Supplement To M6.11 - M7.07 EWIS - Bonding and Grounding Network On Carbon Structure AIrcraft

Supplement to M6.11/M7.
07 EWIS
Bonding and Grounding Network for Composite Structure Aircraft
ISSUE 01/REV. 00/26 SEP 2018

BY JAMES CHUA
Contents
 Introduction to Bonding and Grounding
 Faraday Cage
 Current Return Network (CRN)
 Construction of the CRN
 Maintenance of the CRN
 Test Procedures of the CRN
 Electrical Structure Network (ESN) &
Metallic Bonding Network (MBN)
 Bonding and Grounding on a Metallic
Aircraft
 Point of Voltage Reference
 ESN Elements
 Raceway, Cables, Strips and Junctions
 Overview of ESN functions
 Maintenance of ESN
 ESN and MBN Measurement
Bonding and Grounding Network for Composite Structure Aircraft
Introduction
Bonding and Grounding on Metallic Structure Aircraft
By the turn of the millennium, construction of aircraft with aluminium

structures have been the legacy of aircraft manufacturers where the
fuselage, wings and empennage are electrically bonded together in
production. This is done via fasteners, faying surface bonds and
bonding straps between frames, stringers, skin and other metallic
parts.
Bonding and Grounding on Composite Structure Aircraft

Introduction
The metallic structure has provided the electrical ground

required for the AC and DC current return for many
consumers and equipment of electricity such as the cabin
lights, ovens and chiller or electric motor pumps for hydraulic
pressure and fuel transfer.

Introduction
It also acts as the return path for fault currents from the load back to
the source. The other important function is to reduce electromagnetic
interferences (EMI) and high intensity radiated fields (HIRF) protecting
the aircraft from lightning effects. This is analogous to a Faraday
Cage*. Electric charges present shall be dissipated into the air via
static dischargers on the wings and on the empennage.

Introduction
*In the 19th century, Michael Faraday demonstrated that an enclosure

or mesh formed by a conducting material, blocks external static and
non-static electric fields by dissipating the charges throughout the
mesh resulting in an equal electric potential. Thereby no current nor
electric charge exists in the interior of the enclosure.
Introduction
Increasingly in the last decade, aircraft are being built with composite
materials especially with carbon-fiber reinforced plastic that
constitutes around 50%. This inevitably led to new ways that
necessitates how the airframe is being bonded and grounded in the
entire aircraft. See the single line diagram illustration below.

Current Return Network (CRN)

Current Return Network (CRN) for the B787
To serve the same function of electrical bonding and grounding for
current returns as in the legacy aircraft, the Current Return Network
(CRN) in the B787 comprises of:
• metal straps,
• wires,
• tie brackets,
• longitudinal bars and other
• existing metallic structures
This ensures the provision of electrical power to the various loads by the
network for power return. At the same time, the CRN protects against
fault current on the same return path.

Located in the upper crown and lower bilge areas, the longitudinal
bars are connected electrically in parallel first to achieve several
current paths where these primary pathways are separated physically
on the fuselage to ensure the redundancy for grounding in the event
of external or internal structural threats. The CRN arrangement in the
wing and empennage are similar to the one in the fuselage.
The CRN is also connected to the carbon-fiber composite structure at

certain intervals to protect against lightning strikes that would cause
the joule effect* resulting in its loss of mechanical properties.
*Note: The joule effect is the heat generated when electric current flows through
resistance


Construction of the CRN
In the fuselage, the CRN is made of longitudinal bars which are

connected by cables to provide redundant current paths. In the wings,
the CRN has two cable paths, which also provide for redundant current
pathways.
The CRN in the wing is connected to the fuselage CRN at 4 points at the
wing root area. Unlike the fuselage CRN, the CRN in the wings and
empennage areas is used solely for fault currents and lightning
protection. The AC and DC grounds from individual components are
connected by wires back to the CRN inside the fuselage. The CRN cables
and straps are easily identified in green colour.
Schematic diagram - Redundant pathways on a B787 LH wing
View A

