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REQUIREMENTS
FOR CABIN INTERIOR
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
No.
9200M1F0380 00
Aircraft
A380 PAX/F
System
ELECTRICAL INSTALLATION
ATA/Sub ATA
Number
ATA 92 - 00
Equip.
ELECTRICAL EQUIPMENT
FOR CABIN INTERIOR
Airworthiness
Criticality
Category
Development
Assurance
Level
N/A
Airbus 2004 All rights reserved. This document contains Airbus proprietary information and trade secrets. It shall at all times remain
the property of Airbus; no intellectual property right or licence is granted by Airbus in connection with any information contained in it. It is
supplied on the express condition that said information is treated as confidential, shall not be used for any purpose other than that for
which it is supplied, shall not be disclosed in whole or in part, to third parties other than the Airbus Entities, their subcontractors and suppliers (to the extent of their involvement in Airbus projects), without Airbuss prior written consent.
Page 2/144
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Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
RECORD OF REVISIONS
ISSUE
DATE
EFFECT ON
PAGE
PARA
FIGURE
TABLE
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
20.11.03
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
May 04
ALL
17
18
20
20
21
24
25
26
27
42
45
46
48
49
57
62
63
65
67
77
88
96
112
113
114
116
118
127
130
141
143
ALL
Table 5
Table 8
Table 9
Figure 2
2.1.3.3.3
Table 11
2.1.4.1
2.1.4.2
2.2
Figure 21
Figure 24
2.4.3
2.4.7
2.4.7.2
2.4.14.5
Table 19
2.4.17.1.1
2.4.17.1.2
2.4.17.1.4
Figure 48
2.6.4
2.7.3
Figure 79
2.10.1
2.10.2.1.1
2.10.2.1.2
2.10.6
2.11.7
2.11.10
Table 31
Table 32
FIRST ISSUE
System identification corrected
Table completed
Table simplified
Figure corrected
Text revised
Optical Routes added, Text revised
Chapter added
Chapter Crossing of bundles added
Chapter revised
Figure added
Figure completed
Requirement 899-1 added
Hazardous area defined
Replacement of plastic with non-metallic
Replacement of 5 times with 6 times
ABS1224 added
ABS1339 added, new standard clamp
No standard clamp any longer
ABS1224 added
Separator ABS1144 added
Description of ABS0887 added
Floating insert ABS1006 added
Figure revised
Text revised
Text an figures revised
Ess/ Non-Ess
ASNE number corrected / Requir. revised
Replacement of 4m with 1m
Requirement 649-1 deleted
Documents added
Documents added
Page 3/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
TABLE OF CONTENTS
1
GENERAL ...................................................................................................11
1.1
1.2
1.2.1
TERMS, DEFINITIONS................................................................................................................................. 12
ABBREVIATIONS ........................................................................................................................................ 14
2.1
WIRING SEGREGATION................................................................................................16
2.1.1
ROUTE DESIGNATION................................................................................................................................ 19
2.1.3
2.1.3.1 GENERAL............................................................................................................................................... 19
2.1.3.2 SEGREGATION OF SYSTEM 1 AND SYSTEM 2 ROUTES ................................................................. 19
2.1.3.3 SEGREGATION OF ESSENTIAL AND NON-ESSENTIAL ROUTES.................................................... 20
2.1.3.3.1 MIXING OF ESSENTIAL/NON-ESSENTIAL HARNESSES ............................................................ 20
2.1.3.3.2 GENERAL INSTALLATION PRINCIPLE ......................................................................................... 20
2.1.3.3.3 PARTICULAR CASES ..................................................................................................................... 21
2.1.3.3.4 ESSENTIAL/NON ESSENTIAL CABLE SUPPORT ........................................................................ 21
2.1.3.4 SEGREGATION OF ROUTE CATEGORIE M AND S ........................................................................... 22
2.1.3.5 SEGREGATION WITHIN CONNECTOR AND TERMINAL MODULE ................................................... 22
2.1.3.5.1 OPTICAL CONNECTOR.................................................................................................................. 22
2.1.3.6 SEGREGATION OF GROUNDING (CURRENT RETURN) AND BONDING ........................................ 23
2.1.4
2.2
2.3
POWER SUPPLY............................................................................................................27
CABLE SELECTION.......................................................................................................28
2.3.1
SELECTION OF CABLE-TYPE.................................................................................................................... 28
2.3.2
2.3.3
2.3.4
2.4
2.4.1
DISTANCES.................................................................................................................................................. 35
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2.4.4
JUNCTIONS.................................................................................................................................................. 46
2.4.5
WIRING JOINING ON THE EQUIPMENT REMOVABLE FROM THE FORWARD FACE ......................... 47
2.4.6
2.4.7
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Date: 01.07.2004
2.5
2.5.1
2.5.2
TYING ........................................................................................................................................................... 82
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Issue 02
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Issue: 02
Date: 01.07.2004
2.6
2.6.1
2.6.2
2.6.6
2.6.7
2.6.8
2.7
2.7.1
2.7.2
2.7.3
2.7.4
2.7.5
2.7.6
2.7.7
2.7.8
2.7.9
2.8
2.8.1
2.8.2
2.8.3
2.8.4
CONNECTIONS.......................................................................................................................................... 100
2.8.5
2.8.6
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Issue 02
2.8.7
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.8.9
2.9
2.9.1
MODULE POSITIONING SEQUENCE ON TERMINAL RAIL (E.G.: NSA 937901) ................................. 107
2.9.2
2.9.3
2.9.4
2.9.5
2.9.7
2.9.8
2.9.9
CONNECTION OF TWO OR THREE CABLES IN TERMINAL LUG AND SPLICE ................................. 112
2.10
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Issue 02
2.11
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Date: 01.07.2004
2.11.10.2
3.1
3.2
3.3
GENERAL .....................................................................................................................132
REQUIREMENTS AND RULES FOR MATERIAL QUALIFICATION ...........................132
ENVIRONMENTAL REQUIREMENTS..........................................................................132
3.3.1
TEMPERATURE......................................................................................................................................... 133
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.9
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3.4
3.4.1
CABLES...................................................................................................................................................... 136
3.4.2
3.4.3
CONNECTORS........................................................................................................................................... 136
3.4.4
3.4.5
3.5
APPENDIX.................................................................................................139
4.1
4.2
4.2.1
GENERAL................................................................................................................................................... 141
4.3
4.3.1
4.3.2
STANDARDS.............................................................................................................................................. 142
4.3.3
4.4
4.4.1
GENERAL................................................................................................................................................... 144
4.4.2
4.4.3
STANDARDS.............................................................................................................................................. 144
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Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
1 GENERAL
1.1
The purpose of this document is to specify the requirements for the installation of electrical equipment
within cabin interior in passenger cabins and IFE-Racks in the electrical equipment bay for the A380
aircraft.
The established requirements are mandatory for AIRBUS installation design ATA 25/ ATA 92 and
AIRBUS-supplier.
The requirements are applicable for Buyer Furnished Equipment (BFE) and Seller Furnished Equipment (SFE).
The EDR shall be used as reference document for integration of electrical installation requirements in
TN, ITS, PTS and SES.
Every application that is not mentioned in this document or every deviation from the introduced applications must be explicitly approved by:
Airbus Deutschland GmbH
Kreetslag 10
21129 Hamburg
Dep. BCEGU1
Cabin Electric
Overall
Figure 1
The EDR does not cover electrical installation of equipment / bundle on A/C-structure. For electrical
installation on A/C-structure TDD, SIDP are applicable.
The scope of the EDR is limited as shown in table below:
Zones
Aircraft zones
in the
EDR ?
pressurised zones
(max. temperature <=85C)
scope
of
YES
NO
Page 11/144
Issue 02
1.2
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
MEANING
Panels
Boxes
Structure
Conductive material
MEANING
SHALL
SHALL NOT
SHOULD
MAY
Table 3 Keywords
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Date: 01.07.2004
1.2.2 ABBREVIATIONS
ABBREVIATION
MEANING
ABD
Airbus Directives
ABS
Airbus Standard
A/C
Aircraft
AC
Alternating Current
ACJ
ACP
ADD
AFDX
AINS
AIPS
AMU
ARINC
ASN
ATA
ATC
APU
AWG
CDS
CINS
CoC
Centre of Competence
COM
Commercial
CPMS
CT
Current Transformer
C/B
Circuit Breaker
CWLU
DC
Direct Current
EFCS
ELT
EMC
Electromagnetic Compatibility
EN
European Norm
ESS BUS
Essential BUS
FAA
FAR
FEP
FIN
IFE
In Flight Entertainment
IMA
Page 14/144
Issue 02
ABBREVIATION
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
MEANING
ITS
JAA
JAR
MIL
Military Standard
NDT
PEEK
PTFE
PTS
PU
Parts usage
QTP
QTR
RCCB
SES
SFAR
SIDP
SIRD
SDP
SPDB
SUB.
Subsidiary
TBC
To Be Confirmed
TBD
To Be Defined
TDD
T/R
Transmitter-Receiver
TN
Technical Note
TRU
TWLU
VFG
VU/VE
Electrical References
Table 4 Abbreviations
Page 15/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2 ELECTRICAL REQUIREMENTS
Wording:
Bundle, Harness: A set of cables makes up a bundle, a set of bundles makes up a harness.
2.1
WIRING SEGREGATION
SYSTEM ASSIGNMENT
CATEGORY OF ROUTE
A category of route is defined according to the nature of the cables and/ or the type of signal they
transmit. The next determination is a separation of Essential and Non-Essential routes. This classification shows the different importance and function of the routes.
Also the routes are divided into basic and customised routes:
Wirings are installed generally in phase A or phase B:
Phase A: installed during the manufacturing of the aircraft section (basic routes)
Phase B: installed on or after Final Assembly line (customised routes)
Summing up there are the following general allocations:
-
In the scope of the EDR are only customised circuits installed in phase B.
SYSTEM ASSIGNMENT
Basically, two different electrical systems are defined for each category of routes: P, M, S . in order
to avoid that a single failure affects simultaneously both channels of a redundant system (for definition
of routes see 2.1.1.1). In order to maintain homogeneity in separation of systems, systems powered
by generators 1 and 2 will use route 1 and systems powered by generators 3 and 4 will use route 2.
Routes are called respectively, e.g. route 1 or route 2 of a dedicated route category.
Airbus 2004 All rights reserved
Page 16/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
For above mentioned reasons the design aim of wire bundle installation shall be a cable routing physically separated by distances and without any contact to other components or surrounding structure,
including sagging, vibration, swelling.
Protection means (like conduits, edge profiles etc.) shall be seen as additional help only, if it is absolutely not possible to keep the minimum distances as described in this specification.
Without any chafing marks or abnormal stress on the cables, appropriate bending radii etc., the service life of electrical installations in cabin furnishing equipment could be extended significantly.
2.1.1.1 CATEGORIES OF ROUTES
For cabin interiors, the following route categories are in the scope of EDR:
o
o
o
o
ROUTE
DISTRIBU-
REMARKS
SYSTEM
1P
2P
3P
4P
Essential System
Essential System
Non Essential System
Non Essential System
System 1
System 2
System 1
System 2
21P
22P
23P
24P
System 1
System 2
System 1
System 2
9P
10P
11P
12P
System 1
System 2
System 1
System 2
Page 17/144
Issue 02
CATEGORY
MISCELLANEOUS
-
bus
ARINC 429,
AFDX
ROUTE
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
REMARKS
SYSTEM
1M
2M
3M
4M
Essential System
Essential System
Non Essential System
Non Essential System
System 1
System 2
System 1
System 2
21M
22M
23M
24M
System 1
System 2
System 1
System 2
ROUTE
SENSITIVE
1S
2S
REMARKS
SYSTEM
Essential System
Essential System
System 1
System 2
CATEGORY
ROUTE
3R
-AUDIO / VIDEO
4R
9R
10R
11R
REMARKS
IFE bay- Non Essential System
TV
RF coaxial route- Non Essential System
AIRFONE
Video and audio (Electrical support).
