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ASTM F2639-07

(Practice)

Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems

Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems

SIGNIFICANCE AND USE
Design—The design procedures defined in this practice are intended to provide acceptable guidance in the original design of electrical systems.
Alteration—The alteration procedures defined in this practice are intended to provide acceptable guidance for modification of general aviation aircraft. Design of any modification shall follow the practices and processes defined in the design sections of this practice.
Certification—Certification guidance provided in this practice is intended to provide generally accepted procedures and processes for certification of original and modified electrical systems and equipment. Requirements for certification shall be coordinated with the applicable National Aeronautics Association/Civil Aeronautics Administration (NAA/CAA) regulatory agency.
SCOPE
1.1 Definition - This practice defines acceptable practices and processes for the design, alteration, and certification of electric systems and installations in general aviation aircraft. This practice does not change or create any additional regulatory requirements nor does it authorize changes in or permit deviations from existing regulatory requirements.
1.2 Applicability - The guidance provided in this practice is directed to air carriers, air operators, design approval holders, Supplemental Type Certificate (STC) holders, maintenance providers, repair stations, and anyone performing field approval modifications or repairs.
1.3 Protections and CautionsThis practice provides guidance for developing actions and cautionary statements to be added to maintenance instructions for the protection of wire and wire configurations. Maintenance personnel will use these enhanced procedures to minimize contamination and accidental damage to electrical wiring interconnection system (EWIS) while working on aircraft.
1.4 "Protect and Clean As You Go" Philosophy - This philosophy is applied to aircraft wiring through inclusion in operators maintenance and training programs. This philosophy stresses the importance of protective measures when working on or around wire bundles and connectors. It stresses how important it is to protect EWIS during structural repairs, STC installations, or other alterations by making sure that metal shavings, debris, and contamination resulting from such work are removed.
1.5 Values - The values given in inch-pound units are to be regarded as the standard. The values in parentheses are for information only. See Appendix X2 for SI-based prefixes and powers of 10.Note 1
Where SI units are required, refer to Annex 5 of ICAO.
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 appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

General Information

Status
Historical
Publication Date
31-Aug-2007
ICS
49.060 - Aerospace electric equipment and systems
Technical Committee
F39 - Aircraft Systems
Drafting Committee
F39.01 - Design, Alteration, and Certification of Electrical Systems
Current Stage
Ref Project

Relations

Replaced By
ASTM F2639-07e1 - Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems
Effective Date
01-Sep-2007
Referred By
ASTM F2799-14(2019) - Standard Practice for Maintenance of Aircraft Electrical Wiring Systems
Effective Date
01-Sep-2007
Referred By
ASTM F3231/F3231M-23 - Standard Specification for Electrical Systems for Aircraft with Combustion Engine Electrical Power Generation
Effective Date
01-Sep-2007
Referred By
ASTM F3316/F3316M-19 - Standard Specification for Electrical Systems for Aircraft with Electric or Hybrid-Electric Propulsion
Effective Date
01-Sep-2007
Referred By
ASTM F3060-20 - Standard Terminology for Aircraft
Effective Date
01-Sep-2007

