Cirrus Aircraft Wiring Manual

5. LEVEL OF COVERAGE The level of wiring diagram coverage (breakdown) in this manual is to the line replaceable unit (LRU) level. LRUs in this manual are indicated by a phantom line box with the LRU’s nomenclature at the top of the box. Normally, there is no electrical breakdown of the LRU. However, as an aid for troubleshooting, the circuit function at each pin/socket at the LRU’s connector is normally labeled. Component boxes with a Chapter- Section-Diagram reference in them will have further breakdown at the referenced location. 19 Sep 2017 Intro- Page 2 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 19 Sep 2017 The wiring diagrams in this manual cover the as delivered airplane configuration and airplanes modified by Cirrus Design Service Bulletins only. Documentation for wiring changes or modifications made in any other fashion are the responsibility of the person(s) performing the modification. Troubleshooting may be performed using this manual and any optional avionics & electrical wiring dia- grams provided at delivery of the airplane. 6. WIRING MANUAL ORGANIZATION The content of this manual is arranged and presented in the same Aircraft Group, Chapter, and Section arrangement as appears in the Airplane Maintenance Manual (AMM) and Illustrated Parts Catalog (IPC). Therefore, the user can usually expect to find coverage of items in the AMM, or IPC, in the same Chapter/ Section of the Wiring manual. The numbering system employed in this catalog is composed of a six-digit number containing three ele- ments. Each element consists of two digits as shown in the following example. First Element Second Element Third Element Chapter Section Diagram XX - XX - XX For example, a wiring diagram Chapter-Section-Diagram numbered 27-30-01 provides the following infor- mation: The first element (27) indicates Chapter 27 (Flight Controls); the second element (30) indicates Section 30 (Elevator and Tab); the third element reflects the Diagram Number (Pitch Trim System.) Where these numbers are shown inside component boxes, they are provided as references to the diagram in the Wiring Manual where a detail of that components wiring may be found. Where these numbers are shown at the end of a wire or group of wires, they are provided as references to the location where the wires are con- tinued. Note: When a diagram is referenced to another, the diagram number only is used. Therefore, where there is more than one page of the referenced diagram, it is necessary to refer to the airplane serial effectivity block, at the lower left corner of the page, to determine that the dia- gram applies to the aircraft in question. The page numbers 1 to 100 are used to separate changes in effectivity. The first page (page 1) will show the original configuration. The second page (page 2) and on will shown various configurations on subse- quent aircraft. If a diagram requires more than one page for illustration, sheet numbers will be used, e.g. Stall Warning System (1 of 2). The page numbers 101 and subsequent will be used for component or black box wiring. Page 101 is used for the original configuration. Pages 102 and subsequent are used for subsequent aircraft configurations. If a diagram requires more than one page for an illustration, numbers will be used. 7. ABBREVIATIONS The following abbreviations have been used throughout this manual: 1 ALT. - Single Alternator CONFIG - Configuration P/N - Part Number 2 ALT. - Dual Alternator DET - Detail PFD - Primary Flight Display ALL ELEC. - All Electric EXHTD - Exhausted REF or RF- Reference ALT - Alternate FUS STA - Fuselage Station RH - Right Hand AR - As Required FWD - Forward SNDL HSI - Sandel HSI ASSY - Assembly INSTL- Installation SUBS - Subsequent BHD - Bulkhead LH - Left hand W/ - With BL - Buttock Line NHA - Next Higher Assy WS - Wing Station CNTRY HSI - Century HSI NP - Not Procurable C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T Intro- Page 3 All EFFECTIVITY: 8. AIRCRAFT SERIAL NUMBER EFFECTIVITY Airplane effectivity for each wiring diagram is indicated in the effectivity box located at the lower left corner of each diagram. Effectivity is given by airplane serial number. Breaks in effectivity are indicated by com- mas. For example, an effectivity listing of “22-0005, 22-0009 thru 22-0015, 22-0020 and subsequent” indi- cates that the diagram is effective for airplane serial number 22-0005, skips 22-0006 through 22-0008, is effective for airplane serial number 22-0009 through airplane serial 22-0015, skips airplane serials 22- 0016 through 22-0019, and is effective for airplane serials 22-0020 and subsequent. Note: When effectivities are conditional to modifications, such as Service Bulletins, the airplane logbook should be checked to determine the proper replacement parts. For content specified with serials followed by “and subsequent” or “& subs”, effectivity in this WM ends as follows: A. Special Conditions New features are sometimes introduced on a “pilot” airplane before going into regular production. As a result, certain parts or assemblies are installed on a range of airplanes with a “split” or a break in affected serial number range. For example, a split effectivity listing of “Serials 22-2420, 22-2438 & subs” indicates that the part or assembly is effective for airplane serial number 22-2420, skips airplane serials numbers 22-2421 through 22-2437, and is effective for airplane serials 22-2438 and subsequent. See the following Special Conditions table, for a list of airplane serial numbers affected by split effectiv- ities. Model End Effectivity SR22 22-2234 SR22T 22T-1459, 22T-1461 thru 22T-1470, & 22T-1472 Serial Number Special Condition Disposition 22-1602 Aircraft installed with Primary Engine Instruments. Aircraft installed with Environmental Control System with factory installed Air Conditioning. Unless otherwise noted, refer to serial number 22-1663 for part identification of Engine Instruments. Unless otherwise noted, refer to serial number 22-2438 for part identification of Environmental Control System. 