Non Essential System
Video (Optical support)
Non Essential System
Video (Optical support)
Essential System
Page 18/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
e.g.: M, S...
D-CGU-10-9200-727-1
D-CGU-10-9200-728-1
Any deviation from this rule shall be dealt with as a special case and reported to
ECGU1 (Cabin Electric Overall).
D-CGU-10-9200-731-1
If joining of routes system 1 and 2 cannot be avoided, approval shall be obtained from
the involved system specialist and ECGU1 (Cabin Electric Overall) for each particular
case.
D-CGU-10-9200-782-1
D-CGU-10-9200-732-1
D-CGU-10-9200-733-1
When electrical equipment is powered by system 1 and 2, the grounding plate shall be
allocated to System 1.
D-CGU-10-9200-878-1
A drawing which shows the route segregation should be provided by the supplier.
Page 19/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Table 9 shows how Essential and Non-Essential routes are allowed to fit together.
Fitted on
Essential Basic
Master routing
Essential
Non-Essential
Customised
Basic
Essential
Customised
Not acceptable
Non-Essential
Customised
Not acceptable
Not acceptable
Non-Essential
Customised
Not acceptable
Exception: same
electrical item (e.g.
galley, crew rest
compartment...,
equipment, VU,
VE...), see
2.1.3.3.3
Not acceptable
Exception: same
Acceptable
electrical item (e.g.
(Dedicated routing
galley, crew rest
and dedicated
compartment...,
connectors are
equipment, VU,
preferred)
VE...), see
2.1.3.3.3
Table 9
Note : Same system is the essential condition to fit two harnesses together!
2.1.3.3.2
D-CGU-10-9200-862-1
23M
21M
connectors
Cabin
Interior
Equipment
Figure 2
Page 20/144
Issue 02
2.1.3.3.3
D-CGU-10-9200-865-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
PARTICULAR CASES
For a same electrical item (e.g.: galley, crew rest compartment..., equipment, VU,
VE...), Essential and Non-Essential harnesses for a same system side may be routed
together, according to the following conditions see Figure 3.
For electrical items connected to multi-circuit harnesses:
- Essential routes shall be electrically protected (e.g. PEEK conduit)
- A pin separation within the connector for equipments designed without connectors
segregation shall be provided
For electrical items connected to single circuit harnesses:
- No protection is required if the system specialist validates the mix of the two harnesses. A TDD 92 deviation shall be issued.
- A pin separation within the connector for equipments designed without connectors
segregation shall be provided
EQ
21M
21M
23M
23M
Figure 3
Note: The preferred installation of the electrical protection is on the essential bundle. For the installation of PEEK conduit see 2.6.4.
2.1.3.3.4
D-CGU-10-9200-869-1
The design shall ensure that the installation of Non-Essential harnesses is possible
without action on the Essential harnesses.
D-CGU-10-9200-870-1
The design shall ensure that the installation of Essential Customised harnesses is
possible without action on the Essential Basic harnesses.
Page 21/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Routes M and S shall not be mixed (in all electrical & optical areas, including racks,
boxes and panels).
For connector racks, segregation of the basics routes (1M - 2M - 1S - 2S) shall be
ensured up to ARINC 600 connector inlet. This segregation shall be achieved by a reliable system, which will not be lost during the maintenance operations.
D-CGU-10-9200-741-1
For rectangular connectors (EN 3545 type) and terminal module (NSA937901),
segregation is ensured by dedicated cavities for 1M / 1S /2M / 2S routes.
D-CGU-10-9200-739-1
The electrical and optical route segregation aft of equipment connectors shall be the
same as that of the connector segregation except for connectors racks, which require
more stringent control.
2.1.3.5.1
D-CGU-10-9200-743-1
OPTICAL CONNECTOR
The mix of optical and electrical technology in the same connector is forbidden (except
for ARINC404 and ARINC 600) in order to avoid dust and contamination on optical
contacts (mating aspect).
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Date: 01.07.2004
SIGNAL
SIGNAL TYPE
ESS
SYST 1
&
Ess
Cust.
Syst 1
GROUND POINTS
NonESS
ESS
SYST 2
SYST 1
&
&
Ess
Non-Ess
Cust.
Cust.
Syst 2
Syst 1
NonESS
SYST 2
&
Non-Ess
Cust.
Syst 2
REMARKS
28 V
and discrete signal
DC 1
DC 2
DC3
DC 4
6V
6 DC 1
6 DC 2
6 DC 3
6 DC 4
115 V
115 AC 1
115 AC 2
115 AC 3
115 AC 4
26 V
26 AC 1
26 AC 2
26 AC 3
26 AC 4
5V
5 AC 1
5 AC 2
5 AC 3
5 AC 4
B1
B2
B3
B4
Audio-com
General
General
Table 10
Page 23/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
As a general rule, two routes of the same category which contain duplicated systems
(e.g.: 1M and 2M) should be as far apart as possible.
D-CGU-10-9200-893-1
The distances indicated below are a minimum and may be reduced only where
unavoidable and then only over the minimum possible length (max. length 1m).
For routes of a same category (different systems): The reduction d<25 mm is acceptable with an electrical protection.
50
0
0
25 25
50 25
75 100
25
25
25
0
25 100
25
100
100
150
150
100
100
150
150
100
100 25
150 75 75
150 100 100
100 25 25
100 25 25
150 100 100
150 75 75
M Non-Ess
P Non-Ess
Categories
P
P Non-Ess*
M
M Non-Ess
S
R
R Ess optical (11R)**
R Non Ess optical (10R)**
R Non-Ess
All coax.
Categories
R Non-Ess
For routes of different categories (same system or different system): The reduction
d<25 mm is acceptable with an electrical protection and an EMI protection. For EMI
protection the system specialist shall be contacted.
Such cases shall be reported to ECGU1 (Cabin Electric Overall) for prior agreement.
Page 24/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-884-1
In general minimum distances of 25mm between each route of the same category are
required (e.g 1P and 2P).
D-CGU-10-9200-047-1
D-CGU-10-9200-886-1
For a same system side, the minimum clearance between Essential basic and
Essential customised harnesses (e.g. : 1M/21M) shall be 25mm.
Segregation distance
given in: Table above
Bundle
e.g.: M Ess Customised
Attachment point
Segregation distance
given in: Table above
e.g.: 25 mm
Bundle
e.g.: M Non-Ess Customised
Distances between bundles and electrical devices shall be according to Table 11. For
a reduction of this distance a system specialist shall be contacted. A possible reduction depends on the electrical device.
Electrical Device
structure
Figure 5
Page 25/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Crossing bundles or conduits shall be physically separated. If this is not possible they
should be separated with a specific device (e. g. separator see 2.4.18). Physically
separated means that only chafing aspects are necessary to take into consideration
(see Figure 6).
Route x
NO
CHAFING
ALLOWED
Route y
Figure 6
D-CGU-10-9200-901-1
Page 26/144
Issue 02
2.2
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
POWER SUPPLY
D-CGU-10-9200-871-1
In the cabin the main voltage supply is 115VAC, therefore electrical units in the cabin
shall be designed to be powered by 115VAC only (see Figure 7).
Reason: 28VDC-power-supply from aircraft is very limited and therefore cannot be guaranteed as
being available in certain (customized) aircraft/system configurations.
115VAC, 1 or 3phase
115VAC, 1 to 3phase
28VDC
Electrical unit
Electrical unit
yes
no
Figure 7
D-CGU-10-9200-874-1
If electrical units require a sub-voltage (e.g. 28 VDC), then this voltage should be
converted from the 115 V AC-input by internal AC/DC converter of the requiring unit.
Page 27/144
Issue 02
2.3
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
CABLE SELECTION
The electrical cable selection must take the following basic operating factors into account:
-external temperature (ambient & bundle temperature)
-internal temperature (joule effect / heating temperature)
Only Airbus approved cables, items, material, shall be used, see 3 Design Process Requirements.
D-CGU-10-9200-848-1
The supplier shall be responsible for every wire bundle to be installed in Boxes,
Panels, Monuments, racks for internal interconnection of electronic equipment.
CABLE TYPE
GAUGE (AWG)
DR-Family
ALL
AD-Family
ALL
D-CGU-10-9200-849-1
For Interface-Connector:
In case of different cable-types / cable gauges the matching of pins and sockets shall
be ensured.
Background: Aicraft-wiring may be defined as Aluminium-type cable.
Therefore cable-type on interface connector (between Aicraft-side connector and
equipment connector) may be of different type and - because of different electrical resistances - gauges of these cables may change.
This will be defined by System Engineering and given in wiring-diagrams.
(example: A\C-side: Aluminium-type cable AWG22 / equipment-side: copper-type
cable AWG24).
Page 28/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Copper Cable
Connection Principle
Aluminium Cable
Connection Principle
# 26
Contact
# 10 to # 4
# 24 to # 6
# 3 to # 000
Terminal Lug
# 4 to # 000
Terminal Lug
Table 13
The choice of type and size of contacts shall be in accordance with the cable gauge.
It shall be ensured that temperature derating effects will have no negative influence on
operating performances of all connector parts and accessories.
Type and size of contacts as well as type of connector shells and accessories shall be
selected taking into account this effect.
The wire temperature due to Joule effect (temperature increase, electrical heating) out
of bundle shall not exceed 25C.
Figure 8 - Figure 12 permit to evaluate the temperature rise of a supplied electrical cable.
Example: An "out-of-bundle" gauge 24 cooper-cable supplied with 4 A will be subjected to a joule
effect temperature rise under 20C (Figure 8 Cable temperature with respect to its intensity Out-ofbundle).
2.3.4.2 "IN-BUNDLE" UTILISATION
The grouping of cables "in bundle" reduces the thermal exchanges with the environment. In any case,
these events shall not damage the bundle.
Figure 13 shows the derating coefficient with respect to the bundle load.
D-CGU-10-9200-823-1
For all categories of routes, the elevated temperature due to Joule effect (temperature
rice, electrical heating) shall not exceed 40C.
Page 29/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
The temperature depends on the number of cables making up the bundle and the current intensity. As
the number of cables is fixed, the bundle temperature can only be limited by decreasing the wire
gauge to limit joule heating effect.
Example: As for the cable mentioned in the previous paragraph.
A bundle constituted of 17 cables, 80% loaded would lead to a derating coefficient of 0.5.
This would ask to choose the wire for an intensity of 8 Amps (4 / 0.5 Amps).
In that case the temperature rise by the 24-gauge cable would be 61C (> 40C).
Thus we should take a 22 gauge wire. The joule effect heating will be then about 35C (<40C).
D-CGU-10-9200-820-1
Outside panels, taking into account ambient temperature, the harness temperature
should be limited to a maximum of 60C.
This requirement recognises the disadvantage of having "hot cables" in the aircraft in respect of the
effect upon the installation, risks to servicing personnel, the increased possibility of failure and the
adverse effect upon the harness life.
Page 30/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Page 31/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Page 32/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Page 33/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
COEFFICIENT
(derating)
Number of cables
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
100%
80%
60%
Date: 01.07.2004
40%
20%
Percent
loaded
Page 34/144
Issue 02
2.4
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.4.1 DISTANCES
The Top priority aim of wire bundle design/installation shall be a cable routing physically separated by
distances (air space, without additional protection).
Additional protection (like conduits, edge profiles, grommets etc.) shall be seen as additional help only,
if it is absolutely not possible to keep the minimum distances described in this specification.
