "SPLICE INSIDE" (type ASNE0248) shall be installed ON this conduit.

This placard will be hold by lacing tape NSA8420 or by cable ties NSA935401.

Figure 42


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6.1.10.3 Specific case of Flight Test Installation. (F.T.I)

According to needs of F.T.I (use of tapping points) some junction terminals NSA939590 "JIFFY" may be installed on the normal electrical installation. JIFFY F.T.I installations shall be performed as figure 43.

Figure 43

Note: - In case of areas tapping points junction terminals shall be picked out on harnesses by mean of orange-coloured split conduit (according to the same above process).

- When junction terminals have to be staggered on harnesses a conduit overtaking of 50 mm length shall be performed before the first junction terminal and after the last one.

6.1.10.4 Electrical standard items installed in line behind a connector

Electrical standard items installed in line behind a connector or item of equipment and where bundle is protected by conduit must be installed as shown in figure 44.

Figure 44


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6.1.10.5 Bonding of shielded cable (for Fuel Data Concentrator)

For bonding of shielded cable, nominal value is 60 mm at the rear of the equipment to allow for the connection/disconnection of the contacts. This value can be extended to 140 mm maximum and reduced to 15 mm minimum in exceptional cases with advice from the Design Office specialist. Inside backshell type ABS0872 or equivalent:

- Shield bonds must be integrated into backshell type ABS0872.

- The ground wires from the shield bonds, which are crimped directly onto a contact of the connector, must remain inside the chamber of backshell ABS0872.

Figure 45

Figure 46

Figure 47


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6.1.10.6 Installation of resistors terminal block on modules

The connection of ASNE0072RB57/59/61 type resistors or electrical components (diode, capacitor, etc.) on modules type NSA937901 by crimping to pin contacts NSA937910EA2000 is authorised.

When these resistors or electrical components are placed on either side of end plate NSA937901P, they are held by lacing tape NSA8420 (see sketch below).

FRONT VIEW TOP VIEW

Figure 48 - Horizontal installation with plate

6.1.11 Make-up of bundles and routing rules

Bundles shall be routed and connected so that the identification and connection labels are clearly visible

6.1.11.1 Make-up of bundles

6.1.11.1.1 General

To facilitate installation and maintenance, the bundles are not fanned but:

- Cables passing through the bundle must be avoided,

- Tangled or crossing cables shall be limited,

- Cables protruding beyond the bundle are unacceptable.

6.1.11.1.2 Twisting

When a bundle acts as a hinge, it can be twisted (3 or 4 turns/meter) to provide suitable travel when the movable component is opened.

6.1.11.1.3 Bundle diameter

Figure 49

D = 50 mm max. for distance between frame < 535 mm. D = 45 mm max. for distance between frame > 535 mm (A380).


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6.1.11.1.4 Routes containing 1 or 2 wires

For routes consisting of:

- 1 wire of 20 or 22 or 24 gauge (not acceptable for 26 gauge), or

- 1 bifilar cable of 22 or 24 or 26 gauge

- 2 wires of 22 or 24 or 26 gauge, or

- 1 wire of 20 gauge and 1 wire of 22, 24 or 26 gauge.

The wires shall be adequately supported and protected by a mechanical pro-tection. In this configuration the use of split Conduit EN6049-006 shall be rec-ommended.

Note 1: This mechanical protection does not apply: - to lengths shorter than 150 mm. - to wires linked to grounding/bonding points (VN or VG).

Note 2: Gauge 26 is only available in copper.

6.1.11.2 Tying of harnesses

In routes including several technical bundles, each one shall be tied with lacing tape NSA8420, the use of enclosed cable ties NSA935401 is prohibited. Inside technical bundles, only lacing tape NSA8420 can be used.

Figure 50 - Recommended Figure 51 - Prohibited for technical bundles

6.1.11.2.1 Choice of type of lacing

In routes including several harnesses, each route shall be tied as shown below: Note: These rules also apply to identification labels inside harnesses

Table 8


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Note: For A400M program technical harnesses are named "mission" and commercial harnesses are named "civils" For A380 program technical harnesses are named "essential" and commercial harnesses are named "non-essential"

See rules described in AIPS07-06-002."identification and marking of electrical harnesses"

6.1.11.2.2 General use of cable ties

Bundles are tied with lacing tape NSA8420 or cable ties NSA935401 (Refer to AIPS07-01-003 Cables tying with cable tie NSA935401 or lacing tape NSA8420). These cable ties have different colours used for wiring make-up on table. Only black, sea-green or colourless ties must remain on final wiring on aircraft. Red cable ties are recommended for use inside fuel tanks and shall be used inside A380 fuel tanks . The ties shall be:

- Shape the bundle,

- Spread out the mechanical loads over all the cables,

- Unite the conductors of one bundle and separate them from those of another.

Note 1: Cable ties installation guns must be adjusted so that cable insulation is not damaged by over tightening. This requirement is particularly important for coaxial cables. (Refer to AIPS07-01-003 cables tying with cable tie NSA935401 or lacing tape NSA8420).

Note 2: The head of a cable tie must in no case be in contact with an adjacent bundle. In areas where wiring density is high (example: rear of instrument panel, rear of flight control unit, etc.), the use of cable ties NSA935401 in the design of technical harnesses is prohibited.

Note 3: The use of cable ties inside raceway channels is prohibited. Note 4: Use of small cable-ties (code size 03) is allowed inside split conduits (e.g. EN6049-006) only to perform

deviations between conduits - See chapter 6.1.1.12.4 of AIPS07-07-002.

6.1.11.2.3 In-line tying

The maximum pitch allowed between two ties is 150 mm. This distance is reduced to 100 mm at the ends of the bundle over a length of 500 mm. Additional ties, required for handling, transfer, mock-up or other operations, will be temporary ties coloured according to the routes (except black and red) and must remain exceptional. (These ties must be removed during installation on aircraft). When tying bundles on tables, allow for the bundle to aircraft attachment points in order to avoid all interference on installation. Over the 500 mm of bundle ends connected to a connector, the tying pitch shall be reduced to 100 mm. These distances can be reduced on bend radius, on deviation, inside Vu's, to avoid swelling. In a harness, it is prohibited to take up slack by using closely spaced attachments (cable ties or lacing tape). When wiring terminal blocks, group wires leading to 3 or 4 modules or terminals together in order to reduce the number of ties (see figure 52). In areas considered as stressed (bend radius, high wiring density and on ramps), the tying pitch has to be reduced to 50 mm maximum. In SWAMP areas tying pitch of split conduit EN6049-006 is 150 mm maximum and shall be defined on the drawing.