22-1644 Aircraft installed with Primary Engine Instruments. Unless otherwise noted, refer to serial number 22-1663 for part identification of Engine Instruments. 22-1821 Aircraft installed with Environmental Control System with factory installed fan. Unless otherwise noted, refer to serial number 22-1863 for part identification of Environmental Control System. 22-1840 Aircraft installed with Environmental Control System with factory installed Air Conditioning. Unless otherwise noted, refer to serial number 22-1863 for part identification of Environmental Control System. 19 Sep 2017 Intro- Page 4 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 19 Sep 2017 22-2334 Aircraft installed with G3 Wing and asso- ciated systems. Aircraft installed with Aircraft Data Log- ger (ADL) and associated systems. Unless otherwise noted, refer to serial number 22-2438 for part identification of systems affected by G3 Wing and ADL installations. 22-2420 Aircraft installed with G3 Wing and asso- ciated systems. Aircraft installed with Aircraft Data Log- ger (ADL) and associated systems. Unless otherwise noted, refer to serial number 22-2438 for part identification of systems affected by G3 Wing and ADL installations. 22- 2487 Aircraft installed with Perspective Avion- ics and associated systems. Unless otherwise noted, refer to serial number 22-3026 for part identification of systems affected by Perspective Avionics installation. 22-2979 Aircraft installed with Perspective Avion- ics and associated systems. Unless otherwise noted, refer to serial number 22-3026 for part identification of systems affected by Perspective Avionics installation. 22-2992 Aircraft installed with Perspective Avion- ics and associated systems. Unless otherwise noted, refer to serial number 22-3026 for part identification of systems affected by Perspective Avionics installation. 22-3002 Aircraft installed with Perspective Avion- ics and associated systems. Unless otherwise noted, refer to serial number 22-3026 for part identification of systems affected by Perspective Avionics installation. 22-3003 Aircraft installed with FIKI Ice Protection and associated systems. Unless otherwise noted, refer to serial number 22-3403 for part identification of systems affected by FIKI installation. 22-3310 Aircraft installed with FIKI Ice Protection and associated systems. Unless otherwise noted, refer to serial number 22-3403 for part identification of systems affected by FIKI installation. 22-3326 Aircraft installed with FIKI Ice Protection and associated systems. Unless otherwise noted, refer to serial number 22-3403 for part identification of systems affected by FIKI installation. 22T-0311 Aircraft installed with digital fuel quantity indication. Aircraft installed with digital deicing fluid level indication. Unless otherwise noted, refer to serial number 22T-0319 for part identification of systems affected by identified installa- tions. 22T-0312 22T-0313 22T-0314 22T-0316 22T-0317 Serial Number Special Condition Disposition C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T Intro- Page 5 All EFFECTIVITY: B. Avionics Configuration Airplane serial effectivities shown in the effectivity column may be further limited by the airplane’s avi- onics configuration. Cirrus Design offers the SR22/22T with the avionic options listed in the table below; therefore, the effectivity block for a wiring diagram may also be limited by the installed avionics. Serials 22-0002 thru 22-0434: Serials 22-0435 and subsequent: Configuration A Moving Map Display (Avidyne MFD) Two-Axis Autopilot (S-Tec System 30) Integrated Audio System with Intercom (Garmin GMA 340) Marker Beacon Receiver (Garmin GMA 340) Two IFR Approach-Certified GPS (Garmin GNS 430 and Garmin GNC 420) Two VHF Communications Transceivers (Garmin GNS 430 and Garmin GNC 420) Single Navigation (VOR/LOC/GS) Receiver (GNS 430) Mode C Transponder with Altitude Encoder (Garmin GTX 327) Horizontal Situation Indicator Course Deviation Indicator Configuration B Moving Map Display (Avidyne MFD) Two-Axis Autopilot (S-Tec System 55X) Integrated Audio System with Intercom (Garmin GMA 340) Marker Beacon Receiver (Garmin GMA 340) Two IFR Approach-Certified GPS (Garmin GNS 430) Two VHF Communications Transceivers (Garmin GNS 430) Two Navigation (VOR/LOC/GS) Receiver (GNS 430) Mode C Transponder with Altitude Encoder (Garmin GTX 327) Electronic Navigation Display (Sandel SN3308) Course Deviation Indicator Configuration PFD Moving Map Display (Avidyne MFD) Primary Flight Display (Avidyne PFD) Two-Axis Autopilot (S-Tec System 55X) Integrated Audio System with Intercom (Garmin GMA 340) Marker Beacon Receiver (Garmin GMA 340) Two IFR Approach-Certified GPS (Garmin GNS 430) Two VHF Communications Transceivers (Garmin GNS 430) 19 Sep 2017 Intro- Page 6 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 19 Sep 2017 Serials 0656 thru 0685, 0687 thru 0717, 0730 thru 0768: Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Two Navigation (VOR/LOC/GS) Receiver (GNS 430) Mode C Transponder with Altitude Encoder (Garmin GTX 327) Aircraft Data Logger Configuration Centennial Moving Map Display (Avidyne MFD) Primary Flight Display (Avidyne PFD) Two-Axis Autopilot (S-Tec System 55X) Integrated Audio System with Intercom (Garmin GMA 340) Marker Beacon Receiver (Garmin GMA 340) Two IFR Approach-Certified GPS (Garmin GNS 430) Two VHF Communications Transceivers (Garmin GNS 430) Two Navigation (VOR/LOC/GS) Receiver (GNS 430) Mode C Transponder with Altitude Encoder (Garmin GTX 327) Goodrich SkyWatch Goodrich Stormscope Avidyne EMax Engine Monitoring System Ice Protection System Configuration Perspective Avionics Multi-Function Display (Garmin MFD) Primary Flight Display (Garmin PFD) Two-Axis Autopilot (Garmin GFC 700) Serials 22-2979, 22-2992, 22-3002, 22-3026 thru 22-3827, 22T-0001 thru 22T-0267: Integrated Audio System