D-CGU-10-9200-050-1
Any direct contact between electrical cables and metalic / non-metallic structure shall
be prohibited.
D-CGU-10-9200-045-1
The distances between cable/ bundle and metallic / non-metallic structure (not
applicable for composite conductive structure!) shall be according to Figure 14.
for distance L10mm
200 mm
L 10 mm
metallic / non-metallic structure 2)
Figure 14
Page 35/144
Issue 02
D-CGU-10-9200-850-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
mech. and
electrical protection
(conduit ABS 0887)
120mm
support
L= 0mm
metallic / non-metallic structure 2)
Figure 15
2.4.1.1.1
120mm
120mm
L 10mm
Figure 16
Page 36/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
support
L = 20mm
bundle
L = 25mm
Figure 17
1) Distance/ design of supports shall be defined such, that in no case (slag, vibration etc.) the required distance L can be reduced.Therefore, in confined areas, additional supports may be required.
2) Not applicable for composite conductive structure !
3) Distance/ design of supports shall be defined such, that there is no rel. movement between cable/
bundle and structure.
D-CGU-10-9200-838-1
Page 37/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-839-1
D-CGU-10-9200-840-1
2.4.1.3.2
BETWEEN THE ELECTRIC CABLES AND PIPES WHICH CARRY NONINFLAMMABLE LIQUIDS OR GASES
D-CGU-10-9200-842-1
D-CGU-10-9200-841-1
D-CGU-10-9200-843-1
2.4.1.3.3
D-CGU-10-9200-851-1
D-CGU-10-9200-852-1
D-CGU-10-9200-853-1
Alternatively, in the case where cables or electrical looms are not held securely by a suitable attachment or are unprotected, the oxygen pipe shall be insulated by protection made from non-corrosive
material (the identifications shall remain visible). Or, in the case of a flexible oxygen pipe, it shall be
held in such a way that it cannot come within a distance of 25 mm of electrical cables or bundles (e.g.:
vibration effects).
D-CGU-10-9200-854-1
Page 38/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-855-1
For other routes, for distances when the distance 13 mm d < 25 mm, electrical
cables and bundles shall be:
- protected by conduits or sleeves
And
-secured by attachment point (Clamps, carriers or some other suitable attachment
system) to ensure a distance of 13 mm minimum from the oxygen components.
D-CGU-10-9200-856-1
D-CGU-10-9200-857-1
D-CGU-10-9200-858-1
After installation, the protection shall be still remain in its position and location.
D-CGU-10-9200-859-1
The protection of cable / bundle shall be ensured by conduit with mechanical and
electrical resistances.
Page 39/144
Issue 02
Distance ( L / mm)
electr. Bundel, Cabel
/ Pipes
Mechanical cables,
Moving mechanical parts
Non-flammable
liquids or gases
150 < L 50
50 < L 25
Acceptable
conduits
OR
secured by
attachment
point
P routes
Date: 01.07.2004
25 < L 13
13 < L 10
L < 10
conduits
OR
secured by
attachment
point
Acceptable
conduits
OR
secured attachment point
Gaseous Oxygen
Other than
P routes
Issue: 02
Acceptable
P routes
Ref: 9200M1F0380 00
conduits
OR
secured
attachment point
shall not
be used
Table 14
Supports and distances of supports shall be defined in such a way that in no case the
cables come into contact with surrounding (metallic, non-metallic structure, equipment
structure, e.g. honeycomb-panel) or other equipment because of slack, acceleration,
vibration..).
D-CGU-10-9200-826-1
The maximum distance / pitch between two cable fixations / supports on the
equipment structure shall not exceed 200 mm.
D-CGU-10-9200-062-1
Non-metallic supports (e.g.: ramp system, composite clamp) shall not be used above
150C continuous operation environments.
Page 40/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
All sharp edges or flanged edges on the cable side shall be strictly prohibited, see
Figure 18.
CORRECT
WRONG
Figure 18
SUPPORTS
CONDUITS
SHARP
STRUCTURE
Figure 19
D-CGU-10-9200-059-1
For each support the access to clamp and fitting shall be possible.
Page 41/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.4.2.4 CLAMP
D-CGU-10-9200-068-1
The increase of the bundle diameter (size of clamp) shall not reduce the segregation
distance (see 2.1.4 segregation between route Categories).
This is reached by selection of an adequate and adapted support to avoid sagging.
Using spacer for bundle turning or specific installation (see 2.4.18 Use of separators).
CLAMP OR V SUPPORT
Distance
CORRECT
NOT PREFERED
Figure 20
D-CGU-10-9200-069-1
V support installation shall follow the above shown principle, wether the distance may
change with bundle diameter and size of support.
D-CGU-10-9200-070-1
The position of the clamp shall take into account the tooling (e.g.: cable tie gun).
Generally plastic stand off ABS 1423/24 type (see Figure 21) shall be used on
conductive composite surface.
Figure 21
Airbus 2004 All rights reserved
Page 42/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-714-1
Plastic stand off shall be fixed on metallic/carbon structure with rivet ASNA 0080 or
NAS 1919.
D-CGU-10-9200-715-1
Metallic stand off ASNA2328/27 type may be used for mechanical reason, but not on
carbon.
D-CGU-10-9200-716-1
Stand off type shall be defined in accordance with the route temperature
E.g. : Plastic stand off for M, S and R routes.
Attachment points shall be installed close and before the start of bend radius axis.
ATTACHMENT POINT
BUNDLE
Figure 22
Page 43/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Any cables or harnesses that may be affected by fluids shall be routed with drip loops.
Drip loops shall be designed such that the fluids cannot migrate into the rear of the
connectors or end terminations.
Only when drip loop is not possible, one of the solutions below shall be applied:
-The first attachment point is lower than the connector contacts (preferred installation)
-Cables connected to a ground point
-Cable ends are installed on a plate that is at least tilted 15 downwards.
-For optical cables.
-Connections and first attachment point are water protected by umbrella
-sealing of connectors: see 2.8 Connectors
Clamp
LOWEST POINT
ATTACHEMENT POINT
Figure 23
Page 44/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
see Note
prohibited
preferred
OK
(with drip loop, horizontal-axis
position of connector)
Wrong
without loop
OK
(with drip loop, vertical-axis
position of connector)
Figure 24
Note: The vertical-axis position of the connector is not preferred, additional protection shall be applied,
see 2.8 Connectors and Backshells.
D-CGU-10-9200-087-1
All cables or harnesses shall also conform to the minimum bend radius requirements
see 2.4.14Cable bundle bending radius .
D-CGU-10-9200-088-1
When the cables are installed in a rigid conduit, this conduit shall be drained (see
AIPS 07-07-004).
D-CGU-10-9200-090-1
Design of drip loop shall include an over length for aircraft repairs.
Page 45/144
Issue 02
D-CGU-10-9200-899-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.4.4 JUNCTIONS
A junction corresponds to a physical part of the harness used to change the direction of wires in order
to reach several end elements with branches.
D-CGU-10-9200-094-1
On rigid conduit junctions shall be single junction with one branch equipped.
Figure 25
CORRECT
INCORRECT
Figure 26
Page 46/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.4.5 WIRING JOINING ON THE EQUIPMENT REMOVABLE FROM THE FORWARD FACE
D-CGU-10-9200-095-1
All wiring joining on to equipment/ modular assemblies (removal from front face) fixed
by cable tie of NSA 935401 type shall be designed in such a way that individual removal of each equipment is possible without opening or removing the other items.
D-CGU-10-9200-096-1
Particular care shall be taken in carrying out this wiring, so that the necessary slack is
suitably placed without risk of deterioration when the equipment is in place (see AIPS
07-01-001).
D-CGU-10-9200-097-1
Each removable bundle extremity shall have mechanical protection with textile split
conduit EN6049-006/ 007.
D-CGU-10-9200-098-1
For accessibility to the connector, sufficient harness over-length and its appropriate
stowage shall be provided to give sufficient access to the connector, typically hand
width for bayonet connectors (e.g.: control panel, equipment...).
Page 47/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
PRESSURISED
HAZARDOUS AREA*
Connector
- SEALED CONNECTOR
(GROMMET)
- DUMMY CONTACTS
- SEALING PLUGS
PRESSURISED
NON HAZARDOUS AREA
- SEALED CONNECTOR
(GROMMET)
- DUMMY CONTACTS
Terminal
Modul
- SEALED MODULE
(GROMMET)
- SEALING PLUGS
- SEALED MODULE
(GROMMET)
Terminal
Block
- UMBRELLAS
- NO PROTECTION
* Hazardous Area: under passenger door sill areas, when connectors are installed vertically (not recommended)
Table 15
D-CGU-10-9200-719-1
Page 48/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Electrical connectors shall not be positioned under pipe couplings or under fluidcontaining equipment.
D-CGU-10-9200-110-1
D-CGU-10-9200-111-1
D-CGU-10-9200-113-1
Page 49/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Direct contact between cables/ bundles and conductive composite panels shall be
strictly prohibited.
D-CGU-10-9200-692-1
Distances
(L/ mm)
L 25
Categorie
of route
P routes
M/S/R routes
Acceptable
see Figure 27
25 > L 20
20 > L 10
Acceptable
see Figure 27
10 > L
Not
acceptable
Table 16
D-CGU-10-9200-836005-1
For all categories of routes, in case of intersection between bundle and conductive
composite part, (max. length: 10mm) ( i.e. bundle across hole in carbon structure) a
minimum secured distance of 10 mm shall be ensured, see Figure 27.
D-CGU-10-9200-818-1
Page 50/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
200 mm 1)
support
bundle
Figure 27
Distance between
supports <200mm 1)
Figure 28
Page 51/144
Issue 02
2.4.8.1.1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
L 10mm
1) Distance/ design of supports shall be defined such, that in no case (slag, vibration etc.) the
required distance L can be reduced
Therefore, in confined areas, additional supports may be required.
Figure 29
Page 52/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-835-1
Page 53/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Optical cable may be installed inside R and S routes harnesses in all areas
see 2.4.18.
D-CGU-10-9200-130-1
The mix of electrical and optical technology in the same connector shall be forbidden,
except for ARINC 600/404 connectors, to avoid contamination (dust).
D-CGU-10-9200-786-1
The bending radius of each cable shall be kept before, during, after movements, see
2.4.14. Installed cables or bundles shall return afterwards to defined starting position.
D-CGU-10-9200-789-1
Cables or bundles shall not scrub on the edges of moving mechanical parts.
D-CGU-10-9200-788-1
Movement shall not bear any abnormal mechanical stress on cables or bundles.
