ASTM F2799-14(2019)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F2799 − 14 (Reapproved 2019)
Standard Practice for
Maintenance of Aircraft Electrical Wiring Systems
This standard is issued under the fixed designation F2799; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
1.1 Definition—This practice defines acceptable practices
Barriers to Trade (TBT) Committee.
and processes for the maintenance, preventative maintenance,
and repair of electric systems in general aviation aircraft. This
2. Referenced Documents
practice does not change or create any additional regulatory
2.1 ASTM Standards:
requirements nor does it authorize changes in or permit
F2490 Guide for Aircraft Electrical Load and Power Source
deviations from existing regulatory requirements.
Capacity Analysis
1.2 Applicability—The guidance provided in this practice is
F2639 Practice for Design, Alteration, and Certification of
directed to air carriers, air operators, maintenance providers,
Aircraft Electrical Wiring Systems
repair stations, and anyone performing maintenance or repairs.
2.2 ICAO Standard:
1.3 Protections and Warnings—This practice provides guid-
ICAOAnnex 5 Units of Measurement to Be Used inAir and
ance to minimize contamination and accidental damage to
Ground Operations
electrical wiring interconnection systems (EWIS) while work-
2.3 JEDEC Standard:
ing on aircraft.
EIA 471 Symbol and Label for Electrostatic Sensitive De-
vices
1.4 “Protect and Clean As You Go” Philosophy—This
philosophy is applied to aircraft wiring through inclusion in
2.4 NEMA Standard:
operators’maintenanceandtrainingprograms.Thisphilosophy WC 27500 Standards for Aerospace and Industrial Electric
stresses the importance of protective measures when working
Cable
on or around wire bundles and connectors. It stresses how
2.5 RTCA Standard:
important it is to protect EWIS during structural repairs, (STC)
DO-160C Environmental Conditions and Test Procedures
installations, or other alterations by ensuring that metal
for Airborne Equipment
shavings, debris, and contamination resulting from such work
2.6 SAE Standards:
are removed.
AS4372 Performance Requirements for Wire, Electric, Insu-
lated Copper or Copper Alloy
1.5 Units—The values stated in inch-pound units are to be
regarded as standard. The values given in parentheses are AS4373 Test Methods for Insulated Electric Wire
AS21919 Clamp, Loop Type, Cushioned Support
mathematical conversions to SI units that are provided for
information only and are not considered standard. AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper
NOTE 1—When SI units are required, refer to Annex 5 of ICAO. or Copper Alloy
AS50881 Wiring Aerospace Vehicle
1.6 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro-
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
priate safety, health, and environmental practices and deter-
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
mine the applicability of regulatory limitations prior to use.
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
1.7 This international standard was developed in accor-
Available from International Civil Aviation Organization (ICAO), Customer
dance with internationally recognized principles on standard-
Services Unit, 999 Robert-Bourassa Boulevard, Montréal, Québec, H3C 5H7,
ization established in the Decision on Principles for the
Canada, https://www.icao.int.
Available from the JEDEC Solid State Technology Association, 3103 N. 10th
St., Suite 240-S, Arlington, VA 22201-2107, https://www.jedec.org/.
1 5
This practice is under the jurisdiction of ASTM Committee F39 on Aircraft Available from National Electrical Manufacturers Association (NEMA), 1300
Systems and is the direct responsibility of Subcommittee F39.02 on Inspection, N. 17th St., Suite 900, Arlington, VA 22209, http://www.nema.org.
Alteration, Maintenance, and Repair. Available from RTCA, Inc., 1150 18th NW, Suite 910, Washington, DC 20036,
Current edition approved June 1, 2019. Published June 2019. Originally https://www.rtca.org.
approved in 2009. Last previous edition approved in 2014 as F2799–14. DOI: Available from Society of Automotive Engineers (SAE), 400 Commonwealth
10.1520/F2799–14R19. Dr., Warrendale, PA 15096, https://www.sae.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F2799 − 14 (2019)
ARP1870 Aerospace Systems Electrical Bonding and 3.3.17 UV—ultraviolet
Grounding for Electromagnetic Compatibility and Safety
ARP1928 TorqueRecommendationsforAttachingElectrical
4. Significance and Use
Wiring Devices to Terminal Boards or Blocks, Studs,
4.1 This practice is intended to be used as a standard wiring
Posts, etc.
practice for aircraft when not contrary to standards published
2.7 Federal Standards:
by the aircraft original equipment manufacturer (OEM) or
Advisory Circular 20-53A Protection of Aircraft Fuel Sys-
regulations. This practice is intended to be used for mainte-
tems against Fuel Vapor Ignition due to Lightning
nance and preventive maintenance of electrical wiring inter-
MIL-C-22520/2C Crimping Tools, Terminal, Hand, Wire
connection systems (EWIS).
Termination
4.2 This practice is not intended to supersede or replace any
MIL-S-8802 Sealing Compound, Temperature-Resistant, In-
government specification or specific manufacturer’s instruc-
tegral Fuel Tanks and Fuel Cell Cavities, High Adhesion
tions regarding EWIS maintenance or repair.