Schematic diagram – Identification code of each CRN wire and strap on
the B787 LH wing
View B

Schematic diagram - Redundant pathways on a B787 LH wing
The views below illustrate the Wing CRN being connected to the
fuselage CRN.
View A View B

Maintenance of the CRN
In accordance to the standard wire practices manual (SWPM 20-20-00),
there are bonding resistance tests to be carried out after every
installation or repair to connect CRN components. Below is a table
illustrating the maximum permitted electrical resistances values
measured between metallic or non-metallic faying surfaces as an
example.

Test Procedures for Electrical Bonds
(SWPM 20-20-00)
For a bond that has a jumper or a
designated ground wire, a control
point that is used to measure the
resistance must be:
 In the cleaned area for the terminal

 0.25 inch maximum from the
terminal.
NOTE: Either of the two points can be

used as the control point
M1 Milliohm Meter® Avtron T477W Bonding Meter
Two points must be used to calibrate the meter to zero ohms:
 One point is on one side of the cleaned area

 The other point is on the opposite side of the same cleaned area.
Other bond resistance meters are acceptable if all of these conditions occur:
 The meter is calibrated

 The meter has an accuracy of ±5 percent of the reading in the range specified
by the manufacturer of the equipment
 The meter has a four probe design
 The meter has separate current and potential probes.

General Conditions for the BACC13AU CRN (SWPM 20-20-14)
The following data must be known before you begin any work
procedures:
 The category of the electrical fay surface bond.
 The part numbers of the parts to be joined
 The material and the finish of the parts to be joined
 The part numbers and quantity of the fasteners used to join the parts
 The procedures used to install the fasteners
 The necessary torque values for the fasteners
 If refinishing is necessary
 If the installation is in a fuel vapor area of the airplane

Maximum Resistance of BACC13AU Current Return Network Bonds

(SWPM 20-20-14)
The maximum bond resistance of a BACC13AU dual hole terminal lug and
the structure for a new installation or a repair where the faying surfaces
are prepared for a bond again is 0.000025 ohms (0.025 milliohms).
Some examples of CRN category 2 installation:

Bond Test of a BACC13AU Current

Return Network Bond
The location of the test points for

the bond test of a Current Return
Network terminal lug (revisited).

Electrical Structure Network (ESN) &
Metallic Bonding Network (MBN) on the A350
For the A350XWB, a similar bonding/grounding network known as the
Electrical Structure Network (ESN) and the Metallic Bonding Network
(MBN) shall provide for the bonding of structures, current returns and
lightning protection.
The Electrical Structure Network on the fuselage (ESN) provides:

 Lightning strikes protection
 Electrostatic protection
 Electrical current path (bonding)
 Connection to the earth when the A/C is on the ground
 Electrical current return signal (grounding)
 Provision of common point of voltage reference (PVR) for all electrical
components
The Metallic Bonding Network (MBN)* at the wings and empennage
provides:
 Lightning strikes protection

 Electrostatic protection
 Electrical current path (bonding)
 Connection to the earth when the A/C is on the ground
*Note: The MBN has already been used on the A380 at its the wings, tail cone, empennage
and belly fairing of the A380.

Bonding and Grounding on a A340 aircraft
Schematic Diagram illustrating the current return for AC and DC loads

Schematic Diagram illustrating the current return for AC and DC loads

The Point of Voltage Reference (PVR)
Located in the nose area at the passenger floor level, the PVR is the zero
volt reference shared by all aircraft equipment. The neutral of the aircraft
alternating current power sources and the cold point of the aircraft’s
direct current sources are connected to the PVR, as well as the neutral of
the external ground carts.
The PVR is made of metallic frames, in the nose fuselage area,

longitudinal beams (called PVR-bars) and their associated flexible
junctions.