with Intercom (Garmin GMA 347) Serials 22-3828 & subs, 22T-0268 & subs: Integrated Audio System with Intercom (Garmin GMA 350) Serials 22-2979, 22-2992, 22-3002, 22-3026 thru 22-3827, 22T-0001 thru 22T-0267: Marker Beacon Receiver (Garmin GMA 347) Serials 22-3828 & subs, 22T-0268 & subs: Marker Beacon Receiver (Garmin GMA 350) Two IFR Approach-Certified GPS (Garmin GIA 63W) Two VHF Communications Transceivers (Garmin GIA 63W) Two Navigation (VOR/LOC/GS) Receiver (Garmin GIA 63W) Mode C Transponder with Altitude Encoder (Garmin GTX 32) Configuration PFD (Continued) C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T Intro- Page 7 All EFFECTIVITY: Serials 22T-0079 thru 22T-0188, with Option Installed: C. Optional Equipment Airplane serial effectivities shown in the effectivity column may be further limited by optional equipment installations. Cirrus Design offers the SR22 and SR22T with the optional equipment listed in the table below; therefore, the effectivity column for a figure may also be limited by the installed optional equip- ment. Flight Management System Keyboard (Garmin GCU 478) Attitude and Heading Reference System (Garmin GRS 77) Air Data Computer (Garmin GDC 74A) Engine Airframe Unit (Garmin GEA 71) Configuration Anniversary Perspective Avionics Configuration with following options installed: - 12-inch Garmin MFD/PFD Displays - Three-Axis Autopilot (Garmin GFC 700) - Garmin Mode S Transponder - Dual Attitude and Heading Reference System (Garmin GRS 77) - Dual Air Data Computer (Garmin GDC 74A) - Garmin Synthetic Vision XM Weather/Radio/Remote System FIKI Ice Protection System Carbon Monoxide (CO) Detector Air Conditioning System Enhanced Vision System Artex ME406 Emergency Locator Transmitter (ELT) Terrain Awareness & Warning (TAWS) Engine Pre-Heater LED Landing Light LED Anti-Collision Strobe Light Optional Equipment Serials 22-0002 & subs: L3 SkyWatch Serials 22-0002 & subs: L3 Stormscope Serials 22-0002 & subs, 22T-0001 & subs: S-TEC System 55X Serials 22-0002 & subs: Sandel SN3308 Electronic Navigation Display Serials 22-0142 & subs: Avidyne EX5000C MFD Serials 22-0300 & subs: Avidyne EMax Engine Monitoring System Configuration Perspective Avionics (Continued) 19 Sep 2017 Intro- Page 8 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 19 Sep 2017 D. Notes Affecting Effectivity Service Bulletins - Installation of Service Bulletins are shown by notations in the effectivity or by flag notes on the face of the diagram. The term “Before SB 2X-XX-XX” in the effectivity box indicates that Serials 22-0002 & subs: Avidyne CMax Electronic Approach Charts Serials 22-0334 thru 22-2437: Basic Ice Protection System Serials 22-2438 & subs, 22T-0001 & subs: Basic² Ice Protection System Serials 22-3403 & subs, 22T-0001 & subs: FIKI Ice Protection System Serials 22-0687 & subs: McCauley Propeller Serials 22-0821 & subs: Hartzell DF Propeller Serials 22-2044 & subs, 22T-0001 & subs: Hartzell Composite Propeller Serials 22-0821 & subs, 22T-0001 & subs: Garmin Mode S Transponder Serials 22-1036 & subs, 22T-0001 & subs: Honeywell Terrain Awareness and Warning System Serials 22-1104 & subs, 22T-0001 & subs: XM Weather System Serials 22-3828 & subs, 22T-0268 & subs: Iridium Weather System Serials 22-1307 & subs, 22T-0001 & subs: Flight Director Serials 22-1511 & subs, 22T-0001 & subs: XM Radio System Serials 22-1821, 22-1863 & subs, 22T-0001 & subs: Cabin Air Fan Assembly Serials 22-1602, 22-1840, 22-1863 & subs, 22T-0001 & subs: Air Conditioning System Serials 22-1863 & subs, 22T-0001 & subs: Artex ME406 Emergency Locator Transmitter (ELT) Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Bendix/King Distance Mea- suring Equipment Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Bendix/King Automatic Direction Finder Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Garmin Synthetic Vision Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Garmin GMC 705 AFCS Mode Controller Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Enhanced Vision System Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Yaw Axis Servo Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Garmin GRS 77 AHRS (Sec- ondary) Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Garmin GMU 44 Magnetom- eter (secondary) Serials 22-2979, 22-2992, 22-3002, 22-3026 & subs, 22T-0001 & subs: Carbon Monoxide (CO) Detector Serials 22-4164 & subs, 22T-0954, 22T-0963 & subs: MD302 Standby Attitude Module Serials 22-4300 & subs, 22T-1233 & subs: Garmin GDL 88 Universal Access Transceiver Serials 22-4300 & subs, 22T-1233 & subs: Garmin Flight Stream 210 Wireless Cockpit Transceiver Serials 22-4300 & subs, 22T-1233 & subs: Remote Keyless Entry and Ambient Convenience Lights Optional Equipment C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T Intro- Page 9 All EFFECTIVITY: the diagram effectivity is as written unless SB 2X-XX-XX was installed. The term “After SB 2X-XX-XX” in the effectivity box indicates that the part effectivity is as written when SB 2X-XX-XX is installed. If the wiring change because of the Service Bulletin is small, the wiring change may be indicated on the face of the wiring diagram with a flag note. In this case, no entry will be made in the effectivity box. 9. ELECTRICAL LOAD ANALYSIS AND BUS SCHEMATICS An electrical load analysis showing individual circuit loads and bus schematics showing system current flow for normal operation and during circuit failure is provided in 91-00-00 of this manual. 10. CONNECTOR, SWITCH, AND RELAY DATA A connector list showing a diagram of the pin/socket locations in each plug/jack as well as specific data relating to the connector is provided in 91-10-00 of this manual. Switch and relay identification tables are also provided. 11. WARNINGS, CAUTIONS, AND NOTES Warnings, Cautions, and Notes are used to highlight or emphasize important points. WARNING: Warnings call attention to use of materials, processes, methods, procedures, or limits which must be followed precisely to avoid bodily injury. CAUTION: Cautions call attention to methods and procedures which must be followed to avoid damage to equipment. Note: Notes call attention to methods which make the procedure easier. 