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Washington, D.C. 20591
The Effects of Mixed Wire Types
in Aircraft Electrical Wiring
Interconnection Systems
September 2005
Final Report
This document is available to the U.S. public
through the National Technical Information
Service (NTIS), Springfield, Virginia 22161.
U.S. Department of Transportation
Federal Aviation Administration
NOTICE
This document is disseminated under the sponsorship of the U.S.
Department of Transportation in the interest of information exchange. The
United States Government assumes no liability for the contents or use
thereof. The United States Government does not endorse products or
manufacturers. Trade or manufacturer's names appear herein solely
because they are considered essential to the objective of this report. This
document does not constitute FAA certification policy. Consult your local
FAA aircraft certification office as to its use.
This report is available at the Federal Aviation Administration William J.
Hughes Technical Center's Full-Text Technical Reports page:
actlibrary.tc.faa.gov in Adobe Acrobat portable document format (PDF).
Technical Report Documentation Page
1. Report No.
DOT/FAA/AR-05/26
2. Government Accession No. 3. Recipient's Catalog No.
5. Report Date
September 2005
4. Title and Subtitle
THE EFFECTS OF MIXED WIRE TYPES IN AIRCRAFT ELECTRICAL
WIRING INTERCONNECTION SYSTEMS 6. Performing Organization Code
CNEA50
7. Author(s)
Joseph Kurek and James Meiner
8. Performing Organization Report No.
50-05-054
10. Work Unit No. (TRAIS)
9. Performing Organization Name and Address
Raytheon Technical Services Company
6125 East 21st Street
Indianapolis, IN 46219-2058
11. Contract or Grant No.
DTFACT 03-C-00008
13. Type of Report and Period Covered
Final Report
03/02-8/03
12. Sponsoring Agency Name and Address
U.S. Department of Transportation
Federal Aviation Administration
Office of Aviation Research
Washington, DC 20591
14. Sponsoring Agency Code
ANM-117
15. Supplementary Notes
The FAA William J. Hughes Technical Center COTR was Cesar Gomez.
16. Abstract
Original aircraft manufacturers have designed and built aircraft with various wire types due to the improvement of technology,
materials, and processing of wire. New aircraft may have multiple wire types in the same aircraft to meet various environmental
zone requirements. Wiring sections may be modified or rewired with the same wire that was originally installed in the aircraft or
with a newer, more advanced wire, thus mixing wire types in bundles. Little data has been generated and published indicating
whether mixing wire types creates problems with the long-term integrity of the electrical wiring. The objective of this research
was to assess past and current guidelines, to review prior research and test data, and to perform additional testing to determine the
effects of mixed wire types in electrical wiring interconnection systems in aged aircraft. Where applicable, develop
recommendations regarding the mixing of wire types in aircraft applications.
17. Key Words
Aged aircraft, Mixed wire
18. Distribution Statement
This document is available to the public through the National
Technical Information Service (NTIS) Springfield, Virginia
22161.
19. Security Classif. (of this report)
Unclassified
20. Security Classif. (of this page)
Unclassified
21. No. of Pages
104
22. Price
Form DOT F1700.7 (8-72) Reproduction of completed page authorized
ACKNOWLEDGEMENTS
Assistance from the following personnel was necessary:
Airbus – Dominique Chevant
Air Force – George Selenski
Boeing – Don Andersen
Bombardier – Petar Glamoclija
Lockheed Martin – Bobby Crumb
Raychem – Steve Zingheim
SR Technics – Lukas Zuellig
Raytheon Technical Services Company:
Greg AmRhein
Emmett Perkoski
John Sprung
Chris Hayes
Don Kuhn
Gary Burgan
Ronnie Peterson
Tim Ward
Mike Rediske
Andy Brown
Roy McMahon
John Jacobs
iii/iv
TABLE OF CONTENTS
Page
EXECUTIVE SUMMARY xiii
1. INTRODUCTION 1
1.1 Purpose 1
1.2 Background 1
1.2.1 Wire Installation 1
1.2.2 Design Options 1
1.2.3 Investigation Reason 1
2. APPROACH 1
3. REVIEW OF DOCUMENTATION 2
3.1 Review of Regulations, Proposed Regulations, and Design Specifications 2
3.2 Aircraft Wiring Practices 2
3.2.1 Original Aircraft Manufacturers Wiring Practices 2
3.2.2 Commercial Maintenance and Operator Wiring Practices 3
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