View Latest Blog Entries
Testing & Assessment Certification Standard & Regulation Aging Wires & Systems Maintenance & Sustainment Protection & Prevention Management Conference & Report Research Miscellaneous Arcing
Popular Tags
Visual Inspection High Voltage AS50881 MIL-HDBK MIL-HDBK-525 FAR Electromagnetic Interference (EMI) AS4373 Maintenance FAR 25.1707 Wire System Arcing Damage
All Tags in Alphabetical Order
2021 25.1701 25.1703 abrasion AC 33.4-3 AC 43 Accelerated Aging accessibility ADMT Aging Systems AIR6808 AIR7502 Aircraft Power System aircraft safety Aircraft Service Life Extension Program (SLEP) altitude arc damage Arc Damage Modeling Tool Arc Fault (AF) Arc Fault Circuit Breaker (AFCB) Arc Track Resistance Arcing Arcing Damage AS22759 AS22759/87 AS23053 AS29606 AS4373 AS4373 Method 704 AS50881 AS5692 AS6019 AS6324 AS81824 AS83519 AS85049 AS85485 AS85485 Wire Standard ASTM B355 ASTM B470 ASTM D150 ASTM D2671 ASTM D8355 ASTM D876 ASTM F2639 ASTM F2696 ASTM F2799 ASTM F3230 ASTM F3309 ATSRAC Attenuation Automated Wire Testing System (AWTS) Automotive Avionics backshell batteries bend radius Bent Pin Analysis Best of Lectromec Best Practice bonding Cable Cable Bend cable testing Carbon Nanotube (CNT) Certification cfr 25.1717 Chafing Chemical Testing Circuit Breaker circuit design Circuit Protection cleaning clearance Coaxial cable cold bend collision comparative analysis Compliance Component Selection Condition Based Maintenance Conductor Conductor Testing conductors conduit Connector connector installation Connector rating connector selection connector testing connectors contacts Corona Corrosion Corrosion Preventing Compound (CPC) corrosion prevention Cracking creepage D-sub data analysis data cables degradat Degradation Delamination Derating design safety development diagnostic Dielectric breakdown dielectric constant Dimensional Life disinfectant Distributed Power System DO-160 dry arc dynamic cut through E-CFR electric aircraft Electrical Aircraft Electrical Component Electrical Power Electrical Testing Electrified Vehicles Electromagnetic Interference (EMI) Electromagnetic Vulnerability (EMV) Electrostatic Discharge EMC EMF EMI EN2235 EN3197 EN3475 EN6059 End of Service Life End of Year Energy Storage engines Environmental Environmental Cycling environmental stress ethernet eVTOL EWIS certification EWIS Component EWIS Design EWIS Failure EWIS sustainment EWIS Thermal Management EZAP FAA FAA AC 25.27 FAA AC 25.981-1C FAA Meeting failure conditions Failure Database Failure Modes and Effects Analysis (FMEA) FAQs FAR FAR 25.1703 FAR 25.1707 FAR 25.1709 Fault fault tree Filter Line Cable Fixturing Flammability fleet reliability Flex Testing fluid exposure Fluid Immersion Forced Hydrolysis fuel system fuel tank ignition Functional Hazard Assessment functional testing Fundamental Articles Fuse Future Tech galvanic corrosion Glycol Gold Gold plating Green Taxiing Grounding hand sanitizer handbook Harness Design harness protection hazard Hazard Analysis health monitoring heat shrink heat shrink tubing high current high Frequency high speed data cable High Voltage High Voltage Degradation HIRF History Hot Stamping Humidity Variation HV connector HV system ICAs IEC 60851 IEC60172 IEEE immersion insertion loss Inspection installation installation safety Instructions for Continued Airworthiness insulating material insulating tape Insulation insulation breakdown insulation resistance insulation testing interchangeability IPC-D-620 ISO 17025 Certified Lab ISO 9000 J1673 Kapton Laser Marking life limit life limited parts Life prediction life projection Lightning lightning protection liquid nitrogen lithium battery lunar Magnet wire maintainability Maintenance Maintenance costs Mandrel mean free path measurement mechanical stress Mechanical Testing MECSIP MIL-C-38999 MIL-C-85485 MIL-DTL-17 MIL-DTL-23053E MIL-DTL-3885G MIL-DTL-38999 MIL-E-25499 MIL-HDBK MIL-HDBK-1646 MIL-HDBK-217 MIL-HDBK-454 MIL-HDBK-516 MIL-HDBK-522 MIL-HDBK-525 MIL-HDBK-683 MIL-STD-1353 MIL-STD-1560 MIL-STD-1798 MIL-STD-464 MIL-T-7928 MIL-T-7928/5 MIL-T-81490 MIL-W-22759/87 MIL-W-5088 MIL–STD–5088 Military 5088 modeling moon MS3320 NASA NEMA27500 Nickel nickel plating No Fault Found OEM off gassing Outgassing Over current Overheating of Wire Harness Parallel Arcing part selection Partial Discharge partial discharge at altitude Performance physical hazard assessment Physical Testing polyamide polyimdie Polyimide-PTFE Power over Ethernet power system Power systems predictive maintenance Presentation Preventative Maintenance Program Probability of Failure Product Quality PTFE pull through Radiation Red Plague Corrosion Reduction of Hazardous Substances (RoHS) regulations relays Reliability Research Resistance Revision C Rewiring Project Risk Assessment S&T Meeting SAE SAE Committee Sanitizing Fluids Secondary Harness Protection separation separation distance Separation Requirements Series Arcing Service Life Extension Severe Wind and Moisture-Prone (SWAMP) Severity of Failure shelf life Shield Shielding Shrinkage signal signal cable Silver silver plated wire silver-plating skin depth skin effect Small aircraft smoke Solid State Circuit Breaker Space Certified Wires Splice standards Storage stored energy superconductor supportability Sustainment System Voltage Temperature Rating Temperature Variation Test methods Test Pricing Testing testing standard Thermal Circuit Breaker Thermal Endurance Thermal Index Thermal Runaway Thermal Shock Thermal Testing tin Tin plated conductors tin plating tin solder tin whiskering tin whiskers top 5 Transient Troubleshooting TWA800 UAVs UL94 USAF validation verification video Visual Inspection voltage voltage differential Voltage Tolerance volume resistivity vw-1 wet arc white paper whitelisting Winding wire Wire Ampacity Wire Bend Wire Certification Wire Comparison wire damage wire failure wire performance wire properties Wire System wire testing Wire Verification wiring components work unit code

