ASTM F2639-2018 Standard Practice for Design Alteration and Certification of Aircraft Electrical Wiring Systems.pdf

1、Designation: F2639 15F2639 18Standard Practice forDesign, Alteration, and Certification of Aircraft ElectricalWiring Systems1This standard is issued under the fixed designation F2639; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision,

2、 the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 DefinitionThis practice defines acceptable practices and processes for the design, alteration, and certif

3、ication of electricsystems and installations in general aviation aircraft.This practice does not change or create any additional regulatory requirementsnor does it authorize changes in or permit deviations from existing regulatory requirements.1.2 ApplicabilityThe guidance provided in this practice

4、is directed to air carriers, air operators, design approval holders,Supplemental Type Certificate (STC) holders, maintenance providers, repair stations, and anyone performing field approvalmodifications or repairs.1.3 Protections and CautionsThis practice provides guidance for developing actions and

5、 cautionary statements to be addedto maintenance instructions for the protection of wire and wire configurations. Maintenance personnel will use these enhancedprocedures to minimize contamination and accidental damage to electrical wiring interconnection system (EWIS) while workingon aircraft.1.4 “P

6、rotect and Clean As You Go” PhilosophyThis philosophy is applied to aircraft wiring through inclusion in operatorsmaintenance and training programs. This philosophy stresses the importance of protective measures when working on or aroundwire bundles and connectors. It stresses how important it is to

7、 protect EWIS during structural repairs, STC installations, or otheralterations by making sure that metal shavings, debris, and contamination resulting from such work are removed.1.5 This practice includes the following sections:Title SectionWire Selection 5General 5.1Aircraft Wire Materials 5.2Tabl

8、e of Acceptable Wires 5.3Severe Wind and Moisture Problems (SWAMP) 5.4Grounding and Bonding 5.5Electrical Wire Chart 5.6Wire and Cable Identification 6General 6.1Wire and Cable Identification 6.2Types of Markings 6.3Sleeve and Cable Marker Selection 6.4Placement of Identification Markings 6.5Wiring

9、Installation 7General 7.1Wire Harness Installation 7.2Power Feeders 7.3Service Loops 7.4Drip Loops 7.5Soldering 7.6Strain Relief 7.7Grounding and Bonding 7.8Splicing 7.9Fuel Tank Wiring 7.10Corrosion Preventative Compounds (CPC)(MIL-C-81309)7.111 This practice is under the jurisdiction of ASTM Commi

10、ttee F39 on Aircraft Systems and is the direct responsibility of Subcommittee F39.01 on Design, Alteration, andCertification of Electrical Systems.Current edition approved Aug. 1, 2015Oct. 1, 2018. Published September 2015November 2018. Originally approved in 2007. Last previous edition approved in

11、20072015as F2639 07F2639 15.1. DOI: 10.1520/F2639-15.10.1520/F2639-18.This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Becauseit may not be technically possible to adequately depic

12、t all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current versionof the standard as published by ASTM is to be considered the official document.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 1942

13、8-2959. United States1Electrical Load Considerations 8General 8.1Methods for Determining the Current-CarryingCapacity of Wires8.2Acceptable Means of Monitoring andControlling the Electrical Load8.3Electrical System Components 9General 9.1Alternators 9.2Generators 9.3Ground Power Units 9.4Auxiliary P

14、ower Units 9.5Batteries 9.6Circuit Protection Devices 9.7Conduit 9.8Connectors 9.9Inverters and Power Converters 9.10Junctions 9.11Junction Boxes 9.12Electronic Assemblies 9.13Relays 9.14Studs 9.15Switches 9.16Terminals and Terminal Blocks 9.17Waveguides 9.18Electrical System Component Installation

15、10General 10.1Alternators 10.2Generators 10.3Auxiliary Power Units (APUs) 10.4Batteries 10.5Circuit Protection Devices 10.6Conduit 10.7Connectors 10.8Inverters and Power Converters 10.9Junctions 10.10Junction Boxes, Panels, Shields, andMicroswitch Housings10.11PC Board Assemblies 10.12Relays 10.13St

