Guideline

A 380 Electrics Plateau

L 928
Issue: 02 of 23.10.2006 Reference: L9208WD0603196 Page: 1 of 16

GUIDELINE FOR L928 CHECKING THROUGH ACCELERATED HANDOVER PROCESS

As of October 23, 2006 The following are the guidelines to follow when checking related L928 deliveries as part of the Accelerated Handover Process. These are valid for S13 and S18, unless differences are explicitly specified in the text. Base for the check is the checklist specified in AA-TRQE-05.

Part 1: Clash with structure

point 9(g) of this Guideline

Related to points D8/D9 in the Checklist, and

Part 1a) Minimum distance of 25mm:

As per TDD requirements, the minimum distance between the bundle and structure must be 25mm, as shown below. The picture below, depicts the position of BPPs of the bundle with respect to structure, in an ideal world.

However, in reality, the bundle will sit at the lowest point of the clip (as shown below) and not necessarily at the designated BPPs and thus in this case, the distance between the bundle and the structure may become less than 25mm, in which case now, the distance between the new position of the bundle and the structure must be measured and flagged as Chafing point when it is less than 25mm.

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Part 1b) Straight vs. Curved bundle:

In the case of the bundle running in a straight line along primary structures, as long as the TDD required distance of at least 25mm (between bundle and structure) is met, there is no need to flag any problems related to this (see below picture).

However, if the bundle is making a turn along the structure (as below top view), even though the distance between the bundle and the structure (at the turning point) may be at least 25mm or more (as shown in Picture A below), one must still flag this situation for chafing point, since during flight, some force will be exerted on the VB and the distance between the VB and the structure may decrease and chafing may then occur. The ultimate solution to this chafing point issue, would be to install the clip(s) closer to the turning corner to fix the bundle within the 25mm position, as per design (as shown in Picture B below).

Picture A: clip far from corner

Picture B: clip close to the corner

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Part 2: Clips in correct container Related to point C4 in the Checklist

In the case where there are 2 clips installed at the same hole (one over the other through a common screw), both clips must belong to the same container! In the cases where the two clips belong to different containers, the lower priority clip must be moved to the container with higher priority. (note on priority: M3<M2<ST). This has to do with installation issues, since the clips are installed by priority. The higher priority clips get installed first. Example: If there is an M2 clip positioned over an M3 (or vise-versa), the M3 clip must ultimately be cut out of its M3 container and posted into the M2 container, so that both clips would belong to the same container. Important Note: Do not cut and paste the clip during the check, only report it as an open point.

Part 3: VN positioning
Guideline

Related to point D11 in the Checklist and 9(g) of this

Part 3a) Report incorrectly installed VNs

Generally, in an L928 check, if VN is not connected to its relative fixed bracket, do report the problem as an open issue. The below, is the further details check that must be completed for any VNs of a bundle in the container being checked: Part 3b) Same VNs in the same position

Different VNs (with different voltage and part numbers) cannot be positioned through the same bonding point. For example, the below situation is only allowed when all the three VNs are the same.

Part 3c) Spacing between VNs

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/AC and /DC VNs can be connected to the same bracket as the one /B VN is connected to, provided there is separation between them. The below situation is perfectly acceptable.

However, if the above scenario is not possible, then the alternative would be to position /AC and /B VNs on the same bracket but with /DC VN placed in between, since /AC and /B cannot be connected next to each other, below is the depicts option.

*** For complete guidelines regarding VNs, refer to SIPD 92A001L, pages 149-150.

Part 4: Installing clips on UD-CB (CFK)

Checklist

Related to point D2 in the

This part is applicable to all CFK cross beams. The following, lists where the CFKs exist in the upper deck. Sec 18: All UD-CB are CFK Sec 13: CB 27 to 37 are CFK Part 4a) Use boeing columns on UD-CBs to install clips

When installing clips on upper deck cross beams (UD-CB), because they are carbon fiber cross beams (CFK), a clip and/or a spacer cannot be directly installed on the crossbeams,
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since they will cause oxidization of the material. Instead, a boeing column must be used directly on the CB to support every clip. Examples of two common boeing columns are shown below, the right one (Abs1424-series) can be mounted on the flange of the cross beam to support a clip, whereas the one to the left (ABS1423-series) is mounted on the web of the beam.

Part 4b) Which aircrafts to flag the problem

This problem must be flagged as a open issue for MSN23 and above. In aircrafts up to MSN23, this situation, if found, should not be flagged.

Part 5: Combi Brackets

Related to point D2 in the Checklist

Part 5a) Differences between E0661-21 and E0661-23 & usage on structure:

Clips E0661 (namely known as Combi Brackets) exist in different types, including E0661-21, E0661-22 and E0660-23. Below picture, depicts a typical combi bracket:assembly

Combi-nut

In general Combination Brackets can only be used on Primary metallic structure, single thickness parts where a tooling hole exists. They must not be used on Secondary structure system mounting brackets, also Combination Brackets are not allowed in riveted joint areas. The usage of any of combination brackets is only allowed when they fit to the structure with adequate clearance for installation and removal.

