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EDR - ELECTRICAL DESIGNREQUIREMENTS

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© Airbus 2004 All rights reserved. This document contains Airbus proprietary information and trade secrets. It shall at all times remainthe property of Airbus; no intellectual property right or licence is granted by Airbus in connection with any information contained in it. It issupplied on the express condition that said information is treated as confidential, shall not be used for any purpose other than that forwhich it is supplied, shall not be disclosed in whole or in part, to third parties other than the Airbus Entities, their subcontractors and suppli-ers (to the extent of their involvement in Airbus projects), without Airbus’s prior written consent.

Electrical Design Requirements for CabinInterior (EDR)

No. 9200M1F0380 00

Aircraft A380 PAX/F

System ELECTRICAL INSTALLATION

ATA/Sub ATA ATA 92 - 00 Number

Equip. ELECTRICAL EQUIPMENTFOR CABIN INTERIOR

AirworthinessCriticalityCategory

Development N/AAssurance Level

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RECORD OF REVISIONS

ISSUE DATE EFFECT ON REASON FOR REVISION

PAGE PARA

FIGURE

TABLE

12222222222222222222222222222222

20.11.03May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04May 04

ALL17182020212425262742454648495762636567778896

112113114116118127130141143

ALLTable 5Table 8Table 9Figure 22.1.3.3.3Table 112.1.4.12.1.4.2

2.2Figure 21Figure 24

2.4.32.4.7

2.4.7.22.4.14.5Table 19

2.4.17.1.12.4.17.1.22.4.17.1.4Figure 48

2.6.42.7.3

Figure 792.10.1

2.10.2.1.12.10.2.1.2

2.10.62.11.7

2.11.10Table 31Table 32

FIRST ISSUESystem identification corrected

Table completedTable simplifiedFigure corrected

Text revisedOptical Routes added, Text revised

Chapter addedChapter “Crossing of bundles” added

Chapter revisedFigure added

Figure completedRequirement 899-1 addedHazardous area defined

Replacement of plastic with non-metallicReplacement of 5 times with 6 times

ABS1224 added ABS1339 added, new standard clamp

No standard clamp any longer ABS1224 added

Separator ABS1144 addedDescription of ABS0887 addedFloating insert ABS1006 added

Figure revisedText revised

Text an figures revisedEss/ Non-Ess

ASNE number corrected / Requir. revisedReplacement of 4m with 1mRequirement 649-1 deleted

Documents addedDocuments added

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TABLE OF CONTENTS1 GENERAL ...................................................................................................11 1.1 PURPOSE/ SCOPE/ OBJECTIVES OF THE EDR .........................................................11 1.2 TERMS, DEFINITIONS AND ABBREVIATIONS............................................................12 1.2.1 TERMS, DEFINITIONS.................................................................................................................................12

1.2.1.1 KEYWORD .............................................................................................................................................12 1.2.1.2 SAFETY AND RELIABILITY...................................................................................................................13

1.2.2 ABBREVIATIONS ........................................................................................................................................14

2 ELECTRICAL REQUIREMENTS ................................................................16 2.1 WIRING SEGREGATION................................................................................................16 2.1.1 ALLOCATION OF ELECTRICAL AND OPTICAL CABLES IN ROUTES .................................................. 16

2.1.1.1 CATEGORIES OF ROUTES ..................................................................................................................17 2.1.2 ROUTE DESIGNATION................................................................................................................................19 2.1.3 SEGREGATION RULES ..............................................................................................................................19

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 SEGREGATION BETWEEN ROUTE CATEGORIES.................................................................................. 24 2.1.4.1 DISTANCES BETWEEN BUNDLE AND ELECTRICAL DEVICES........................................................ 25

2.1.4.2 CROSSING OF SEPARATING BUNDLES AND CONDUITS................................................................26 2.2 POWER SUPPLY............................................................................................................27 2.3 CABLE SELECTION.......................................................................................................28 2.3.1 SELECTION OF CABLE-TYPE....................................................................................................................28 2.3.2 SELECTION OF CONTACTS AND TERMINAL LUGS...............................................................................29 2.3.3 CABLE SELECTION FOR GROUNDING/ BONDING.................................................................................29 2.3.4 TEMPERATURE EFFECTS ......................................................................................................................... 29

2.3.4.1 "OUT-OF-BUNDLE" UTILISATION.........................................................................................................29 2.3.4.2 "IN-BUNDLE" UTILISATION...................................................................................................................29

2.4 CABLE AND BUNDLE INSTALLATION ........................................................................35 2.4.1 DISTANCES.................................................................................................................................................. 35

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2.4.1.1 DISTANCES BETWEEN BUNDLE AND STRUCTURAL ITEMS (EXCEPT COMPOSITECONDUCTIVE STRUCTURE)................................................................................................................35

2.4.1.1.1 FOR INTERSECTION: CABLE, BUNDLE - STRUCTURE.............................................................36 2.4.1.2 DISTANCES BETWEEN ELECTRIC CABLES AND CONDUCTIVE COMPOSITE

SURFACE (CARBON, GLARE…) .......................................................................................................... 37 2.4.1.3 DISTANCES BETWEEN ELECTRICAL BUNDLES/CABLES AND DIFFERENT

SYSTEMS (PIPES, MECH. CABLE…)...................................................................................................37 2.4.1.3.1 BETWEEN EL. CABLES AND MECHANICAL CABLES, MOVING PARTS ................................... 37 2.4.1.3.2 BETWEEN THE ELECTRIC CABLES AND PIPES WHICH CARRY NON-

INFLAMMABLE LIQUIDS OR GASES.............................................................................................38 2.4.1.3.3 DISTANCE TO GASEOUS OXYGEN..............................................................................................38

2.4.2 PRINCIPLE OF SUPPORT INSTALLATION ............................................................................................... 40 2.4.2.1 DISTANCES BETWEEN SUPPORTS....................................................................................................40 2.4.2.2 SHARP EDGES......................................................................................................................................41 2.4.2.3 DISTANCES BETWEEN CONDUITS AND SHARP STRUCTURE.......................................................41 2.4.2.4 CLAMP....................................................................................................................................................42 2.4.2.5 STAND OFF (SPACER) .........................................................................................................................42 2.4.2.6 ATTACHMENT OF HARNESSES BENDING RADIUS.......................................................................... 43

2.4.3 DRIP LOOPS FOR FLUIDS .........................................................................................................................44 2.4.4 JUNCTIONS..................................................................................................................................................46 2.4.5 WIRING JOINING ON THE EQUIPMENT REMOVABLE FROM THE FORWARD FACE......................... 47 2.4.6 INTERFACE CONNECTION POSITIONING................................................................................................47

2.4.7 ELECTRICAL INSTALLATION POSITIONED IN CONTAMINATION AREAS .......................................... 48 2.4.7.1 ELECTRICAL CONNECTIONS POSITIONING .....................................................................................49 2.4.7.2 FLUID INGRESS PROTECTION OF ELECTRICAL EQUIPMENT........................................................49