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Figure 52 - General pitch for straight bundles

Figure 53 - Type of VT wiring

6.1.11.2.4 Tying of branches

6.1.11.2.4.1 Conventional ties

According to figures 54 Dia. > 25 mm with cables arriving from the

General case 2 harness sides.

Figure 54


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6.1.11.2.4.2 Crossed tying

Crossed tying can be used only with lacing tape NSA8420. The use of cable ties NSA935401 is prohibited.

Figure 55

6.1.11.2.5 Installation of coaxial cables on bundles in rack

Set the pliers to minimum tension. Cross the cable tie to spread out the pressure. Do not position the head of the cable tie on the coaxial when tightening. Position the heads of ties on previously made-up bundle so that they are at least 90° from the vertical axis of the coaxial.

Crossed cable tie (two turns) NSA935401

Figure 56

Figure 57


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Figure 58

6.1.11.3 Swelling of bundles

The variation in the diameter of a tied bundle, composed of same number of cables, must not be greater than 10% of its nominal diameter. For bundles leading to end fittings, connector, ground or connecting module, the volume of the bundle must be within the maximum volume of these end fittings (it is good practice to stagger shielding pick-ups to comply with this point).

6.1.12 Routing rules

- The harnesses are routed so as not to exert abnormal mechanical stresses at the connection points. They must in no case be under tension after connection.

- Generally, bundles must be routed above or beside piping and as far as possible (at least 50 mm away) from lines containing flammable fluids such as fuel, oxygen, hydraulic fluid, etc..

- For distances lower than this, cables must have additional protection, such as conduits shown in drawings - The harnesses must be routed so that in no case, even intermittently, they come into contact with the adjacent

fixed or moving equipment or structure (flight controls, bell cranks, etc.). Bundles must be at least 10 mm away from flat metallic surfaces. This distance must in no case be lower than 5 mm. Special protection must be considered if this requirement cannot be met (AIPS07-07-002).

- PTFE adhesive tape DAN269 can be used on the structure shown by drawing. In straight sections harness is not twisting. In movable parts (e.g.: doors) harness twisting can be necessary to facilitate the movement.

Note 1: See the minimum distances required between electrical bundle and pipes for A380 in annex D. Note 2: See the minimum distances required between electrical bundle and structure in annex E.

6.1.12.1 Structure feedthroughs

When bundles without protection pass through holes in the structure the wiring must in no case be in contact with the edge protection.

Figure 59

The cut must be made so that the extrusion is tensioned and the cut positioned diametrically opposite to the wiring.


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6.1.12.2 Positioning bundle / piping or insulating blanket

When the bundle comes into contact with insulating blanket studs, the studs must be cut so that they no longer touch the bundles. The bundle must in no case be directly or indirectly attached to piping. Precautions must be taken to keep bundle as far as possible from high temperature sources.

Note: Contact between cables P, M, S, T, U, V and blankets is authorised. Contact between G route and blanket is not allowed.

6.1.13 Use of separators

In all cases the use of separators shall be specified in the drawings (location and type). The use of spacers or separators for such installations must be kept to a minimum. Spacer NSA5527 will be used only if required by production drawing (ABS0731 preferred).

Note 1: Exceptionally spacers not required in the drawings can be added to the appreciation of the manufacture and the quality (not for P and G routes see note 2) to guarantee punctually the distances of segregation between routes. However separators shall not be used for managing over length or contact with structure.

Note 2: Addition of spacers not required in drawings is not allowed for P and G routes because a special care must be taken due to the P and G routes constraints (temperature) (see chapter 6.1.13.2)

6.1.13.1 Separators ABS0054, ABS0731, ABS1526 and ABS1144 type

According to figures bellow:

Figure 60 - Separators ABS0731/ABS1144

Figure 61 -Separator ABS0054


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Figure 62 - Ladder ABS0054 bundle position

Figure 63 - Separator ABS1526

Note 1: The cable tie NSA935401 on ladder ABS0054 shall be installed on the right position following ladder gorge. Note 2: ABS1526 or ASNE0688 at rear connectors ARINC 600 type shall be used with cable ties NSA935401 to attach each bundle.

6.1.13.2 Two ABS1339 clamps in butterfly configuration

This configuration can be used in non-pressurized protected areas (e.g.: belly fairing). This configuration is mandatory for P route segregation when segregation distances between bundles shall be secured.

Figure 64


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6.1.13.3 By lacing tape

This knot shall be used in hot areas for hot routings (routes P, G, E) and be specified in the drawing. The knot of the lacing tape shall be secured according to AIPS07-01-003.

Lacing tape NSA8420

Figure 65

6.1.13.4 By use of G routes bobbin

Metallic clamp (e.g. AS62200 , ASNA0033) can also be used in order to be compliant with environmental constraints Caution: when the use of a metallic clamp (e.g. ASNA0033) is required a special care must be taken because the end of the metallic part may injure people. In order to secure the metallic end of the clamp, install a cable-tie to link the protuberant part to the support.

6.1.14 E.F.C.S wiring

6.1.14.1 Manufacture of bundles

On E.F.C.S harnesses, all defects detected during the bundle manufacturing stage in the workshop and before assembly of the main associated harness must be corrected by replacing the damaged cables. The installation of any additional cables on the outside of the E.F.C.S harness is prohibited. These harnesses are made up and tied separately then integrated into the main harness in accordance with the recommendations given in paragraph" make up of bundles"

Figure 66


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6.1.14.2 E.F.C.S harnesses installed on aircraft

All defects detected on an E.F.C.S harness installed on the aircraft can be corrected by adding additional E.F.C.S cables to the outside of the E.F.C.S harness

Figure 67

6.1.15 Protection of bundles

Precautions to be taken:

- Do not step, sit or lie on the bundles.

- When bundles are moved, they must be carried and not dragged (manually or using a handling system).

- Protect sharp edges and holes across with foam or non-abrasive plastic fittings when bundles are routed near to or through these on installation.