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See ASN-E0661 Table 1 for possible combination of clips

Maximum bundle diameter = 21mm Part 5b) Clips allowed on X-Struts:

Maximum bundle diameter = 20mm

Section 13.
The only types of Combi Bracket that are allowed for installation on X-struts on the upper deck utilizing the tooling holes are combi-bracket assemblies E0661-01 and E0661-02, providing the bundle diameter does not exceed 10mm, with a maximum mass 0,5kg per X strut.

Section 18.
The only types of Combi Bracket that are allowed for installation on X-struts upper deck from C74 till C90, utilizing the tooling holes are combi-bracket assemblies E0661-01 and E066102, providing the bundle diameter does not exceed 15mm, with a maximum mass 1,0kg per X strut. Examples of installation on X-struts

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WRONG

CORRECT

Part 5c) Clips allowed on Pull Struts between crossbeams:

The only type of Combi Bracket allowed for installation on Pull Struts between crossbeams on the main deck utilizing the tooling holes is combi-bracket assembly E0661-01, providing the bundle diameter does not exceed 15mm, with a maximum mass 0,5kg per X strut.

No other brackets are allowed.

Part 6: Distance between two branches

Guideline

Related to point 9(g) of this

When doing L928 checks, checker must take a note of not only the segregation between bundles (checkpoint D7), but also the distance between bundle branches. Sometimes the same bundle drifts off into two branches at a point. According to SIDP, a distance of at least 150 mm must be maintained between the two branches. Please see below picture for clarity:

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Part 7: Modified areas in L928

General Point

There is no specific outline for where the modified and non-modified areas of L928s are and therefore, when doing an L928 check, most relative problems must be flagged as open points and not corrected - only formal changes that do not affect L929s and do not change BOM (Bill of Materials) must be corrected.

Part 8: Terminal blocks (VT) Installation

Guideline Part 8a) General orientation of VT:

Related to point 9(g) of this

All terminal blocks (or VTs) in the aircraft must be correctly installed and oriented with respect to their location in the aircraft, according to the SIDP. Below, summarizes the VT orientation check:
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Each terminal block must be oriented and positioned in such a way, that if you were standing in the aircraft looking at that front face of the terminal located anywhere in the aircraft, you would always see from left to right: one empty space, first fixation clamp, first module, second module (and all other consecutive modules), the second fixation plate, and finally the remaining empty spaces, as shown below:

Part 8b) Other type of VT (with screwed studs):

In addition to the VT shown in part (a), the below VT is also often used. Similar rules apply to this type of VT also, where in this case, the module with nut must be positioned at the first slot (far left) followed by remaining screwed studs.

Part 8c) Six possible faces that the VT can be located on:

There are six faces to every cube, and likewise, inside the volume of the aircraft, there exists six different possible faces that the VT can be oriented. Picture below depicts the position and orientation of VTs with respect to a persons position in the aircraft while looking in flight direction.

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Part 8d) Examples from D-Vise: Below are all some actual D-Vise examples of VT orientation for different VT locations: Position 1 Example: Located on the right hand side shell In the below picture (right), as the model avian clearly indicates the In Flight direction (View), we can first conclude that the VT is located in the right hand side while we are looking FWD, therefore, we then must confirm that the VT sustains position 1 in the above diagram, part 6(b). Which it does, and thus it is correctly oriented. The correct orientation matches the conditions of diagram in part 7(a), such that when looking at VT from left to right, one will first see one empty space ( orange), then the first fixation clamp (blue), next the three modules (green, purple and yellow), next the second fixation plate (blue), and finally the remaining empty spaces (orange). Position 2 Example: Located on the left hand side shell In the below picture (left), once again, the avian is clearly in the FWD In Flight Direction and thus, we can say that the VT is located in the left hand side of the plane in Flight Direction and therefore, the orientation of this VT must match to that of position 2 in the diagram of part 6(b). Looking at position 2 of picture 6(b), one can confirm that from left to right, there is first one empty position (orange), then next there is the first fixation clamp ( blue), next the one and only module (purple), followed by the second fixation clamp (blue) and finally the remaining empty spaces (orange). This is exactly the case with this D-vice example, and thus, one can conclude that it is oriented correctly.

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Left hand side picture . Part

Right hand side picture

9: General DOs and DONTs:

9a) DO load D-vise fully General Point When loading D-vise, it is vitally important to load all ATA chapters as per latest D-vise manual. This will ensure that there are no missing bundles, structures and systems etc and thus will help in avoiding the creation of invalid open points, that would not have been flagged if D-vise was loaded properly. 9b) DO check the whole container General Check Normally, when doing L928 checks, one must check only the related zone of the container, however, in the rare cases where the container has a few clips outside of its designated zone, it is required that check gets done on those few clips as well, even though they are housed outside of the zone. It is important to check the whole container and not neglect clips outside of the zone. 9c) DO flag outside of the zone clips Related to points C1 and/or C4 in the Checklist With reference to the above point, checker must flag the fact that there exist clips outside of the container zone and must flag this issue as an open point. 9d) DO report missing clips from other containers in your zone Related to point C5 in the Checklist When doing L928 check for a certain container, if you come across missing clips in your zone and the bundles in your container, DO report the problem. If that missing clip belongs to your L928 container, then correct the problem. If the missing clip belongs to the priority containers relating to your container or belonging to another container in the same zone, then flag the problem as an open point. 9e) DO flag missing support for Stirrups Related to point D2 in the Checklist If during the L928 check, a Stirup with no bracket support is found, DO flag the problem as an open issue with missing structure support. One might neglect this problem in the L928 check since this can also be a L929 problem/check point for the relative VT rail missing bracket support. This is a rare case in which the problem gets flagged in both L928 & L929.