2.4.8 INSTALLATION OF BUNDLES ON CONDUCTIVE COMPOSITE PARTS................................................ 50 2.4.8.1 BUNDELS ON CONDUCTIVE COMPOSITE SURFACE.......................................................................50

2.4.8.1.1 INTERSECTION: BUNDLE AND COMPOSITE CONDUCTIVE STRUCTURE .............................. 52 2.4.8.2 ELECTRICAL EQUIPMENT ON COMPOSITE CONDUCTIVE STRUCTURE...................................... 53

2.4.9 OPTICAL CABLE INSTALLATION..............................................................................................................54 2.4.10 INSTALLATION ON MOVING MECHANICAL PARTS ...............................................................................54 2.4.11 COMPATIBILITY OF CONDUCTIVE MATERIALS .....................................................................................54 2.4.12 FIXATION SCREW.......................................................................................................................................56 2.4.13 ARRANGEMENT AND INSTALLATION OF P ROUTES............................................................................56 2.4.14 CABLE BUNDLE BENDING RADIUS ......................................................................................................... 56

2.4.14.1 26 TO 12 GAUGE COPPER................................................................................................................... 56 2.4.14.2 BENDING RADIUS OF COPPER AND ALUMINIUM CABLES (P ROUTES) ....................................... 56 2.4.14.3 BENDING RADIUS OF COAXIAL CABLE .............................................................................................56 2.4.14.4 BENDING RADIUS OF OPTICAL CABLE.............................................................................................. 57 2.4.14.5 BENDING RADIUS OF QUAD CABLE (DATABUS CABLES)............................................................... 57 2.4.14.6 BENDING RADIUS OF BUNDLES.........................................................................................................57

2.4.15

CABLE LENGTHS........................................................................................................................................57 2.4.15.1 CALCULATION OF THE BUNDLE LENGTH .........................................................................................57

2.4.15.2 ELECTRICAL CABLE OVER- LENGTH................................................................................................. 57

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2.4.15.2.1 CABLE LENGTHS FOR REPAIRS FOR COPPER CABLES.......................................................... 58 2.4.15.3 OPTICAL CABLE OVER LENGTH.........................................................................................................58

2.4.15.4 COAXIAL CABLE OVER LENGTH......................................................................................................... 58 2.4.15.5 QUAD CABLE OVER LENGTH (AFDX)................................................................................................. 58 2.4.15.6 STOWAGE AREA FOR BUNDLE LENGTH CONTROL ........................................................................58

2.4.16 PRECAUTIONS TO ENSURE CORRECT CONNECTOR MATING ........................................................... 60 2.4.16.1 BY CONNECTORS.................................................................................................................................60 2.4.16.2 BY ROUTING..........................................................................................................................................61 2.4.16.3 BY CHAINS.............................................................................................................................................61

2.4.17 FIXING ..........................................................................................................................................................62 2.4.17.1 HARNESSES FIXING PRODUCTS ....................................................................................................... 62

2.4.17.1.1 FIXING BY PLASTIC CLAMPS ABS 1339 ......................................................................................63 2.4.17.1.2 FIXING BY METALLIC CLAMPS NSA 5516 ...................................................................................65 2.4.17.1.3 FIXING BY V SUPPORT TYPE NSA 935504..................................................................................66 2.4.17.1.4 FIXING OF MODULAR CABLE SUPPORT ABS 1224....................................................................67 2.4.17.1.5 FIXING OF OPTICAL CABLES........................................................................................................ 67 2.4.17.1.6 FIXING OF OPTICAL CABLES INSTALLED INSIDE ELECTRICAL HARNESSES....................... 69

2.4.17.1.6.1 FIXING OF OPTICAL CABLES INSTALLED OUTSIDE ELECTRICALHARNESSES TBC......................................................................................................................69

2.4.17.1.6.2 SEPARATE ROUTING ............................................................................................................... 70 2.4.17.1.6.3 ROUTINGS ON ELECTRICAL HARNESS................................................................................. 70 2.4.17.1.6.4 OUTSIDE CLAMPS ....................................................................................................................72 2.4.17.1.6.5 INSIDE NSA 5516 OR PLASTIC CLAMP ABS1 1339 ...............................................................72

2.4.17.1.7 FIXING OF COAX CABLES............................................................................................................. 72 2.4.17.1.8 ADHESIVE FASTENERS ................................................................................................................ 74

2.4.17.2 FIXING OF ELECTRICAL HARNESSES WITH PROTECTION ............................................................74 2.4.17.2.1 ATTACHMENT OF RIGID CONVOLUTED CONDUITS ABS 0887 ................................................ 74 2.4.17.2.2 ATTACHMENT OF TEXTILE CONDUITS EN 6049-006/007..........................................................74 2.4.17.2.3 ATTACHMENT OF CONDUITS CONNECTED TO A CONNECTOR............................................. 74 2.4.17.2.4 ACCORDANCE BETWEEN BACKSHELL ASNE 0199 (INOX/ASNE 0455 ALU) AND

CONDUIT ABS 0887........................................................................................................................75

2.4.17.3 FIXING OF ROUTES CONTAINING 1 OR 2 WIRES............................................................................. 75 2.4.18 USE OF SEPARATORS...............................................................................................................................76

2.4.18.1 ON BUNDLES.........................................................................................................................................76 2.4.18.1.1 SEPARATORS TYPE ABS 1144..................................................................................................... 77 2.4.18.1.2 SEPARATORS TYPE ABS 0054..................................................................................................... 77

2.4.18.2 ON RIGID CONVOLUTED CONDUITS/ SHIELDED CONDUITS..........................................................78 2.4.19 INSTALLATION OF NON- CODED EQUIPMENT....................................................................................... 78

2.4.19.1 “IN LINE” NON-CODED EQUIPMENT ................................................................................................... 78 2.4.19.2 INSTALLATION OF ACTIV NON- CODED EQUIPMENT......................................................................78 2.4.19.3 INSTALLATION OF ELCETRONIC DEVICES ON MODULE ................................................................79

2.5 HARNESS CONSTRUCTION .........................................................................................80 2.5.1 BUNDLE DIAMETER ...................................................................................................................................80 2.5.2 TYING ...........................................................................................................................................................82

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2.5.2.1 HARNESS TYING...................................................................................................................................82 2.5.2.2 USE OF CABLE TIES BETWEEN ESSENTIAL AND NON-ESSETIAL HARNESSES ......................... 82

2.5.2.3 TYING OF PROTECTED BUNDLES...................................................................................................... 83 2.6 PROTECTION AND INSTALLATION OF PROTECTION...............................................84 2.6.1 USE OF CONDUITS MADE OF INSULATING MATERIAL ........................................................................84 2.6.2 PROTECTION BY SPLIT ELASTOMERE CONDUIT ABS 0596................................................................ 85