MIL-T-7928 Terminal, Lug Splices, Conductors, Crimp
Style, Copper
5. Maintenance
MIL-T-43435 Tape, Lacing and Tying
MS17821 Specification for Cable and Marker Color Code
5.1 Electrical Systems:
Numbers
5.1.1 Maintenance:
MS17822 Specification for Cable and Marker Color Code
5.1.1.1 Scheduled and unscheduled maintenance activities,
Numbers
if done improperly, may contribute to long-term problems and
NAVAIR 01-1A-505 Installation Practices—Aircraft Elec-
degradation of wiring. Certain repairs may have limited dura-
tric and Electronic Wiring
bility and shall be evaluated to ascertain if rework is necessary.
Repairs that conform to manufacturers’recommended mainte-
3. Terminology
nance practices are generally considered permanent and should
3.1 Definitions:
not require rework. Care shall be taken to prevent undue
3.1.1 maintenance, n—inspection, overhaul, repair,
collateral damage to EWIS while performing maintenance on
preservation, and the replacement of parts but excludes pre-
other systems. Metal shavings and debris have been discovered
ventive maintenance.
on wire bundles after maintenance, repairs, or modifications
3.2 Definitions of Terms Specific to This Standard:
have been performed. Care shall be taken to protect wire
3.2.1 electrical wiring interconnection system (EWIS),
bundles and connectors during maintenance and repair. Work
n—as used in this practice, any wire, wiring device, or
areas should be cleaned while the work progresses to ensure
combination of these, including termination devices, installed
that all shavings and debris are removed.The work area should
in any area of the aircraft for the purpose of transmitting
be thoroughly cleaned after work is complete, and the area
electrical energy between two or more intended termination
shall be inspected after the final cleaning. Maintenance,
points.
repairs, and alterations should be performed using the most
effective methods available to protect the surrounding EWIS.
3.3 Acronyms:
Since wire splices are more susceptible to degradation, arcing,
3.3.1 AC—alternating current
and overheating, the recommended method of repairing a wire
3.3.2 CFC—carbon fiber composite
is with an environmentally sealed splice. (Warning—For
3.3.3 DC—direct current
personal safety and to avoid the possibility of fire, turn off all
3.3.4 EDS—electronic data system electrical power before starting an inspection of the aircraft
electrical system or performing maintenance.)
3.3.5 EMI—electromagnetic interference
5.1.1.2 Repair of any system component that fails an elec-
3.3.6 ESD—electrostatic discharge
trical measurement test shall conform to manufacturer’s in-
3.3.7 EWIS—electrical wiring interconnection system
structions and, in lieu of manufacturer’s manuals, Practice
3.3.8 ICAO—International Civil Aviation Organization
F2639 or appropriate regulatory guidance materials.
5.1.1.3 Wire bundles should be routed in accessible areas
3.3.9 NiCad—nickel cadmium
that are protected from damage from personnel, cargo, and
3.3.10 OEM—original equipment manufacturer
maintenance activity.They should not be routed in areas where
3.3.11 PC—personal computer
they are likely to be used as handholds or as support for
3.3.12 PTFE—polytetrafluoroethylene
personal equipment or where they could become damaged
during removal of aircraft equipment.
3.3.13 RF—radio frequency
5.1.1.4 Replacement wires (see Tables 1 and 2) should be
3.3.14 SOC—state of charge
clamped so that contact with equipment and structure is
3.3.15 STC—supplemental-type certificate
avoided. Where this cannot be accomplished, extra protection
3.3.16 SWAMP—severe wind and moisture problem
in the form of grommets, chafe strips, and so forth, should be
provided. Protective grommets shall be used wherever wires
cannot be clamped in a way that ensures at least a ⁄8 in. (9.5
Available from U.S. Government Publishing Office, 732 N. Capitol St., NW,
Washington, DC 20401, http://www.gpo.gov. mm) clearance from structure at penetrations.