9f) Do verify the BM validity for Aircrafts Related to points F1 and/or F2 in the Checklist When doing an L928 check, DO confirm that all the listed BMs and changes for that specific L928 delivery have been fully incorporated and if not, report it as open issue.

9g) DO flag L929 related issues in the L928 check General Check: Important When doing L928 checks, please DO flag relative L929 issues and report problems as open points. This will help with installation process. The L929 issues that must be reported in the L928 check are problems related to VT, VC and chafing points (see also parts 1, 3, 6 and 8
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and points 9h and 9i of this guideline). Other exclusive L929 issues such as wrong diameter or wrong bend radius or VB being in wrong layer, etc should not be flagged. 9h) DO flag loose connectors positioned at the (0,0,0) axis Related to point 9(g) of this Guideline

When checking L928 deliveries, there may exist many cases in which the connector of any given bundle is positioned at the (0,0,0) axis of section 13 or section 18 (this is the case when the same bundle from adjacent sections are to be entered and routed through our section). These connectors are interface connectors and they are placed at the zero axis of that section on purpose. However, the checker must report this as an open point (that the connector is located at the (0,0,0) axis), since installation Drawings cannot be created because the installer does not know the exact and actual location of that connector. 9i) DO flag Bundle ends with no FIN Related to point 9(g) of this Guideline

When checking L928 deliveries, DO flag cases where the bundle looks as thought its been cut and not connected to any FIN (such as either VN, VT or VC). This case is possible and done on purpose because the bundle is continuing into an adjacent section. However, as with the above point, this will create problems with installation DRW and installation process.

9j) DO create clear pictures General Point When creating open point pictures (or any other pictures), it is important to depict the picture as clearly as possible and representing the problem in best possible way. This will help others to visualize the problem (Also, a clear description of the problem is required). The below picture should be used as a guide to help choose the necessary angels when taking camera shots at different locations of the aircraft. As a rule of thumb, make sure that the avian is always on a horizontal and level position when you are taking camera shuts or, take the picture as if the worker/technician is looking at the problem in the aircraft with his eyes level with the problem location.

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9k) DO NOT flag duplicate FIXED brackets - Related to point D9 in the Checklist When doing L928 checks, duplicated fixed brackets (exactly at the same position) should NOT be flagged. However, if there are duplicated fixed brackets that are not exactly at the same position, this can be flagged during the L928 check, since it is considered to be a secondary structure clash. 9l) DO NOT include information slides General Point When doing L928 checks, DO NOT include information pictures (such as why VB is designed the way it is, or bad or good design, etc) with the Open Points. They are not necessary. However, if there is an issue that you feel must be highlighted (but is not an open issue), bring it up in the next meeting to get suggestions and/or instructions as how to over come the problem. 9m) DO NOT flag false problems when bundle is in fact going through the clip Related to point C2 in the Checklist

For every clip, there is an imaginary cylinder in which the bundle must pass though. DO NOT flag problems as long as the bundle passes through this cylinder, and not necessarily through the center of it. The three examples below are all correct and must NOT be flagged.

CORRECT
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However, in the cases where the bundle is completely out of this cylinder, the problem must be flagged/corrected. Below pictures depicts this situation:

WRONG

Some additional points on using clips:

Use rivet clip ASNE0675 on deu plates only. Do not use this type of clip on cross beams or other structures.

Please note ASNE0675 technical specification has recently been updated to issue C (Oct 06) and includes a new variant of the above clip. The new clip has a larger attachment hole and can be used with a scew fixing. The new clip has not yet been approved for the A380 program Clip not valid for A380. Please do not use.

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Do not use the clips in the red box, instead replace with clips listed on the right.

If more than two coaxial bundles (T, U or V) are routed together, clips ABS1339 or ASNA5107 must be used to support them.

Some additional points Bundle routing:

Segregation between essential and non-essential routes:

For bundle segregation purposes, essential and non-essential routes cannot be routed together. For example, routes 1M and 3M cannot be together and routes 2M and 4M cannot be routed together. In cases where these route types must be routed together, protection sleeve or conduits must be used.

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Segregation requirements between all route types:

Below is the segregation matrix used to ensure the necessary distance between route types. As an example, the necessary distance between any given P route and an M route must be 100 mm.

Metallic spacers must be used on clips supporting P and G routes.

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