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PRACTICES MANUAL (ESWPM): 10/31/02
Appendix IV
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Comment: Table in this Appendix includes the following Major Topic:
WIRE AND CABLE TYPES
The principle material component of airplane wiring; includes type identification and basic
description; alternative wire types (replacements, substitutions).
14. DEPARTMENT OF TRANSPORTATION, FEDERAL AVIATION ADMINISTRATION
14 CFR PART 25:
25.1353 Electrical equipment and installations.
(a) Electrical equipment, controls and wiring must be installed so that operation of any one
unit or system of units will not adversely affect the simultaneous operation of any other
electrical unit or system essential to the safe operation
(b) Cables must be grouped, routed, and spaced so that damage to essential circuits will be
minimized if there are faults in heavy current-carrying cables
15. BOEING SPECIFICATION SUPPORT STANDARD BSS 7324F OF 02-DEC-1998,
PARA 7.57 WIRE-TO-WIRE ABRASION
Comment: Some aircraft wire types are required to withstand a minimum number of wire-towire
rubbing cycles without insulation failure. The number of cycles to failure vary with wire
type and compression weight. Cycles to failure range from 6,150,000 to 18,500,000 cycles, and
compression weight varies from 1 to 5 pounds depending on the wire type and insulation
thickness. Wire-to-wire abrasion between two different types of wires is not required.
16. MCDONNELL AIRCRAFT COMPANY REPORT MDC B0482 OF 16 DECEMBER
1987 PARA 3.5.12
Comment: An abrasion comparison between various wire types was performed. The abrasion
test consisted of a rubbing action using a small diameter rod compressed on the insulation with
three different weight values. There was no wire-to-wire abrasion between two different types of
wires.
II. AIRCRAFT WIRING PRACTICES DOCUMENTS
1. NAVAIR 01-1A-505.2, TECHNICAL MANUAL: INSTALLATION PRACTICES FOR
AIRCRAFT ELECTRIC AND ELECTRONIC WIRING: 09/01/1996
Work Package 004, Wire Selection, Page 3
6. COMMONALITY. An objective in the selection of parts shall be to maximize commonality
and minimize the variety of wiring components and related servicing tools required in the
construction, installation, and maintenance of the electrical wiring system.
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Work Package 006, Single Conductor Wire Repair, Page 3
WARNING: If M81381 type wire is damaged along its length, the damaged area must be
removed and replaced with appropriate M22759, refer to table 1.
Work Package 006, Single Conductor Wire Repair, Page 5
Comment: Table 1 (not repeated here) provides specific MIL-W-81381 to MIL-W-22759
Replacement wires.
2. T.O. 1-1A-14 TECHNICAL MANUAL: INSTALLATION PRACTICES FOR
AIRCRAFT ELECTRIC AND ELECTRONIC WIRING, PAGE 14-3
14-7. Wire Separation.
Military Specification MIL-W-5088 restricts the grouping or bundling of certain wires, such as
electrically unprotected power wiring, and wiring to duplicate vital equipment. Do not add such
wires to existing bundles unless specifically authorized.
3. BOEING STANDARD WIRING PRACTICES MANUAL (DOCUMENT D6-54446, 20-
00-14) PAGES 1-9 [Proprietary]
Comment: Tables 1-7 (not repeated here because of proprietary reasons) provide standard wire
type replacements permitted for wires. No specific information pertaining to mixing of
dissimilar wire types was discovered. The Boeing document contained a plethora of substitution
tables, which allow the substitution of various wire types and show interchangeability for
general-purpose BMS 13-48 and BMS 13-60 wire types. The tables also showed other generalpurpose
wire types that can be replaced by BMS 13-48 and BMS 13-60 wire types. As with
military wiring practice documents, the promotion of wire mixing in bundles is evident through
repair and maintenance guidelines and actions.
4. AIRBUS INDUSTRIE, ELECTRICAL STANDARD PRACTICES MANUAL
(20-33-10): 10/01/02
Comment: There is no information pertaining to mixing of dissimilar wire types in bundles.
III. TEST DOCUMENTATION (FORMAL AND INFORMAL)
1. ENG. REPORT, VIBRATION OF DC-10 WIRE BUNDLES, MDC J1530: 09/73
ENG. REPORT, VIBRATION OF DC-10 WIRE BUNDLES, MDC J1530/01: 08/74
EMA REPORT, WIRE CONTAINMENT, MDC J6573: 04/76
FINAL EMA REPORT, AIRCRAFT WIRE, MDC J6998: 09/76
Comment: The MDC test reports were written in response to wire bundle containment problems
observed on DC-10 aircraft due to high vibration environments. Reports discuss wire damage by
containment devices as well as drifting of plastic straps and tying tape. Most (if not all) wire
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bundles designed for the test programs use a single wire type. Mixing of wire types into a single
bundle is not addressed.
2. INTERVIEW WITH PRINCIPLE TECHNOLOGIST MR. GEORGE SELENSKI AT
　
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