12. PUBLICATION CHANGE REQUEST FORM A Publication Change Request form can be found online at the following link: http://servicecenters.cirrusdesign.com/TechPubs/serviceloopform.asp Use the form to submit a Publications Change Request to our Engineering Department and/or to tell us what you think of the quality of the publication. We will use the data you provide us to improve the quality of our technical publications. 19 Sep 2017 Intro- Page 10 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 01 Feb 2013 Intentionally Left Blank CHAPTER STANDARD PRACTICES: AIRFRAME CHAPTER 20 - STANDARD PRACTICES: AIRFRAME Intentionally Left Blank C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-LOEP Page 1 All EFFECTIVITY: CHAPTER 20 - STANDARD PRACTICES: WIRING LIST OF EFFECTIVE PAGES Chapter-Section Page Date 20-LOEP 1 31 MAY 2011 20-LOEP 2 31 MAY 2011 20-TOC 1 31 MAY 2011 20-TOC 2 31 MAY 2011 20-00 1 31 MAY 2011 20-00 2 31 MAY 2011 20-00 3 31 MAY 2011 20-00 4 31 MAY 2011 20-00 5 31 MAY 2011 20-00 6 31 MAY 2011 20-00 7 31 MAY 2011 20-00 8 31 MAY 2011 20-10 1 31 MAY 2011 20-10 2 31 MAY 2011 20-10 3 31 MAY 2011 20-10 4 31 MAY 2011 20-10 5 31 MAY 2011 20-10 6 31 MAY 2011 31 May 2011 20-LOEP Page 2 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 Intentionally Left Blank C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-TOC Page 1 All EFFECTIVITY: CHAPTER 20 - STANDARD PRACTICES: WIRING TABLE OF CONTENTS Subject Chapter-Section Page STANDARD PRACTICES: WIRING 20-00 General 1 Terminology 1 Wire and Cable Marking 1 Numbering 1 Marking 1 Wire Harness Marking 2 Markings 2 Plug and Jack Marking 2 Markings 2 Fault Isolation 7 Test Leads 7 Inspection/Test 7 WIRING REPAIR 20-10 General 1 Maintenance Practices 1 Stripping Insulation and Shielding 1 Strip Insulation, Single Conductor 1 Strip Cable Jacket and Shielding 1 Crimping 1 Crimp Machine Pins or Sockets 1 Crimp Continuous Roll Pins or Sockets 1 Crimp Terminal Rings 2 Soldering 2 General 2 Soldering Two Wires 2 Soldering a Wire to a Device 2 Solder Sleeve Splices 3 Heat Shrink/Shrinkable Devices 3 General 3 Installation of Heat Shrink and Shrinkable Devices 3 Splicing 3 Solder Splices 3 Terminating 4 General 4 Connectors 4 General 4 Coaxial Cable 4 Radio Rack Connectors 4 31 May 2011 20-TOC Page 2 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 CHAPTER 20 - STANDARD PRACTICES: WIRING TABLE OF CONTENTS Subject Chapter-Section Page BNC Crimp Type Connectors 4 Routing Wires and Wire Bundles 4 General 4 Tying 4 Chafing Protection 4 General 4 Lightning Protection Over-Braiding of Wire Harnesses and Coax Cables 5 General 5 Coax Cable Over-Braid Specification 5 Inspection 5 Conformal Coating Process 6 Discrete LED Lamps 6 LED Strain Relief 6 C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-00 Page 1 All EFFECTIVITY: STANDARD PRACTICES: WIRING 1. GENERAL This chapter contains requirements and procedures for the fabrication, repair, and marking of wire harness assemblies, cables, and wires. All wiring repairs and marking of wire harness assemblies, cables, and wires should be accomplished in accordance with the procedures in this chapter and in accordance with FAA Advisory Circular AC 43-13 (latest revision). A. Terminology The following terms are used throughout this chapter. The maintenance technician should be familiar with the following definitions, materials, and procedures: • Wire: An individual insulated wire. Either stranded or solid. • Cable: A multi-conductor cable. In most cases this is a shielded twisted-wire cable that is jacketed with a Teflon material. • Wire: Bundle A group of wires and/or cables that are tied together using tie string, tie wraps, or other methods. In some cases the wire bundle may be covered with an external sheath. • Wire Harness: A complete assembly including a wire bundle and the associated connectors, fas- teners, and markings. • Plug: A connector with female pins (sockets) normally used on the power side (coming from an electrical source) of a connection of two or more bundles or devices. • Jack: A connector with male pins normally used on the device side of a connection. B. Wire and Cable Marking Wire marking aids the technician in locating and identifying individual wires within a wire bundle. Wire marking consists of a combination of letters and numbers that identify the wire, circuit or system, wire gauge, and additional data that helps in wire identification. (1) Numbering (a) Wires are numbered to identify the system, circuit, wire number, wire gauge, and signal type. For example, wire ANGP003-20N indicates a 20 AWG ground wire for the GPS receiver. (b) Each wire is numbered within 6 inches of the termination at each end and every 12 to 15 inches along the length of the wire with the following exceptions: 1 Wires less than 6 inches in length may not be marked. 2 Wires installed within conduit are marked within 6 inches of termination ends. 3 Wires 6 to 24 inches in length and having one end terminated by a terminal ring, spade lug, or soldered to a device are marked by a single marker on the external connector end. 4 Assemblies consisting of a single wire with terminal rings or spade lugs on each end and not having a wire number are not marked but are labeled with the part's assem- bly number and revision level. 5 Wires 6 to 24 inches in length, not meeting the above criteria, are marked within 6 inches of each termination end. (2) Marking (a) Wires are marked by stamping directly onto the wire insulation, or are marked by attaching printed sleeving or tape. (b) Each wire and/or cable is marked by using the codes listed in Figure 20-001. 