The ESN comprises of the following parts to establish the network:
• Structure metallic elements • Specific ESN components
 metallic frames,  raceways with
 crossbeams, approximately 2.000 flexible
 seat tracks, junctions all along the
 roller tracks fuselage
 other assemblies  bonding cables and straps
• Mechanical elements
 electronics bay rack,
 mechanical junctions,
 cabin furnishing structures in the crown area and
 other assemblies or support equipment,
Types of Raceways
Raceways are tracks running the length of the aircraft which provide
many electrical functions, such as current return and electromagnetic
compatibility.
They also offer protection against the effects of lightning strikes and
short circuit, and support the ESN electrical harnesses, other
commercial electrical equipment and mechanical equipment such as
air ducts.
Cable, Strips and Junctions are basically to provide electrical

connections to maintain a zero voltage potential throughout the
network.
Mechanics working beneath the raceways at the crown area

Different Part Numbers Crossbeams

of Flexible Junctions

Bonding Cable Flexible Junctions

Crossbeams
Cabin Floor & Cargo Cross Beams


Identification of the ESN elements with labels and sleeves

Note: EPDCs are

Electrical Power
Distribution
Centres
Overview of the functions of ESN
The ESN and MBN are mechanically connected together. The

environment protection functions are:
• To contribute to lightning strike protection (direct effect and indirect

effect)
• To discharge static electricity and prevent its accumulation
• To contribute to the Electro-Magnetic Compatibility (EMC) between
aircraft systems

The electrical functions are:
 To keep current injection in the Carbon-Fiber-Reinforced Plastic

elements to a minimum
 To give protection to people against dangerous voltage
 To provide current return
 To distribute a common voltage reference (PVR)
 To give a current circulation path for fault currents if there is a short
circuit

The Faraday Cage revisited

Maintenance of the ESN
a – For Installation/Removal/Repair:
 In case of repair, electrical properties have to be maintained
between the different elements.
 To validate the flexible junction installation (surface preparation,
application of the right torque value), a test under high current will
have to be performed for each electrical connection.
 To remove and install ESN parts, Airbus’ documentation needs to be
followed in order to ensure the operator’s safety.
 Precautions are similar to the ones applicable to electrical systems
on legacy programmes.
Therefore, electricians or mechanics are to be trained in ESN for

maintenance purposes:
ATA 24-77 Electrical Structure Network Maintenance (levels 2 and 3)

and the ESN Measurement/Test tool,
ATA 51 Electrical Structure Network (ESN) and Metallic Bonding

Network (MBN) awareness. These are part of mandatory courses for
B1 and B2 aircraft maintenance licences (specific aeronautical
qualifications).

ESN parts documentation
In the Electrical Standard Practices
Manual (ESPM) ATA 20, it will give
descriptive data and procedures for
the electrical standard parts’
installations (e.g. raceways, flexible
junctions, etc.).
It will provide instructions for part

removal and installation, damage
assessment and repair solutions to be
applied.

b - Scheduled inspection
The ESN in-service integrity is ensured by scheduled maintenance to
be performed in accordance with the documentation found in AirN@v.
Scheduled maintenance will be performed through general visual

inspections (GVI) during the zonal inspections planned, every six years
for ESN parts located in the nose/fuselage (and especially close to the
PVR) and every twelve years for the complete fuselage.

Aircraft modification
The ESN modification has to be treated with precaution. In case of
operator modification needs, the following cases shall be considered:
• In case of system modification or addition, an electrical load analysis*

has to be done for return current in order to guarantee the performance
of the ESN.
• Any ESN physical modifications have to be analysed by Airbus before

their implementation.
*Electrical load analysis (ELA) is to determine electrical system capacity (including generating sources, converters,
contactors, bus bars, and so forth) needed to supply the worst-case combinations of electrical loads by evaluating the
average demand and maximum demands under all applicable normal, abnormal and emergency flight conditions.

