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Wire Identification - Aircraft Electrical System

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The proper identification of electrical wires and cables with their circuits and voltages is necessary to provide
safety of operation, safety to maintenance personnel, and ease of maintenance. All wire used on aircraft must
have its type identification imprinted along its length. It is common practice to follow this part number with the
five digit/letter Commercial and Government Entity (CAGE) code identifying the wire manufacturer. You can
identify the performance capabilities of existing installed wire you need to replace, and avoid the inadvertent Recent Posts
use of a lower performance and unsuitable replacement wire.
1 AIRCRAFT AND POWERPLANT
CLEANING
Aircraft CleaningCleaning an aircraft and
Placement of Identification Markings keeping it clean are extremely...
Read more

EQUIPMENT CHANGE AND AIRCRAFT

2
ALTERATION - AIRCRAFT WEIGHT
AND BALANCE
When the equipment in an aircraft is
changed, such as the installation of a
new...
Read more

PAINTING TRIM AND IDENTIFICATION

3
MARKS - AIRCRAFT PAINTING AND
FINISHING
Figure 1. Wire markings for single wire without sleeve Masking and Applying the TrimAt this
point in the project, the entire aircraft...
Read more

Identification markings should be placed at each end of the wire and at 15-inch maximum intervals along the
DAMAGE CLASSIFICATION,
4
length of the wire. Wires less than 3 inches in length need not be identified. Wires 3 to 7 inches in length should SANDWICH STRUCTURES AND SOLID
LAMINATES - AIRCRAFT COMPOSITE
be identified approximately at the center. Added identification marker sleeves should be located so that ties, HONEYCOMB SANDWICH REPAIRS
clamps, or supporting devices need not be removed to read the identification. The wire identification code must A large proportion of current aerospace
composite components are light
be printed to read horizontally from left to right) or vertically (from top to bottom). The two methods of marking sandwich...
wire or cable are as follows: Read more

AIRCRAFT CORROSION PRONE

5
AREAS
Discussed briefly in this section are most
of the corrosion problem areas...
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Figure 2. Spacing of printed identification marks (indirect marking)

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1. Direct marking is accomplished by printing the cable’s outer covering. [Figure 1B] Aircraft Air Conditioning Systems
There are two types of air
2. Indirect marking is accomplished by printing a heat-shrinkable sleeve and installing the printed sleeve on conditioning systems commonly used
the wire or cables outer covering. Indirectly-marked wire or cable should be identified with printed sleeves on aircraft. Air cycle air conditioning is
used on most turbine-powered airc...
at each end and at intervals not longer than 6 feet. [Figure 2] The individual wires inside a cable should be
Types of Aviation Fuel
identified within 3 inches of their termination. [Figure 1A]
Each aircraft engine is designed to
burn a certain fuel. Use only the fuel
specified by the manufacturer. Mixing
fuels is not permitted. T...

Types of Wire Markings Control of Cabin Pressure - Aircraft

Pressurization Systems
Pressurization Modes Aircraft cabin
The preferred method is to mark directly on the wire without causing insulation degradation. Teflon-coated pressurization can be controlled via
two different modes of operation. The
wires, shielded wiring, multiconductor cable, and thermocouple wires usually require special sleeves to carry first is the isobaric mod...
identification marks. There are some special wire marking machines available that can be used to stamp Aircraft Hydraulic System
directly on the type wires mentioned above. Whatever method of marking is used, the marking should be legible The word “hydraulics” is based on the
Greek word for water and originally
and the color should contrast with the wire insulation or sleeve. meant the study of the physical
behavior of water at rest and ...

Several different methods can be used to mark directly on the wire: hot stamp marking, ink jet printers, and Aircraft Fuel System Indicators
Fuel Quantity Indicating Systems All
laser jet printers. [Figure 3] The hot stamp method can damage the insulation of a newer type of wire that aircraft fuel systems must have some
utilizes thin insulators. Fracture of the insulation wall and penetration to the conductor of these materials by the form of fuel quantity indicator. These
devices vary widely dep...
stamping dies have occurred. Later in service, when these openings have been wetted by various fluids or

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Aircraft Systems: Wire Identification - Aircraft Electrical System https://www.aircraftsystemstech.com/2017/06/wire-identification.html

moisture, serious arcing and surface tracking have damaged wire bundles.
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Advanced Composite Materials

Aerodynamics of Flight

Air Conditioning System

Aircraft Painting

Aircraft Welding

Aircraft Wood and Structural Repair

Airframe

Cabin Environment System

Cleaning and Corrosion Control

Communication and Navigation

Figure 3. Laser wire printer Electrical System

Engine Lubrication System

Engine Maintenance and Operation

Identification sleeves can be used if the direct marking on the wire is not possible. [Figure 4]
Fabric Covering

Fire Protection

Fuel System

General maintenance

Human Factors

Ice and Rain Protection

Instrument System

Oxygen System

Powerplant

Pressurization System

Radio Navigation

Figure 4. Alternate method of identifying wire bundles Rotorcraft

Structural Repair

Weight and Balance

Flexible sleeving, either clear or opaque, is satisfactory for general use. When color-coded or striped
component wire is used as part of a cable, the identification sleeve should specify which color is associated
with each wire identification code. Identification sleeves are normally used for identifying the following types of Contact Form
wire or cable: unjacketed shielded wire, thermocouple wire, coaxial cable, multiconductor cable, and high
temperature wire. In most cases, identification tape can be used in place of sleeving. For sleeving exposed to
Name
high temperatures (over 400 °F), materials, such as silicone fiberglass, should be used. Polyolefin sleeving
should be used in areas where resistance to solvent and synthetic hydraulic fluids is necessary. Sleeves may
be secured in place with cable ties or by heat shrinking. The identification sleeving for various sizes of wire is Email *

shown in Figure 5.
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Wire size Sleeving size

AN # AL # No. Nominal ID (inch)

24 12 0.085
22 11 0.095
20 10 0.106
Useful Links
18 9 0.118
This Day in Aviation History
16 8 0.113
Flight Dynamics - How Things Fly
14 7 0.148
NASA Beginner's Guide to Aeronautics
12 6 0.166
FAA Handbooks & Manuals
10 4 0.208
8 8 2 0.263
6 6 0 0.330
4 4 3/ inch 0.375
8

2 2 1/ inch 0.500
2

1 1 1/ inch 0.500
2

0 0 5/ inch 0.625
8

00 00 5/ inch 0.625
8

000 000 3/ inch 0.750

4

0000 0000 3/ inch 0.750

4

Figure 5. Recommended size of identification sleeving

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