31 May 2011 20-00 Page 2 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 C. Wire Harness Marking Wire harnesses are also marked for ease of identification during fabrication and installation. Wire har- nesses are marked using the following methods: (1) Markings Each wire harness shall be marked with a unique number that identifies its location in the air- plane. Wire harness numbers shall start with a “W” followed by a unique three (3) digit number that corresponds to the wire harness location. The following numbering convention is used: (a) 001-299 Firewall Forward (b) 300-399 Left Wing (c) 400-499 Right Wing (d) 500-999 Fuselage Wire harnesses are marked with a tag that identifies the wire harness number and the wire har- ness part number. This tag is attached to the wire harness adjacent to the plug or jack that pro- vides primary power or signals to the wire harness. D. Plug and Jack Marking Plugs and jacks are marked to aid in identification during fabrication, installation, and troubleshooting. Plugs and jacks are be marked using the following methods: (1) Markings Plugs and jacks are marked with a unique number that identifies their location in the airplane. The first character is a “P” for plugs or a “J” for jacks. The plug or jack designation is followed by a unique three (3) digit number that corresponds to the plug/jack location. The following number- ing convention is used: (a) 001-299 Firewall Forward (b) 300-399 Left Wing (c) 400-499 Right Wing (d) 500-999 Fuselage Plugs and jacks are marked with a tag that identifies the plug or jack number. This tag is attached to the wire harness adjacent to the plug or jack. Relay bases or sockets do not require marking. Bases are directly marked with paint or visible permanent marker with the base identification number. C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-00 Page 3 All EFFECTIVITY: SYSTEM / CODE CIRCUIT, GENERAL CIRCUIT, SPECIFIC Power (P) BAPR Generation Battery 2 PAC Power Air Conditioning PACC Power Autopilot PACF Ground PFD Cooling Fan PADL Power ADL PAPS Power Pitch Servo PARS Power Roll Servo PAYS Power Yaw Servo PBLU Ground Air Conditioning PCAU Power Audio Panel PCP Power Convenience Power PCPR Power Convenience Power PDM Power DME PEP Entertainment Power PFD Navigation Display PG Shield Ground Flaps PGAL Generation Alternator PGCB Generation Circuit Breaker PGCF Power Avionics Cooling Fan PGEA Power GEA PGLV Generation Low Voltage Figure 20-001 Wire Number Codes (Sheet 1 of 4) XXXX0000 - XX (X) SYSTEM FUNCTION CIRCUIT GENERAL CIRCUIT SPECIFIC SIGNAL TYPE N = Ground WIRE GAUGE WIRE NUMBER 000 - 299, 5000 - 5999 Firewall Forward 300 - 399, 3000 - 3999 Left Wing 400 - 499, 4000 - 4999 Right Wing 500 - 999, 1000 - 2999 Fuselage 31 May 2011 20-00 Page 4 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 PGMS Generation Master Switch PGST Generation Starter PMCF Power MFD Cooling Fan PNAD Power ADF PNDM Power DME PPCF Power PFD Cooling Fan PRDM Power ADL PXF Power Transponder Cooling Fan PXM Power XM Weather Avionics (A) AACC Autopilot Controller/Computer AAGP Autopilot GPS AAPT Autopilot Pitch Trim AART Autopilot Roll Trim ACAU Communications Audio ACEA Data GEA ACEL Shield Ground ELT ACFD Switch TO/GA Switch ACMD MFD Display ACMS Switch Avionics Switch ACPD Data PFD ACSB Data GEA ACTL Communications Telephone ACTX Communications Transponder ACVH Communications VHF Radio AEVS Data EVS ANAD Navigation ADF ANAU Navigation Audio ANDM Navigation DME ANEG Navigation TAWS SYSTEM / CODE CIRCUIT, GENERAL CIRCUIT, SPECIFIC Figure 20-001 Wire Number Codes (Sheet 2 of 4) C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-00 Page 5 All EFFECTIVITY: ANFM Power Keypad ANGP Navigation GPS ANHS Navigation HSI ANMD Navigation Display ANRS Data AHRS, Air Data ANSK Data Skywatch ANSS Data Stormscope ANTA Power Skywatch ANVH Navigation VHF Radio ANXM Data XM Weather Instruments (I) ANEN Power Engine Instruments IEFL Engine Indicator Fuel Level IEHB Engine Indicator Hobbs IEOP Engine Indicator Oil Pressure IEOT Engine Indicator Oil Temperature INFD Navigation Flux Detector INHS Navigation HSI IPAT Power Attitude 2 IPCL Power Clock IPEI Power Engine Instruments IPHS Power HSI IPTC Power Turn Coordinator IPVA Power Volt/Amp IPYT Power Yaw Trim ISAN System Indicator Annunciator ISOA System Indicator OAT Engine (E) EEFP Electric Fuel Pump EFGS Switch Gascolator SYSTEM / CODE CIRCUIT, GENERAL CIRCUIT, SPECIFIC Figure 20-001 Wire Number Codes (Sheet 3 of 4) 31 May 2011 20-00 Page 6 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 EPMA Power Magnetos Lights (L) LELD Exterior Landing LENV Exterior Navigation LEST Exterior Strobe LIBG Interior Baggage LICB Power Attitude 2 LIFL Interior Flood LIIL Interior Instrument Lights LILS Ground Dimmer Switch Controls (C) CAC Control Air Conditioning CASD Switch Autopilot Disconnect CFL Flaps CPT Pitch Trim CRT Roll Trim CSAC Power Air Conditioning CSAV Switch Avionics Switch CSIC Power Ice Protection CSMS Switch Master Switch CSST Switch Starter Switch CSTM Switch Trim Switch CSVA Switch Vacuum CSYT Switch Yaw Trim SSW Switch Stall Warning SYSTEM / CODE CIRCUIT, GENERAL CIRCUIT, SPECIFIC Figure 20-001 Wire Number Codes (Sheet 4 of 4) C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-00 Page 7 All EFFECTIVITY: 2. FAULT ISOLATION Malfunction symptoms will normally be a result of operational checkout or functional test procedures that fail at some point. Discrepancies must be resolved before the procedures can be completed. Another source of malfunction symptoms are the crew member squawks. WARNING: Use extreme caution when performing maintenance operations on the airplane. Unless otherwise instructed, troubleshooting will be performed with the system de- energized. If a circuit is being tested with a lampload or a Meggar which may result in arcing, safety procedures relating to fuel vapors must be observed. Do not wear rings, wrist watches, metal bracelets, or other jewelry which can cause a short circuit resulting in serious injury. Repairing or troubleshooting of wiring must be accomplished by referring to the electrical