Standard parts let the current flow along longitudinal and
circumferential pathways. The standard parts (raceways, ESN cables,
electrical junctions, etc.) are the link between all the parts of the ESN.
The electrical junctions are composed of the structural junctions
(fasteners) and the flexible junctions (used to connect electrically the
raceways to the other ESN elements). Prior to working on the ESN,
you must de-energize the aircraft electrical circuits and ensure the
aircraft is correctly grounded.
WARNING: BEFORE YOU DO WORK ON ESN PARTS, MAKE SURE

THAT YOU OBEY THE ESN SAFETY PROCEDURE. THIS WILL PREVENT
INJURY TO PERSONS AND/OR DAMAGE TO THE AIRCRAFT.

Electrical Structure Network Measurement
 Unit tests are necessary for all the flexible junctions when you do
ESN measurements and tests. To do the tests of ESN junctions, you
must use a special tool and high current values (up to 100 A). Use a
special current clamp for the current injection. For the junction lugs,
it is necessary to measure the contact resistance.
 When you measure the voltage at the junctions, it can be necessary

to remove the blue varnish to have a good conductivity for the
voltage probes. After the measurement, apply blue varnish on the
applicable surfaces. The test procedure is related to the type of ESN
junctions.
ATEQ LRT 6000 FUCHS BLRT 2 LOOP

Current Clamp RESISTANCE TESTER
Avionic Test Equipment

Contact resistance test setup

4-wire measurement
of bonding resistance Contact resistance measure-
ment with current clamp

Supplement To M6.11 - M7.07 EWIS - Bonding and Grounding Network On Carbon Structure AIrcraft

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Supplement To M6.11 - M7.07 EWIS - Bonding and Grounding Network On Carbon Structure AIrcraft

Caricato da

Copyright:

Formati disponibili

Supplement to M6.11/M7.

ISSUE 01/REV. 00/26 SEP 2018

By the turn of the millennium, construction of aircraft with aluminium

Bonding and Grounding on Composite Structure Aircraft

The metallic structure has provided the electrical ground

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

*In the 19th century, Michael Faraday demonstrated that an enclosure

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

The CRN is also connected to the carbon-fiber composite structure at

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

In the fuselage, the CRN is made of longitudinal bars which are

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

 In the cleaned area for the terminal

NOTE: Either of the two points can be

Two points must be used to calibrate the meter to zero ohms:

 One point is on one side of the cleaned area

 The meter is calibrated

Bonding and Grounding on Composite Structure Aircraft

General Conditions for the BACC13AU CRN (SWPM 20-20-14)

Bonding and Grounding on Composite Structure Aircraft

Maximum Resistance of BACC13AU Current Return Network Bonds

Some examples of CRN category 2 installation:

Bonding and Grounding on Composite Structure Aircraft

Bond Test of a BACC13AU Current

The location of the test points for

Bonding and Grounding on Composite Structure Aircraft

The Electrical Structure Network on the fuselage (ESN) provides:

 Lightning strikes protection

Bonding and Grounding on Composite Structure Aircraft

Schematic Diagram illustrating the current return for AC and DC loads

Schematic Diagram illustrating the current return for AC and DC loads

The Point of Voltage Reference (PVR)

The PVR is made of metallic frames, in the nose fuselage area,

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Cable, Strips and Junctions are basically to provide electrical

Mechanics working beneath the raceways at the crown area

Different Part Numbers Crossbeams

Bonding and Grounding on Composite Structure Aircraft

Bonding Cable Flexible Junctions

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Identification of the ESN elements with labels and sleeves

Bonding and Grounding on Composite Structure Aircraft

Note: EPDCs are

The ESN and MBN are mechanically connected together. The

• To contribute to lightning strike protection (direct effect and indirect

Bonding and Grounding on Composite Structure Aircraft

 To keep current injection in the Carbon-Fiber-Reinforced Plastic

Bonding and Grounding on Composite Structure Aircraft

Bonding and Grounding on Composite Structure Aircraft

Maintenance of the ESN

Therefore, electricians or mechanics are to be trained in ESN for

ATA 24-77 Electrical Structure Network Maintenance (levels 2 and 3)