2.6.2.1 CONDUIT OVERLAP..............................................................................................................................85 2.6.2.2 TYING .....................................................................................................................................................85

2.6.3 PROTECTION BY SPLIT CONDUIT EN 6049-006/007 (TEXTILE WOVEN CONDUIT) ............................ 86 2.6.3.1 CONDUIT OVERLAP..............................................................................................................................86 2.6.3.2 TYING .....................................................................................................................................................87

2.6.4 PROTECTION BY PEEK CONDUIT ABS0887............................................................................................88 2.6.4.1 CONDUITS FILLING...............................................................................................................................90 2.6.4.2 DRAINING OF RIGID CONVOLUTED CONDUITS ...............................................................................90

2.6.5 BONDING JUMPER PROTECTION.............................................................................................................90 2.6.6 PROTECTION BY HEAT- SHRINK SLEEVES............................................................................................91 2.6.7 PROTECTION OF OPTICAL CABLE .......................................................................................................... 91 2.6.8 PROTECTION BY TAPE.............................................................................................................................. 92

2.6.8.1 ASNA 5107 .............................................................................................................................................92 2.6.8.2 ABS 5334................................................................................................................................................ 92

2.6.9 PROTECTION OF CABLES ON BACKSHELL...........................................................................................92

2.6.9.1 ON CLOSED METAL BACKSHELLS (CLAMPS)...................................................................................92 2.6.9.2 FILLING, PROTECTING OF OPTICAL CABLES ON BACKSHELLS....................................................93

2.6.10 PROTECTION OF CONNECTION ELEMENTS...........................................................................................93 2.6.10.1 LUG INSULATION PROTECTION ......................................................................................................... 93 2.6.10.2 ANCILLARY PLUG CONNECTORS ...................................................................................................... 93

2.7 PANELS AND BOXES....................................................................................................95 2.7.1 RIVETS ON BOXES OR ELECTRICAL PANELS.......................................................................................95 2.7.2 ARRANGEMENT OF EQUIPMENT ON PANELS .......................................................................................95 2.7.3 FIXING OF PANELS AND BOXES .............................................................................................................. 96 2.7.4 FIXING INSIDE PANELS AND BOXES ....................................................................................................... 96 2.7.5 USING SPACER INSIDE PANEL.................................................................................................................96 2.7.6 FIXING OF HARNESS HINGE ..................................................................................................................... 96 2.7.7 SWITCH POSITIONS ................................................................................................................................... 98 2.7.8 ILLUMINATED PUSH- BUTTONS ...............................................................................................................99 2.7.9 PRECAUTION TO INSURE A CORRECT RELAY MATING....................................................................... 99 2.8 CONNECTORS AND BACKSHELLS...........................................................................100 2.8.1 PINS AND SOCKETS.................................................................................................................................100 2.8.2 PROTECTION / STORAGE OF UNUSED CONNECTORS....................................................................... 100 2.8.3 INSTALLATION DIRECTION.....................................................................................................................100 2.8.4 CONNECTIONS.......................................................................................................................................... 100 2.8.5 DISTANCE BETWEEN CONNECTORS....................................................................................................100 2.8.6 FIXING OF CONNECTORS........................................................................................................................101

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2.8.7 INSTALLATION OF CIRCULAR CONNECTORS .....................................................................................101 2.8.7.1 EN 2997 CONNECTORS .....................................................................................................................102

2.8.8 INSTALLATION OF RECTANGULAR CONNECTORS EN 3545 .............................................................103 2.8.9 INSTALLATION OF BACKSHELLS .......................................................................................................... 104

2.8.9.1 ELBOW BACKSHELL ORIENTATION.................................................................................................104 2.8.9.2 BACKSHELLS ON OPTICAL CONNECTORS.....................................................................................105

2.8.10 SEALING OF CONNECTORS....................................................................................................................105 2.8.10.1 SEALED CONNECTORS.....................................................................................................................105 2.8.10.2 CONTACTS NOT IN USE AND SEALING PLUGS.............................................................................. 106

2.8.11 SEALING OF CONNECTIONS WITH TERMINAL LUGS (TR) .................................................................106 2.8.12 SEALING OF CONNECTIONS WITH TERMINAL BLOCK MODULE NSA 937901M ............................. 106 2.9 TERMINAL BLOCK AND LUG INSTALLATION..........................................................107 2.9.1 MODULE POSITIONING SEQUENCE ON TERMINAL RAIL (E.G.: NSA 937901) ................................. 107 2.9.2 INSTALLATION OF SEVERAL LUGS ON TERMINAL (E.G. NSA 937905) ............................................108 2.9.3 BENDING OF LUGS...................................................................................................................................108 2.9.4 INSTALLATION OF TERMINAL LUGS ..................................................................................................... 109 2.9.5 USE OF WASHER ON TERMINAL BLOCK..............................................................................................109

2.9.5.1 SPRING WASHER ASNA 2553 ........................................................................................................... 109 2.9.5.2 ADDITIONAL WASHER........................................................................................................................109

2.9.6 INSTALLATION OF LUGS ON CIRCUIT BREAKERS .............................................................................109 2.9.7 INSTALLATION OF DIFFERENT TYPES OF TERMINAL LUGS............................................................. 109

2.9.7.1.1 TERMINAL LUG INSTALLATION ORDER....................................................................................109 2.9.7.1.2 LUG/WASHER/NUT INSTALLATION ORDER.............................................................................. 110

2.9.8 TERMINAL BLOCK PROTECTION AND INSTALLATION....................................................................... 111 2.9.9 CONNECTION OF TWO OR THREE CABLES IN TERMINAL LUG AND SPLICE................................. 112 2.10 GROUNDING AND BONDING......................................................................................113 2.10.1 DEFINITION / WORDING...........................................................................................................................113 2.10.2 GROUNDING AND BONDING POINTS .................................................................................................... 114

2.10.2.1 GROUNDING AND BONDING VIA BRACKETS..................................................................................114 2.10.2.1.1 FIXED BRACKETS ........................................................................................................................114 2.10.2.1.2 REMOVABLE BRACKETS ............................................................................................................ 116

2.10.3 GROUNDING OF EQUIPMENT IN MONUMENTS.................................................................................... 117 2.10.4 BONDING AND GROUNDING RESISTANCE...........................................................................................117 2.10.5 TERMINAL LUGS.......................................................................................................................................118 2.10.6 BONDING JUMPERS.................................................................................................................................118 2.10.7 SURFACE PREPARATION AND PROTECTION......................................................................................119 2.10.8 BONDING OF EQUIPMENT.......................................................................................................................119

2.10.8.1 GENERAL REQUIREMENTS...............................................................................................................119 2.10.8.2 BONDING OF ELECTRICAL EQUIPMENT .........................................................................................120

2.10.8.2.1 BOXES, PANELS; OPERATING DEVICES ..................................................................................120

2.10.8.2.2 BONDING OF NON-ESSENTIAL MONUMENTS/ EQUIPMENT..................................................120 2.10.8.3 BONDING OF CONDUCTIVE PARTS EXPOSED TO CREW / PASSENGER................................... 120