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ASTM F2639-07 - Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring SystemsASTM F2639-07 - Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems
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ASTM F2639-07 - Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems
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Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation: F2639 – 07
Standard Practice for
Design, Alteration, and Certification of Airplane Electrical
1
Wiring Systems
This standard is issued under the fixed designation F2639; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope priate safety and health practices and determine the applica-
bility of regulatory limitations prior to use.
1.1 Definition—This practice defines acceptable practices
and processes for the design, alteration, and certification of
2. Referenced Documents
electric systems and installations in general aviation aircraft.
2.1 Unlessapprovedbytheadministrator,thelatestrevision
This practice does not change or create any additional regula-
of the listed documents shall be used for reference.
tory requirements nor does it authorize changes in or permit
2
2.2 ASTM Standards:
deviations from existing regulatory requirements.
F2490 GuideforAircraftElectricalLoadandPowerSource
1.2 Applicability—Theguidanceprovidedinthispracticeis
Capacity Analysis
directed to air carriers, air operators, design approval holders,
3
2.3 ANSI Standards:
Supplemental Type Certificate (STC) holders, maintenance
ANSI/EIA-5200000 Generic Specification for Special-Use
providers, repair stations, and anyone performing field ap-
Electromechanical Switches of Certified Quality
proval modifications or repairs.
ANSIEIA/TIA-568-B CommercialBuildingTelecommuni-
1.3 Protections and Cautions—This practice provides guid-
cations Cabling Standard
ance for developing actions and cautionary statements to be
ANSI J-STD-004 Requirements for Soldering Fluxes
added to maintenance instructions for the protection of wire
4
2.4 FAA Standards:
and wire configurations. Maintenance personnel will use these
Advisory Circular 20-53A Protection of Aircraft Fuel Sys-
enhanced procedures to minimize contamination and acciden-
tems Against Fuel Vapor Ignition Due To Lightning
tal damage to electrical wiring interconnection system (EWIS)
AC 20-136 Protection ofAircraft Electrical/Electronic Sys-
while working on aircraft.
tems Against the Indirect Effects of Lightning
1.4 “Protect and Clean As You Go” Philosophy—This
AC 21-160E RTCA Document DO-160E
philosophy is applied to aircraft wiring through inclusion in
AC 23.1309-1C Equipment, Systems, and Installations in
operators’maintenanceandtrainingprograms.Thisphilosophy
Part 23 Airplanes
stresses the importance of protective measures when working
AC 25-16 Electrical Fault and Fire Prevention and Protec-
on or around wire bundles and connectors. It stresses how
tion
important it is to protect EWIS during structural repairs, STC
AC 25.869-1 Electrical System Fire and Smoke Protection
installations, or other alterations by making sure that metal
AC 25.981-1B Fuel Tank Ignition Source Prevention
shavings, debris, and contamination resulting from such work
Guidelines
are removed.
AC 25.1353-1 Electrical Equipment and Installations
1.5 Values—The values given in inch-pound units are to be
AC 25.1357-1 Circuit Protective Device Accessibility
regarded as the standard. The values in parentheses are for
DOT/FAA/CT 86/8 Determination of Electrical Properties
information only. See Appendix X2 for SI-based prefixes and
of Bonding and Fastening Techniques
powers of 10.
DOT/FAA/CT-83/3 Users Manual for FAAAdvisory Circu-
NOTE 1—Where SI units are required, refer to Annex 5 of ICAO.
lar 20-53a
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-
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
1 3
ThispracticeisunderthejurisdictionofASTMCommitteeF39onNormaland Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
Utility CategoryAirplane Electrical Wiring Systems and is the direct responsibility 4th Floor, New York, NY 10036, http://www.ansi.org.
4
of Subcommittee F39.01 on Design, Alteration, and Certification. AvailablefromU.S.GovernmentPrintingOfficeSuperintendentofDocuments,
Current edition approved Sept. 1, 2007. Published October 2007. DOI: 10.1520/ 732 N. Capitol St., NW, Mail Stop: SDE, Washington, DC 20401, http://
F2639-07. www.access.gpo.gov.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
1

---------------------- Page: 1 ----------------------
F2639 – 07
DOT/FAA/CT-89-22 Aircraft Lightn
...

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SIGNIFICANCE AND USE
4.1 To show compliance with 14 CFR 23.1351, you must determine the electrical system capacity.  
4.2 14 CFR 23.1351(a)(2) states that:  
4.2.1 For normal, utility, and acrobatic category airplanes, by an electrical load analysis or by electrical measurements that account for the electrical loads applied to the electrical system in probable combinations and for probable durations; and  
4.2.2 For commuter category airplanes, by an electrical load analysis that accounts for the electrical loads applied to the electrical system in probable combinations and for probable durations.  
4.3 The primary purpose of the electrical load analysis (ELA) is to determine electrical system capacity (including generating sources, converters, contactors, bus bars, and so forth) needed to supply the worst-case combinations of electrical loads. This is achieved by evaluating the average demand and maximum demands under all applicable flight conditions. A summary can then be used to relate the ELA to the system capacity and can establish the adequacy of the power sources under normal, abnormal, and emergency conditions.
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ASTM F2696-14(2019)(Practice)
Standard Practice for Inspection of Aircraft Electrical Wiring Systems

SIGNIFICANCE AND USE
4.1 The term “electrical system” as used in this practice means those parts of the aircraft that generate, distribute, and use electrical energy, including their support and attachments.  
4.2 The satisfactory performance of an aircraft is dependent upon the continued reliability of the electrical system.  
4.3 Damaged wiring or equipment in an aircraft, regardless of how minor it may appear to be, cannot be tolerated. It is, therefore, important that maintenance be accomplished using the best techniques and practices to minimize the possibility of failure.  
4.4 When inspecting and evaluating EWIS, improper wiring, routing, or repairs shall be corrected regardless of the origin of the error.  
4.5 This practice is not intended to supersede or replace any government specification or specific manufacturer’s instruction regarding electrical system inspection and repair
SCOPE
1.1 This practice covers basic inspection procedures for electrical wiring interconnect systems for aircraft electrical wiring systems.  
1.2 This practice is not intended to replace any instructions for continued airworthiness published by the aircraft or accessory manufacturer or type design holder.  
1.3 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
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ASTM F2799-14(2019)(Practice)
Standard Practice for Maintenance of Aircraft Electrical Wiring Systems