D-CGU-10-9200-137-1
Page 54/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Gold/carbon
Stainless steel
Titanium
Silver - Mercury
Nickel
Copper alloy
Copper
Alu-bronze
Brass 30 % ZN
Silicon
Brass 50 % ZN
Bronze
Tin
Lead
Light alloy
NSA 3001
Steels
Aluminium A5
Cadmium
Chromium
Zinc
Manganese
Magnesium
130
130
340
250
110
110
250
210
340
90
220
90
430
180
320
110
450
200
440
320
470
535
570
360
640
520
670
550
710
590
810
690
870
660
1000
750
960
650
750
1090
840
970
740
760
1100
850
1070
950
1270
670
770
1050
1340
1620
1040
1120
1610
1700
1520
1600
1285
1350
1110
1150
300
200
Page 55/144
Magnesium
750
270
0
70
270
850
850
370
550
70
0
550
750
Table 17
860
380
100
370
860
Manganese
Zinc
Chromium
470
200
380
950
1010
Cadmium
Aluminium A5
Steels
NSA 3001
470
950
310
300
310
530
400
110
0
1010
530
200
100
400
630
460
100
110
460
670
1180
1250
Lead
Tin
Bronze
700
770
200
560
600
90
1110
630
260
150
100
260
560
160
150
160
360
630
805
870
1380
1500
Brass 50 % ZN
Silicon
Alu-bronze
Brass 30 % ZN
Copper
900
260
400
700
90
1150
670
300
150
0
600
260
60
1180
700
400
250
150
300
430
735
800
1020
290
500
830
950
60
250
330
535
600
630
300
160
1250
770
435
290
100
160
200
400
630
970
1150
1220
435
700
330
200
1285
805
500
320
140
100
320
390
500
750
1050
300
530
40
735
400
230
1350
870
353
390
170
140
230
425
490
650
850
1150
400
170
335
520
640
750
860
1200
550
70
800
435
300
1380
900
600
425
240
30
40
240
430
650
70
275
340
140
830
500
335
1500
1020
630
490
275
100
140
370
570
70
30
175
240
490
175
950
530
400
1520
1040
750
520
340
135
100
270
510
590
105
135
200
240
970
650
430
1600
1120
770
640
370
200
35
70
230
390
170
105
170
350
410
600
940
200
370
490
35
100
320
450
500
840
130
340
460
800
270
1050
670
530
1610
1150
850
650
490
230
100
65
390
1050
750
570
1700
1220
860
740
510
350
200
65
250
420
320
130
95
270
430
770
30
410
1150
760
650
1620
1340
950
750
590
370
250
95
215
350
340
215
150
490
1270
850
660
1950
1470
1070
840
600
450
270
120
30
235
235
170
150
315
450
Copper alloy
170
325
700
120
250
415
420
970
750
500
1400
1200
960
690
460
350
140
20
140
220
350
665
Nickel
20
260
600
315
250
870
590
430
1100
1090
810
550
360
220
100
100
230
570
1950
80
80
710
520
325
260
1000
940
670
450
230
110
640
415
350
840
800
570
320
90
0
535
470
200
770
700
440
180
10
685
600
320
100
100
300
300
90
570
450
220
10
350
1470
430
350
210
1400
AG - HG
Titanium
Platinum
Cold/Carbon
ORDINATE
Platinum
ABSCISSA
Stainless steel
Issue 02
480
480
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-752-1
D-CGU-10-9200-754-1
In a general way threads of anchor nut, after tightening, shall protrude of at least one
and a half. Threads of inserts shall protrude of at least three.
P routes shall be attached by clamp supports (e.g.: ABS 1339, NSA 5516).
D-CGU-10-9200-756-1
P routes in scope of EDR and the material of the concerning clamps shall withstand to
a max of +150 C.
D-CGU-10-9200-757-1
26 TO 12 GAUGE COPPER
CABLE GAUGE
26 to 22
6 mm
20
7,5 mm
18 to 12
10 mm
Table 18
2.4.14.2
D-CGU-10-9200-758-1
The minimum radius shall be equal to 10 times of the outside diameter of the cable.
D-CGU-10-9200-759-1
In exceptional cases, it may be reduced to 6 times of the outside diameter of the cable.
2.4.14.3
D-CGU-10-9200-157-1
Page 56/144
Issue 02
D-CGU-10-9200-158-1
2.4.14.4
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-159-1
The minimum radius shall be equal to 10 times of the outside diameter of the cable.
D-CGU-10-9200-160-1
2.4.14.5
D-CGU-10-9200-182-1
The minimum radius shall be equal to 10 times of the outside diameter of the Quad
cable.
D-CGU-10-9200-761-1
6 times may be accepted in exceptional cases only for fixed cables which can not
move.
2.4.14.6
D-CGU-10-9200-161-1
The minimum bending radius of a bundle shall be equal to 6 times of the outside
diameter of the bundle when there is no optical or coaxial cable inside (bundle diameter see 2.5.1).
D-CGU-10-9200-162-1
With coaxial and optical cables inside, the minimum bend radius shall be equal to 10
times of the outside diameter of the largest coaxial or optical cable.
D-CGU-10-9200-163-1
It shall not be less than the minimum allowable radius for the largest cable in the
bundle concerned (see 2.5).
Applicable for all electrical and optical harnesses between two attachment points when routing is
linear
D-CGU-10-9200-168-1
2.4.15.2
The length of the bundle shall take into account the shape of the bundle and the
structural tolerance. If required, at each end an over-length shall be provided for drip
loop.
ELECTRICAL CABLE OVER- LENGTH
D-CGU-10-9200-171-1
There shall be no stress on connection bars and when cables are connected to
moving parts (plugs, hinges...).
D-CGU-10-9200-172-1
Over-length more than mentioned below shall be managed by a stowage area (see
2.4.15.6).
Page 57/144
Issue 02
2.4.15.2.1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-173-1
D-CGU-10-9200-174-1
For 10 to 04 and coaxial cables, this over-length nominal shall be 20 mm at each end.
D-CGU-10-9200-175-1
2.4.15.3
D-CGU-10-9200-177-1
D-CGU-10-9200-178-1
A bracket shall be installed near each end of harness to cover thus over-lengths
(+50mm maximum at each extremity).
D-CGU-10-9200-179-1
2.4.15.4
D-CGU-10-9200-180-1
D-CGU-10-9200-181-1
The length and number of coaxial cable is fixed with system agreement and cannot be
changed.
2.4.15.5
D-CGU-10-9200-184-1
D-CGU-10-9200-186-1
Quad cable may be installed inside the electrical harness like the other cables but with
a minimum of 250mm free at the extremities.
D-CGU-10-9200-187-1
For all bundles the extremities shall be tied after plug in.
D-CGU-10-9200-188-1
Quad cables shall be installed only in M, S and R routes, network designation shall be
defined by Airbus.
D-CGU-10-9200-763-1
An overlength of 50 mm TBC shall be provided for contact repair on quad cable links.
D-CGU-10-9200-764-1
Each extremity of the Quad cable is marked (A and B), this biasing shall appear on the
electrical drawing.
2.4.15.6
D-CGU-10-9200-680-1
For electrical and optical cable over-length management shall be provided in each
interface area.
D-CGU-10-9200-681-1
Moving attachment points (see Figure 30 and Figure 31) shall be designed in the
same attachment philosophy as used on the other part of the harness.
Page 58/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Attachment points
mech. stress
crushing
Page 59/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-766-1
For coaxial cables a complete loop should not be used unless authorised by system
engineers.
D-CGU-10-9200-189-1
Insulation for metallic supports shall consist of paint, according to Airbus directive ABD
0078 and Specification ASNA 2101 where cable temperature remains lower than
150C.
BY CONNECTORS
D-CGU-10-9200-767-1
D-CGU-10-9200-199-1
Connectors of the same type positioned less than 300 mm from one to another shall
be prevented from the possibility of cross connections by size, polarisation or contact
arrangement.
D-CGU-10-9200-200-1
Key polarisation shall be achieved by different coding on each connector on the plate.
D-CGU-10-9200-201-1
Page 60/144
Issue 02
2.4.16.2
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
BY ROUTING
D-CGU-10-9200-768-1
The length of cable may only be sufficiently reduced to prevent any incorrect
connection if the use of different connectors is not possible.
D-CGU-10-9200-202-1
WRONG
CORRECT
Figure 33
2.4.16.3
BY CHAINS
If it is not possible to change the routing and the connector configuration to avoid a
possible permutation of connectors, small chains or leads shall be provided.
D-CGU-10-9200-204-1
The chains or leads shall be crimped on the lugs and screwed to a backshell ASNE
0199/0455.
Page 61/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.4.17 FIXING
2.4.17.1
D-CGU-10-9200-770-1
Electrical harnesses (protected, non protected) shall be fixed on the aircraft interior by:
categorie of route
Area
- Fuselage
- Inside BOXES/ PANELS
ABS1339-D
NSA5516 +
(limited use)
ASNA5107
Table 19
*Bundle is considered to be strained when the bundle bending radius is > 6 and < 10 times the outside
of the largest cable inside.
Page 62/144
Issue 02
2.4.17.1.1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
1: Screw
2: Cable clamp
3: Elastomer protection
4: Cable tie
Figure 34
D-CGU-10-9200-206-1
Page 63/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-775-1
D-CGU-10-9200-209-1
D-CGU-10-9200-794-1
Figure 35
D-CGU-10-9200-795-1
For bundles 25 mm
Figure 36
Page 64/144
Issue 02
2.4.17.1.2
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-684-1
D-CGU-10-9200-772-1
D-CGU-10-9200-774-1
Clamp NSA 5516 shall be installed only on a straight bundle part, not in the curve of a
bundle.
D-CGU-10-9200-804-1
Figure 37
D-CGU-10-9200-793-1
In exceptional cases only for bundles 25mm the installation principle Figure 38
shall be used.
Page 65/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
For bundles 25 mm
Figure 38
2.4.17.1.3
D-CGU-10-9200-212-1
V supports may be used only in pressurised areas where cable or cable bundle
temperature does not exceed 135 C.
D-CGU-10-9200-213-1
D-CGU-10-9200-214-1
D-CGU-10-9200-215-1
When using open V supports, the diameter of the bundle shall not be greater than the
width of the V including 20% of the bundle diameter section for growth provision, see
Figure 39 Principle of installation for V supports.
D-CGU-10-9200-216-1
Cable ties NSA 935401 shall be used with 3.7 mm wide minimum.
D-CGU-10-9200-218-1
For small bundle diameter ( 5 mm) (not recommended) which can move easily
between the support and the cable tie, a silicone bobbin NSA 5539 S or tape ASNA
5107 shall be fitted.
D
DL
L
Figure 39 Principle of installation for V supports
D-CGU-10-9200-219-1
The V - support should be installed with mouth upward (see Figure 39).
Page 66/144
Issue 02
2.4.17.1.4
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
This cable support is used to fasten cable harnesses with a max. diameter of 12 mm. Each cable harness is fastened to the traverse by separate cable tie per NSA 935401 (see Figure 40). For fixing this
support additional glue is necessary. The gluing process has to be in accordance with the gluing process of inserts. This support shall be used for M-routes on lining materials (Composites, Prepreg, laminated).
2.4.17.1.5
The optical cable may be installed inside the bundle for basic design.
D-CGU-10-9200-227-1
Optical cables may be installed outside the electrical harness for optional installations.
D-CGU-10-9200-228-1
When optical bundle escapes, an additional identification shall be added near the
connection point.
Page 67/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-229-1
D-CGU-10-9200-230-1
The standard tying pitch shall be between 150 mm and 200 mm. The minimum
distance between fixing points shall be 20mm.
Page 68/144
Issue 02
2.4.17.1.6
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Protection
Optical
cables
Harness
Figure 41
D-CGU-10-9200-232-1
If optical cables are integrated within a bundle, protection (tape ASNA 5107) shall be
installed with each support.
D-CGU-10-9200-233-1
D-CGU-10-9200-234-1
The cable or harness deviation shall be attached by two points to avoid stress. Bend
radius requirements shall be ensured.
D-CGU-10-9200-776-1
Optical cables, fixed by other means than clamps, shall be protected by:
- Tape ASNA 5107 for 2 optical cables minimum
- Bobbin NSA 5539 for a single optical cable
2.4.17.1.6.1
D-CGU-10-9200-777-1
Page 69/144
Issue 02
2.4.17.1.6.2
D-CGU-10-9200-235-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Separate routing
The installation shall be in accordance with Figure 42.
V support
Protection
Optical cable
Cable tie
Figure 42
2.4.17.1.6.3
D-CGU-10-9200-236-1
The installation of optical cable on el. harness shall be in accordance with Figure 43.
D-CGU-10-9200-778-1
Optical bundle made of 5 optical cables minimum shall be fixed with V clamps / plastic
clamps ABS 1339.