2.10.9 BONDING OF COAXIAL CONNECTORS:................................................................................................ 120

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2.11 IDENTIFICATION OF CABLES ....................................................................................122 2.11.1.1 IDENTIFICATION RULES ACCORDING TO CABLE CATEGORIES.................................................. 122 2.11.1.2 UNIDENTIFIED CABLES......................................................................................................................122 2.11.1.3 IDENTIFICATION BY SLEEVES.......................................................................................................... 122 2.11.1.4 PRINTABLE CABLES...........................................................................................................................122 2.11.1.5 BASIC OR SHIELDED MULTICORE CABLE.......................................................................................123 2.11.1.6 SPECIFIC CASES ................................................................................................................................123

2.11.2 FIN IDENTIFICATION ON HARNESS ENDS ............................................................................................124 2.11.2.1 IDENTIFICATION SLEEVE/LABEL ON BUNDLES .............................................................................125

2.11.3 OPTICAL HARNESSES.............................................................................................................................126 2.11.4 PHASE IDENTIFICATION SLEEVES ........................................................................................................ 126 2.11.5 FOR MULTICORE CABLES AND TWISTED CABLES WITH OR WITHOUT SCREEN.......................... 126 2.11.6 HARNESS IDENTIFICATION MARKER....................................................................................................126

2.11.6.1 USUAL HARNESSES...........................................................................................................................126 2.11.7 ROUTE IDENTIFICATION MARKERS ...................................................................................................... 127 2.11.8 ADDITIONAL IDENTIFICATION ................................................................................................................ 127

2.11.8.1 ADDITIONAL IDENTIFICATION FOR OPTICAL CABLES AND BUNDLES ....................................... 127 2.11.9 IDENTIFICATION OF PANELS AND BOXES ...........................................................................................127

2.11.9.1 ON VE...................................................................................................................................................128 2.11.9.2 ON ARINC 600 EQUIPMENT............................................................................................................... 128 2.11.9.3 ON EQUIPMENT..................................................................................................................................129

2.11.9.4 IDENTIFICATION IN SMALL VE´S ...................................................................................................... 129 2.11.10 LABEL IDENTIFICATION ON STRUCTURAL PART ...............................................................................130

2.11.10.1 LABELS FOR VOLTAGE > 42 VOLTS.......................................................................................... 130 2.11.10.2 LABEL POSITIONING ................................................................................................................... 131

3 DESIGN PROCESS REQUIREMENTS.....................................................132 3.1 GENERAL.....................................................................................................................132 3.2 REQUIREMENTS AND RULES FOR MATERIAL QUALIFICATION...........................132 3.3 ENVIRONMENTAL REQUIREMENTS..........................................................................132 3.3.1 TEMPERATURE.........................................................................................................................................133 3.3.2 ALTITUDE, PRESSURE.............................................................................................................................133 3.3.3 TEMPERATURE VARIATION....................................................................................................................133 3.3.4 HUMIDITY...................................................................................................................................................133 3.3.5 SHOCK AND CRASH SAFETY .................................................................................................................133 3.3.6 VIBRATIONS ..............................................................................................................................................134 3.3.7 WATERPROOFNESS ................................................................................................................................134 3.3.8 FLUIDS SUSCEPTIBILITY.........................................................................................................................134 3.3.9 FUNGUS RESISTANCE.............................................................................................................................134 3.3.10 SALT SPRAY..............................................................................................................................................134

3.3.11 CORROSION ..............................................................................................................................................135 3.3.12 HERMETIC..................................................................................................................................................135 3.3.13 FIRE ............................................................................................................................................................135

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3.3.14 FLAMMABILITY/ SMOKE/ TOXICITY (FIREWORTHINESS DESIGN CRITERIA) .................................. 135 3.4 ELECTRICAL REQUIREMENTS..................................................................................135 3.4.1 CABLES......................................................................................................................................................136 3.4.2 OPTICAL CABLES.....................................................................................................................................136 3.4.3 CONNECTORS........................................................................................................................................... 136 3.4.4 OPTICAL CONNECTORS..........................................................................................................................137 3.4.5 CONTACTS ................................................................................................................................................137 3.5 QUALIFICATION TEST PLAN/ QUALTIFICATION TEST REPORD

(QTP/QTR) ....................................................................................................................138

4 APPENDIX.................................................................................................139 4.1 PURPOSE OF THE APPENDIX....................................................................................140 4.2 AIPS (AIRBUS INDUSTRIES PROCESS SPECIFICATION) .......................................141 4.2.1 GENERAL................................................................................................................................................... 141 4.3 LIST OF REFERENCED DOCUMENTS .......................................................................141 4.3.1 AIPS ............................................................................................................................................................141 4.3.2 STANDARDS.............................................................................................................................................. 142 4.3.3 ATTACHMENT OF DOCUMENTS............................................................................................................. 144 4.4 ELECTRICAL STANDARD ITEMS...............................................................................144 4.4.1 GENERAL................................................................................................................................................... 144 4.4.2 STANDARD SELECTION LIST..................................................................................................................144 4.4.3 STANDARDS.............................................................................................................................................. 144

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1 GENERAL

1.1 PURPOSE/ SCOPE/ OBJECTIVES OF THE EDR

The purpose of this document is to specify the requirements for the installation of electrical equipmentwithin cabin interior in passenger cabins and IFE-Racks in the electrical equipment bay for the A380aircraft.

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 Equip-ment (SFE).

The EDR shall be used as reference document for integration of electrical installation requirements inTN, ITS, PTS and SES.

Every application that is not mentioned in this document or every devia-tion from the introduced applications must be explicitly approved by:

Figure 1

The EDR does not cover electrical installation of equipment / bundle on A/C-structure. For electricalinstallation 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 scope ofEDR ?

crew and passenger compartmentcargo: inside crew rest compartmentIFE-Racks

YES pressurised zones(max. temperature

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1.2 TERMS, DEFINITIONS AND ABBREVIATIONS

1.2.1 TERMS, DEFINITIONS

The meaning of terms, used in the EDR :

TERM MEANING

Panels boxes with control-/ service elements, accessible during flight

Boxes chassis containing electrical devices etc., not accessible

Structure structure of monuments, components,(non-conductive or conductive material)

not: main-A/C-structure

Conductive material conductive (metal, metalized) and at least partly conductive(conductive composite: carbon, glare..) material

Table 2 Used terms

The symbol § is used to indicate a section.

1.2.1.1 KEYWORD

The significance of each requirement is defined by a keyword.

The use of the keywords: " shall ", "shall not ”, "should ", and " may " within this document shall observethe following rules:

KEYWORD MEANING

SHALL -Denotes a mandatory requirement.-Departure from such a requirement is not permissible without formal agreement.

SHALL NOT -Denotes a mandatory prohibition.-Departure from such a requirement is not permissible without formal agreement.