wiring diagrams contained in this manual. After the malfunction is cleared, perform appropriate operational checkout or functional test procedure. In light circuits with only one lamp, the isolation procedure usually starts with the possibility of a defective lamp. In a light circuit that has two or more lamps, the isolation procedures do not isolate defective lamps. A fault that results from shorted light circuits is often caused by foreign metal objects that have fallen into the wiring or by pinched wires resulting from maintenance work on other equipment in the area. A thorough visual inspection may often locate a fault in shorted light circuits. A. Test Leads When using test leads to make voltage checks, the following procedures shall be followed: (1) Inspection/Test (a) Remove system power. (b) Disconnect applicable connector. (c) Install test lead between designated connector or receptacle pins which complete circuit to be tested. (d) Apply system power and perform check. 31 May 2011 20-00 Page 8 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 Intentionally Left Blank C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-10 Page 1 All EFFECTIVITY: WIRING REPAIR 1. GENERAL This section contains procedures applicable to the fabrication and repair of wire harness assemblies, cables, and wires. All wiring repairs of wire harness assemblies, cables, and wires shall be accomplished in accordance with the procedures in this chapter and in accordance with FAA Advisory Circular AC 43-13 (latest revision). 2. MAINTENANCE PRACTICES A. Stripping Insulation and Shielding (1) Strip Insulation, Single Conductor (a) Wire insulation is stripped with a hand held wire stripper. Ensure wire is placed in correct slot for the wire size. (b) The handles should be squeezed in a smooth continuous motion as not to nick or kink the wire. (2) Strip Cable Jacket and Shielding Cable jackets and shielding are stripped with a sharp razor blade (or coaxial cable stripper) and a sharp pair of flush-cut pliers. To remove the jacketing of a multi-conductor cable: (a) Score jacketing with razor blade around entire circumference of cable. (b) Bend cable at score mark and break jacketing. If cable jacketing does not break, repeat scoring and bending process until it breaks. Some jacketing can be slid off end of cable after breaking process. Score jacketing from break point to end of cable and bend cable to break along score line. (c) Mark strip length on shielding then slide shielding from exposed end to produce slack in shielding and trim with flush-cut pliers completely around cable at mark. (d) Remove excess shielding. (e) Inspect all wires and cables after stripping for unintentional breaks in insulation and nicks or broken strands of wire in the stripped area. B. Crimping Crimping of any device on end of stripped wire is done with crimping tool specified by manufacturer or equivalent crimping tool. (1) Crimp Machine Pins or Sockets (a) Strip wire to correct length so wire is showing in hole on side of pin/socket (witness hole) and not protruding past end of pin/socket. (b) Place pin socket into crimping device and insert wire into pin/socket. (c) Using a smooth continuous stroke, squeeze handle of crimping tool until crimp is complete (the handle will not release until crimp is complete). (d) Inspect crimp by pulling on wire. The crimp should hold. If crimp does not hold, crimping tool should be checked and/or recalibrated. (e) Bend wire directly behind pin/socket to inspect that insulation does not protrude into crimp portion of pin/socket and that wire does not extend more than 0.032 inch (0.8 mm) past end of pin/socket. (2) Crimp Continuous Roll Pins or Sockets (a) Strip wire to a length that allows wire insulation to be secured by insulation grip and stripped wire to be gripped by wire grip(s). (b) Insert pin/socket into correct size slot of crimping tool and squeeze crimping tool until pin is secure (but not crimped). (c) Insert wire with end of insulation located between insulation grip and wire grip. 31 May 2011 20-10 Page 2 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 (d) Using a smooth continuous stroke, squeeze handle of crimping tool until crimp is complete (the handle will not release until crimp is complete). (e) Inspect crimp by pulling on wire. The crimp should hold. If crimp does not hold, crimping tool should be checked and/or recalibrated. (f) Verify end of insulation is located between insulation grip and wire grip. The insulation grip should snugly capture insulation. (3) Crimp Terminal Rings (a) Insert terminal into correct size slot of crimping tool and squeeze crimping tool until termi- nal ring is secure (but not crimped). (b) Insert stripped wire into wire grip hole so that wire insulation is completely within terminal ring insulation (or insulation grip on uninsulated terminals) and wire is just visible on termi- nal ring end. (c) Using a smooth continuous stroke, squeeze handle of crimping tool until crimp is complete (the handle will not release until crimp is complete). (d) Inspect crimp by pulling on wire. The crimp should hold. If crimp does not hold, crimping tool should be checked and/or recalibrated. C. Soldering (1) General (a) Acquire necessary tools, equipment, and supplies. (2) Soldering Two Wires (a) Strip both wires approximately 0.5 inch (13 mm). (b) Slide a 1.0 inch (25.4 mm) or more piece of heat shrink of correct size onto one of the wires. (c) Untwist wire strands until straight on both wires. Push wire ends together meshing strands. Twist meshed wires together. (d) Apply solder paste and heat solder until all strands are full and not overflowing. (e) Inspect solder joint to ensure that solder has flowed into splice. (f) Slip heat shrink sleeve over joint and apply heat using a heat gun until heat shrink has uni- formly sealed the splice. (3) Soldering a Wire to a Device (a) If required, slide a piece of heat shrink sleeve over wire prior to soldering wire to device (terminal, contact, etc.). (b) If necessary, conform end of wire to a shape that will enhance mechanical strength of joint (e.g. for a terminal post wrap, position stripped portion of wire around post). (c) While holding pre-tinned and pasted wire onto device, simultaneously apply heat and sol- der to device/wire. Melt solder into joint until all gaps are filled but not overflowing. (d) Inspect solder joint to ensure that solder has flowed into all gaps. Description P/N or Spec. Supplier Purpose Solder, Soft, Rosin Core At least 60% tin and 40%, or less, lead. 50412-001 QQ-S-571 QQSS571 QQS571F Type RMA Any Source Solder low temp joints. Solder, Silver, Rosin Core At least 60% tin, less than 40% lead, and minimum 2% silver. 