FAA wire incidents report: January 2009

Conference & Report

The following are the wire incidents reported in the FAA wire incidents report for January 2009 Advisory Circular 43-16A – Alert Number 366.

Incident #1

  • Aircraft Make: Beechjet
  • Aircraft Model: 400A
  • Part Name: Wire
  • Part Condition: Chafing
  • Part Location: Right Forward Galley

“The pitch-trim (was found to be) inoperative. (I) removed the right forward galley and the right forward partition. A wire bundle was found chafed behind the partition. I repaired three wires that were chafed (completely) through to the conductors. Clearance was provided between the wire bundle and the partition, and anti-chafe material was installed. At the time of the repair no other components had malfunctioned from the other two chafed wires.”

Incident #2

  • FAA Control Number: CA081113002
  • Part Name: Wire
  • Part Condition: Chafed
  • Difficultly Date: 11/13/2008
  • Part Location: Magneto

(can) coil to points wire worn through to strands due to rubbing on frame of distributor block.

Incident #3

  • FAA Control Number: CA081207001
  • Aircraft Make: LYC
  • Aircraft Model: DC981
  • Part Name: Magneto
  • Part Condition: Failed
  • Difficultly Date: 12/2/2008
  • Part Location: Engine

(Can) after start MAG check performed and LT MAG failed. MX was notified and when MAG was looked at found that the breaker point wires had vibrated off. Wires repaired and reinstalled.

Wire Degradation
This is where one power wire chaffed against the fwd partition

Incident #4

  • FAA Control Number: CA081118001
  • Aircraft Make: Beech
  • Aircraft Model: 300Beech
  • Part Name: Relay
  • Part Condition: Unserviceable
  • Part Number: MS24166DI
  • Difficultly Date: 11/15/2008
  • Part Location: Windshield heat

(Can) crew defect pilot windshield heat not working, troubleshoot to low heat relay, terminal a2 melted off the relay assy, damaging wires attached to the terminal approx 3 inches back the wire cover melted off. Relay was replaced and sys operates properly.