- Avoid contact between bundles and sharp edges.

If the surrounding structure is to be reworked or modified, fit adequate protection over the bundles (sheath, sleeve, etc.) in order to prevent all foreign bodies from entering the bundle (especially, under floor installation). The bundles must be kept constantly clean, to do this:

- Avoid all contact with hydraulic or cleaning fluids, chips or cutting oils.

- Movable foreign bodies shall be vacuumed away. Traces of oil, hydraulic fluid or sealant will be thoroughly cleaned off.

- It is forbidden to hang items such as test bundles, torches or any instruments on the bundles.

-The cleaning products must be in compliance with those defined in AIPS09-01-002 Cleaning with solvents.

Wire and unconnected items shall be protected, until connected on the aircraft, by protective caps type NSA936601/604 or equivalent or placed inside plastic bags.

6.1.15.1 Protection of bundles

6.1.15.1.1 Protection during installation

Preferably install bundles after all mechanical operations have been performed in the area concerned. If adjacent structure is reworked or modified, fit the bundles with suitable protection (sheath, sleeve, etc.) to prevent penetration of foreign bodies (in particular for the under floor and raceway installation). The bundles must be kept permanently clean. Inside bundles raceways and cabinets, all loose foreign bodies (rivets, scarves, nuts, etc.) shall be vacuumed away. Traces of oil, hydraulic fluid and sealant shall be thoroughly cleaned with solvent (see AIPS09-01-002 Clearing with liquid non aqueous agents ). The installation of the harness requires special attention. It is often useful to equip them with a temporary protective sheath to perform this operation if it may turn out to be tricky.


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Additional ties required for handling, transfer, mock-up or other purposes shall be temporary ties coloured according to the routes and must remain exceptional (these ties must be removed during installation on aircraft). The sleeves must be removed progressively during final attachment on aircraft. Use the protective tools specified on the manufacturing work sheets. The harness when positioned on the various supports is held by untightened clamps to allow it to be correctly positioned. It is prohibited to pull on the bundle behind standard electric items to avoid damaging the contacts and the cables. It is prohibited to leave the bundle suspended even temporarily (for attachment to a support or an operation on the structure), the bundle must be protected and held to stop it from coming into contact with any item liable to damage it by fretting.

6.1.15.1.2 Locking/safetying of VU hinges

When electrical panels /VU doors are equipped with hinge type MS20001, operators have to verify if axis of this kind of hinges are secured (locked) in translation. To perform this check , two possibilities : 1- Preferred solution : each extremity of hinge axis has to be penned and

located in a 45° chamfer performed on each ½ hinge . or 2- extremities of hinge have to be pinched (about 1,5 mm on each side)

after shortening the hinge axis (about 4 mm).

6.1.15.2 Attachment of bundles

The bundle is positioned on the aircraft by means of removable or fixed installation flags (see AIPS07-06-002) Identification and marking of electrical installations. On installation of harnesses, the bundles will be positioned on the mounts and held by untightened clamps so that slight movements can be made to find final installation position. Once the harnesses have been completely uncoiled and connected, these clamps will be tightened. This procedure is not applicable to clamps NSA5516 to avoid the insulating part of the clamp from coming out. Clamp NSA5516 or ABS1339 must be preferred in zones with high mechanical stresses ( example: junction zone ) as a replacement for clamp MS21919 If clamps MS21919 are used in these zones , self-amalgamating tape ASNA5107 must be applied between the clamps and the cable loom. It is strictly forbidden to space out over lengths by pulling on the harnesses once the attachments have been tightened.

6.1.15.3 Elements of extremities protection pending connection

Wired and unconnected elements of extremities shall be temporarily protected until connected on the aircraft.

Before delivery connectors in provision on the aircraft shall be stored on the bundle once the following operations have been carried out:

- Install a plastic cap on the front face of the connector.(e.g. ASNE0680)

- OR cover with a vinyl plastic bag

- OR install a heat shrink tubing NSA937211.

Note: For flight-tests and after A/C delivery protections must be in accordance with the drawings. For ferry flight, elements of extremities (connectors, lugs, terminal blocks) located in non-pressurized areas shall be protected against the infiltration of liquids by mean of vinyl plastic bag OR by heat shrink tubing.

6.1.16 Routing modification principles

Adding electric cables in bundles must in no case modify the basic principles (manufacture and installation) of the initial electrical installation. The added cable or cables must be fully integrated into the basic existing bundles (normal or FBW). Route segregations must be complied with in full for the added cables. As far as possible use conduits already existing in the basic installation.


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A single # 16 single-wire cable will be added to the bundle by progressively passing the cable under the ties (lacing tape NSA8420 or cable tie NSA935401). To add more than two single-wire cables (# 24 to # 18) or a twisted two-wire cable to a bundle, systematically untie then retie the bundle step by step (5 ties maximum). For higher cable characteristics, step by step untying is required. To add a coaxial cable, route is directly installed on the basic cable (route compatibility to be observed if applicable) without untying it and tie the added cable directly to the mother bundle by crossed tie cable. Then check on installed that the heads of the cable ties NSA935401 do not interfere with the coaxial cable. Additional cables can be either placed under or over the positioning markers. If these cables are placed over the markers, avoid masking the identification on these markers. To remove cables, remove them one by one (end fittings disconnected). If you remove more than two #16 single-wire cables and one # 20 twisted two-wire cable, the loom must be retied. To remove cables passing through pressure seals cables will be cut and protected 100 mm before the last loom mount on either side of the pressure seal . It's forbidden to use metallic tools to add cables inside bundles.

6.1.17 Positioning, Attachment of wiring items and equipment

6.1.17.1 General rule for choosing fasteners

In all cases, the fasteners specified in the drawings must be used. Example: non-magnetic fasteners near to ADF ANTENNAS or in magnetic compass

6.1.17.2 Positioning and coupling of connectors

Fixed connectors must be positioned in the same way on all aircraft.

6.1.17.2.1 Circular connectors

These connectors shall be installed with the key upwards. When the connector is located in a horizontal plane, the key must be positioned towards the front of the aircraft. For specific installations, the position of the key will be specified on the drawing or the work sheet. Check that the connectors are correctly positioned:

- Make connection by pushing along contact axis.

