3-1 CHAPTER 3. OPERATIONAL REQUIREMENTS
3.1 Operator Incorporation of Federal Aviation Administration (FAA)-Approved Electrical Wiring Interconnection System (EWIS) Instructions for Continued Airworthiness (ICA) into the Maintenance Program. Title 14 of the Code of Federal Regulations (14 CFR) part 121, § 121.1111 and part 129, § 129.111 require operators to incorporate into their maintenance program inspections and procedures for EWIS contained in ICA approved by the responsible Aircraft Certification Service office. The FAA expects that type certificate holders (TCH) will incorporate the approved EWIS ICA into their Maintenance Review Board Report (MRBR) or Maintenance Implementation Document (MID) and make them available to operators either electronically or in hard copy. The FAA expects that Supplemental Type Certificate (STC) holders will make them available by similar means. (Refer to Advisory Circular (AC) 20-188, Compatibility of Changes to Type Design Installed on Aircraft.)
3.1.1 Operator’s Tracking System. The operator should establish a tracking system within its maintenance program that tracks the incorporation of, and any revisions to, the responsible Aircraft Certification Service office-approved EWIS ICA, so the ICA will not lose their identity as an FAA-approved EWIS ICA. This includes:
1. Task and intervals;
2. Instructions and procedures in the Aircraft Maintenance Manual (AMM), Standard Wiring Practice Manual (SWPM), and Electrical Standard Practices Manual (ESPM);
and
3. Protections and caution instructions and information in the AMM, SWPM, and ESPM.
3.1.2 Controlling Reference Numbers. TCHs’ controlling reference numbers uniquely identify the EWIS ICA for identification and traceability purposes throughout the operational life of the airplane. During the initial incorporation of the EWIS ICA into the operator’s maintenance program, the operator should use these controlling reference numbers or an operator-developed system that correlates to them for the purposes of traceability. This will provide operator traceability during future maintenance program changes that contain EWIS ICA. This will help prevent inadvertent deletion, changes to the type of task, or escalation of EWIS ICA without proper consideration of the reason for the task and its interval. The tracking system should correlate to the controlling reference number for the EWIS ICA and be acceptable to the principal inspector (PI).
3.1.3 P rotections and Caution Instructions and Information in the Maintenance Program/Manual. It is important that the operator incorporate protections and caution instructions and information into its maintenance program/manual to minimize contamination and accidental damage to the EWIS when performing maintenance, alteration, or repairs. In addition, the operator should have procedures in its maintenance program/manual that instruct its maintenance personnel “to clean the EWIS and surrounding area after completion of any maintenance, alterations, or repairs.” It is especially important to include the same or a similarly worded statement in their
3-2 program/manuals, work cards, job/task cards, Engineering Authorizations/Engineering Orders (EA/EO), etc.
3.1.4 O perator-Developed Instructions and Procedures for EWIS Tasks. The operator can develop its own instructions and procedures to carry out the EWIS tasks provided the operator-developed ones produce an equivalent result to those approved by the responsible Aircraft Certification Service office. If the AMM, SWPM, and ESPM allow for the use of alternative or equivalent tools or materials, further approval by the responsible Aircraft Certification Service office is not required. If the operator proposes to change the instructions, procedures must be submitted and found acceptable by the PI.
The operator should include supporting technical justification and data with its submittal.
PIs should contact the responsible Aircraft Certification Service office for concurrence.
3.1.5 Ensuring Th at Protections and Caution Instructions and Information are in Operator Documents. The operator is responsible for ensuring that protections and caution instructions and information approved by the responsible Aircraft Certification Service office are incorporated into its maintenance program manuals, work cards, job/task cards, EA/EOs, etc., and any other documents the operator uses in administering their maintenance program. The operator should have procedures in its maintenance program manuals that instructs personnel who write or revise manuals, work cards, job/task cards, EA/EOs, etc., that all protections and caution instructions and information must be incorporated in those documents as appropriate. It is especially important to include and clearly identify the protections and caution instructions and information on work cards, job/task cards, and EA/EOs.
3.1.6 Operator-Developed Docume nts That Include EWIS Inspection Tasks.
Operator-developed work cards, job/task cards, EA/EOs, etc., that include any EWIS inspection tasks should have the protections and caution instructions and information included, and should reference the location in the AMM, SWPM, or ESPM.
3.2 O perator Changes to Enhanced Zonal Analysis Procedure ( EZAP)-Developed EWIS Task or Task Intervals.
3.2.1 T ypes of Changes . There are two types of changes to the operator’s EWIS maintenance program:
• D eletion of or changes to an EWIS task, or
• Escalation of an airplane check package/interval, such as “C check” containing the EWIS tasks and intervals.