SHOULD -Denotes a recommendation or advice on implementing such a requirement of thedocument.-such recommendations or advice is expected to be followed unless good reasonsare stated for not doing so.

MAY -Denotes a permissible practice or action. It does not express a requirement.

Table 3 Keywords

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1.2.1.2 SAFETY AND RELIABILITY

The installation of the electrical equipment within cabin interior shall ensure a safe and reliable opera-tion of the equipment.

The installation of the electrical equipment within cabin interior shall not create a hazard in any man-ner for injuries to persons and shall minimize the potential of human errors that would significantlyreduce the safety.

The general safety and reliability requirements are contained in the- GCP (General Conditions of purchase)- ABD0100.1.3 (Equipment-Design-General Requirements for suppliers)

- ABD0200.2.3 (Requirements and Guidelines for System Designers - Safety and ReliabilityRequirements) - if applicable -- the appropriate PTS for the particular application.

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1.2.2 ABBREVIATIONS

ABBREVIATION MEANING

ABD Airbus Directives ABS Airbus Standard

A/C Aircraft

AC Alternating Current

ACJ Advisory Circular - Joint

ACP Audio Control Panel

ADD Addition, Additional, Additive

AFDX Avionics Full Duplex Ethernet Switched

AINS Aircraft Information Network System

AIPS Airbus Industry Process Specification

AMU Audio Management Unit

ARINC Aeronautical Radio INC

ASN Aerospatiale Norme (Standard)

ATA Air Transport Association of America

ATC Air Traffic Control

APU Auxiliary Power Unit

AWG American wire gaugeCDS Control and Display System

CINS Cabin Information Network system

CoC Centre of Competence

COM Commercial

CPMS Cabin and Passenger Management System

CT Current Transformer

C/B Circuit Breaker

CWLU Cabin Wireless LAN Unit

DC Direct CurrentEFCS Electrical Flight Control System

ELT Emergency Locator Transmitter

EMC Electromagnetic Compatibility

EN European Norm

ESS BUS Essential BUS

FAA Federal Aviation Administration

FAR Federal Aviation Regulations

FEP Flour Ethylene Propylene

FIN Functional Item Number

IFE In Flight Entertainment

IMA Integrated Modular Avionics

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ABBREVIATION MEANING

ITS Internal Technical Specification

JAA Joint Airworthiness Authority (Europe)JAR Joint Aviation Requirements

MIL Military Standard

NDT Non Destructive Test

PEEK Poly Ether Ether Keton

PTFE Poly Tetra Flour Ethylene

PTS Purchaser Technical Specification

PU Parts usage

QTP Qualification Test Plan

QTR Qualification Test ReportRCCB Remote Control Circuit Breaker

SES Supplier Equipment Specification

SFAR Supplementary Federal Aviation Regulations

SIDP System Installation Design Principles

SIRD System Installation Requirement Document

SDP Supplier Development Plan

SPDB Secondary Power Distribution Box

SUB. Subsidiary

TBC To Be Confirmed

TBD To Be Defined

TDD Technical Design Directive

T/R Transmitter-Receiver

TN Technical Note

TRU Transformer Rectifier Unit

TWLU Terminal Wireless LAN Unit

VFG Variable Frequency Generator

VU/VE Electrical References

Table 4 Abbreviations

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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

2.1.1 ALLOCATION OF ELECTRICAL AND OPTICAL CABLES IN ROUTES

Due to the „Fly-by-Wire“ technology on Airbus aircraft, the installation of electrical components arebased on highest possible quality standards and therefore have to follow certain rules that are notnecessarily applicable in other industries.

For above reasons and possible electro-magnetic interference, the electrical & optical cables are in-stalled physically separated in routes.

Route: A route is the way taken by an electric cable to go from one point to another.

Routes are classified according to main criteria:

„CATEGORY OF ROUTE“ „SYSTEM ASSIGNMENT “

CATEGORY OF ROUTE

A category of route is defined according to the nature of the cables and/ or the type of signal theytransmit. The next determination is a separation of Essential and Non-Essential routes. This classifica-tion 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:

- Essential basic (phase A)- Non-Essential basic (phase A)- Non-Essential customised (phase B)- Essential customised (phase B)

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 orderto avoid that a single failure affects simultaneously both channels of a redundant system (for definitionof routes see § 2.1.1.1) . In order to maintain homogeneity in separation of systems, systems poweredby 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.

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For above mentioned reasons the design aim of wire bundle installation shall be a cable routing physi-cally 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 abso-lutely 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 ser-vice 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 P (Power distribution; >15A)o M (Miscellaneous cables)o S (Sensitive Cables)o R (Audio and Video cables).

- Power distribution: P (Ref. Table 5: POWER DISTRIBUTION (P)) This category includes power supplies of systems with loads greater than 15 A.

- Miscellaneous cables: M (Ref. to Table 6: MISCELLANEOUS ROUTES (M)) This category includes power supply up to 15 Ampere, passive cables (i.e. cables which do not ne-cessitate special separation requirements).

- Sensitive cables: S (Ref. to Table 7: SENSITIVE ROUTES (S)) This category includes cables, which are sensitive to interference.

- Audio and Video cables: R (Ref. to Table 8: AUDIO AND VIDEO ROUTES (R)) Specific routes are required for analogue audio lines in order to avoid interference.

CATEGORY ROUTE REMARKS SYSTEM

POWER DISTRIBU-TION

Rating of the protectiondevice greater than15 Ampere

1P2P3P4P

21P22P23P24P

9P10P11P12P

Essential SystemEssential SystemNon Essential SystemNon Essential System

Essential Customised SystemEssential Customised SystemNon Essential Customised SystemNon Essential Customised System

Galleys power, Commercial systemGalleys power, Commercial systemGalleys power, Commercial systemGalleys power, Commercial system

System 1System 2System 1System 2



Table 5: POWER DISTRIBUTION (P)

Segregation between P routes is required taking into consideration:- system 1 / system 2- Essential system / Non Essential system

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MISCELLANEOUS

- wiring not affectedby interference orwhich does notcause interference

- bus ARINC 429, AFDX

- low power supplies(max C/B rating: 15

A)

1M2M3M4M

21M22M23M24M

Essential SystemEssential SystemNon Essential SystemNon Essential System

Essential Customised SystemEssential Customised SystemNon Essential Customised SystemNon Essential Customised System



Table 6: MISCELLANEOUS ROUTES (M)

Note 1: As a general rule ARINC 429 cables shall be routed in M, nevertheless when fully justified forsegregation purposes some ARINC 429 cables may be routed in route S.

Note 2: Maximum voltage permissible: 115 VAC.


SENSITIVE

- wiring susceptible to interfer-ence

- low level circuits (AFDX..)

1S2S

Essential SystemEssential System

System 1System 2

Table 7: SENSITIVE ROUTES (S)

Note 1: Maximum voltage permissible: 28 VDC.