- After coupling of the various connectors, check that locking indications are correct.

Figure 68


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6.1.17.2.2 Rectangular connectors

Vertical position: Looking at the front of the receptacle (view A) , male contact No. 1 shall be located on the bottom left and the backshell / strain relief is installed on RH side. When female contact No.1 is installed on the bottom right, the backshell /strain relief is installed on LH side.

VIEW A

Figure 69 - Fixed Connector

Horizontal position: Looking at the front of the receptacle (view A) , the contact No. 1 shall be in the upper contact row (left or right). The backshell / strain relief is installed on the bottom .

VIEW A

Figure 70


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6.1.17.2.3 Elbow back shell orientation

Referential:

- At the connector contacts side (front face)

- Locating pin positioned at the top

Figure 71

6.1.17.2.4 Installation of fixed connectors (receptacles)

When installing a fixed connector (VC) a special care must be taken for the counter plate positioning See figure 72 below

Figure 72


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6.1.17.3 Packing protection on open backshell

6.1.17.3.1 Composite backshell (without insert)

Figure 73

Composite backshell ABS0638 shall be installed in same way as metal backshells ASNE0080 (see AIPS07-01-009 Attachment of cables in backshells of connectors) in all aircraft zones except for hot areas when we need an important mechanical resistance (example: pressure seals) and on connectors requiring electrical continuity.

6.1.17.3.2 Open metal backshell

Figure 74

The electrical bundle will be held onto the backshell by a cable tie NSA935401.

6.1.17.3.3 Closed metal backshell

When using backshells type ASNE0455 / 0199, silicone tape NSA935403 (big thickness) or ASNA5107 (small thickness) shall be installed around cable bundle for mechanical protection and packing when (diameter of bundle lower than diameter of backshell)

B

Figure 75


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6.1.17.4 Positioning, Orientation of modular terminal blocks

Modules shall be installed on terminal blocks in increasing numerical order from left to right when observer is facing the modular terminal block in an horizontal position. Terminal 1 shall be positioned on the top when the terminal block is located in a vertical position and the terminals shall be in increasing numerical order from top to bottom for an observer facing the terminal block. The installation drawings shall always show direction by the module 1 position. Note: For assembly and connection of terminal blocks, see AIPS07-05-005. Terminal block modules shall be aligned in numerical sequence as follows:

Figure 76

6.1.17.5 Connection by lugs

6.1.17.5.1 Bending of lugs

The maximum angle allowed for bending lugs is 30° for size 10 to 0000 and 45° for size 12 to 24 with a minimum radius of 2 mm. Exceptionally, lugs of 10-24 size cables can be bent once to an angle of 90°. After bending, check that there are no cracks.

IMPORTANT: COPPER LUGS MAY ONLY BE BENT ONCE

ALUMINIUM LUGS SHALL NOT BE BENT


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6.1.17.5.2 Installation of different terminal lugs types.

Special care shall be taken for stacking assembly position of copper and aluminium terminal lugs when they are installed in the same terminal stud.(VT). The lug installation principles must follow the rules below in order of preference :

1/ The lug with the largest contact surface shall always be installed first on the stud. 2/ When different material lugs are superposed (cooper -aluminium), the copper terminal lug should be

positioned under the nut. 3/ When possible the feeder lug shall positioned in between the distribution lugs.

Figure 77

Notes: 1. In any case after the terminal lug has been tightened, distance between barrel of terminal lug and the structure (conductive or not) shall be at least 5 mm away from structure or any conductive elements.

2. Contact between the terminal lug and the terminal block partitions shall be avoided. A straight routing and a centered lug positioning shall be performed.on the VT stud.

6.1.17.5.3 Wiring of terminal studs

Installation of several lugs on a terminal studs (VT: e.g. NSA937905):

- The nuts shall be tightened to the values given in AIPS07-01-004

- After the nut has been tightened, at least one and a half thread of the stud must be visible on each terminal.

- when connected cables are routed in two opposite directions use method shown in case No. 1 of figure 74 below.

- when connected cables are routed in the same direction use method shown in case No. 2.

- Four lugs maximum for case Nos 1 and 2; five lugs maximum for case No. 3.

CAUTION: Use of spacers is not allowed between G route terminal lugs


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Figure 78 - Lugs on VT terminal block

6.1.17.5.4 Use of washer on terminal blocks

Washers shall be used in cases below:

- Use of spring washer ASNA2553 : (see figure 79 case 1 below)

Single spring washer ASNA2553 shall be used when:

connections are in aluminium components (bus bar, lugs ...)

studs diameter is up to 9.52 mm.

- Use of an additional washer: (see figure 79 case 2 below)

For copper lugs only when the contact surface between the nut and the lug is less than 50% of the lug surface, an additional washer shall be used:

spring washer ASNA2553 (preferred solution) or

washer NSA5307-XC

Figure 79 - Use of washer on a terminal block


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6.1.17.6 Wiring of grounding / bonding points

When several lugs are connected on the same point they have to be positioned as defined in figure 80. Electrical bonding / grounding points shall be carried out in accordance with AIPS07-01-006.

The unused grounding points shall be protected by blue varnish.

Figure 80 - Lug on the ground point (VN)

For basic design, maximum of three lugs per terminal is recommended; this number may be extended to four for further modifications.

The screw diameter fixing the terminal lugs to the structure shall be consistent with the wire gauge and in accordance with drawings.

26 gauge wire is not applicable to terminal lugs.

6.1.17.7 Attachment of cables to aircraft

A very wide range of clamps and mounts are used to attach electrical cables to the aircraft. These items to be used are specified on the drawings. Clamps and mounts must not be distorted. Cable mounts ASNE0663 equipped with retainer must in no case be handled before final attachment as this may damage the rack.

6.1.17.8 Clamp installation principle

The clamps (e.g. ABS1339, NSA5516...) must grip the bundle in the conventional manner to prevent fretting. Clamp references are given on drawings. Clamps orientations shall be in accordance with drawings. If a clamp of correct dimension is not available, choose a clamp with a diameter slightly above that of the bundle to be attached and wrap tape ASNA5107 around the bundle to obtain a correct grip of the clamp after installation On P routes comprising large-section three-wire cables where loom diameter does not match the diameter of the clamp, a protection ASNA5107 will be applied. On structural circular metallic or carbon rod, the clamp NSA5516 shall be used with a protection ASNA5107.

