ASTM F2639 - 07e1

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

    Active Standard ASTM F2639 | Developed by Subcommittee: F39.01

    Book of Standards Volume: 15.11


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    Significance and Use

    DesignThe design procedures defined in this practice are intended to provide acceptable guidance in the original design of electrical systems.

    AlterationThe 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.

    CertificationCertification 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.

    1. Scope

    1.1 DefinitionThis 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 ApplicabilityThe 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 PhilosophyThis 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 This practice includes the following sections:

    TitleSection
    Wire Selection5
    General5.1
    Aircraft Wire Materials5.2
    Table of Acceptable Wires5.3
    Severe Wind and Moisture Problems (SWAMP)5.4
    Grounding and Bonding5.5
    Electrical Wire Chart5.6
    Wire and Cable Identification6
    General6.1
    Wire and Cable Identification6.2
    Types of Markings6.3
    Sleeve and Cable Marker Selection6.4
    Placement of Identification Markings6.5
    Wiring Installation7
    General7.1
    Wire Harness Installation7.2
    Power Feeders7.3
    Service Loops7.4
    Drip Loops7.5
    Soldering7.6
    Strain Relief7.7
    Grounding and Bonding7.8
    Splicing7.9
    Fuel Tank Wiring7.10
    Corrosion Preventative Compounds (CPC)
    (MIL-C-81309)
    7.11
    Electrical Load Considerations8
    General8.1
    Methods for Determining the Current-Carrying
    Capacity of Wires
    8.2
    Acceptable Means of Monitoring and
    Controlling the Electrical Load
    8.3
    Electrical System Components9
    General9.1
    Alternators9.2
    Generators9.3
    Ground Power Units9.4
    Auxiliary Power Units9.5
    Batteries9.6
    Circuit Protection Devices9.7
    Conduit9.8
    Connectors9.9
    Inverters and Power Converters9.10
    Junctions9.11
    Junction Boxes9.12
    Electronic Assemblies9.13
    Relays9.14
    Studs9.15
    Switches9.16
    Terminals and Terminal Blocks9.17
    Waveguides9.18
    Electrical System Component Installation10
    General10.1
    Alternators10.2
    Generators10.3
    Auxiliary Power Units (APUs)10.4
    Batteries10.5
    Circuit Protection Devices10.6
    Conduit10.7
    Connectors10.8
    Inverters and Power Converters10.9
    Junctions10.10
    Junction Boxes, Panels, Shields, and
    Microswitch Housings
    10.11
    PC Board Assemblies10.12
    Relays10.13
    Studs10.14
    Switches10.15
    Terminals and Terminal Blocks10.16
    Waveguides10.17
    EMI/RFI11
    General11.1
    Grounding and Bonding11.2
    HIRF11.3
    Lightning11.4
    Alterations12
    General12.1
    Wire Substitutions12.2
    Commercial Off-the-Shelf (COTS) Components12.3
    Electrical Load Considerations12.4
    Batteries12.5
    Circuit Breakers12.6
    Junction Boxes12.7
    Relays12.8
    Switches12.9
    Wire Marking12.10
    Wire Bundle Routing12.11
    Wire Bundle Combing12.12
    Interference Tests12.13
    System Safety Assessments12.14
    Certification Processes13
    General13.1
    Certification13.2
    Alterations and Maintenance13.3

    1.6 ValuesThe 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.

    1.7 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.


    2. Referenced Documents (purchase separately) The documents listed below are referenced within the subject standard but are not provided as part of the standard.

    ANSI Standards

    ANSIJ-STD-004 Requirements for Soldering Fluxes

    ASTM Standards

    F2490 Guide for Aircraft Electrical Load and Power Source Capacity Analysis


    ICS Code

    ICS Number Code 49.060 (Aerospace electric equipment and systems)

    UNSPSC Code

    UNSPSC Code 25202000(Aircraft power systems)


    DOI: 10.1520/F2639-07E01

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