16、uds 10.14Switches 10.15Terminals and Terminal Blocks 10.16Waveguides 10.17EMI/RFI 11General 11.1Grounding and Bonding 11.2HIRF 11.3Lightning 11.4Alterations 12General 12.1Wire Substitutions 12.2Commercial Off-the-Shelf (COTS) Components 12.3Electrical Load Considerations 12.4Batteries 12.5Circuit Br

17、eakers 12.6Junction Boxes 12.7Relays 12.8Switches 12.9Wire Marking 12.10Wire Bundle Routing 12.11Wire Bundle Combing 12.12Interference Tests 12.13System Safety Assessments 12.14Certification Processes 13General 13.1Certification 13.2Alterations and Maintenance 13.31.6 ValuesThe values given in inch-

18、pound units are to be regarded as the standard. The values in parentheses are forinformation only. See Appendix X2 for SI-based prefixes and powers of 10.NOTE 1Where SI units are required, refer to Annex 5 of ICAO.1.7 This standard does not purport to address all of the safety concerns, if any, asso

19、ciated with its use. It is the responsibilityof the user of this standard to establish appropriate safety safety, health, and healthenvironmental practices and determine theapplicability of regulatory limitations prior to use.F2639 1821.8 This international standard was developed in accordance with

20、internationally recognized principles on standardizationestablished in the Decision on Principles for the Development of International Standards, Guides and Recommendations issuedby the World Trade Organization Technical Barriers to Trade (TBT) Committee.2. Referenced Documents2.1 Unless approved by

21、 the administrator, the latest revision of the listed documents shall be used for reference.2.2 ASTM Standards:2F2490 Guide for Aircraft Electrical Load and Power Source Capacity Analysis2.3 ANSI Standards:3ANSI/EIA-5200000 Generic Specification for Special-Use Electromechanical Switches of Certifie

22、d QualityANSI EIA/TIA-568-B Commercial Building Telecommunications Cabling StandardANSI J-STD-004 Requirements for Soldering Fluxes2.4 FAA Standards:4Advisory Circular 20-53A20-53( ) Protection of Aircraft Fuel Systems Against Fuel Vapor Ignition Due To LightningAC 20-13620-136( ) Protection of Airc

23、raft Electrical/Electronic Systems Against the Indirect Effects of LightningAC 21-160E21-16( ) RTCA Document DO-160EDO-160D/E/F/GAC 23.1309-1C23.1309-1E Equipment, Systems, and Installations inSystems Safety Analysis and Assessment for Part 23AirplanesAC 25-16 Electrical Fault and Fire Prevention an

24、d ProtectionAC 25.869-125.869-1( ) Electrical System Fire and Smoke ProtectionAC 25.981-1B25.981-1( ) Fuel Tank Ignition Source Prevention GuidelinesAC 25.1353-125.1353-1( ) Electrical Equipment and InstallationsAC 25.1357-125.1357-1( ) Circuit Protective Device AccessibilityAC 27-1B Certification o

25、f Normal Category RotorcraftAC 29-2C Certification of Transport Category RotorcraftDOT/FAA/CT 86/8 Determination of Electrical Properties of Bonding and Fastening TechniquesDOT/FAA/CT-83/3 Users Manual for FAA Advisory Circular 20-53aDOT/FAA/CT-89-22 Aircraft Lightning Protection HandbookTitle14 Cod

26、e of Federal Regulations Part 23 Airworthiness Standards: Normal, Utility, Acrobatic, and Commuter CategoryAirplanesTitle14 Code of Federal Regulations Part 25 Airworthiness Standards: Transport Category AirplanesTitle14 Code of Federal Regulations Part 27 Airworthiness Standards: Normal Category Ro

27、torcraftTitle14 Code of Federal Regulations Part 29 Airworthiness Standards: Transport Category RotorcraftTitle14 Code of Federal Regulations Part 31 Airworthiness Standards: Manned Free BalloonsTitle14 Code of Federal Regulations Part 33 Airworthiness Standards: Aircraft EnginesTitle14 Code of Fede

