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9/8/98 AC 43.13-1B SECTION 6. AIRCRAFT ELECTRICAL WIRE SELECTION 11-76. GENERAL. Aircraft service im poses severe environmental condition on elec trical wire. To ensure satisfactory service, in spect wire annually for abrasions, defective in sulation, condition of terminations, and poten tial corrosion. Grounding connections for power, distribution equipment, and electro magnetic shielding must be given particular attention to ensure that electrical bonding re sistance has not been significantly increased by the loosening of connections or corrosion. a. Wire Size. Wires must have sufficient mechanical strength to allow for service con ditions. Do not exceed allowable voltage drop levels. Ensure that the wires are protected by system circuit protection devices, and that they meet circuit current carrying requirements. If it is desirable to use wire sizes smaller than #20, particular attention should be given to the mechanical strength and installation handling of these wires, e.g. vibration, flexing, and termination. When used in interconnect ing airframe application, #24 gauge wire must be made of high strength alloy. b. Installation Precautions for Small Wires. As a general practice, wires smaller than size #20 must be provided with additional clamps, grouped with at least three other wires, and have additional support at terminations, such as connector grommets, strain-relief clamps, shrinkable sleeving, or telescoping bushings. They should not be used in applica tions where they will be subjected to excessive vibration, repeated bending, or frequent dis connection from screw terminations. c. Identification. All wire used on air craft must have its type identification im printed along its length. It is common practice to follow this part number with the five digit/letter Commercial and Government En tity (C.A.G.E). code identifying the wire manufacturer. Existing installed wire that needs replacement can thereby be identified as to its performance capabilities, and the inad vertent use of a lower performance and unsuit able replacement wire avoided. (1) In addition to the type identification imprinted by the original wire manufacturer, aircraft wire also contains its unique circuit identification coding that is put on at the time of harness assembly. The traditional “Hot Stamp” method has not been totally satisfac tory in recent years when used on modern, ul tra-thin-walled installations. Fracture of the insulation wall and penetration to the conduc tor of these materials by the stamping dies have occurred. Later in service, when these openings have been wetted by various fluids, serious arcing and surface tracking have dam aged wire bundles. (2) Extreme care must be taken during circuit identification by a hot stamp machine on wire with a 10 mil wall or thinner. Alter native identification methods, such as “Laser Printing” and “Ink Jet,” are coming into in creasing use by the industry. When such mod ern equipment is not available, the use of stamped identification sleeving should be con sidered on thin-walled wire, especially when insulation wall thickness falls below 10 mils. 11-77. AIRCRAFT WIRE MATERIALS. Only wire, specifically designed for airborne use, must be installed in aircraft. a. Authentic Aircraft Wire. Most air craft wire designs are to specifications that re quire manufacturers to pass rigorous testing of wires before being added to a Qualified Prod ucts List (QPL) and being permitted to produce the wire. Aircraft manufacturers who maintain their own wire specifications invariably exer cise close control on their approved Par 11-78 Page 11-35PDF Image | AFS-640
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