6.1.17.8.1 Metallic clamps NSA5516 and AS62200

Select the smallest clamp that can be installed on the bundle without crushing the bundle. When installing the bundle on the aircraft, take care to adapt the diameter of clamp NSA5516 to suit the diameter of the loom so that:

- The loom does not slide when the clamp is tightened.

- No cables are pinched between the legs of the clamp.

- The legs of the clamp are correctly aligned when clamp is tightened.

- The lining does not come out of the mount.

- The two ends of the lining correctly overlap.

Clamps must be completely closed.


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The clamp legs must not be distorted by the gripping force exerted when the clamps are completely closed. Attaching holes must not be elongated.

Figure 81

6.1.17.8.1.1 Additional protection

For all A380 bundles without protection and for the last attachment point of dynamic bundle, the clamps NSA5516 shall be used with an additional protection tape ASNA5107 (see figure 77). Note 1: For clamps NSA5516 - dash numbers 02, 03 and 04 without tabs, wrap around the bundle with tape ASNA5107.

Figure 82

6.1.17.8.1.2 List of different NSA5516 clamps

Aluminum clamps NSA5516 shall be used only in pressurized areas.

Stainless steel clamp NSA5516C shall be used:

- In high mechanical constraints areas (example: junction areas).

- For hinge bundles when bundles are in movement.


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Table 9

Table 10 -Area application

6.1.17.8.2 Clamp NSA5515

For clamps NSA5515 (Polyamide), the silicone tape can be replaced by one or more (3 maximum) protective sleeves NSA5539.

6.1.17.8.3 Clamp ABS1339

Plastic clamp shall be locked by cable tie NSA935401 width 4,8 mm. This cable tie shall be installed with the standard tool to guaranty cable tie tightening. The tool volume shall be took into account for installation process One cable tie NSA935401 can be added the clamp in order to avoid bundle swelling inside the clamp.

Figure 83


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Table 11 -Installation of ABS1339

6.1.17.8.4 Coaxial installation in clamp ABS1339 or NSA5516

6.1.17.8.4.1 For 1 or 2 coaxial cables

- In clamp ABS1339 use tape ASNA5107 for light coaxial (example: ASNE0406 (WD), ASNE0692 (WN), ASNE0690 (WL), EN4604 003 (WZ)) only.

- In clamp NSA5516 use tape ASNA5107 for all coaxial cable.

Figure 84


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6.1.17.8.4.2 For 3 coaxial cables and more on clamp

- In clamp ABS1339 use tape ASNA5107 if one of coaxial cable is a light coaxial cable (example: ASNE0406WD, ASNE0692WN, ASNE0690WL, EN4604-003WZ).

- In clamp NSA5516 use tape ASNA5107 for all coaxial cable.

Figure 85

6.1.17.9 Installation of supports NSA935504

Supports to be attached by screws and nuts, torque value given in AIPS07-01-004. Insertion of cable tie NSA935401-04, always on side opposite attachment and tightening with gun set to standard position (AIPS07-01-003). On bundles of diameter greater than or equal to 35 mm, use cable ties NSA935401 with a minimum width of 7 mm. Silicone tape ASNA5107 or NSA935403 shall be added to protect the periphery of the bundle at location of support (around 2 turns). When open supports are used, example NSA935504 and equivalents, the diameter of the bundles must not exceed the width of the V in the support.

Figure 87


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Light coaxial installation on supports NSA935504 or derivative. Protection shall be:

• A bobbin NSA935510 for ASNE0406WD/ASNE0692WN, EN4604-003WZ (see figure below).

• A sleeve for NSA5539 for ASNE0690WL.

Figure 88

6.1.17.10Installation of support ABS1095

Insulated bracket ABS1095 on structural circular metallic or carbon rod shall be attached by 2 metallic clamps ASNA0033 and with additional protection tape ASNA5107.

Figure 89

6.1.17.11 Installation of the cable brackets and supports

According to AIPS07-05-042 Installation of cable brackets and supports.

6.1.17.11.1 Installation of the cable brackets type ASNE0663

The support shall not be handled before the installation on A/C to avoid damaging it. It shall be installed to be perpendicular to the frame of in to the crossbeam (see figure 90). The anti-rotation plate of the support shall be pushed away without excess (see figure 91).


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Figure 91

6.1.17.12Tying to U support (type NSA935501S / ASNE0435)

When bundles are attached to U-clamps NSA935501S, they must be manufactured such that each bundle or sub bundle does not exceed 35 mm of diameter at the support.


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6.1.17.12.1 ForNSA935501

Figure 92

6.1.17.12.2 ForASNE0435

Each route will be tied on ASNE0435 support by cable tie NSA935401 tie plate NSA935501-P is not used with ASNE0435.

6.1.17.13 Holding harnesses by clipped ramps ABS5147

When the ramp has been clipped into brackets ASNE0664, lacing tape NSA8420 shall first be installed to hold the ramp in each bracket (place the knot on the side), then harnesses shall be installed like on standard V support (with cable ties NSA935401) see figure 93 below. Note: Each ramp ABS5147A4 dia 6,35 mm is defined (length and shape) by a definition drawing.

Each end of this metallic ramp shall be protected by a heat shrinkable cap (e.g :ABS0065).

Figure 93


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6.1.18 Fasteners

The fasteners are defined on the assembly drawing. If the fixing screw is not stated on the assembly drawing. The standard harness and cable bundle supports (V support, clamp etc) should be fastened with NAS1801 type screws. Screw diameter should be 4,16 or 4,82 mm. This is dependent on the mechanical resistance aspect and standard fixation clamp/support. For weight saving reasons the preferred diameter shall be 4,16 mm. The fixing screw, after tightening, shall protrude one and a half thread minimum.

6.1.19 Routing of monitoring cables on circuit breakers

Monitoring cables between adjacent circuit breakers will be held face to face at each unit (one cable on either side of the circuit breaker concerned) and the two cables of each circuit breaker will be held to their own power cables.

The circuit breaker monitoring circuit cables must in no case be in contact with metal parts (cable connecting items on circuit breaker or electrical distribution shunts).