28、ral Regulations Part 34 Fuel Venting and Exhaust Emission Requirements for Turbine Engine PoweredAirplanesTitle14 Code of Federal Regulations Part 35 Airworthiness Standards: PropellersTitle14 Code of Federal Regulations Part 36 Noise Standards: Aircraft Type and Airworthiness Certification2.5 SAE S

29、tandards:5AMS-S-8802 Sealing Compound, Temperature-Resistant, Integral Fuel Tanks and Fuel Cell Cavities, High Adhesion (ReplacesMIL-S-8802)ARP 1199 Selection, Application, and Inspection of Electric Overcurrent Protective DevicesARP 1308 Preferred Electrical Connectors for Aerospace Vehicles and As

30、sociated EquipmentARP 1870 Aerospace Systems Electrical Bonding and Grounding for Electromagnetic Compatibility and SafetyARP 1928 Torque Recommendations for Attaching Electrical Wiring Devices to Terminal Boards or Blocks, Studs, Posts, EtcARP 4761 Guidelines and Methods for Conducting the Safety A

31、ssessment Process on Civil Airborne Systems and EquipmentARP 5369 Guidelines for Wire Identification Marking Using the Hot Stamp ProcessARP 5414 Aircraft Lightning ZoningARP 5583 Guide to Certification of Aircraft in a High Intensity Radiated Field (HIRF) EnvironmentAS 4372 Performance Requirements

32、for Wire, Electric, Insulated Copper or Copper AlloyAS 4373 Test Methods for Insulated Electric Wire2 For referencedASTM standards, visit theASTM website, www.astm.org, or contactASTM Customer Service at serviceastm.org. For Annual Book of ASTM Standardsvolume information, refer to the standards Doc

33、ument Summary page on the ASTM website.3 Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http:/www.ansi.org.4 Available from U.S. Government Printing Office Superintendent of Documents, 732 N. Capitol St., NW, Mail Stop: SDE, Washington, DC

34、 20401, http:/www.access.gpo.gov.5 Available from Society of Automotive Engineers (SAE), 400 Commonwealth Dr., Warrendale, PA 15096-0001, http:/www.sae.org.F2639 183AS 4461 Assembly and Soldering Criteria for High Quality/High ReliabilityAS 6136 Conduit, Electrical, Flexible, Shielded, Aluminum Allo

35、y for Aircraft Installations. (Replaces MIL-C-6136)AS 7351 Clamp, Loop Type Bonding-FSC 5340 (replaces AN735)AS 7431 Bracket, Support Clamp-FSC 5340 (replaces AN743)AS 7928 Terminals, Lug: Splices, Conductor: Crimp Style, Copper, General Specification for (Replaces MIL-T-7928)AS 22759 Wire, Electric

36、al, Fluoropolymer-Insulated, Copper or Copper Alloy. (Replaces MIL-W-22759)AS 23190 Straps, Clamps, Plastic and Metal, and Mounting Hardware, Plastic for Cable Harness Tying and Support Clamp,Loop, Metal, Cushioned, Adjustable, Wire Support, Type V, Class 1-FSC (replaces MIL-S-23190)AS 25064 Conduit

37、 Flexible, Radio Frequency Shielding use in place of MIL-C-7931?AS 25281 Clamp, Loop, Plastic, Wire Support-FSC 5340 (replaces MS25281)AS 25435 Terminal-Lug, Crimp Style, Straight Type, for Aluminum Aircraft Wire, Class 1 (Replaces MS254350)AS 25436 Terminal-Lug, Crimp Style, 90 Upright Type, for A

38、luminum Aircraft Wire, Class 1 (Replaces MS25436)AS 25438 Terminal-Lug, Crimp Style Right Angle Type, for Aluminum Aircraft Wire, Class 1 (Replaces MS25438)AS 33671 Strap, Tie Down, Electrical Components, Adjustable, Self Clinching, Plastic, Type I, Class 1 (Replaces MS3367)AS 50881A Wiring Aerospac

39、e Vehicle (Replaces MIL-W-5088)AS 70991 Terminal, Lug and Splice, Crimp Style Aluminum, for Aluminum Aircraft Wire. (Replaces MIL-T-7099E)2.6 Military Standards:4A-A-52080 Nylon Lacing Tape (replaces MIL-T-43435)A-A-52081 Polyester Lacing Tape (replaces MIL-T-43435)A-A-52082 Tape, Lacing and Tying,