SIGNIFICANCE AND USE
4.1 This practice is intended to be used as a standard wiring practice for aircraft when not contrary to standards published by the aircraft original equipment manufacturer (OEM) or regulations. This practice is intended to be used for maintenance and preventive maintenance of electrical wiring interconnection systems (EWIS).  
4.2 This practice is not intended to supersede or replace any government specification or specific manufacturer’s instructions regarding EWIS maintenance or repair.
SCOPE
1.1 Definition—This practice defines acceptable practices and processes for the maintenance, preventative maintenance, and repair of electric systems in general aviation aircraft. This practice does not change or create any additional regulatory requirements nor does it authorize changes in or permit deviations from existing regulatory requirements.  
1.2 Applicability—The guidance provided in this practice is directed to air carriers, air operators, maintenance providers, repair stations, and anyone performing maintenance or repairs.  
1.3 Protections and Warnings—This practice provides guidance to minimize contamination and accidental damage to electrical wiring interconnection systems (EWIS) while working on aircraft.  
1.4 “Protect and Clean As You Go” Philosophy—This philosophy is applied to aircraft wiring through inclusion in operators’ maintenance and training programs. This philosophy stresses the importance of protective measures when working on or around wire bundles and connectors. It stresses how important it is to protect EWIS during structural repairs, (STC) installations, or other alterations by ensuring that metal shavings, debris, and contamination resulting from such work are removed.  
1.5 Units—The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.
Note 1: When SI units are required, refer to Annex 5 of ICAO.  
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 appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
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ASTM F2639-18(Practice)
Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring Systems

SIGNIFICANCE AND USE
4.1 Design—The design procedures defined in this practice are intended to provide acceptable guidance in the original design of electrical systems.  
4.2 Alteration—The alteration procedures defined in this practice are intended to provide acceptable guidance for modification of general aviation aircraft. Design of any modification shall follow the practices and processes defined in the design sections of this practice.  
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SCOPE
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1.5 This practice includes the following sections:    
Title  
Section  
Wire Selection  
5  
General  
5.1  
Aircraft Wire Materials  
5.2  
Table of Acceptable Wires  
5.3  
Severe Wind and Moisture Problems (SWAMP)  
5.4  
Grounding and Bonding  
5.5  
Electrical Wire Chart  
5.6  
Wire and Cable Identification  
6  
General  
6.1  
Wire and Cable Identification  
6.2  
Types of Markings  
6.3  
Sleeve and Cable Marker Selection  
6.4  
Placement of Identification Markings  
6.5  
Wiring Installation  
7  
General  
7.1  
Wire Harness Installation  
7.2  
Power Feeders  
7.3  
Service Loops  
7.4  
Drip Loops  
7.5  
Soldering  
7.6  
Strain Relief  
7.7  
Grounding and Bonding  
7.8  
Splicing  
7.9  
Fuel Tank Wiring  
7.10  
Corrosion Preventative Compounds (CPC)
(MIL-C-81309)  
7.11  
Electrical Load Considerations  
8  
General  
8.1  
Methods for Determining the Current-Carrying
Capacity of Wires  
8.2  
Acceptable Means of Monitoring and
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8.3  
Electrical System Components  
9  
General  
9.1  
Alternators  
9.2  
Generators  
9.3  
Ground Power Units  
9.4  
Auxiliary Power Units  
9.5  
Batteries  
9.6  
Circuit Protection Devices  
9.7  
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9.8  
Connectors  
9.9  
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9.10  
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9.11  
Junction Boxes  
9.12  
Electronic Assemblies  
9.13  
Relays  
9.14  
Studs  
9.15  
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4.2.1 For normal, utility, and acrobatic category airplanes, by an electrical load analysis or by electrical measurements that account for the electrical loads applied to the electrical system in probable combinations and for probable durations; and  
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SCOPE
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This specification applies to the electrical systems, electrical equipment, and electrical power distribution aspects of airworthiness and design for aircraft with electric or hybrid-electric propulsion. Developed through open consensus of international experts in general aviation, this material focused on Normal Category Airplanes. The content may be more broadly applicable; it is the responsibility of the applicant to substantiate broader applicability as a specific means of compliance.
This specification establishes the Aircraft Type Code (ATC) compliance matrix based on certification level, number of engines, type of engine(s), stall speed, cruise speed, meteorological conditions, altitude, and maneuvers. An ATC is defined by taking into account both the technical considerations regarding the design of the aircraft and the airworthiness level established based upon risk-based criteria. Requirements for electrical systems for electric propulsion cover power source capacity and distribution, electrical systems and equipment, circuit protective devices, master switch arrangement, switches, electrical cables and equipment, electrical system fire protection, electronic equipment, and storage battery design and installation.
SCOPE
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SIGNIFICANCE AND USE
4.1 This practice is useful as a screening basis for acceptance or rejection of transparencies during manufacturing so that units with identifiable flaws will not be carried to final inspection for rejection at that time.  
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SCOPE
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1.3 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.4 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 appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use. For specific precautionary statements, see Section 6.  
1.5 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.

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  • Standard
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    English language
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