Figure 94

6.1.20 Data bus cable

6.1.20.1 Quad cable

Quad cable can be installed inside the electrical harness like other cables but with a minimum of 250 mm free at the extremities to avoid straining the cable when twisting during connection. The installation of data bus cable procedure shall be in accordance with the following procedures (with respect to the length of the cables):

1) Connect an extremity of the cable.

2) Position the cable on the bundle.

3) Connect the other extremity of the cable. Significant twisting of the contact may be necessary but only be done with a slack cable in the last 250 mm minimum. The following procedure shall be applied to reduce the amount of twisting and stress on the contact: The required twist on the contact in order to line up the polarisation key and the polarisation key of the connector cavity, are approximately 30° to the right. Bend the cable for moving the contact at the back of connector at approximately 50 mm. Apply the twist previously identified. Little effort is required for this action due to the bend in the cable. At the same time: With one hand holding the contact: push the contact towards the receptacle in order to straighten the cable (do not fully connect at this stage). With the


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other hand takes the cable between the thumb and index fingers firmly, for apply the twist along the last 250 mm of cable. The loop should disappear and the twisting stress is spread over the last 250 mm.

4) Add cable ties:

-Twisting stress shall be avoided near the extremities.

- Bus cable extremities shall be tied after connecting.

- The minimum quad cable length is 400 mm.

6.1.20.2 Cable WX

Special attention shall be taken when installing, in order to avoid any cable crushing. WX cable shall be preferably integrated inside the bundle. The bundle shall be attached like usual bundle. When integration inside the bundle is not possible (e.g. repair) WX cable shall be attached outside the bundle with lacing tape NSA8420 on the bundle and tape ASNA5107 installed at each attachment point except for ABS1339 clamp. (see figure 95)

Figure 95

When bundle is constituted by WX cable WX cable type bundle shall be protected with tape ASNA5107 when attached: (according to figure 96)

-with clamp NSA5516

- on V support NSA935504 type

- on ramp

Figure 96

Note: WX cable bundle could also be attached on ramp with lacing tape NSA8420 without tape ASNA5107 protection


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6.1.21 Bundles in pressure seals

During the pressure seal assembly onto the aircraft, the blanket insulation shall be secured to avoid blanket damage. Exceptionally the assembly of pressure seal ABS1378 can be inverted (part not pressurized in pressurized zone) according to the drawing. Refer to AIPS07-05-007 Installation of seal bundle NSA934710 and AIPS07-05-046 Installation of pressure seals ABS1378 and AIPS07-05-062 for ABS1571.

6.1.21.1 Protection as near as possible to the pressure seal

This applies on all type of pressure seal, when system requirements specify a protection (e.g.: 1MG, thrust reverse 3rd line of defense). This protection is necessarily interrupted when passing through the pressure seal. The protection (conduit ABS0887/NSA935805) shall be terminated as close as possible (5 mm maximum) to the pressure seal, the contact with pressure seal shall be avoided.

Note 1: In case of wiring with several convoluted conduits a distance pressure seal / conduits of 10 mm maximum is acceptable.

Figure 97

6.1.21.2 Specificity of pressure seals ABS1378 / ABS1571

See AIPS07-05-046 and AIPS07-05-062.

Conduits penetrate into the pressure seal body of 10 mm. These conduits shall be held with ABS5334 self-adhering silicone tape.

6.1.22 Installation of raceways and cables

6.1.22.1 Installation of raceways for A318/A319/A320/A321

Install the raceways to the relevant engineering process ensuring that the raceways are correctly aligned with no contact to structure and that the cables are not able to chafe against the Raceway Fins.


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Figure 98

6.1.22.1.1 Installation of cables for A318/A319/A320/A321.

- Electrical bonding of raceways shall be carried out in accordance with AIPS07-01-006 Electrical bonding. The protective coating must not be removed. Only probe the Raceway foot during the bonding check.

- All bonding joints shall be over seal in accordance with AIPS05-05-002. Bolt threads must be dipped prior to assy where rear over coating is impossible.

- During the installation of the cable harness, great care must be taken to prevent any damage to the cables. All potentially dangerous structural items must be covered to prevent damage of the cables prior to the harness Installation.

- Ensure harpoons are secured in raceway.

Figure 99

- Ensure cables are equalled out either side of the harpoon ties and that retainers clamp the cables securely.

- Conduit ferrules (end caps) to be adjacent to the retainers and in line with Raceway route at the position of the breakout.

- Ensure the breakout tags are tight inside each raceway channel.


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Figure 100

6.1.22.1.2 Installation of cables for A330/A340

- Bonding connections are to be made in according to engineering doc, manufacturing doc and AIPS07-01-006. - Route the cables in the appropriate raceways channel (per engineering doc, manufacturing doc). Make sure that

the filling factor of max. 65% is not exceeded (see figure 101).

Figure 101 -Installation of raceways and cables

- Ensure that all cable harnesses lie in the raceway channels without being tensioned or twisted. Cable shall not lie in loops.

- In accordance with the engineering document or manufacturing documents (observe the specified distances) press the retainer bridges by hand onto the raceways until they are engaged. The retainer bridges are provided with a "nose" (see figure 102), which must point upwards after installation.


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Figure 102 - Raceway - Cross sectional view

- When all bridges have been installed, the pressure pads are to be pressed into the retainer bridges so that the cables are properly fixed in the raceway channel. A little distance between the pressure pads and cables is allowed.

Furthermore the following applies:

- The pressure pads must engage in the serration of the bridges and must be located in the respective positions provided for them.

- The insulation of the cables must not be damaged or deformed.

- The cables shall, as far as possible, not lie between pressure pad and raceway channel wall.

- If a raceway channel is in accordance with the engineering documents with no cable inside, do not install the pressure pads into this channel.

- Cables shall not lie in loops.

- Unused raceway channels need not be fitted with pressure pads.

- For junctions of cable harnesses out of the raceways, the cables must not be routed across the web edges. The strain relief shall guide centrically from the lighting protection tubes. The protective conduit shall protrude approx 75 mm on both sides of the lighting protection tube (see figure 101).

- For repairs, the retainer bridge plus pressure pads shall be removed by hand or with a suitable non-metallic tool (e.g. Plastic screwdriver). After repair, use always new retainer bridges and pressure pads.