50036-001 QQ-S-561F QQ-B-654 Any Source Solder high temp joints. C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-10 Page 3 All EFFECTIVITY: (e) Slip heat shrink sleeve over joint and apply heat using a heat gun until heat shrink has uni- formly sealed the splice. D. Solder Sleeve Splices The solder sleeve is a durable and reliable alternative to traditional crimping methods. Made of heat shrinkable thermoplastic, the sleeve contains a fluxed solder pre-form which provides the exact amount of solder and flux required to connect coaxial wire to the contact. The solder sleeve's one- piece, pre-assembled design makes application as easy as stripping the wire, inserting it and heating the contact. After shrinking, the sleeve acts as an insulator and provides strain relief for the solder joint. E. Heat Shrink/Shrinkable Devices Heat shrink is a sleeved material used as a replacement for wire insulation during wire harness fabri- cation, installation, and repair. Heat shrink sleeves shrink to approximately half the original diameter during heating. Heat shrinkable devices are used for joining and splicing wires and often contain solder in a shrinkable housing. Shrinkable devices include solder sleeve splices (with or without lead wire), and cap splices. (1) General (a) Cut heat shrink to twice the length of exposed area to be covered. (b) Size heat shrink to ensure the heat shrink is not loose after shrinking. (c) Size heat shrinkable devices to ensure the device is not loose after shrinking. (d) Prior to installation, inspect each sleeve to ensure that the sleeve is not damaged. (e) Heat shrink may be used for repairing nicks or cuts in wire insulation. (f) Heat shrinkable devices without grounding wires may be substituted for heat shrinkable devices with grounding wires and vice versa provided the above regulations and installa- tion methods are followed. (2) Installation of Heat Shrink and Shrinkable Devices (a) Install heat shrink sleeve shrinkable device on end of wire and apply heat using a heat gun. When heating soldering device, solder sleeve must be melted to a fluid state, and ends shrunk before heating process is complete. (b) Inspect that solder has flowed into wire being soldered. Reheat as necessary. F. Splicing Splicing of electric wire should be kept to a minimum and avoided entirely in locations subject to extreme vibrations. Individual wires in a group or bundle may be spliced provided the completed splice is located so it can be periodically inspected. Stagger splices so bundle does not become excessively enlarged. Many types of aircraft splice connectors are available for use when splicing individual wires. Use of a self-insulated splice connector is preferred, however, a non-insulated splice connector may be used provided the splice is covered with plastic sleeving and secured at both ends. (1) Solder Splices Solder splices may be used, however, they are particularly brittle and not recommended. Splices are subject to the following: (a) There shall be not more than one splice in any one wire segment between any two con- nectors or other disconnect points. (b) Stagger splices in bundles so as to not increase size of bundle which could prevent bundle from fitting in designated space or cause congestion adversely affecting maintenance. (c) Do not use splices to salvage scrap lengths of wire. (d) Do not use splices within 12 inches of a termination device, except for the following: 1 Attaching to pigtail spare lead of a potted termination device. 2 Splicing multiple wires to a single wire. 3 Adjusting wire sizes to be compatible with contact crimp barrel sizes. 31 May 2011 20-10 Page 4 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 G. Terminating (1) General (a) All wires must be terminated with the appropriate device. (b) Open or spare wires should be capped using heat shrink tubing. H. Connectors (1) General (a) Refer to manufacturers installation details. I. Coaxial Cable (1) Radio Rack Connectors (a) Refer to the manufacturer's installation details. (2) BNC Crimp Type Connectors (a) Refer to manufacturer’s instructions. J. Routing Wires and Wire Bundles (1) General (a) Route engine compartment wires so that sufficient slack is provided near connectors to account for engine vibration and torque. (b) Route wires at least 3.0 inches (76 mm) away from control cables and moving parts. When 3.0 inches (76 mm) separation cannot be achieved, a clamp or guard must be used. (c) Run wires parallel and above combustible fluid lines, and maintain a 6.0 inch (152 mm) clearance whenever possible. When a 6.0 inch separation cannot be achieved, wires must be clamped away from combustible fluid lines and have a minimum of 0.5 inch (13 mm) clearance. (d) Use a bulkhead connector to pass wires through a bulkhead, rib or panel. When a connec- tor cannot be used, secure wires and use grommets to protect wires. (2) Tying (a) Ties may consist of any knot which firmly secures bundle, cannot be easily loosened, and is not excessive in size. (b) Lacing cord, tie wraps, adel clamps or other approved methods must be used to hold loose wires together to form a bundle. (c) Adel clamps must be sized to ensure that clamp does not pinch wires or bundles, and