F2799 − 14 (2019)
TABLE 1 Open Wiring
Voltage Rating Rated Wire
Document Insulation Type Conductor Type
(Maximum) Temperature, °C
A
MIL-W-22759/1 600 200 Fluoropolymer-insulated TFE and TFE coated glass Silver-coated copper
A
MIL-W-22759/2 600 260 Fluoropolymer-insulated TFE and TFE coated glass Nickel-coated copper
A
MIL-W-22759/3 600 260 Fluoropolymer-insulated TFE-glass-TFE Nickel-coated copper
A
MIL-W-22759/4 600 200 Fluoropolymer-insulated TFE-glass-FEP Silver-coated copper
A
MIL-W-22759/5 600 200 Fluoropolymer-insulated extruded TFE Silver-coated copper
A
MIL-W-22759/6 600 260 Fluoropolymer-insulated extruded TFE Nickel-coated copper
A
MIL-W-22759/7 600 200 Fluoropolymer-insulated extruded TFE Silver-coated copper
A
MIL-W-22759/8 600 260 Fluoropolymer-insulated extruded TFE Nickel-coated copper
A
MIL-W-22759/9 1000 200 Fluoropolymer-insulated extruded TFE Silver-coated copper
A
MIL-W-22759/10 1000 260 Fluoropolymer-insulated Nickel-coated copper
A
MIL-W-22759/13 600 135 Fluoropolymer-insulated FEP PVF2 Tin-coated copper,
A
MIL-W-22759/16 600 150 Fluoropolymer-insulated extruded ETFE Tin-coated copper,
A
MIL-W-22759/17 600 150 Fluoropolymer-insulated extruded ETFE Silver-coated high-strength copper alloy
A
MIL-W-22759/20 1000 200 Fluoropolymer-insulated extruded TFE Silver-coated high-strength copper alloy
A
MIL-W-22759/21 1000 260 Fluoropolymer-insulated extruded TFE Nickel-coated high-strength copper alloy
A
MIL-W-22759/34 600 150 Fluoropolymer-insulated cross-linked modified ETFE Tin-coated copper
A
MIL-W-22759/35 600 200 Fluoropolymer-insulated cross-linked modified ETFE Silver-coated high-strength copper alloy
A
MIL-W-22759/41 600 200 Fluoropolymer-insulated cross-linked modified ETFE Nickel-coated copper
A
MIL-W-22759/42 600 200 Fluoropolymer-insulated cross-linked modified ETFE Nickel-coated high-strength copper alloy
A
MIL-W-22759/43 600 200 Fluoropolymer-insulated cross-linked modified ETFE Silver-coated copper
B B
MIL-W-25038/3/2/ 600 260 See specification sheet See specification sheet
MIL-W-81044/6 600 150 Cross-linked polyalkene Tin-coated copper
MIL-W-81044/7 600 150 Cross-linked polyalkene Silver-coated high-strength copper alloy
MIL-W-81044/9 600 150 Cross-linked polyalkene Tin-coated copper
MIL-W-81044/10 600 150 Cross-linked polyalkene Silver-coated high-strength copper alloy
MIL-W-81044/12 600 150 Cross-linked polyalkene Tin-coated copper
A
MIL-W-22759 has been replaced by SAE AS22759.
B
Inorganic fibers—glass—TFE.
TABLE 2 Protected Wiring
Voltage Rating Rated Wire
Document Insulation Type Conductor Type
(Maximum) Temperature, °C
A
MIL-W-22759/11 600 200 Fluoropolymer-insulated extruded TFE Silver-coated copper
A
MIL-W-22759/12 600 260 Fluoropolymer-insulated extruded TFE Nickel-coated copper
A
MIL-W-22759/14 600 135 Fluoropolymer-insulated FEP-PVF2 Tin-coated copper
A
MIL-W-22759/15 600 135 Fluoropolymer-insulated FEP-PVF2 Silver-plated high-strength copper alloy
A
MIL-W-22759/18 600 150 Fluoropolymer-insulated extruded ETFE Tin-coated copper
A
MIL-W-22759/19 600 150 Fluoropolymer-insulated extruded ETFE Silver-coated high-strength copper alloy
A
MIL-W-22759/22 600 200 Fluoropolymer-insulated extruded TFE Silver-coated high-strength copper alloy
A
MIL-W-22759/23 600 260 Fluoropolymer-insulated extruded TFE Nickel-coated high-strength copper alloy
A
MIL-W-22759/32 600 150 Fluoropolymer-insulated cross-linked modified ETFE Tin-coated copper
A
MIL-W-22759/33 600 200 Fluoropolymer-insulated cross-linked modified ETFE Silver-coated high-strength copper alloy
A
MIL-W-22759/44 600 200 Fluoropolymer-insulated cross-linked modified ETFE Silver-coated copper
A
MIL-W-22759/45 600 200 Fluoropolymer-insulated cross-linked modified ETFE Nickel-coated copper
A
MIL-W-22759/46 600 200 Fluoropolymer-insulated cross-linked modified ETFE Nickel-coated high-strength copper alloy
MIL-W-81044/13 600 150 Cross-linked polyalkene – PVF2 Silver-coated high-strength copper alloy
MIL-W-81381/17 600 200 Fluorocarbon polyamide Silver-coated copper
MIL-W-81381/18 600 200 Fluorocarbon polyamide Nickel-coated copper
MIL-W-81381/19 600 200 Fluorocarbon polyamide Silver-coated high-strength copper alloy
MIL-W-81381/20 600 200 Fluorocarbon polyamide Nickel-coated high-strength copper alloy
MIL-W-81381/21 600 150 Fluorocarbon polyamide Tin-coated copper
A
MIL-W-22759 has been replaced by SAE AS22759.
5.1.1.5 Wire should not have a preload against the corners 5.1.2.1 The term “electrical wiring interconnection system
or edges of chafing strips or grommets. Wiring shall be routed (EWIS)” as used in this practice means any wire, wi
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