Incident #5

  • FAA Control Number: 2008FA0000842
  • Aircraft Make: Bell
  • Aircraft Model: 206B3
  • Part Name: Ground Wire
  • Part Condition: Missing
  • Difficultly Date: 11/24/2008
  • Part Location: Boost Pump

Mfg has removed a ground wire from both electric boost pumps. Ground has been on earlier models, removed since SAN: 4205 JAW wiring diagrams. Caution lights for boost pumps not operational since no ground available to base of pressure switch. Ground wire installed from motor housing to base of boost pump. Mm shows ground wire to base of boost pump 206-062-681-101. Ops normal after ground routed to base of boost pump.

Incident #6

  • FAA Control Number: CA081125001
  • Aircraft Make: Boeing
  • Aircraft Model: 75728A
  • Part Name: Wire Harness
  • Part Condition: Chafed
  • Difficultly Date: 11/25/2008

(CAN) in flight crew noticed smoke and flashes above row 4DEF. MX found wiring harness chafed by ceiling panel resulting in exposed wires arching.

Incident #7

  • FAA Control Number: CA081114001
  • Aircraft Make: Bombardier
  • Aircraft Model: DHC8400
  • Part Name: Wire Harness
  • Part Condition: Shorted
  • Location: Proximity Switch
  • Difficultly Date: 11/13/2008

(CAN) crew selected gear down and got 3 greens and LT MLG door amber light. Alternate extension c/o and crew observed alternate indication showed LT MLG (unsafe). Crew declared emergency and landed. Pax deplaned on runway and after gears were pinned acft taxied to gate. Fault confirmed by pseu to be LT LGDNLK2 open circuit. Proximity switch harness assy PN 46460-5 replaced and acft returned to service.

Incident #8

  • FAA Control Number: CA081112002
  • Aircraft Make: Bombardier
  • Aircraft Model: DHC8400
  • Part Name: Shroud
  • Part Condition: Mis-manufactured
  • Location: Wing Box
  • Difficultly Date: 5/29/2008

(CAN) during production of 4208 it was discovered that the center wing lower shroud RT drain holes were not present. A discrepancy was raised and cleared by drilling new holes in siter. Upon the delivery/acceptance flight, it was discovered that the aft coffee marker was unserviceable. A technical investigation revealed 6 of 9 (115 VAC) wires damaged. A repair was made JAW WDM 20-16-00. A SMS/SRS was raised.

Incident #9

  • FAA Control Number: 2008FA0000853
  • Aircraft Make: Cessna
  • Aircraft Model: T303
  • Part Name: Alternator
  • Part Condition: Shorted
  • Location: Engine
  • Difficultly Date: 11/30/2008

Have had multiple failures, both in flight and during maintenance ground operations. Hours on failed alternators range from as low as 30 to a maximum of 220 hours time in service. The one common factor in all failures has been the discovery of loose hex head case bolts installed and safety wired by manufacturer. This problem is not restricted to one side only, both engines drive the same alternator with same part number.

Incident #10

  • FAA Control Number: CA081024006
  • Aircraft Make: Lear
  • Aircraft Model: 45Lear
  • Part Name: Ground Wire
  • Part Condition: Open
  • Location: Trim System
  • Difficultly Date: 10/10/2008

(Can) on landing, a white CAS message (secondary trim fault) appeared. Sys troubleshot and found an open ground wire at rba0664n-22 at splicesp322. Splice repaired and function checked serviceable.

Incident #11

  • FAA Control Number: CA081001006
  • Aircraft Make: Urocop
  • Aircraft Model: EC130B4
  • Part Name: Wire
  • Part Condition: Shorted
  • Location: Comm1
  • Difficultly Date: 9/24/2008

(CAN) No pilot or copilot side tone on comm 1. Tech found the audio phone wire shorted by the shielding. Repaired and side tones were returned to normal.

Michael Traskos

This article was written by the Lectromec technical team. Aircraft wiring is our passion and we strive to make a contribution to the field by sharing our expertise through blogs, podcasts, and videos. We hope you find this information helpful. We also encourage you to submit comments and spur discussions.