3.2.2 R esponsible Aircraft Certification Service Office Approval. If the operator proposes to delete or change an EWIS task, it must be approved by the responsible Aircraft Certification Service office. The operator should submit its proposed changes with supporting technical justification/data through the PI. The PI adds comments (if any) and forwards the proposed changes to the responsible Aircraft Certification Service office for approval.
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3.2.3 Escalation of an Airplane Check Package/Interval. If the operator proposes an escalation of an airplane check package/interval, such as the “C check” that contains EWIS tasks and intervals, the responsible Aircraft Certification Service office does not have to approve the change. This change is within the authority of the PI and the procedures in the operator’s maintenance program and manuals. The operator should provide the PI with technical justification for escalating any EWIS tasks and intervals.
3.3 Operator Changes to EWIS ICA Developed Under 14 CFR Part 25, § 25.1729.
3.3.1 Requirements. EWIS ICA compliant with part 25 appendix H, §§ H25.4 and H25.5 are required if the airplane has § 25.1729 in its certification basis, or if the responsible Aircraft Certification Service office has determined that an STC applicant must comply with 14 CFR part 21, § 21.101 and, therefore, require the applicant to comply with all or parts of the EWIS requirements of § 25.1729.
3.3.2 A pproval. Operators should discuss any proposed changes to the EWIS requirements with the PI and the responsible Aircraft Certification Service office to see if the proposed changes are within the authority of the PI and the procedures within the operator’s maintenance program, or if they must be approved by the responsible Aircraft Certification Service office.
3.4 EAPAS Maintenance Training. The Enhanced Airworthiness Program for Airplane Systems/Fuel Tank Safety (EAPAS/FTS) Rule introduced new requirements that affect design approval holders (DAH) and operators. To realize fully the objectives of EAPAS/FTS requirements, the FAA encourages operators to rethink their current philosophical approach to maintaining, inspecting, and altering aircraft wiring and systems in the aircraft. The FAA has also adopted the “Protect and Clean as You Go” philosophy. This philosophy stresses:
3.4.1 Protective Measures. The importance of protective measures when working on or around wire bundles and connectors.
3.4.2 D ebris Removal . The importance of protecting the EWIS during structural repairs, STC installations, or other alterations by making sure that metal shavings, debris, and contamination resulting from such work are removed during work in progress and after completion.
3.4.3 O perator Training . This philosophical approach begins at the airplane manufacturer with enhancements of ICA for scheduled maintenance, changes to ICA maintenance procedures, and maintenance training programs. Operators will need to educate and train their employees of addition and identification in their AMM, SWPM, ESPM, work cards, job/task cards, EA/EOs, etc., that include any EWIS inspection tasks, protections and caution instructions and information. In addition, there will be new procedures, inspection devices, graphical information showing required tasks, changes in tasks such as wiring splicing, etc. Operators should provide training to maintenance, inspection, and engineering personnel, including persons who write and edit job cards and engineering orders. The FAA has published AC 120-94, Aircraft Electrical Wiring Interconnection
3-4 Systems Training Program, to assist operators in development of the EWIS training programs.
3.4.4 Manufacturer-D eveloped Training Programs. Operators can also take advantage of any airplane manufacturer-developed training programs that address the EWIS.
3.5 Operator’s Maintenance Program Approval Under §§ 121.1111 and 129.111.
Operators of transport category airplanes to which §§ 121.1111 and 129.111 apply must incorporate the EWIS ICA into their maintenance programs inspections and procedures for EWIS on the basis of ICA developed in accordance with the provisions of § H25.5(a)(1) and (b), or § H25.4 and all of § H25.5, as applicable. Sections 121.1111(e) and 129.111(e) state that these changes to the maintenance program and any later revisions to the EWIS provisions of the maintenance program must be submitted to the PI for review and approval. The operator will submit to the PI for review the revisions to their maintenance program incorporating inspections and procedures for EWIS, and their revisions. The PI will ensure the operator has incorporated into their maintenance programs inspections and procedures based on EWIS ICA and any subsequent revisions that have been approved by the responsible Aircraft Certification Service office. When the review is complete, the PI will issue or amend Operations Specification (OpSpec)/Management Specification (MSpec) D097, Aging Aircraft Programs.
3.6 Operations That are Authorized OpSpec D097. The issuance of this OpSpec signifies the FAA has reviewed the operator’s, certificate holder’s (CH), or program manager’s policy and procedures incorporated into their maintenance programs for compliance with the Aging Aircraft Program rules. Table 1 of D097 will consist of three columns that list:
• The applicable Aging Aircraft Program rules;
• The manual and section where the policy and procedures are located for the applicable Aging Aircraft Program; and
• The date of the manual and section where the current policy and procedures are located for the applicable Aging Aircraft Program.