CATEGORY ROUTE REMARKS

-AUDIO / VIDEO

3R

4R

9R

10R

11R

IFE bay- Non Essential SystemTVRF coaxial route- Non Essential System

AIRFONEVideo and audio (Electrical support).Non Essential SystemVideo (Optical support)Non Essential SystemVideo (Optical support)Essential System

Table 8: AUDIO AND VIDEO ROUTES (R)

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2.1.2 ROUTE DESIGNATIONThe designation of the electrical routes comprises a number of digits allowing unambiguous identifica-tion of the electrical routes.

Generally, this designation is related to segregation and allows the physical separation of the electricalwiring and/or interconnections to be guaranteed and verified.

Routes R generally only comprise 2 digits. Routes P, M and S may have up to 6 digits.

Only the 1 st ,2 nd and 3 rd digit are of interest to the EDR, digit 4-6 are used for Airbus internal designa-tions:

1st and in some cases 2 nd digit: Assignment of system to route e.g.: 1, 2, 3….(a route namedwith a 2 in front, shows a cus-tomised route, e.g.: 21, 22,23...)

2nd or 3 rd digit: A letter shows the Category of route e.g.: M, S...

2.1.3 SEGREGATION RULES

2.1.3.1 GENERAL

D-CGU-10-9200-726-1 No single electrical failure should affect simultaneously electrical supplies of aircraft

system 1 and system 2.

D-CGU-10-9200-727-1 Route segregation shall be maintained throughout the aircraft inclusive of productionbreak joints, connections and wiring.This also applies to cabin interior equipment including sub components.

D-CGU-10-9200-728-1 Any deviation from this rule shall be dealt with as a special case and reported toECGU1 (Cabin Electric Overall).

2.1.3.2 SEGREGATION OF SYSTEM 1 AND SYSTEM 2 ROUTES

D-CGU-10-9200-730-1 Routes of system 1 and routes of system 2 shall not be mixed

(in all electrical & optical areas, including racks, boxes and panels).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 particularcase.

D-CGU-10-9200-782-1 Segregation should be ensured by physical wiring segregation, distances see §2.1.4 segregation between route Categories.

D-CGU-10-9200-732-1 Only when segregation cannot be ensured by physical wiring segregation (distances),this shall be ensured by approved protective elements (see § 2.6 Protection and instal-lation of protection) which will be added to the harnesses.

D-CGU-10-9200-733-1 When electrical equipment is powered by system 1 and 2, the grounding plate shall beallocated to System 1.

D-CGU-10-9200-878-1 A drawing which shows the route segregation should be provided by the supplier.

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2.1.3.3 SEGREGATION OF ESSENTIAL AND NON-ESSENTIAL ROUTES

2.1.3.3.1 MIXING OF ESSENTIAL/NON-ESSENTIAL HARNESSES

Table 9 shows how Essential and Non-Essential routes are allowed to fit together.

Master routingFitted on Essential Basic Essential

CustomisedNon-Essential

BasicNon-EssentialCustomised

EssentialCustomised

Not acceptable Not acceptable

Not acceptableException: same

electrical item (e.g.galley, crew restcompartment...,equipment, VU,

VE...), see2.1.3.3.3

Non-EssentialCustomised

Not acceptable

Not acceptableException: same

electrical item (e.g.galley, crew restcompartment...,equipment, VU,

VE...), see2.1.3.3.3

Acceptable(Dedicated routing

and dedicatedconnectors are

preferred)

Table 9

Note : Same system is the essential condition to fit two harnesses together!

2.1.3.3.2 GENERAL INSTALLATION PRINCIPLE

D-CGU-10-9200-862-1 Essential and Non-Essential Routes shall have a dedicated routing and dedicatedconnectors, see Figure 2.

Figure 2

23M

connectors

21M

CabinInteriorEquipment

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2.1.3.3.3 PARTICULAR CASES

D-CGU-10-9200-865-1 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 routedtogether, according to the following conditions see Figure 3.For electrical items connected to multi-circuit harne sses:- 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 har-

nesses. A TDD 92 deviation shall be issued.- A pin separation within the connector for equipments designed without connectors

segregation shall be provided

Figure 3

Note: The preferred installation of the electrical protection is on the essential bundle. For the installa-tion of PEEK conduit see 2.6.4.

2.1.3.3.4 ESSENTIAL/NON ESSENTIAL CABLE SUPPORT

D-CGU-10-9200-869-1 The design shall ensure that the installation of Non-Essential harnesses is possiblewithout action on the Essential harnesses.

D-CGU-10-9200-870-1 The design shall ensure that the installation of Essential Customised harnesses ispossible without action on the Essential Basic harnesses.

23M

EQ

Electrical items connected tomulti-circuit harnesses

Electrical items connected tosingle circuit harnesses

23M21M

21M

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2.1.3.4 SEGREGATION OF ROUTE CATEGORIE M AND S

D-CGU-10-9200-783-1 Routes M and S shall not be mixed (in all electrical & optical areas, including racks,boxes and panels).

2.1.3.5 SEGREGATION WITHIN CONNECTOR AND TERMINAL MODULE

Applicable for system 1 and 2 and route P, M & S.

D-CGU-10-9200-740-1 For connector racks, segregation of the basics routes (1M - 2M - 1S - 2S) shall beensured up to ARINC 600 connector inlet. This segregation shall be achieved by a re-liable 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 thesame as that of the connector segregation except for connectors’ racks, which requiremore stringent control.

2.1.3.5.1 OPTICAL CONNECTOR

D-CGU-10-9200-743-1 The mix of optical and electrical technology in the same connector is forbidden (exceptfor ARINC404 and ARINC 600) in order to avoid dust and contamination on opticalcontacts (mating aspect).

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2.1.3.6 SEGREGATION OF GROUNDING (CURRENT RETURN) AND BONDING

GROUND POINTS

SIGNAL SIGNAL TYPE

ESSSYST 1

&Ess

Cust.Syst 1

ESSSYST 2

&Ess

Cust.Syst 2

Non-ESS

SYST 1&

Non-EssCust.Syst 1

Non-ESS

SYST 2&

Non-EssCust.Syst 2

REMARKS

28 Vand discrete signal DC 1 DC 2 DC3 DC 4 /

6 V 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 /

5 V 5 AC 1 5 AC 2 5 AC 3 5 AC 4 /

All cable shields andEQUIPMENT bonding

(except audio-com)General B 1 B 2 B 3 B 4 /

Audio-com General S

All low signalsand screeningfor audio-com

are in thiscategory

Table 10

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D-CGU-10-9200-884-1 In general minimum distances of 25mm between each route of the same category arerequired (e.g 1P and 2P).

D-CGU-10-9200-047-1 The distances given by Table 11 Minimum distances between routes-shall be respected on the overall length of the harness.-shall consider slagging of cable / bundle-shall be ensured during lifetime.

D-CGU-10-9200-886-1 For a same system side, the minimum clearance between Essential basic andEssential customised harnesses (e.g. : 1M/21M) shall be 25mm.