Note: When working on raceways, take care not to damage the surface protection.

6.1.22.1.3 Use of the harpoon tie removal tool.

The tool P/N 99D57004005000 is designed to compress the barbs on the harpoon tie (p/n ABS0127T) and thus allow it, the fairlead and cable retainer to be pulled out of the raceway in one operation according to the figure 103 below.

The method of use is as follows:

a. Place tool under the raceway and locate the hole in the end of the tool over the barbs of the tie to be removed.

b. Rock the tool downwards in order to compress the tie barbs and pull the tie, fairlead and cable retainer out of the raceway channel.

c. Carry out a visual check of the wiring to ensure that there is no damage. Any damaged wiring must be replaced or repaired in accordance with the ESPM.


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Figure 103

6.1.22.2 Miscellaneous

6.1.22.2.1 Protection against damage

Protection from possible damage between routes shall be achieved by either a metallic barrier, or a specific device designed for this purpose (ABS0596-003).

This is applicable to raceway gaps greater than 3 mm on A320 (MSN 002 to MSN 339 with CF cable) only, and gaps greater than 6 mm for all other aircraft with DK/DM/DR cable types

The raceways shall be aligned for installation. Alignment is judged by eye with the aid of a steel rule, which is placed across the webs of the raceways. The suitable template orientates the relative position of the raceway channels. A height position difference of 0,5 mm is allowed if the height position of the raceways one to another is > 0,5 mm, washer per AN960D10 or D10L shall be installed.

Figure 104 - Installation of raceway - Top view


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If it is not possible to align the raceways or if the gap between two raceways is greater than 3 mm for CF cables or 6 mm for DK/DM/DR cables, the bundle shall be protected with heat shrinkable sleeve (a length about 80 mm) as per NSA937210 installed over the cables and into the channels to prevent chafing.

CAUTION do not shrink the sleeve, the shrinking will damage the cables.

6.1.22.2.2 Cable loom support at raceway / conduit breakouts

Breakouts from raceways, whether or not in conduits, are to be supported such that cables do not come in contact with structure or other metallic surfaces, e.g. equipment, due to mechanical movement, slackening, acceleration or vibration. The minimum distance between a cable bundle and structure or equipment is 10 mm.

Segregation distance between bundles must be ensured for the life of the aircraft.

6.1.22.2.3 F.O.D (Foreign object damage)

Prior to drilling or modifying structure in the vicinity of raceway and cables, the operator is required to pro-tect the cables inside and outside of the raceway and conduit assemblies by covering then with a suit-able protective covering. On completion, ensure all debris (metallic and non-metallic) is removed and the installation inspected for correctness.

6.1.23 Positioning of harnesses (datum marker)

The datum marker is used to position the harness with regard to aircraft structure. The position harness drawing of datum marker is defined by design office. Refer to AIPS07-06-002 Identification and markings of electrical installations.

6.1.24 Identification of rack ventilation holes

For identification of unblanked ventilation holes refer to AIPS07-06-002 Identification and markings of elec-trical installations.

6.1.25 Rules for applying anticorrosion products to electrical installation.

When applying anticorrosion products (DINITROL, etc.) to electrical installations:

-All unconnected electrical connection items must be covered:

- Connectors, all types, lugs and contacts "pending connection": - Relay mount without relay, - Electrical bonding points on structure, - Terminal blocks (VT),

- Unsealed connected electrical items must be covered:

- Circular or rectangular connectors not equipped with sealing plugs, - Relay mounts with relays not equipped with sealing plugs, - Connecting modules (VT) not equipped with sealing plugs, - Ground modules (VG), - Wired terminal blocks (VT) (lugs installed), - Coaxial connectors type TNC or BNC,

- The drain hole or holes of convoluted conduits and equipped shielded conduits must not be blanked.

- Application inside racks (VU) is not authorised.

- Other electrical items (shielded conduit fittings, cables, connected sealed connectors, ground points made, etc.), does not need to be covered when applying anticorrosion products.


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6.1.26 Over braided bundles

Over braiding is defined by ABS1353-003 and AIPS07-01-012 Braided electrical wire bundle, AIPS07-01-013 Shielded over braiding of electrical harnesses and AIPS07-01-015 Modification and repair of harness protection components

Over braided bundles can be attached together between two attachment points with cable ties NSA935401 see figure below in accordance with drawing.

Figure 105

The pitch P between two cable ties shall be included between 70 and 100 mm.

6.2 Quality instruction

The operator, by performing self-checks and the quality department, by sampling, shall check that the instructions of this AIPS are observed with particular attention to:

- The protection of the end fittings, - Route segregation, - Tightening torques, - Locking of connectors, - Safe tying, - Mechanical protection of bundles.

6.2.1 General points to be checked

Minimum distances observed and chafing protection provided. Segregation between not compatible electrical routes in particular on interface connector plate are observed and respected. Bend radii of cables are not lower than the minimum specified values. Cable sag is not too great and cables do not cause tension at the connecting parts. Sufficient length is available at the cable ends for replacement of end parts. Drip loops are provided at the necessary locations. Conduits are provided with drain holes at the lowest (deepest) points. The harness diameters allowable for the supports are not exceeded. Cable clamps are installed properly (correct position, no wires squeezed in). Cable harnesses have been tied with the approved devices (e.g. cables ties). In the case of multiple cable harnesses, the head of the cable tie points outwards. If cables are installed in conduits or tubes, draw wires are inserted in accordance with the instructions rules. Connectors have been wire-locked or secured with glue in accordance with PQ10053-056-00, as specified in the instructions rules.


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Bonding connections have been produced in the proper manner as per drawing and AIPS07-01-006. In particular, the position of cable terminals at multiple connectors must be in accordance with the requirements of this instruction. The location of receptacles and terminal blocks is in compliance with the requirements of this instruction.

Cable harnesses are identified correctly. Adhesive labels have been attached to the structure for connectors. If required, the cable harnesses are provided with protective conduits.