Note 1: Table 3-1 below illustrates a sample D097 Table 1 that lists the various 14 CFR part rules. The operator/CH/program manager will have a specific OpSpec D097 template for their operation.
Note 2: If the rule does not apply to the CH’s operation, list the associated rule f or their operation (e.g., § 121.1113) in the first column and enter “N/A” in the second and third columns.
3-5 Table 3-1. Sample D097 Table 1 – Aging Aircraft Maintenance Programs Aging Aircraft Program Rules Certificate Holder/Program Manager’s Maintenance and Inspection Program Policy and Procedures (Manual and Section) Date Repairs Assessment for Pressurized Fuselages — § 121.1107, § 129.107
Supplemental Inspections — § 121.1109, § 129.109
Electrical Wiring Interconnection Systems (EWIS) Maintenance Program — § 121.1111, § 129.111
Fuel Tank System Maintenance Program — § 121.1113, § 129.113
Flammability Reduction Means — § 121.1117, § 129.117
3.6.1 Submission to PI for Review.
3.6.1.1 Initial submission and any subsequent revisions to these policy and procedures sections must be submitted to the PI for review for compliance with the Aging Aircraft Program rules.
3.6.1.2 Any changes to the operator/CH/program manager’s maintenance program policy and procedures must be submitted to the PI for review and approval.
When the maintenance program policy and procedures are revised, the date of the revision will be inserted into column 3 of Table 3-1.
3.6.2 FAA Aircraft Certification Service Office-Approved ICAs. Any proposed revisions or deletions of responsible Aircraft Certification Service office-approved ICAs must be coordinated with the PI for review and concurrence. The PI will then forward the proposed revisions or deletions to the responsible Aircraft Certification Service office for approval prior to implementation or incorporation into the maintenance program.
3.6.3 O perator Action. An operator/foreign air carrier/foreign operator must have procedures to ensure that EWIS ICAs for inspections and procedures are incorporated into their maintenance program.
Appendix A A-1 APPENDIX A. ACRONYMS 14 CFR Title 14 of the Code of Federal Regulations A4A Airlines for America AC Advisory Circular AD Airworthiness Directive AED Aircraft Evaluation Division AIR Aircraft Certification Service ALS Airworthiness Limitations Section AMM Aircraft Maintenance Manual APU Auxiliary Power Unit ASI Aviation Safety Inspector CH Certificate Holder CMM Component Maintenance Manual CWT Center Wing Fuel Tank DAH Design Approval Holder DET Detailed Inspection DRS Dynamic Regulatory System EA Engineering Authorization EAPAS Enhanced Airworthiness Program for Airplane Systems EAPAS/FTS Enhanced Airworthiness Program for Airplane Systems/Fuel Tank Safety EO Engineering Order ESPM Electrical Standard Practices Manual EWIS Electrical Wiring Interconnection System EZAP Enhanced Zonal Analysis Procedure FAA Federal Aviation Administration FQIS Fuel Quantity Indicator System FR Federal Register FS Flight Standards Service FTS Fuel Tank Safety GVI General Visual Inspection ICA Instructions for Continued Airworthiness MPD Maintenance Planning Document MRB Maintenance Review Board
Appendix A A-2 MRBR Maintenance Review Board Report MSG-3 Maintenance Steering Group – 3rd Task Force MSI Maintenance Significant Items MSpec Management Specification NTSB National Transportation Safety Board OEM Original Equipment Manufacturer OpSpec Operations Specification PI Principal Inspector SB Service Bulletin SFAR Special Federal Aviation Regulations STC Supplemental Type Certificate SWPM Standard Wiring Practice Manual TC Type Certificate TCH Type Certificate Holder TSB The Transportation Safety Board of Canada
Appendix B B-1 APPENDIX B. DEFINITIONS B.1 Affected Persons. For the purposes of this advisory circular (AC), operators and others required to comply with the requirements of Title 14 of the Code of Federal Regulations (14 CFR) part 25, § 25.1729; part 26, § 26.11; part 121, § 121.1111; and part 129, § 129.111.
B.2 Aircraft Maintenance Manual (AMM). A manual developed by the manufacturer of a particular airplane that contains information necessary for the continued airworthiness of that airplane.
B.3 Airworthy. An aircraft, aircraft engine, or component which conforms to its type design and is in safe condition for operation.
B.4 Component Maintenance Manual (CMM). A manual developed by a manufacturer that contains information necessary for the continued airworthiness of a particular component.
B.5 Continued Airworthiness. Certified aircraft, engines, propellers, and appliances are safe to operate for the intended purpose; they are maintained safely throughout their service life; the product meets its type design and is in a condition for safe operation.
B.6 Design Approval Holder (DAH). For the purposes of this AC, a DAH is a type certificate holder (TCH) and Supplemental Type Certificate (STC) holder.