Figure 4 Segregation Distances (Cross-Section-View)

2.1.4.1 DISTANCES BETWEEN BUNDLE AND ELECTRICAL DEVICES

D-CGU-10-9200-898-1 Distances between bundles and electrical devices shall be according to Table 11. Fora reduction of this distance a system specialist shall be contacted. A possible reduc-tion depends on the electrical device.

Figure 5

Bundlee.g.: M Non-Ess Customised

Attachment point

Segregation distancegiven in: Table above

Segregation distancegiven in: Table abovee.g.: 25 mm

Bundlee.g.: M Ess Customised

Electrical Device

structure

Distance according to Table 11

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2.1.4.2 CROSSING OF SEPARATING BUNDLES AND CONDUITS

D-CGU-10-9200-900-1 Crossing bundles or conduits shall be physically separated. If this is not possible theyshould be separated with a specific device (e. g. separator see 2.4.18) . Physicallyseparated means that only chafing aspects are necessary to take into consideration(see Figure 6) .

Figure 6

D-CGU-10-9200-901-1 For crossing of feeder cables a minimum distance of 5 mm between the cables isrequired.

Route x

Route y

NO CHAFINGALLOWED

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2.3 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.

2.3.1 SELECTION OF CABLE-TYPE

D-CGU-10-9200-819-1 Cable type shall be selected as shown in table below:For equipment (Boxes, Panels, Monuments, Racks) cooper-type cable shall be used.

AIRCRAFT ZONING / ROUTE CABLE TYPE GAUGE (AWG)

Boxes, Panels, Monuments, Racks

Grounding and BondingDR-Family ALL

P route AD-Family ALL

Table 12

D-CGU-10-9200-849-1 For Interface-Connector:In case of different cable-types / cable gauges the matching of pins and sockets shallbe ensured.Background: Aicraft-wiring may be defined as Aluminium-type cable.Therefore cable-type on interface connector (between Aicraft-side connector andequipment connector) may be of different type and - because of different electrical re-sistances - 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-typecable AWG24).

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2.3.2 SELECTION OF CONTACTS AND TERMINAL LUGSD-CGU-10-9200-821-1 Contact and terminal lugs shall be chosen according to Table 13:

Copper Cable Connection Principle Aluminium Cable Connection Principle

# 26 Contact # 10 to # 4 Contact / Terminal Lug

# 24 to # 6 Contact / Terminal Lug # 3 to # 000 Terminal Lug

# 4 to # 000 Terminal Lug

Table 13

Note: Above 23 Amps terminal blocks shall be used.

D-CGU-10-9200-822-1 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 onoperating performances of all connector parts and accessories.Type and size of contacts as well as type of connector shells and accessories shall beselected taking into account this effect.

2.3.3 CABLE SELECTION FOR GROUNDING/ BONDINGsee § 2.10 Grounding and Bonding

2.3.4 TEMPERATURE EFFECTS

2.3.4.1 "OUT-OF-BUNDLE" UTILISATION

D-CGU-10-9200-825-1 The wire temperature due to Joule effect (temperature increase, electrical heating) outof bundle shall not exceed 25°C.

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 jouleeffect temperature rise under 20°C ( Figure 8 Cable temperature with respect to its intensity Out-of-bundle ).

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 (temperaturerice, electrical heating) shall not exceed 40°C.

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The temperature depends on the number of cables making up the bundle and the current intensity. Asthe number of cables is fixed, the bundle temperature can only be limited by decreasing the wiregauge 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 61°C (> 40°C).Thus we should take a 22 gauge wire. The joule effect heating will be then about 35°C (

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Figure 9 Cable temperature with respect to its intensity Out-of-bundle


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Figure 13 Derating coefficient with respect to the bundle load

N u m

b e r o

f c a b

l e s

1 3

1 5

1 7

1 9

2 1

2 3

2 5

2 7

2 9

3 1

3 3

3 5

3 7

3 9

1 0 0 %

8 0 %

6 0 %

4 0 %

2 0 % P

e r c e n t

l o a d e d

D e r a t

i n g c o e f

f i c i e n t w

i t h r e s p e c

t t o

t h e

b u n d

l e

0 . 3

0 . 4

0 . 5

0 . 6

0 . 7

0 . 8

0 . 9

1 . 0

1

3

5

7

1 1

C O E F F I C I E N T ( d e r a t i n g )

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2.4 CABLE AND BUNDLE INSTALLATION Applicable also for optical cables.

Wording:- Bundle, Harness: see § 2- Secured position of cable /bundle: Distance/design of supports/fasteners shall be defined such

that in no case (slag, vibration etc.) the required distance (L) may be reduced through any kindof relative movement (slack, acceleration, vibration..).

- Secured attachment point: clamps, carriers or some other suitable attachment systems

2.4.1 DISTANCES

The Top priority aim of wire bundle design/installation shall be a cable routing physically separated bydistances (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 Distances shall be ensured until the end of the aircraft life.

2.4.1.1 DISTANCES BETWEEN BUNDLE AND STRUCTURAL ITEMS (EXCEPT COMPOSITECONDUCTIVE STRUCTURE)

D-CGU-10-9200-837-1 Any direct contact between electrical cables and metalic / non-metallic structure shallbe 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.

Figure 14

L≥ 10 mm

metallic / non-metallic structure 2)

≤ 200 mm

for distance L ≥ 10mm

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D-CGU-10-9200-850-1 Except for P-routes:Distance between structure and bundle protected with convoluted conduit ABS0887may be reduced to L=0 mm if there is no relative movement between structure andconduit

Figure 15

2.4.1.1.1 FOR INTERSECTION: CABLE, BUNDLE - STRUCTURE

Figure 16

for distance L= 0mm –10mmexcept for P-routes


≤ 120mm

mech. andelectrical protection(conduit ABS 0887)

L= 0mm

support

L ≥ 10mm


with secured attachment point 1)


≤ 120mm ≤ 120mm

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Figure 17

2.4.1.2 DISTANCES BETWEEN ELECTRIC CABLES AND CONDUCTIVE COMPOSITE SURFACE(CARBON, GLARE…)

see § 2.4.8 INSTALLATION OF BUNDLES ON CONDUCTIVE COMPOSITE PARTs

2.4.1.3 DISTANCES BETWEEN ELECTRICAL BUNDLES/CABLES AND DIFFERENT SYSTEMS(PIPES, MECH. CABLE…)

2.4.1.3.1 BETWEEN EL. CABLES AND MECHANICAL CABLES, MOVING PARTS

D-CGU-10-9200-838-1 Between the electrical cables and:- Pipes carrying flammable liquids [e.g.: Fuel, hydraulic fluid, … (except gaseousoxygen)],- Mechanical cables,- Moving parts,- the distance should be 50 mm .