40、TFE Fluorocarbon (tetra fluorocarbon) (replaces MIL-T-43435)A-A-52083 Tape, Lacing and Tying, Glass (replaces MIL-T-43435)A-A-52084 Tape, Lacing and Tying, Aramid (replaces MIL-T-43435)A-A-59163 Insulation Tape, Electrical, Self Adhering, Unsupported Silicone RubberAN735 ClampAN960JD10L Conductive W

41、asherMIL-C-22520 Wire Termination Crimp ToolsMIL-C-26482 Connectors, Electrical, (Circular, Miniature, Quick Disconnect, Environment Resisting), Receptacles and Plugs,General Specification forMIL-C-39029 Contacts, Electrical Connector, General Specification forMIL-PRF-81309 Corrosion Preventative Co

42、mpounds, Water Displacing, Ultra-Thin FilmMIL-DTL-22520 Crimping Tools, Wire Termination, General Specification for (replaces MIL-C-22520/2)MIL-DTL-27500 Cable, Power, Electrical and Cable Special Purpose, Electrical Shielded and Unshielded, General SpecificationforMIL-DTL-5015 Connectors, Electrica

43、l, Circular Threaded, AN Type, General Specification forMIL-DTL-83723 Connectors, Electrical, (Circular, Environment Resisting), Receptacles and Plugs, General Specification forMIL-F-14256F Flux, Soldering, Liquid, Paste Flux, Solder Paste and Solder-Paste Flux (for Electronic/Electrical use), Gener

44、alSpecification forMIL-M-81531 Marking of Electrical Insulating MaterialsMIL-PRF-39016 Relays Electromagnetic, Established Reliability, General Specification forMIL-PRF-5757 Relays, Hermetically SealedMIL-PRF-6106 Relays, Electromagnetic, General Specification forMIL-PRF-83536 Relays, Electromagneti

45、c, Established Reliability, 25 Amperes and Below, General Specification forMIL-S-8516 Sealing Compound, Polysulfide Rubber, Electric Connectors and Electric Systems, Chemically CuredMIL-STD-704 Aircraft, Electrical Power CharacteristicsMIL-T-8191 Test and Checkout Equipment, Guided Missile Weapons S

46、ystems, General Specification for should this be SAEAMS-T-81914 replaces MIL-T-81914?MIL-W-25038 Wire, Electrical, High-Temperature, Fire Resistant, and Flight CriticalMIL-W-81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkine-Imide, or Polyarylene Insulated, Copper or CopperAlloyMIL-W-8

47、1381 Wire, Electric, Fluorocarbon/Polyimide InsulatedMS21919 Cable ClampsMS25440 Flat WasherMS3057 Cable Clamp AdaptersMS3109 Boots, Heat-Shrinkable, Strain-Relief, Right AngleMS3115 Connectors, Receptacle, Electrical, Dummy Stowage, Bayonet Coupling, for MIL-C-26482 Connectors, Series 1 and2MS3117

48、Boots, Heat-Shrinkable, Strain-Relief, Right AngleMS3142 Connector, Receptacle, Electrical, Box Mounting, Solder Contact Hermetic, AN TypeF2639 184MS3143 Connector, Receptacle, Electrical, Solder Mounting, Solder Contact Hermetic, AN TypeMS3158 Backshells Shrinkable Boot, for Electric ConnectorMS318

49、0 Cover, Protective, Electrical Connector Plug, Bayonet Coupling for MIL-C-26482 ConnectorsMS3181 Cover, Protective, Electrical Connector Receptacle, Bayonet Coupling for MIL-C-26482 ConnectorsMS3416 Backshells, Straight, for Electrical ConnectorsMS3440 Connectors, Receptacle, Electric Series 2, Narrow Flange Mount, Bayonet Coupling, Solder Pin Contact Class HMS3443 Connectors, Receptacle, Electric, Series 2, Solder Flange Mount, Bayonet Coupling, Solder Pin Contact Class HMS3450 Connectors, Receptacle, Electrical, Wall Mounting, Rear Release, Crimp Contact,