Page 70/144
Issue 02
Protection
Issue: 02
Date: 01.07.2004
Optical cable
V support
Ref: 9200M1F0380 00
Cable tie
or
Protection
V support
Electrical harness
Figure 43
Optical cable
Protection
Cable tie
Page 71/144
Issue 02
2.4.17.1.6.4
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Outside clamps
Protection
Protection
Figure 45
2.4.17.1.6.5
D-CGU-10-9200-238-1
2.4.17.1.7
D-CGU-10-9200-242-1
Page 72/144
Issue 02
Only in BOXES/
PANELSs or in
electric and electronic bay :
Coax fixed on harness
All coax
All zone
2 coax
Page 73/144
COAX
Bundle
Coaxial
cable
Cable tie
NSA 935401
LOOM
COAX
SPECIAL PRECAUTIONS
3)V supports
All zone
3 coax and more
EN 4604 WZ
All zone
1 coax
All zone
All coax
7.7
8.0
2.3
8.6
28
2
4.9
5
ASNE 0406WD
ASNE 0692WN
ASNE 0690WL
Light coax:
Normal coax:
ASNE 0291SW
ASNE 0293XF
NSA 935359WB
NSA 935358 WA
NSA 935344XE
COAX REF.
ATTACHING RULES FOR LIGHTENED AND NORMAL COAX (see details in AIPS 07-01-001)
Issue: 02
Date: 01.07.2004
Table 20
Issue 02
D-CGU-10-9200-797-1
2.4.17.1.8
D-CGU-10-9200-798-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
When installing coax cables on ramp outside BOXES/ PANELS (under TDD deviation)
they shall be installed like optical cables see 2.4.17.1.6.
ADHESIVE FASTENERS
Adhesive fasteners shall not be used.
2.4.17.2
2.4.17.2.1
D-CGU-10-9200-251-1
D-CGU-10-9200-252-1
20 mm
Attachment point
Figure 46
2.4.17.2.3
D-CGU-10-9200-253-1
Page 74/144
Issue 02
5 to 10 mm
Connector
sleeve
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
5 mm min
identification
5 to 10 mm
Cable tie NSA 935401 for ASN E0080
screw device for ASN E0199
Figure 47
2.4.17.2.4
D-CGU-10-9200-254-1
Table 21
D-CGU-10-9200-255-1
For the minimum conduit size, the conduit shall be adjusted by packing if necessary
following 2.6.
D-CGU-10-9200-256-1
The end of the conduit shall not bear against the insulation of the end fitting.
2.4.17.3
Page 75/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-260-1
In all cases the use of separators shall be clarified in the drawing (location and type).
2.4.18.1
D-CGU-10-9200-261-1
ON BUNDLES
If separators are used with optical cables, the optical cables shall be protected.
Page 76/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Following separators are used for bundles non protected or protected by conduit EN 6049
006/007.
2.4.18.1.1
D-CGU-10-9200-262-1
1: Head 1
2: Tube
3: Head 2
Figure 48
2.4.18.1.2
D-CGU-10-9200-264-1
Page 77/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
ABS 0054
Figure 49
2.4.18.2
D-CGU-10-9200-266-1
Separator may be used between conduits ABS 0887, shielded conduits and over
braided bundle in exceptional cases.
D-CGU-10-9200-267-1
In all cases the location and type shall be defined in basic on relevant documentation.
D-CGU-10-9200-268-1
Rigid convoluted conduit ABS 0887 and shielded conduit shall not be crushed.
D-CGU-10-9200-269-1
D-CGU-10-9200-270-1
D-CGU-10-9200-271-1
D-CGU-10-9200-272-1
D-CGU-10-9200-273-1
Splices shall not be used in contamination areas (below toilets and galleys), unless
effective protection against the infiltration of liquids is provided.
2.4.19.2
D-CGU-10-9200-274-1
Page 78/144
Issue 02
2.4.19.3
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-275-1
D-CGU-10-9200-276-1
Page 79/144
Issue 02
2.5
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
HARNESS CONSTRUCTION
The maximum number of cables or bundles allowed in one routing shall be such that
its diameter does not exceed 45 mm.
45
Page 80/144
Issue 02
Page 81/144
10
9
8
7
20
30
40
50
60
70
10
100
90
80
Diameters in mm
10
20
20
30
30
40
40
50
50
90 100
7 8 9 100
60 70
200
200
400 500
7 8 9 1000
2000
3000
300
K = Sections in mm
400 500 6 7 8 9 1000
2000
3000
300
10
9
8
7
20
30
40
50
60
70
5 6
100
90
80
Issue: 02
Date: 01.07.2004
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.5.2 TYING
2.5.2.1 HARNESS TYING
D-CGU-10-9200-282-1
Bundles shall be tied either with lacing tape NSA 8420 or cable ties NSA 935 401.
D-CGU-10-9200-283-1
D-CGU-10-9200-285-1
Cable ties NSA 935401 for technical harnesses with or without conduit shall not be
used in zones where is a risk of cable chafing or cable tie locking head catching (locations where units are removed via the front, e.g.: behind instrument panel, overhead
panel).
D-CGU-10-9200-286-1
In these cases cable bundles shall be tied by flat tapes of the NSA 8420-3 (low
temperature areas) in general cases.
D-CGU-10-9200-287-1
Cables ties NSA 935401 shall not be used inside the conduits.
D-CGU-10-9200-288-1
The pitch of tie-up devices depends on cable configuration (see AIPS 07-01-001).
D-CGU-10-9200-289-1
Optical cables shall be tied either by lacing tapes NSA 8420 or cable ties NSA
935401-03 only.
In routes including several harnesses, each one shall be tied according to Table 23.
Essential harness /
Essential harness
- Use lacing tape
NSA 8420
only
Non-essential harness/
Non-essential harness/
E
E
Non-essential harness/
Essential harness
N
- Use either
lacing tape
NSA 8420 or
cable tie NSA
935401
-Use lacing
tape NSA 8420
only
Page 82/144
Issue 02
D-CGU-10-9200-292-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Page 83/144
Issue 02
2.6
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
PRESSURISED AREA
-2 Fluids protection
ABS 0887
-2 Modification/punctual repair
-1 T maxi 200 C
-2 Mechanical protection
EN 6049-006
-3 Modification/repairs
-1 T maxi 260 C
EN 6049-007
-3 Modification/repairs
SHRINK CONDUIT
-1 Mechanical protection
ABS 0916
EN 6049-006/007
Table 24
Page 84/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-319-1
Split conduit ABS 0596 should be used to protect electrical bundel against arc
tracking.
D-CGU-10-9200-320-1
Drawing shall define the size and length of the open conduit for each bundle.
The size of the split elastomer conduit ABS 0596 shall be adapted to suit the diameter
of the cable bundle so that lip overlap angle is 90 minimum.
90
0
conduit overlap
Figure 51
2.6.2.2 TYING
D-CGU-10-9200-322-1
Split conduit ABS 0596 shall be tied by cable ties NSA 935401in accordance with
Figure 52.
Page 85/144
Issue 02
20 mm
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
20 mm
Bundle
Figure 52
D-CGU-10-9200-326-1
The size of the open conduit shall be adapted to suit the diameter of the cable bundle
so that lip overlap angle is in accordance with the standard EN 6049-006/007 (see
Table 25).
Page 86/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
conduit overlap
Figure 53
Conduit EN 6049-006/007
size
BUNDLE DIAMETER
Max. (mm)
5
8
13
19
25
32
40
Min. (mm)
5
8
13
19
25
32
40
1
5
8
13
19
25
32
Table 25
D-CGU-10-9200-328-1
2.6.3.2 TYING
D-CGU-10-9200-330-1
Cable tie NSA 935401 shall be used for tying split conduit EN 6049-006/007 except in
confined area (choice of device depending on the local conditions) where lacing tape
NSA 8420 is used.
Page 87/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
For the installation of the PEEK conduit the clamp ABS 1339 should be used.
D-CGU-10-9200-889-1
If the clamp ABS 1339 cant be installed, a V-support on PEEK conduit may be used.
For using a V-support 2 overlapped layers of tape ASNA 5107 (see Figure 54) shall be
used. The installation of V-supports on PEEK conduit without tape leads to a crushing
at the cable tie level due to the stress. This damage is not acceptable.
Figure 54
D-CGU-10-9200-890-1
For conduit fixation on structure clamp ABS 1339 shall be used in all areas except:
- in hot temperature area, on dynamic bundles..., there a P clamp may be used
- in inaccessible pressurised areas, a V-support may be used with additional tape
ASNA5107 (2 overlapped layers) under the cable-tie in order to absorb the stress
(not preferred solution).
D-CGU-10-9200-891-1
Page 88/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Compensator NSA935829
ABS1339
PEEK conduit
Figure 55
ABS1339
PEEK conduit
10 to 15mm
20mm
Additional clamp
Figure 56
tape
ABS1339
PEEK conduit
Figure 57
D-CGU-10-9200-892-1
Page 89/144
Issue 02
D-CGU-10-9200-902-1
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
When conduits are routed together, they shall be attached by lacing tape NSA8420.
When conduits are routed along a bundle, they should be attached by lacing tape
NSA8420.
Conduits shall only be partially filled in such a way that the external diameter of the cable bundle
represents:
D-CGU-10-9200-339-1
For conduits with length shorter than 2 m the filling rate shall not exceed 80% of the
conduit section at the aircraft delivery.
For conduits with length greater than 2 m the filling rate shall not exceed 60% of the
conduit section at the aircraft delivery.
D-CGU-10-9200-802-1
To avoid chafing, the size of the conduit shall be determined in order to obtain the
maximum permissible fill factor.
Non-braided conduits shall have the drain hole incorporated after installation at the
lowest point. See AIPS 07-07-004.
D-CGU-10-9200-344-1
Lengths of rigid convoluted conduit NSA ABS 0887 shall not be connected end to end
by screwing a size with another.
D-CGU-10-9200-351-1
D-CGU-10-9200-352-1
A bonding lead may be installed and tied directly on a non-protected electric bundle if
there is an additional protection placed between the braid and the non-protected electric bundle (textile conduit EN 6049-006/007 on electric harness or heat-shrink conduit
on bonding jumper).
Page 90/144
Issue 02
BONDING JUMPER
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
ADDITIONALPROTECTION
NSA 937210
NON-PROTECTED BUNDLE
Figure 58
In case a harness is in contact with water condensation it shall be sealed with heat
shrink conduits.
D-CGU-10-9200-357-1
Bundles may be locally protected mechanically by sleeve ABS 0916 in vibration zones
(see appendix 1).
D-CGU-10-9200-360-1
ABS 0916 shall not be used for high temperature (>135C) and P routes.
D-CGU-10-9200-362-1
For segregation between harnesses in confined area only two thicknesses of conduits
are required without shrinking.
Sheaths (tape ASNA 5107 or textile EN 6049-006/ 007) shall be used for protecting an
optical cable or harness when there is a risk of mechanical wear.
Page 91/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Tape ASNA 5107 self-adhesive reinforced tape shall be used for mechanical
protection of electrical cable in all area from 55C to +260C.
D-CGU-10-9200-365-1
D-CGU-10-9200-366-1
An attachment (e.g.: NSA 935401) shall be added to secure the end of the tape.
This tape shall be used for punctual external protection of bundles without any fixation
(e.g. by clamp).
When using backshells type ASNE 0455/0199, silicone tape NSA 935403 (big
thickness) or ASNA 5107 (small thickness) shall be installed around cable bundle.
Bundle
Half backshell
Silicone tape
Figure 59
D-CGU-10-9200-369-1
The two half backshell shall be in contact and maintained by backshell screws.
Page 92/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-376-1
Terminal lugs referenced NSA 936507 TG and ASN 0422 (limited use) TR require,
after crimping, the installation of a single conduit (ABS 0916) to ensure electrical and
mechanical protection.
