FALCON 2000 / FALCON 900 EX / FALCON 50 EX / FALCON 900 C / FALCON 2000 EX

SECTION 03 - 60

GENERAL INSTRUCTIONS

TABLE OF CONTENTS
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Page

1- INTRODUCTION 002

2- DESCRIPTION OF HARNESSES 003

2 - 1. Construction 003
2 - 2. Electrical boxes harnesses 003
2 - 3. Harnesses in pressurized aera 003
2 - 4. Coaxial harnesses 004
2 - 5. Optic harnesses 004
2 - 6. Segregation of harnesses 004
2 - 7. Manufacturer’s procedures 004

3- MANUFACTURING RULES 005

3 - 1. Construction of bundles 005
3 - 1.1 Conductors 005
3 - 1.2 Twisting 005
3 - 1.3 Twining 005
3 - 1.4 Fasteners 006
3 - 2. Fitting out of bundles 006
3 - 2.1 Branches 006
3 - 2.2 Protection 006
3 - 2.3 Shielding 006
3 - 2.4 Binding 007
3 - 2.5 Sealed passage 008
3 - 2.6 Ends 008
3 - 3. Marking 008
3 - 3.1 Identification and marking of wires 008
3 - 3.2 Marking of electrical equipments 009
3 - 3.3 Marking of harness ends 009
3 - 3.4 Marking of sealed passage 010
3 - 3.5 Marking inside electrical boxes 010
3 - 3.6 Marking of components on the aircraft structure 010
3 - 4. Identification 011
3 - 4.1 Identification of harnesses 011
3 - 4.2 Identification of electrical boxes 011
3 - 5. Assembly on aircraft and attachment 011

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 FALCON 2000 / FALCON 900 EX / FALCON 50 EX / FALCON 900 C / FALCON 2000 EX

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1- INTRODUCTION

The purpose of this document is:

- to describe harnesses and wiring,
- to specify the rules to be followed in the manufacture of harnesses and the harness
installation on aircraft,
- to list components, tools and equipment needed for their manufacturing,
- to give examples of general manufacturing details.
Failure to follow the instructions given in this document should be subject of a previous, written
approval by the Head of the Engineering and Design Department for Electrical Systems and
requires that this document be updated.
Computer handling of harnesses and wiring observes all rules given in this document.

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2- DESCRIPTION OF HARNESSES

2 - 1. CONSTRUCTION
A harness is a group or bundle of marked conductors which generally branch out and connect
components such as connectors, sealed passage, etc.
A harness may be also be made up of a single conductor which cannot be integrated into a bundle
due to its size or its fragile composition.
All component parts of a harness belong to that harness alone. This is a basic rule which must
be observed during the design of a harness.
Harness ends are marked and equipped with connection devices.
Each harness is provided with those items necessary for its easy identification.
The electrical installation of an aircraft consists of a certain number of harnesses which are
different in size, depending on whether are provided to fit out a given part of fuselage, wing or
removable sub-assemblies.
Harnesses are also designed to enable the manufacturer of separate harnesses designed to suit a
set of functions (electricity generation, radio, navigation, automatic piloting system, etc.).
The set of harnesses also includes boxes designed to house protection and switching
components, etc.

2 - 2. ELECTRICAL BOX HARNESSES

Electrical boxes housing components for distribution, switching, branching of circuits using
fuses, relays, junction modules, etc., are manufactured to the rules and regulations of harnesses.
Electrical boxes may be connected to other parts of aircraft harness by removable connectors or
include external wiring for connection to the box by means of grommets.

2 - 3. HARNESSES IN PRESSURIZED AREAS

The installation of these types of harnesses requires that special measures be taken during
manufacturing so as to fulfill certain requirements:
- housing of slack for assembly and disassembly of instrument panel equipment,
- prevent interference reflection in the windshield,
- obtain a uniform colour in the flight compartment,
- etc.
These requirements make it necessary to use a special technology which will described in
following sections.

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2 - 4. COAXIAL HARNESSES
Cables used in these types of harnesses are more fragile than other types of cables, use special
connectors and are covered by a special technology.

Reminder: If a coaxial cable is routed between two collars, the curve radius will be equal to or
greater than five times the cable diameter.

The removal end of a coaxial cable (connection to an item of equipment) will not
have a curve radius less than ten times the cable diameter.

2 - 5. OPTIC HARNESSES
Optic cables which are used for the transmission of optic signals require the use of special
connectors and are covered by a special technology which is described in following sections.
As a general rule, these cables are routed inside the electrical harnesses. In the dangerous aeras
or when the preceding rule cannot be applied, these cables are routed into tubes.
Monitoring procedures applicable during the manufacture of optic harnesses are defined in
DASSAULT-AVIATION Inspection Instruction n° 3.4.0.6.

2 - 6. SEGREGATION OF HARNESSES
It is necessary to respect the segregation between coaxial harnesses, feeders, distribution and
ardio harnesses.
Each of these harnesses will have its own attachment and, unless special indications the radio
harnesses and electrical harnesses will be separated by at least 50 mm.