1) Distance/ design of supports shall be defined such, that in no case (slag, vibration etc.) the re-quired 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.


bundle


support

≤ 200 mm

L = 25mm

L = 20mm

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D-CGU-10-9200-839-1 Only if these distances cannot be observed:For distance 25 mm ≤ d < 50 mm, cables or bundles-shall be protected by conduits or sleeves.

Or -shall be secured by attachment point (Clamps, carriers or some other suitableattachment system) to ensure a distance of 25 mm minimum.

D-CGU-10-9200-840-1 Distances less than 25 mm shall be strictly prohibited.

2.4.1.3.2 BETWEEN THE ELECTRIC CABLES AND PIPES WHICH CARRY NON-INFLAMMABLE LIQUIDS OR GASES

D-CGU-10-9200-842-1 For P routes, the distance shall be 25 mm minimum.

A distance of less than 25 mm shall be strictly prohibited . For other than P routes, the distance should be greater than 13 mm.

D-CGU-10-9200-841-1 Only if these distances cannot be observed:For distance less than 13 mm and greater than 10 mm, electrical cables or bundlesshall be-protected by conduits or sleeves.

Or-secured by attachment point (Clamps, carriers or some other suitable attachmentsystem) to ensure a distance of 10 mm minimum to non-inflammable liquids or gases.

D-CGU-10-9200-843-1 Distances of less than 10 mm shall be strictly prohibited.

2.4.1.3.3 DISTANCE TO GASEOUS OXYGEN

D-CGU-10-9200-851-1 The distance should be equal or greater than 150 mm.

D-CGU-10-9200-852-1 Only if 150mm cannot be observed, for distances 50 mm ≤ d ≤ 150 mm, electricalcables or bundles shall be- protected by conduits or sleeves (see 2.6)

Or- Supported by additional attachment point (Clamps, ramps…)

D-CGU-10-9200-853-1 Only for exceptional cases:For distances 25 mm ≤ d ≤ 50 mm, electrical cables or bundles shall be-protected by conduits or sleeves.

Or -secured by attachment point (clamps, carriers or some other suitable attachmentsystem) to ensure a distance of 25 mm minimum to oxygen components.

Alternatively, in the case where cables or electrical looms are not held securely by a suitable attach-ment or are unprotected, the oxygen pipe shall be insulated by protection made from non-corrosivematerial (the identifications shall remain visible). Or, in the case of a flexible oxygen pipe, it shall beheld 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 For P routes, a distance of less than 25 mm shall be strictly prohibited.

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D-CGU-10-9200-855-1 For other routes, for distances when the distance 13 mm ≤ d < 25 mm, electricalcables and bundles shall be:- protected by conduits or sleeves

And -secured by attachment point (Clamps, carriers or some other suitable attachmentsystem) to ensure a distance of 13 mm minimum from the oxygen components.

D-CGU-10-9200-856-1 Alternatively, in the case where cables or electrical looms are unprotected, oradditionally, the affected area of the oxygen components, such as the rigid or flexiblepipes, shall be insulated by protection made from non-corrosive material (the identifi-cations shall remain visible).- If the distance of P routes (unprotected) falls within these values, the affected sectionof the oxygen pipe shall be insulated by protection made from non-corrosive material(the identifications shall remain visible).- If the distance with a coaxial cable is within these values, the affected section of theoxygen pipe shall be insulated by non-corrosive protection material (the identificationsmust remain visible).

D-CGU-10-9200-857-1 A distance of less than 13 mm shall be strictly prohibited.

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.

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Distance ( L / mm)electr. Bundel, Cabel

/ Pipes150 < L ≤ 50 50 < L ≤ 25 25 < L ≤ 13 13 < L ≤ 10 L < 10

Mechanical cables,Moving mechanical parts Acceptable

conduitsOR

secured byattachment

point

P routes Acceptable

shall not be used

Non-flammable

liquids or gases(air, water, nitro-gen) Other than

P routes Acceptable

conduitsOR

secured byattachment

point

shall notbe used

P routesconduits

OR secured attachment point

shall not be used

Gaseous Oxygen

Other thanP routes

conduitsOR

securedattachment point

conduitsAND secured

attachmentpoint

shall not be used

Table 14

2.4.2 PRINCIPLE OF SUPPORT INSTALLATION Applicable also for optical cables

Note: Glued supports are generally prohibited.

2.4.2.1 DISTANCES BETWEEN SUPPORTS

D-CGU-10-9200-829-1 Supports and distances of supports shall be defined in such a way that in no case thecables come into contact with surrounding (metallic, non-metallic structure, equipmentstructure, 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 theequipment 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 above150°C continuous operation environments.

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2.4.2.2 SHARP EDGES

Applicable also for optical cables

D-CGU-10-9200-067-1 All sharp edges or flanged edges on the cable side shall be strictly prohibited, seeFigure 18.

Figure 18

2.4.2.3 DISTANCES BETWEEN CONDUITS AND SHARP STRUCTURE

D-CGU-10-9200-058-1 Except for P-routes, except for conductive composite:Distance between structure and bundle protected with convoluted conduit ABS 0887may be reduced to 0 mm, if there is no relative movement between structure and con-duit, see § 2.4.1.1”Distances Between bundle and structural items (except compositeconductive structure)” .

Figure 19

D-CGU-10-9200-059-1 For each support the access to clamp and fitting shall be possible.

SUPPORTS CONDUITS

SHARPSTRUCTURE

CORRECT WRONG

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2.4.2.4 CLAMP

D-CGU-10-9200-068-1 The increase of the bundle diameter (size of clamp) shall not reduce the segregationdistance (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 separa-tors) .

Figure 20

D-CGU-10-9200-069-1 V support installation shall follow the above shown principle, wether the distance maychange 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).

2.4.2.5 STAND OFF (SPACER)

D-CGU-10-9200-713-1 Generally plastic stand off ABS 1423/24 type (see Figure 21) shall be used onconductive composite surface.

Figure 21

Distance

CLAMP OR V SUPPORT

NOT PREFEREDCORRECT

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D-CGU-10-9200-714-1 Plastic stand off shall be fixed on metallic/carbon structure with rivet ASNA 0080 orNAS 1919.

D-CGU-10-9200-715-1 Metallic stand off ASNA2328/27 type may be used for mechanical reason, but not oncarbon.

D-CGU-10-9200-716-1 Stand off type shall be defined in accordance with the route temperatureE.g. : Plastic stand off for M, S and R routes.

2.4.2.6 ATTACHMENT OF HARNESSES BENDING RADIUS

Respecting cable bundle bend radius rules see chapter: ”Cable Bundle Bending radius”§ 2.4.14.

D-CGU-10-9200-082-1 Attachment points shall be installed close and before the start of bend radius axis.

Figure 22

ATTACHMENT POINT

BEND RADIUS AXIS

BUNDLE

R

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2.4.3 DRIP LOOPS FOR FLUIDS

D-CGU-10-9200-085-1 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 theconnectors 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

Figure 23

Clamp

ATTACHEMENT POINTLOWEST POINT

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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

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