D-CGU-10-9200-377-1
After tightening the terminal lug, it shall be ensured that the lug insulation protection is
at least 3 mm away from the structure or a conductive part.
2.6.10.2
With or without
conduit
Heat-shrink
conduit
50 mm 5mm
Connector
Figure 60
D-CGU-10-9200-381-1
Connectors shall be protected with a heat-shrink sleeve ASNE 0126 or equivalent from
base flange over a length of 50 mm 5 mm after shrinking.
Page 93/144
Issue 02
b)
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Heat-shrink conduit
Rear of connector
Base
Figure 61
D-CGU-10-9200-382-1
Connectors shall be protected with a heat-shrink sleeve ASNE 0126 or equivalent from
base flange to flush with rear part of connector.
Page 94/144
Issue 02
2.7
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-805-1
Inside the boxes or on panels containing electrical wiring, all rivet-heads and riveting
shall be countersunk type, or, exceptionally, mushroom type. Cheese head type rivets
shall not be used.
CORRECT
ACCEPTABLE
WRONG
WRONG
Figure 62
Equipment on panels shall be laid out from left to right in the order 1, 2, 3, 4, etc, for
an operator facing the panel (whatever the built-in position of the panel).
Page 95/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
For fixing of panels and boxes on modules floating inserts ABS1006 should be used
(see Figure 63).
Figure 63
Clamps placed inside boxes, which contain power cables, shall be plastic clamp ABS
1339 or clamp NSA 5516 CND (for stressed and big harnesses only).
Clamps holding the cable across hinges shall be type NSA 5516 CND with silicone
tape ASNA 5107 (two thickness are required).
D-CGU-10-9200-405-1
For harness diameter > 15mm, double clamps shall be used, see Figure 64.
D-CGU-10-9200-806-1
D-CGU-10-9200-406-1
Two positioning flags tape (ASNA 5107) shall be fitted at the two clamps level.
Page 96/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Positioning flag
Bundle
2 Clamps ABS 1339
Figure 64
D-CGU-10-9200-814-1
They shall not be in contact with any items during the movements of the harness.
Page 97/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
ON
RIGHT HAND
LATERAL PANEL
FRONT
PANELS
ON
Figure 65
D-CGU-10-9200-407-1
The anti-rotation spigot in the switch body should be positioned on the ACTUATED
SIDE.
D-CGU-10-9200-408-1
Circuit breakers shall be positioned with the anti-rotation spigot above, or, exceptionally, on the left, see Figure 66.
Normal
Exceptional
Figure 66
Airbus 2004 All rights reserved
Page 98/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
To prevent the possibility of mismating relays, installation shall take into account:
-Size or contact arrangement
-Mechanical key polarisation for same connection but different function of the relay
(e.g.: suppressed or not suppressed)
Page 99/144
Issue 02
2.8
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
a)
D-CGU-10-9200-379-1
b)
At contacts with reduced barrels (ARINC 600 gauge 12 contact with gauge 24 to
gauge 18 cables), two heat-shrink sleeves shall be installed.
D-CGU-10-9200-380-1
Gauge 8 contacts protruding beyond the rear of hard insulators shall be protected by
heat-shrink sleeves (ABS 0916).
Connectors permanently unused shall be stored and sealed protected, e.g. by plastic
protection cap, sealed mating connector etc.
2.8.4
CONNECTIONS
D-CGU-10-9200-828-1
Page 100/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
16 mm minimum
16mm
Connectors
30 mm
minimum
16mm
Figure 67
D-CGU-10-9200-421-1
Rectangular connector EN 3545 shall be installed in accordance with the Figure 67.
Sufficient clearance must be provided near a rectangular connector in order to permit
easy access (Connection disconnection and cleaning procedures).
Fixed circular connectors with square flanges - type ASNE 0053 or similar - shall be
fixed with two (minimum) diametrically opposed screws.
D-CGU-10-9200-427-1
Connectors ABS 0364 or type ASNE 0053 or equivalent mounted in the cabin for
commercial electric systems may be attached in a connector bracket with two opposite
quick release fasteners.
D-CGU-10-9200-881-1
D-CGU-10-9200-882-1
D-CGU-10-9200-428-1
Page 101/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
receptacle
receptacle
plug
plug
Figure 68
D-CGU-10-9200-430-1
If installation with vertical axis is used every practical precaution shall be taken to
avoid contamination by liquid (protective covers, low point, sealing plug), e.g. drip
loops.
D-CGU-10-9200-845-1
FRONT VIEW
Figure 69
D-CGU-10-9200-425-1
When the connector is mounted with vertical axis (not preferred solution), the keyway
shall be at the aircraft forward reference.
Page 102/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Looking at the connector from the front (view A): The pin contact No.1 EN 3545-P shall
be positioned at bottom left and the backshell is installed on RH side.
Backshells
VIEW
1
1
Pin contact
EN 3545-P
Socket
contact
EN 3545-S
FIXED CONNECTOR
vertical position (preferred)
Figure 70
D-CGU-10-9200-443-1
EN3545-P
Pin contact
VIEW A
EN3545-S
Socket contact
Backshell
FIXED CONNECTOR
horizontal position (NOT preferred )
Figure 71
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Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
TYPE OF BACKSHELL:
Straight or elbow backshell
ABS0638 (thermoplastic)
Circular connector
type ASNE 0052/ Utilisation zones
ASNE 0053
type Plug and
main use
except in small small boxes/panels
Recaptacle
Plug
Connector without backshell
Recaptacle
Rectangular
connector type
EN 3545
Plug
Backshell type EN 3545-007 (thermoRecaptacle
plastic)
TYPE OF BACKSHELL:
NO.
YES, except risks of contamination/
mechanical protection in pressurised
zones and in small small boxes/panels.
Utilisation zones
Pressurised zones
Pressurised zones except on interface
connectors of large small boxes/panels.
Table 26
D-CGU-10-9200-437-1
Backshells shall be used for plugs (removable and fixed connectors). Exception:
Connector inside PSU-Channel.
The elbow backshell orientation (angular) shall be defined in drawing definition. The
definition shall consider:
-with view at the connector contacts side (front face)
-Connector master keyway positioned at the top
Page 104/144
Issue 02
0 angle reference
and connector axis
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Backshell
angle
Connector master keyway
Figure 72
D-CGU-10-9200-440-1
When contact technology used which is not of the full pull proof type, backshells shall
be used. These backshells shall prevent all unwanted movement of the optical contact
transmitted by the cable.
Sealing
D-CGU-10-9200-445-1
Electrical components equipped with sealing plugs shall be defined in the relevant
module specification.
SEALED CONNECTORS
In all pressurised areas- except inside boxes, panels - connectors shall be fitted with
sealing grommets.
Page 105/144
Issue 02
2.8.10.2
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-450-1
Sealing plugs in contacts (male or dummy contacts) shall be used where contamination is possible as specified in the module specification, e.g.:
-when connectors are installed with vertical axis (not recommended)
-when connectors are installed in ceiling between stringers 22 and 22
-under junction panel floor
-door frame areas
D-CGU-10-9200-452-1
The use of small gauge cables on large gauge contacts with reduced barrels requires
the installation of a heat shrink sleeve e.g.: NSA 937210 (for high temperature cable)
to ensure sealing when a connector with grommet is used.
D-CGU-10-9200-446-1
D-CGU-10-9200-454-1
If terminal lugs ASN0422 TR with YV-type aluminium cables are used, one or 2 heat
shrink sleeves ABS 0061 only (depending on cable gauge) on the cable insulation
shall be installed prior to crimping see AIPS 07-04-009.
When using 22 or 24 gauge cable AD, DR and BF, a heat-shrink conduit ABS 091601-10 or sleeve NSA 937210MB0215 shall be added to the cable at the rear of the
contacts (installation of heat-shrink conduit without overlapping onto contact barrel),
see Figure 73.
Cable
End fitting
2mm
Figure 73
Page 106/144
Issue 02
2.9
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-533-1
INCORRECT
X
X
1
2
CORRECT
X
CORRECT
2
3
4
X
X = end clamps
Figure 74
D-CGU-10-9200-535-1
Terminal and module blocks shall be wired in groups of four (maximum) (see Figure
74)
Figure 75
Page 107/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
If the connected cables are routed in opposing directions (e.g.: on a terminal block):
method shown in Figure 76 FIG. a) or b) shall be used.
D-CGU-10-9200-537-1
If the terminal is such that the connected cables are routed in the same direction:
method shown in FIG. b) shall be used. (See AIPS 07-01-001)
D-CGU-10-9200-538-1
Four lugs maximum shall be used for configurations as shown in Figure 76 a) and b),
five lugs maximum shall be used for a configuration as shown in Figure c.
FEEDER
FIG. a
FIG. b
DISTRIBUTION
FIG. c
Figure 76
D-CGU-10-9200-559-1
The preferred assembly position of the copper and aluminium terminal lug shall be
considered (see also 2.9 Terminal Block and Lug Installation) when they are installed in the same terminal stud.
D-CGU-10-9200-539-1
The largest contact surface of the lug shall be installed first on the stud.
D-CGU-10-9200-540-1
When two different terminal lugs are superposed and are electrochemical compatible,
(terminal lug for copper cables and terminal lug for aluminium cables) the copper cable
terminal lug shall be positioned under the nut.
D-CGU-10-9200-542-1
Design shall take into account the difference in electro-chemical potential between
different materials in contact, see 2.4.11.
The maximum allowed terminal lug bending angle shall be 30 for 10 to 0000 gauge
terminal lugs and 45 for 12 to 24 gauge terminal lugs with a minimum radius of 2 mm.
D-CGU-10-9200-544-1
D-CGU-10-9200-545-1
Page 108/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
After the terminal lug has been tightened, its insulation shall be at least 3 mm away
from the structure or any conductive elements.
D-CGU-10-9200-547-1
Additional washer NSA 5307-XC shall be used with copper lugs when the contact
between the screw and the lug is less than 50%.
D-CGU-10-9200-665-1
One lug per circuit breaker terminal shall be installed except for circuit breaker shunts
(flag lugs) or monitoring cables where there will be two lugs at cable inlet and shunt
outlet.
Page 109/144
Issue 02
Copper lug
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Copper lug
Aluminium lug
Copper lug
Copper/Copper lugs
Copper/Aluminium lugs
Aluminium lug
Copper lug
Copper lug
Aluminium lug
Aluminium/Copper/Aluminium lugs
Aluminium lug
Copper lug
Copper/Aluminium/Copper lugs
Figure 77
2.9.7.1.2
D-CGU-10-9200-553-1
Page 110/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Nut
Lug
Figure 78
Terminal blocks with screw studs shall be covered by plastic cover (electrical shock
protection) outside cabin interior equipment.
D-CGU-10-9200-556-1
To avoid fluid ingress (e.g.: water proximity,...) Terminal block (VT) shall be installed
above bundles with an above additional umbrella or with cover protection, e.g. Figure
79.
Page 111/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Umbrella
Terminal block plastic cover
Bundle
Cabin
Interior
Equipment
Figure 79
Installation of two cables in the same terminal lug barrel shall be permitted in
accordance with AIPS 07-04-003.
D-CGU-10-9200-558-1
Three cables in the same terminal lug and splice shall be avoided or with specialist
agreement.
Page 112/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Electrical Bonding
Bonding refers to the establishment of a current path between electric conductive parts in order to assure
electrical continuity. This path may be between two points on a system ground plane as well as between
ground reference and a part, circuit or structure element.
Grounding
Grounding refers to the establishment of a current path to a reference potential (ground reference). The
ground reference for aircraft is the metallic aircraft structure.
Safety Ground
Equipment inside Passenger Cabin shall be electrically grounded.
to prevent personnel from receiving electrical shock due to insulation breakdown in equipment and cables.