2 - 7. MANUFACTURER’S PROCEDURES
Each harness is defined on a design office drawing which gives all specifications required for
its manufacture:
- shape,
- length,
- equipment,
- special manufacturing details.
The drawing includes a parts list given part numbers of all components required for
manufacture.
These harnesses are independent of each other and are only assembled during the final assembly
on aircraft structure.
Monitoring procedures applicable during the manufacture of harnesses are defined in
DASSAULT-AVIATION Inspection Instruction n° 0.4.3.56.

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3- MANUFACTURING RULES

3 - 1. CONSTRUCTION OF BUNDLES

3 - 1.1 Conductors
Various types of conductors may be used in a harness. They are:
- single conductors,
- shielded conductors,
- twisted conductors,
- molded conductors.
Conductors may be shielded or twisted, either at the time they are manufactured or when
harnesses are manufactured.

3 - 1.2 Twisting
To make laying and bundling easier while considerably reducing the weight, harness conductors
will not be twisted or laid flat unless specified otherwise in manufacturing drawings. In this case,
the pitch depends on the diameter of conductors and the diameter of the harness.

3 - 1.3 Twining
Several conductors may be twisted together for reasons of operation.
In all cases, twisting specifications are mentionned on drawings.
For wire gauge sizes 24 to 14, conductors are provided twisted together at a 50 mm pitch
(approximately). They are called “ordinary pair” (two conductors), “ordinary tierce” (three
conductors) and “ordinary quad” (four conductors).
The identification of each conductor of a pair, a tierce or a quad is provided by a special colour.
When the number of conductors to be twisted together is greater than four or the wire gauge size
is greater than 14, the wiring workshop twists wires by hand:
- twisting is always to the minimum pitch distance,
- twisting is always clockwise.

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3 - 1.4 Fasteners
During the manufacture on the table, bundle conductors are held definitely together by means
of quick-disconnect collars except in certain special cases (example: instrument panel harnesses,
small diameter bundles, branch, etc.) described in following sections where fastening is made
by means of a binding braid.
Exceptionally, in order to deal with handling or transport problems, temporary fastening may
use a bow-tie knot with a vinyl binding cord. These cords are removed during assembly on
aircraft.

3 - 2. FITTING OUT OF BUNDLES

3 - 2.1 Branches
When a signal must be sent to several destinations, the connection of conductors involved will
be permanent and made by means of a splice.
This method is also used to make connections when the wire gauge size changes over a given
route of a given conductor.
Splices are grouped together per zone when they are not close to an outlet.

3 - 2.2 Protection
In certain cases, it is necessary to protect certain parts of a bundle or its branches by means of a
sheath:
- exceptionally exposed aera,
- connection of conductors to a plug connector,
- dangerous aera,
- high-temperature aera,
- small diameter bundle connected to the rear of connector.
The protected parts of the bundle as well as the type of protection to be used are mentionned in
the lenght specification drawing.

3 - 2.3 Shielding
In order to prevent transmission or reception of interference, certain links are made with a pair,
tierce or quad insulated shielded.
These pairs, tierces and quads are normally manufactured by cable manufacturers for wire gauge
sizes between 24 to 14 (inclusive).

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When the number of conductors to be shielded is more than four or if their gauge size is greater
than 14, the shielding is made during the bundle manufacturing with a copper sheath.
Conductors in this sheath do not have printed references but are marked by sleeves. Before
shielding, the bundle will be taped with a special adhesive tape. This copper sheath is covered
with an insulating sheath. The type of insulating sheath and copper sheath (tin-plated or nickel
plated) to be used are mentioned in manufacturing drawings.
In certain cases, it may be necessary to shield all conductors of a given part of bundle.
The shielding sheath is always connected at least by one of its ends to:
- another shielding sheath,
- a connector contact,
- aircraft structure earth,
- etc.
This connection is made by means of a wire called “shielding pick-up” which is connected by
means of:
- self-soldering sleeves for pre-shielded conductors,
- soldering to the copper sheath for conductors shielded during the bundle
manufacturing.
This pick-up wire must have the same temperature range as wires to which it is connected.

3 - 2.4 Binding
At a branch, conductors are bound to each other with a binding of a lenght equal to the bundle
diameter (maximum 20 mm).
The end of protection sheaths is bound with a binding braid and a “Fisherman’s knot”.
At the rear of connectors, conductors are held together by a binding made with a “Fisherman’s
knot”.
When connectors are equipped with GLENAIR quik-ty type accessory, the sheath is turned up
and fixed on the accessory by means of quick-disconnect collar.
Bundle positioning marks in relation to the aircraft structure are made of a red binding braid with
a “marine knot”. A red adhesive tape may be also used for these marks.
For coaxial and optic cables, these marks are made with a red adhesive tape.