6.2.2 Point to be checked for raceways

The raceways are aligned (judgement by eye with the aid of a steel rule, and the specified distances are observed. The cable harnesses are routed according to engineering document and the filling factor (max. 65%). for the individual raceway channels has not been exceeded. The insulation of the cables may not be damaged or deformed and the cable harnesses must lie in the raceway channels without being tensioned or twisted. The retainer bridges are properly placed ("nose" pointing upwards) and the specified distances are observed. The pressure pads in the retainer bridges are engaged and fitted in the correct positions. Each required position is provided with a pressure pad. Junctions from the raceways are in accordance with engineering document and do not run across the web edges of the raceways. No foreign objects (e.g. cut off residues of protruding pressure pads) may remain in the raceways. Visual inspection (100%) on every wing. Proper performance is to be documented on the job card. Note: The inspection criteria of clause 6.1.1 also apply to raceways, as applicable.

7 Health and safety

This specification does not necessarily detail all the precautions necessary to meet the requirements of health and safety.

It is the responsibility of the user of this specification to consult and establish appropriate health and safety precautions and the method should be operated only by trained personnel.

8 Appendix


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Annex A (INFORMATIVE)

A.1 Segregation between routes

Table A.1 - For A300/A310


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Annex A (continued)

(INFORMATIVE)

Table A.2 - For A318/A319/A320/A330/A340


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Annex A (continued)

(INFORMATIVE)

Table A.3 - For A340-500/600


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Annex A (continued) (INFORMATIVE)

Table A.4-For A380


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Annex A (concluded) (INFORMATIVE)

Table A.5-For A400M

As a general rule, two routes of the same category (e.g.: 1M and 2M) which contain duplicated systems should be as far apart as possible: Main systems (system 1 and system 2) shall be installed on opposite sides of the fuselage

Clearance between Civil and Mission routes shall be ensured.


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Annex B

(INFORMATIVE)

Connector locking check

B.1 Circular connectors

Table B.1 - Bayonet locking (visualisation by the three studs)

Table B.2 - Screw locking (various items can be secured together with lock wire)

Table B.3 - Screw locking , clicker nut or prevalence to mating


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Annex B (concluded)

(INFORMATIVE) Connector locking check

B.2 Rectangular connectors

Table B.4

Table B.5 - Coaxial connectors


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Annex C

(INFORMATIVE)

C.1 Connector NAS1599 and derivatives (screw-locking)

A' on S: lockwire B on A' or S: lockwire A' on A : adhesive plus a red paint in all zones C on B or A : nothing, adhesive in vibration zone plus a red paint mark, D on B or A : nothing, adhesive in vibration zone plus a red paint mark, E on B or A : nothing, adhesive in vibration zone plus a red paint mark. Note 1: A' or B can be secured by lockwire to another A' or B

Figure C.1


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Annex C (continued)

(INFORMATIVE)

C.2 Connectors NSA1599 and derivatives (bayonet-locking)

A' on S: lockwire B on A: nothing A' on A : adhesive plus a red paint in all zones C on B or A : nothing, adhesive in vibration zone plus a red paint mark, D on B or A : nothing, adhesive in vibration zone plus a red paint mark, E on B or A : nothing, adhesive in vibration zone plus a red paint mark.

Note 1: A' can be secured by lockwire to A' of adjacent connector

Figure C.2


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Annex C (continued) (INFORMATIVE)

C.3 Pressure seal ASNE0073

A' on S: lockwire A' on A : nothing, adhesive in vibration zone plus a red paint mark, C on A : nothing, adhesive in vibration zone plus a red paint mark, D on A : nothing, adhesive in vibration zone plus a red paint mark, E on A : nothing, adhesive in vibration zone plus a red paint mark,

Note 1: A' can be secured by lockwire to another A'

Figure C.3


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Annex C (continued)

(INFORMATIVE)

C.4 Connector ASNE0684/ASNE0724

B on A: nothing. C on B or A: nothing, adhesive in vibration zone plus a red paint mark. D on B or A: nothing, adhesive in vibration zone plus a red paint mark.

Figure C.4


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Annex C (continued) (INFORMATIVE)

C.5 Screw connectors type MIL-C-83723 (Screw locking)

B on A o S: nothing. Lockwire in vibration zone.

C on B or A: nothing, adhesive in vibration zone plus a red paint mark.

D on B or A: nothing, adhesive in vibration zone plus a red paint mark plus lockwire on screws of D.

Note 1: B can be secured by lockwire to another adjacent connector B.

Figure C.5


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Annex C (continued)

(INFORMATIVE)

C.6 Connector EN2997

B on A or S: nothing. Lockwire in vibration zone

C on B or A: nothing, adhesive in vibration zone plus a red paint mark.

D on B or A: nothing, adhesive in vibration zone plus a red paint mark. Plus lockwire on screws of D

Note 1: B can be secured by lockwire to another adjacent connector B.

Figure C.6


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Annex C (concluded)

(INFORMATIVE)

C.7 Connectors MIL-C-83723/53 '

D on A or S: If the connector has no integrated Snap-On nut use lockwire in engine, Pylon, APU, landing gear, and flight control zones.

E on B or A or D: Lockwire (ring + screw) F on A or D: Lockwire (ring + screw) C on D or A: : nothing, adhesive in vibration zone plus a red paint mark.

Figure C.7


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Annex D

(INFORMATIVE)

Table D.1 - Distance between electrical harnesses and others systems to be applied from A380


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Annex E

(INFORMATIVE)

E.1 Distances required between electrical bundle and metallic / non-conductive composite surfaces:

• 25 mm from a structure or an equipment located below (see figure E.1). • 20 mm from structure or equipment located at the side or above (see figure E.1).

Note 1: When these distances cannot be observed, a support shall be provided in line with the obstacle, so the distances it and cables are constant and at least equal to 10 mm (see figure E.2)

Note 2: Distances can be reduced to 0mm if there is no relative movement of a protected bundle with the structure (Example: protection by conduit ABS0887).

Figure E.1 Figure E.2

E.2 Distances required between electrical bundle and conductive composite surfaces.

• 50 mm for G routes, 25 mm for P routes 20mm and for the other routes

Note: These distances shall be respected when the bundle, the conductive composite surface or both are in movement the distance shall be respected in the worst position.

- For G routes an additional protection is required.

E.3 Distances between electrical bundle and fuel tank boundaries or any structure parts in fuel vapour areas

• 50 mm for all routes including G route • 25 mm for Q routes


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RECORD OF REVISIONS SHEET

Airbus

Engineering

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