To ensure electrostatic protection:
Electrostatic charges may be accumulated on dielectric surfaces or on non conductive components
that are electrically insulated from the conductive aircraft main structure. The protection against the
adverse effects of electrostatic charging includes the prevention of equipment damage or upset when
touched by a person that may carry electric charges.
Current Return
Current return refers to the return of power supply currents. It is not primarily a subject of electrical bonding.
However often current return is established by using the metallic A/C structure as a return conductor. In such
cases the bonding points of the current return leads shall be segregated in order to avoid cross coupling with
other bonding leads.
Conductive or semi-conductive surface
included conductive surfaces (metall, metalized) and partly conductive surfaces (conductive composite:
carbon, glare...)
D-CGU-10-9200-472-1
Each bonding path shall have a current rating suitable to carry the largest current expected
under normal, fault and ageing conditions throughout the aircraft life.
Page 113/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-460-1
All grounding points shall be identified, see NSA 936002, ABD 0004 Part 2
D-CGU-10-9200-481-1
The thickness of the sheets to which grounding points are attached shall be consistent with
the maximum current carried, minimum thickness see table below.
Up to
I (A)
0.6
0.8
1.2
2
2.6
Table 27
Note:
D-CGU-10-9200-897-1
2.10.2.1
2.10.2.1.1
D-CGU-10-9200-463-1
FIXED BRACKETS
The minimum number of rivets between the part to which the grounding point is attached and
the primary A/C structure shall be in accordance with Table 28.
Page 114/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
0 to 5
5 to 35
35 to 70
70 to 100
100 to 200
200 to 300
> 300
3
6
9
12
15
18
Ground return to be achieved using a
direct contact grounding method. A
special surface preparation process
shall be carried out (see AIPS07-01006)
Table 28
D-CGU-10-9200-464-1
Grounding points for AC and DC may be connected to the same bracket but to separate
connection points, see Figure 80, or alternatively Figure 81.
Normal
Figure 80
Page 115/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Alternative
Figure 81
2.10.2.1.2
REMOVABLE BRACKETS
D-CGU-10-9200-469-1
When removable grounding brackets are used, separate grounding plates shall be used for
AC, DC, System 1, System 2, ESS / Non Ess, Basic and customised segregation.
D-CGU-10-9200-470-1
D-CGU-10-9200-471-1
When electrical equipment is powered by System 1 and System 2, the grounding plate shall
be allocated to System 1.
Page 116/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
The max resistance between aircraft structure and electrical box shall be 50 m (see Figure
82).
Aircraft structure
10 m
10 m
Furniture
50 m
20 m
Equipment
50 m
20 m
e.g
Electrical
Box #1
Electrical
coffee
Box #2
maker
20 m
20 m
Figure 82
All required bonding paths shall be subjected to an electrical bonding resistance measurements.
D-CGU-10-9200-510-1
For each ground, the resistance measurement shall be taken between the terminal and the
aircraft structure immediately adjacent to it.
Page 117/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
The size of the screws fixing the terminal lugs to the A/C-structure shall be in accordance
with table below:
Screw diameter (Screw type)
24 - to - 10
8-6
4 and less
4 and less
Table 29
D-CGU-10-9200-474-1
Bonding jumpers should be as short as practicable and not longer than 220 mm, see Figure
83 (in case that a longer jumper is necessary, the acceptance of EMH specialist is required).
Electrical
component to
be bonded
Intermediate
fixing point
Metallic
primary
structure
Bonding leads no
longer than 220mm
D > 220mm
NON ACCEPTABLE WITHOUT
EMH SPECIALIST APPROVAL
Figure 83
D-CGU-10-9200-475-1
D-CGU-10-9200-476-1
D-CGU-10-9200-477-1
The electrical bonding jumpers or leads used for bonding shall be made of nickel-plated
copper.
Types of braid:
ASNE0088: lead bonding round bonding (for section 1.4 mm)
Page 118/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-502-1
D-CGU-10-9200-812-1
Bonding points shall be protected from corrosion and contamination. The protection shall be
done in accordance with AIPS 07-01-006 (Electrical bonding).
D-CGU-10-9200-503-1
When it has been necessary to remove the protective coating from a metallic surface, the
complete assembly should be refinished with its original finish or other suitable protective finish (ref. AIPS 07-01-006).
GENERAL REQUIREMENTS
D-CGU-10-9200-472-1
Each bonding path shall have a current rating suitable to carry the largest fault current
expected for this equipment.
D-CGU-10-9200-473-1
The diameter of each wire used for bonding shall be at least equal to powerlines and
AWG 18 minimum.
D-CGU-10-9200-811-1
Equipment for passenger cabin interior shall be bonded according to Figure 84.
D-CGU-10-9200-832-1
In general, all equipment shall be electrically bonded to aircraft structure, via one or more
bonding connections, either by the mating face of the equipment or a bridge contact.
Exception: small, non electrical conductive parts A<400cm, which are not chafing to
electrical cables, see Figure 84.
Page 119/144
Issue 02
2.10.8.2
2.10.8.2.1
D-CGU-10-9200-846-1
D-CGU-10-9200-847-1
2.10.8.2.2
D-CGU-10-9200-486-1
2.10.8.3
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Any equipment with electrical function (supplied with electrical power) shall be bonded by at
least two independent bonding pathes.
- Exception: max. power supply less / equal 28V AC or DC.
- protective insulation
Boxes, Panels; operating devices shall be bonded by two wires via connector pin (independent pathes minimum wire-diameter: equal to powerlines, minimum gauge AWG 18).
Each connector used for power supply shall provide at least one pin for protective ground
connection.
Exception:
-max. power supply less / equal 28V AC or DC.
-protective insulation....
D-CGU-10-9200-830-1
Conductive parts exposed to crew / passenger with surface >400cm shall be grounded
(AWG 18).
D-CGU-10-9200-496-1
The bell cranks, pulley, rods which are essentially composed of small hinged parts, will not be fitted with
individual bonding jumpers. Trims may not need to be bonded.
The coaxial connectors associated with the following systems shall be insulated from the
structure:
MH system (Passenger Entertainment Video)
MK system (PES: Passenger Entertainment Music)
MM system (PVIS: Passenger Video Information System)
RD system (Phone)
RF system (CPMS: Cabin and Passenger Management System)
For all other coaxial connectors contact system specialist.
Page 120/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
YES
electrical equipment
AC / DC
28V
?
with electrical
function (supplied
with electrical
power) ?
NO
no
protective
ground
required
YES
NO
NO
conductive
chassis 2)
?
conductive parts 2) 3)
(exposed to cabin crew / passenger/
maintenance crew)
non-electrical components
(used for electrical cabel support)
conductive
surface2)
?
YES
shall be
grounded by
minimum one
connection
YES
conductive
surface
>400cm
?
NO
protective
insulation4)
?
NO
YES
NO
YES
monuments, equipment
examples
Non-essential monuments/ equipment shall be bonded by independent bonding pathes to the
primary A/C structure, the dimension of the bonding pathes shall be confirmed by the system
specialist
each connector used for power supply shall provide at least one pin for protective
ground connection
1) independent protective ground connection = two or more bonding pathes which do not influence the electrical function of each other in case of failure, each path shall be able to carry the maxmum ground return current during both normal and failure condition, with diameter minimum equal to powerlines
2) conductive = conductive (metall, metalized) or at least partly conductive (conductive composite: carbon, glare...)
3) in no case (including wire chafing, equipment failure, vandalism, fluid spillage) contact with live wires of power supply.
4) requirements of protective insulation (according DIN VDE 0100)
Figure 84
Airbus 2004 All rights reserved
Page 121/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
2.11.1.3
UNIDENTIFIED CABLES
Unidentified cables shall be:
-very short cables (length < 75 mm)
-monitoring cables in line on adjacent circuit breakers
IDENTIFICATION BY SLEEVES
Sleeved cables are cables which cannot be directly marked on account of their physical make-up or
where marking may damage the insulation (e.g.: coaxial).
D-CGU-10-9200-564-1
D-CGU-10-9200-565-1
Sleeved cables shall be identified using NSA 937201ME sleeves placed at each end
of the cable and bearing the cable identification characters. The sleeves shall be
white, printed in black except for sensitive cables (print code S) where the sleeves
are pink, printed in black.
2.11.1.4
PRINTABLE CABLES
D-CGU-10-9200-567-1
This category should mainly concern gauge 26 to gauge 6 cables, which may have
lengths greater than 75 mm.
D-CGU-10-9200-568-1
AD
DR
KB
LF optical cable
PRINTABLE CABLES
by UV laser
Figure 85
Page 122/144
Issue 02
2.11.1.5
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-570-1
D-CGU-10-9200-571-1
2.11.1.6
D-CGU-10-9200-573-1
SPECIFIC CASES
Twisted cables which will be partially untwisted over a length of 20 cm shall be
identified by as many additional individual sleeves as there are untwisted cables.
Additional sleeves
Original sleeves
Figure 86
Page 123/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
EQUIPMENT
+ FUNCTIONAL
IDENTIFICATION
LABEL IF
NECESSARY
VC
IF NECESSARY
OUT OF
VU's
ONLY
VG
VT
VT
TERMINAL
BOLCK
VN
Figure 87
A)
Connectors (VC)
Page 124/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Installation of a label.
C)
Installation of a label .
D)
Installation of a label.
F)
No label needed
D-CGU-10-9200-666-1
2.11.2.1
D-CGU-10-9200-574-1
Plates ASNE 0248 or sleeve shall be installed at all the extremity FIN (Functional
Identification Number) connectors, bulkhead, grounding module or components fitted
in the bundle except for terminal module type.
D-CGU-10-9200-575-1
D-CGU-10-9200-576-1
D-CGU-10-9200-577-1
In panels and boxes identification of cable shall be made by ASNE 0646 and
identification of extremities (switches, connectors, ) by ASNE 0248.
D-CGU-10-9200-578-1
ASNE 0248A14HP identification plates (4 holes) bearing the identification of the extremities.
D-CGU-10-9200-580-1
The identification shall be composed of the FIN (Functional Item Number) of the
extremities with, in certain cases, the abbreviated functional designation.
D-CGU-10-9200-581-1
D-CGU-10-9200-582-1
The bundle manufacturer shall verify the label positioning on bundle to permit correct
reading (not opposite reading) when the harness extremities are connected.
Page 125/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-584-1
For bundles less than 5 mm in diameter, these plates shall be replaced by NSA
937201 sleeves.
D-CGU-10-9200-586-1
The identification plate shall be installed only on the related single harness and shall
not group together different routes.
D-CGU-10-9200-587-1
The identification label length shall be adapted to the length of the identification marks.
D-CGU-10-9200-589-1
D-CGU-10-9200-590-1
For twisted 3-wire cables with different colours phase identification sleeves shall not
be used.
D-CGU-10-9200-592-1
D-CGU-10-9200-593-1
When each of the wires in a 3-wire cables have the identical colour, red, yellow and
blue sleeves shall be used to identify phases A, B and C respectively.
D-CGU-10-9200-594-1
This identification sleeve shall be located at less than 150 mm from the cable end.
D-CGU-10-9200-596-1
When only one multi-conductor cable exists in a panel or box, identification may be
either by sleeve or by colour on each conductor.
USUAL HARNESSES
D-CGU-10-9200-597-1
This marker shall be a white ASNE 0248A label printed black on the harnesses.
D-CGU-10-9200-598-1
D-CGU-10-9200-883-1
Page 126/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
Route identification markers shall indicate the routes inside harnesses and how to
position them.
D-CGU-10-9200-601-1
They shall mainly be placed in zones of high wiring density in accordance with the
production line, and density where knowledge of routes is necessary: at each harness
extremities and every 1 meters maximum.