positioned so that wires or bundles are supported with less than 0.5 inch (13 mm) of deflection between support points. This measurement may be exceeded if there is no pos- sibility of wires or bundles touching a surface which may cause abrasion. (d) Bundles should be laced before and after every branch break, and at least every 12 inches (305 mm). Thicker wires and bundles with more bends may need lacing more often. Bun- dles installed in conduit only need to be laced at exposed ends. K. Chafing Protection (1) General (a) Chafing protection should be used whenever wires or bundles pass within 0.25 inches (6.3 mm) of structures which would cause abrasion to the wire insulation. (b) Grommets or flexible grommeting should be used as chafing protection when wires pass through holes in structures. (c) Flexible grommets may be used in holes or along edges not suitable for standard grom- mets. This material should be fastened to metal using RTV silicon adhesive, or equivalent. This material should be fastened to composite using 5-minute epoxy or equivalent. C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 20-10 Page 5 All EFFECTIVITY: L. Lightning Protection Over-Braiding of Wire Harnesses and Coax Cables (1) General Lightning protection is provided by over-braid essential wire harnesses and/or cables that have been determined to be susceptible to indirect effects of lightning. Wire harness shall be sent to an approved vendor for over-braiding. Note: Over-braided wire harnesses and coax cables do not require wire marking since over-braiding will cover the marking. Connector tags and wire harness tags are installed after over-braiding. String tie should be used only at branches to minimize deformities in the over- braid. As necessary, electrical or cloth tape can be used to secure wire bundles. (a) Lightning protection over-braid of wire harnesses shall be in accordance with the following: 1 Material: 36 AWG tinned copper wire per ASTM-B-33. 2 Coverage: 98% - 100% optical (i.e. cannot see wiring under braid). 3 Braid Coverage Area: Per CDC drawing. 4 Braid Tails: Each tail shall be a minimum of 6.0 inches (152 mm) long prior to termi- nal ring installation. 5 Braid Ends: Other than braid tails, all other branches should be terminated as close to connector as possible with a back braid to provide a clean end. On connectors with backshells, the braid shall be captured by the connector backshell. On connec- tors without backshells or branches without connectors, the over-braid may be secured to the wire bundle using plastic tie-wraps. Typically, this is not required since the over-braid and back braid create a secure termination. 6 Splices/Broken Wires: Must be trimmed without affecting coverage area as defined above. (2) Coax Cable Over-Braid Specification (a) Coax cables shall be sent to an approved vendor for over-braiding. (b) Lightning protection over-braid of coax cables shall be in accordance with the general over-braid specification above. (3) Inspection Note: During inspection, the wire harness/coax cable shall be laying flat with branches extending outward from main branch. (a) Inspection of completed over-braid assemblies shall use the following criteria for pass/fail: 1 Over-braid should completely cover defined area with minor openings in braid. Openings (holes) are not to exceed 0.125 inch (3.18 mm) diameter and no more than five openings in a 6.0 inch (152 mm) section of over-braid. 2 Connector backshells shall secure over-braid under backshell. 3 Terminal rings crimped to braided tails shall be crimped in accordance with this sec- tion. Braided tails shall be trimmed as short as possible to minimize induced current. 4 Branches that terminate at connectors without backshells or with no connectors shall be secured on wire bundle. Plastic tie-wraps may be used to secure over-braid. (b) Conformal Coating of Circuit Card Assemblies 31 May 2011 20-10 Page 6 All EFFECTIVITY: C I R R U S A I R C R A F T W I R I N G M A N U A L M O D E L S S R 2 2 A N D S R 2 2 T 31 May 2011 M. Conformal Coating Process (a) Acquire necessary tools, equipment, and supplies. (b) Clean CCA and allow to dry thoroughly prior to application of conformal coating. (c) Mask off all areas that will not be coated. Ensure that all edges of masking tape are pressed down to maintain a good seal. Note: Switches, connectors, through-hole circuit board solder pads that will be used, annunciators, LEDs, and lights should not be coated. (d) While keeping circuit card as flat as possible, apply three layers of conformal coating. Use the following techniques to ensure uniform application for each layer: 1 Spray from top-to-bottom then from side-to-side (this will apply two thin layers rather than 1 thick coat). 2 Hold spray nozzle 10 to 12 inches (25.4 to 30.5 cm) from CCA surface. 3 Use a stroking motion. (e) Allow circuit card to dry thoroughly between layers (approximately ½ hour). (f) After third layer is completely dry, measure conformal coating to ensure that coating is 0.003 +0.002/-0.001 inch (0.076 +0.050/-0.025 mm) thick. If required, add additional lay- ers to achieve correct coating thickness. (g) Remove masking tape from masked components. If necessary, use isopropyl alcohol to remove residual adhesive. N. Discrete LED Lamps (1) LED Strain Relief (a) Provide adequate strain relief to discrete LEDs in wire harnesses as follows: 1 Before soldering wires to LED legs, trim legs to 0.2 to 0.3 inch (5.1 to 7.6 mm). 2 Solder wire to leg. (Refer to 20-10) 3 Protect individual legs after soldering with a minimum of 0.5 inch (12.7 mm) of heat shrink. 4 Heat shrink LED legs together for strain relief. Description P/N or Spec. Supplier Purpose Clear Acrylic Sealer S02000 Sherwin Williams Sealant. Clear Polyurethane 1A33 Humiseal Sealant. Masking Tape - Any Source Masking. Isopropyl Alcohol TT-I-735 Grade A or B Any Source Cleaning. CHAPTER ENVIRONMENTAL SYSTEMS CHAPTER 21 - ENVIRONMENTAL SYSTEMS Intentionally Left Blank