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3 - 2.5 Sealed passage
Bundles designed to fit both a pressurized aera and a non-pressurized aera are fitted with sealed
passage at the time of manufacturing.
These sealed passages consist of:
1- a metal base and a sealing block, predrilled with blind holes corresponding to
diameters of various conductors used,
2- a metal base designed to accomodate a cone-shaped dish which ensures after
compounding the watertightness of the bundle going throught it,
3- an assembly fitted with a heat-shrinkable part which ensures, after compounding
and shrinking, the required sealing capacity.
When the type “1” sealed passage is used:
- pairs and tierces, whether shielded and twisted or not, are routed through a single hole,
- conductors, whether shielded or not, twisted during bundle manufacturing are routed
in a hole. Twisting is continued after routing in the sealed passage.

3 - 2.6 Ends
Each end of harness is fitted out for connection to:
- another harness,
- an electrical box,
- an item of equipment.
For non-connected conductors (for example: spares), ends of each conductor are insulated.

3 - 3. MARKING

3 - 3.1 Identification and marking of wires

3 - 3.1.1 Identification
A conductor is identified by its appearance (diameter, colour, etc.).
Characteristics of conductors are indicated in sections:
- “CABLES FOR GENERAL USE”,
- “SPECIAL CABLES”,
- “COAXIAL CABLES”.

3 - 3.1.2 Marking
Each conductor carries the marking which is assigned to it in electrical drawing specifications.

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According to the conductor type, this marking is:

- either by printing on the conductor itself,
- or by means of a printed sleeve slipped over the conductor.
Some antenna coaxial cables are identified by means of coloured sleeves.

3 - 3.2 Marking of electrical equipments

The symbolic marking of an item equipment consists of an order number followed by one or two
letters, which are identical for all items of equipment in a given system, and a figure for identical
items of equipment (example: motors).
The symbolic marking of connection elements is as follows:

Connection element Symbol Example

Plug connector ...P 608P

Receptacle connector ...J 608J
Receptacle earth connector or earth module ...JN 504JN
Terminal strip .TB 5TB
Junction module terminal strip .J 4J
Independent junction module ...JM 522JM
Splice ...SP-. L18SP-1
Sealed passage ..FT 58FT

3 - 3.3 Marking of harness ends

Each end of harness is fitted with a plate or a marking sleeve, on which the symbolic
identification of connected connector or equipment is printed.
Most items of equipment are connected by means of electrical connectors.
An item of equipment may include several electrical connectors. In this case, the symbolic
marking is completed by a sub-reference which may be an upper case or lower case letter, a
number or both.
Example: 8X1A
78Fd

NOTA: On computer documents, a lower case letter is printed as the corresponding upper case
letter preceded by an asterisk.
Example: 78Fd is written on computer outputs as 78F*D.
When adjacent connectors are identical, their marking sleeve is of a different colour to help
identification.

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Non-insulated terminals of power cables are marked with sleeves, shrunk on the barrel part, on
which is printed the equipment identification number on which the terminal is fitted.
Insulated terminals have a marking sleeve fitted just behind the skirt part.

3 - 3.4 Marking of sealed passage

Marking of sealed passage fitted to harness is performed by means of a plate or a marking sleeve
placed onto the harness in accordance with design drawings.

3 - 3.5 Marking inside electrical boxes

3 - 3.5.1 Marking of electrical connectors

Plug connectors are marked as described above.
Receptacle connectors are marked as follows:
- outside the box, by means of a printed stick-on label secured to the box structure and
readable when the box is installed in the aircraft.
- If electrical connectors are differentiated by coloured sleeves, this label will be of the
same colour as the marking sleeve of the electrical connector or the connector
designation on the sticker is underlined with a coloured line.
- inside the box, by means a marking sleeve installed on the back-nut of the connector
in such manner that the marking is readable when the cover of the box has been
removed.

3 - 3.5.2 Marking of components

Internal electrical components (relays, contactors, circuit breakers, etc.) of a box are marked by
means of stick-on labels; one on the component and one on the box structure close to the
component. The marking must be readable once wiring is finished and the cover not fitted.
For contactors, a stick-on label installed inside the box cover will specify the value of tightening
torques to respect for the power terminals.

3 - 3.6 Marking of components on aircraft structure

The method used is similar to that employed for making receptacle connectors outside electrical
boxes.
This marking is not the responsability of the harness manufacturer.

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3 - 4. IDENTIFICATION

3 - 4.1 Identification of harnesses

All harnesses and certain branches have a plate or a registration sleeve on which the harness
reference is printed.

3 - 4.2 Identification of electrical boxes

The reference of the box is engraved on an identification plate. This identification plate must be
visible through the access door to the box. It may be fixed to the cover of the box.

3 - 5. ASSEMBLY ON AIRCRAFT AND ATTACHMENT

Once harnesses are on board the aircraft, they have to be secured together and attached to the
aircraft structure. To this end, the following may be used:
- quick-disconnect collars,
- custom-made clamps,
- special covers or trays.
In electrical boxes, harnesses are generally short and rigid and do not require any special
attachment devices.

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