D-CGU-10-9200-602-1
D-CGU-10-9200-604-1
For routes yellow markers ASNE 0248 secured with cable ties or lacing tape shall be
used.
D-CGU-10-9200-608-1
For single optical cable or optical cable bundles a specific identification along the route
harness should be fitted.
D-CGU-10-9200-609-1
Sleeve NSA 937201 ME shall be used, text shall be black on white background.
OPTICAL CABLE
Figure 88
D-CGU-10-9200-610-1
D-CGU-10-9200-611-1
All panels or boxes with identification shall have their references in a place, which is
visible after installation on the aircraft, except for passenger cabin panels, for which
identification is inside the panels.
D-CGU-10-9200-632-1
All panels or boxes shall have their identification label following NSA 9117.
Page 127/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
D-CGU-10-9200-633-1
D-CGU-10-9200-815-1
For connection boxes connector identifications shall be provided outside the boxes.
2.11.9.1
ON VE
VE
503 VE
Electrical harness
1160 VCA
503 VE
1160 VC
Figure 89
D-CGU-10-9200-634-1
2.11.9.2
For VE interface connector the label shall bear the functional item.
ON ARINC 600 EQUIPMENT
220 VC
1XG.A
1XG
220 VC A
92 VE
SHELF
1XG
GPCU
92 VE
Figure 90
D-CGU-10-9200-635-1
VE identification shall be mandatory in high density VE areas and shall be recommended on other cases.
Page 128/144
Issue 02
2.11.9.3
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
ON EQUIPMENT
2RN4
1PU1
TR-1
2RN4.A
ACP-AYNCS
COMPTS
1PU1.A
GENERAL
EXCEPTIONAL
(If structural label not easy to read)
Figure 91
2.11.9.4
D-CGU-10-9200-639-1
One sleeve, showing the identification reference of the non-coded equipment for the
bundle of cables which ends at this equipment shall be mounted on the whole bundle.
D-CGU-10-9200-640-1
5 HA
Figure 92
D-CGU-10-9200-816-1
In confined areas where label ASNE 0248 cannot be installed sleeve NSA 937201
shall be used.
D-CGU-10-9200-817-1
D-CGU-10-9200-642-1
An ASNE 0248 label is used to identify all equipment and electrical standard items
except for the following items:
-Cut-off connectors (VC)
Page 129/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
IDENTIFICATION SLEEVES
FOR CONNECTION
5 HA
EQUIPMENT
1
2
5
10
1
2
5
10
5 HA
1
2
4 SX
VN
VC
VT
VC
Figure 93
2.11.10
2.11.10.1
D-CGU-10-9200-647-1
Boxes or panels containing parts with voltages exceeding 42 V which are liable to
expose maintenance personnel to hazardous operations should be fitted with a label
reading: Caution High Voltage inside.
D-CGU-10-9200-648-1
This label shall have 6 mm white letters on red background, according to AIPS 07-06005 and NSA 931031 requirements.
Page 130/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
CAUTION
HIGH VOLTAGE INSIDE
Figure 94
2.11.10.2
LABEL POSITIONING
D-CGU-10-9200-660-1
As a general rule, these plastic labels shall be positioned at the top or left hand side of
the item of equipment when looking at the front face.
D-CGU-10-9200-661-1
D-CGU-10-9200-662-1
Other positions, i.e.: bottom or right hand side, are allowed only when the top and the
left-hand positions cannot be used.
Page 131/144
Issue 02
Ref: 9200M1F0380 00
Issue: 02
Date: 01.07.2004
GENERAL
Electrical components to be installed in the A380 aircraft have to accomplish the Airbus standard.
Items, which fulfil these conditions are registered in the Airbus electrical component Standard Selection List. Sections of this document, which include the relevant parts for the EDR are listed in the Appendix.
For searching a particular Airbus qualified electrical component, it is possible to take it directly from
this list. This procedure ensures that the selected item is approved.
In the case of special items, which are not listed in this document, it is necessary to qualify them. This
procedure includes a variety of tests, depending on the function of the component. Common tests for
standard components are listed in 3.4. The full test description is published by the European Association of Aerospace Industries Standardization (AECMA-STAN). Due to proprietary issues the test
procedures cant be provided by Airbus, but it is possible to get the tests under www.aecma-stan.org.
For the qualification a complete Qualification Test Plan and Report (see 3.4) is essential. The QTP
shall be approved by the responsible Airbus system specialist. After the approval the QTR can be
created.
Generally all requirements for parts and components which are not listed in this document and which
shall be meet are in responsibility of the Airbus system specialist.
3.3
ENVIRONMENTAL REQUIREMENTS
For the equipment, which is used inside the cabin the following test parts are relevant:
- temperature
- altitude, pressure
- temperature variation
- humidity
- shock and crash safety
- vibration
- waterproofness
- fluids susceptibility
- fungus resistance
Airbus 2004 All rights reserved
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salt spray
corrosion
hermetic
fire
flammability/ smoke/ toxicity
3.3.1 TEMPERATURE
This definition is according to DO160.
Tests are available for Category A1: Components intended for installation in a controlled temperature
pressurized location, on an aircraft where pressure is normally not lower than the altitude of 15.000 ft
Sea Level.
At flight operation low...high temperature: -15+55C
At short time flight operation high temperature: +70C
At ground survival lowhigh temperature: -55+85C
At cooling air temperature: +70C
3.3.4 HUMIDITY
This definition is according to DO160.
The standard humidity environment, category A, provides a test environment for components, which
are intended for installation in civil aircraft. The severe humidity of the environmentally controlled compartments of the aircraft is normally not encountered (e.g. 95% rel. humidity at 50C).
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3.3.6 VIBRATIONS
This definition is according to DO160.
Category S or S2 Standard Vibration Test.
The standard vibration tests ensure that components will meet their functional performance requirements during normal operating conditions. For components located in the fuselage and Category S or
S2 the test curve is specified as type C. The test level for this type C is shown in Figure 8-1 Standard
Random Vibration Test Curves for Components Installed in Fixed-Wing Aircraft with Turbojet or Turbofan Engines.
3.3.7 WATERPROOFNESS
This definition is according to DO160.
This test specifies how the components can withstand water, which is sprayed or fallen on the equipment. Components which are installed in locations where they subject to falling water are identified as
Category W. For components intended for installation in such locations, the drip proof test procedure
is necessary and the components are identified as Category W.
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3.3.11 CORROSION
The Supplier has to demonstrate that the materials, which he used for the design of the component,
are adequately protected against corrosion. He has to use only qualified methods.
3.3.12 HERMETIC
The PTS defines if EN 60068-2-17 is applicable. In case of electrical components EN 60068-2-17 Test
of Dive into liquids is not applicable. It shall determine a degree of protection provided by enclosures
(IP-Code) according to IEC 60529.
3.3.13 FIRE
The PTS will define if ISO2685 is applicable.
Not applicable are no fire zones in accordance to ISO2685 (Resistance to fire in designated fire
zones).
3.4
ELECTRICAL REQUIREMENTS
The values of electrical parameters during the qualification test are provided in ABD0100.1.8 Electrical and Installation Requirements.
These regulations are very general and correspond to the well-known relevant regulations of electrical
technology.
During a component qualification test, it shall be shown that the electrical components are in compliance with the electrical requirements.
Generally, all electrical requirements for parts and components are in the responsibility of the Airbus
system specialist.
The required tests for the main components are available, e.g.
- EN3475 for cables
- EN3745 for optical cables
- EN2591 for connectors and contacts
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The following chapters describe standard tests for these main components. For components, which
are not listed here, appropriate tests according to the function of the component have to be accomplished. The supplier has to decide by himself which tests are required. The final necessary tests have
to be described in a test procedure (QTP see 3.5), which has to be approved by Airbus.
3.4.1 CABLES
EN3475
302
303
305
401
402
407
410
411
412
505
511
601
602
604
605
3.4.3 CONNECTORS
EN2591
206
207
210
301
305
307
315
Airbus 2004 All rights reserved
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317
402
403
406
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Flammability
Shock
Sinusoidal and random vibration
Mechanical endurance
3.4.5 CONTACTS
EN2591
201
202
301
305
307
315
406
417
508
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Content
Qualification number, issue
Including the manufacturer name, plant, CAGE code, proprietary part identification, proprietary part description and components, manufacturing schedule
3. Reference documents
4. Qualification Body
5. QTP
6. Test results
Name + Supplier
Reference number
Results according to the QTP like mechanical, physical-chemical and physical test results.
Results of additional tests.
Including individual and average values and standard deviations of every
batch/lot and average value and standard deviation of all batches/lots.
Format in accordance with the specification.
Including detailed information; NDT results (if applicable)
7. Manufacturing of
specimens
8. Confidential
information
9. Additional Test
Reports/Information
10. Summary and
conclusion
Annex
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4 APPENDIX
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4.1
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The purpose of the APPENDIX is to provide the user with all information, standards, documents referred in the:
EDR- ELECTRICAL DESIGN REQUIREMENTS FOR CABIN INTERIOR, Airbus A380 Program.
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4.2.1 GENERAL
The purpose of AIPS is to give detailed Design and Quality Requirements to manufacturers.
4.3
This chapter lists all process specifications and items mentioned in the EDR document.
4.3.1 AIPS
AIPS
Title
AIPS 07-01-001
AIPS 07-01-003
AIPS 07-01-006
AIPS 07-01-009
AIPS 07-02-001
AIPS 07-02-002
AIPS 07-03-001
AIPS 07-04-003
AIPS 07-04-005
AIPS 07-04-009
AIPS 07-04-014
AIPS 07-05-003
AIPS 07-05-005
AIPS 07-05-006
AIPS 07-05-010
AIPS 07-05-023
AIPS 07-05-032
AIPS 07-06-001
AIPS 07-06-002
AIPS 07-06-005
AIPS 07-07-004
AIPS 07-11-001
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4.3.2 STANDARDS
Standard
ASNA0080
ASNA2101
ASNA2327
ASNA2328
ASNA2553
ASNA5107
Title
Blind Rivets with shank locking universal head
Protections
Bracket
Bracket
Washer- Locking
Tape-reinforced Silicone, self- adhesive
ASNE0052
ASNE0053
ASNE0072
ASNE0080
ASNE0088
ASNE0089
ASNE0090
ASNE0091
ASNE0092
ASNE0126
ASNE0199
ASNE0248
ASNE0291
ASNE0293
ASNE0354
ASNE0406
ASNE0422
ASNE0455
ASNE0466
ASNE0646
ASNE0690
ASNE0692
ASNE0731
ABS0054
ABS0061
ABS0364
ABS0394
ABS0596
ABS0638
ABS0688
ABS0713
ABS0731
ABS0887
ABS0916
ABS1006
ABS1144
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ABS1224
ABS1339
ABS1423
ABS1424
ABS5334
NSA5307
NSA5516
NSA5539
NSA8420
NSA9117
NSA931031
NSA935344
NSA935358
NSA935359
NSA935401
NSA935403
NSA935504
NSA935829
NSA936002
NSA936507
NSA937201
NSA937210
NSA937401
NSA937901
NSA937905
NSA937910
NSA938150
EN2997
EN3545
EN4604
EN6049
EN60068
EN3475
EN3745
EN2591
Connector
Rectangular connector
Cable
Textile conduit
Test procedure
Test procedure
Test procedure
Test procedure
Table 32
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4.4
4.4.1 GENERAL
According to EDR, Chapter 3: Design Process Requirements AIRBUS recommended for design
definition of the A380 program the use of items, defined as Airbus Standards.
The standard items defined by AIRBUS are listed in folder Standard Selection List.
4.4.3 STANDARDS
It is in the own responsibility of the supplier, to procure standards which are covered by any copyright.
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