B.7 Electrical Wiring Interconnection System (EWIS). EWIS is defined in § 25.1701(a) to mean “any wire, wiring device, or combination of these, including termination devices, installed in any area of the airplane for the purpose of transmitting electrical energy, including data and signals, between two or more intended termination points.”
Section 25.1701(a) includes a list of items that are specifically included in the definition of EWIS, and § 25.1701(b) includes a list of items that are specifically excluded from the definition of EWIS.
B.8 EWIS Certification and Operation Requirements. Part 25 subpart H contains certification and operation requirements for the airplanes’ EWIS. It requires the development of EWIS instructions for continued airworthiness (ICA) to be approved by the Federal Aviation Administration (FAA) responsible Aircraft Certification Service office (previously described as Aircraft Certification Office).
B.9 Enhanced Zonal Analysis Procedure (EZAP). A logical process for developing maintenance and inspection instructions for EWIS.
B.10 Flammable. Per 14 CFR part 1, § 1.1, “flammable, with respect to a fluid or gas, means susceptible to igniting readily or to exploding.”
B.11 Flight Standards Service (FS). Offices located in the FAA Flight Standards Service are responsible for developing guidance and policy applicable to transport category airplanes for Aircraft Evaluation Division (AED) personnel and FS personnel (Maintenance,
Appendix B B-2 Avionics, and Operations aviation safety inspectors (ASI)) in the conduct of their responsibilities.
B.12 Instructions for Continued Airworthiness (ICA). The information developed in accordance with applicable airworthiness requirements that includes the applicable inspection tasks, intervals, methods, processes, procedures, and airworthiness limitations (AL) to keep the product airworthy throughout its operational life.
B.13 Maintenance and Inspection Instructions. Information that provides for each part of the airplane and its engine auxiliary power units (APU), propellers, accessories, instruments, and equipment the recommended periods at which they should be cleaned, inspected, adjusted, tested, and lubricated, and the degree of inspection, the applicable wear tolerances, and work recommended at these periods necessary to provide for the continued airworthiness of the airplane. They also include the recommended overhaul periods and necessary cross-reference to the Airworthiness Limitations Section (ALS) of the manual.
B.14 Maintenance Implementation Document (MID). A document developed by one aircraft manufacturer that contains a comprehensive list of all EWIS and fuel tank safety (FTS) ICA which will satisfy the requirements contained in the Enhanced Airworthiness Program for Airplane Systems/Fuel Tank Safety (EAPAS/FTS) operational rules.
B.15 Maintenance Planning Data. Data developed by the manufacturer of a particular airplane which contain the information each operator of that airplane needs to develop a customized, scheduled maintenance program.
B.16 Maintenance Review Board Report (MRBR). Intended for air carriers, a report which contains the initial minimum scheduled maintenance and inspection requirements for a particular transport category airplane and on-wing engine program. Air carriers may use those provisions—along with other maintenance information contained in the ICA—in the development of their maintenance programs.
B.17 Maintenance Steering Group – 3rd Task Force (MSG-3). A voluntary structured process developed by the industry and maintained by Airlines for America (A4A) to make decisions used to develop maintenance and inspection tasks and intervals for an airplane.
B.18 Products. Certified aircraft, engines, propellers, and appliances.
B.19 Representative Airplane’s EWIS. For the purposes of the EAPAS/FTS Rule, the “representative airplane’s” EWIS is the configuration of each model series airplane that incorporates all variations of the EWIS used in production on that series airplane and all TCH-designed modifications mandated by Airworthiness Directive (AD) as of the effective date of the rule.
Appendix B B-3 B.20 Responsible Aircraft Certification Service Office. The responsible Aircraft Certification Service office having oversight responsibility for the relevant type certificate (TC) or STC, as determined by the Administrator.
B.21 STC-Developed EWIS ICA. STC holders may use the Maintenance Review Board (MRB) process or any other process they choose. Regardless of the process used, the end result must be ICA that include the applicable inspection tasks, intervals, methods, processes, and procedures to keep the EWIS airworthy throughout its operational life.
B.22 STC EWIS ICA. The inspections and procedures to keep an alteration affecting the EWIS approved under an STC airworthy throughout its operational life.
B.23 TCH EWIS ICA. The inspections and procedures to keep the EWIS airworthy throughout its operational life.
B.24 TCH Original EWIS ICA. The result of the MRB process. During this process, TCH-developed Maintenance Significant Items (MSI) are subjected to maintenance program development logic, such as in MSG-3 or later revisions. The result is an ICA that includes the applicable inspection tasks, intervals, methods, processes, and procedures to keep the EWIS airworthy throughout its operational life.
Appendix C C-1 APPENDIX C. CONTACT INFORMATION FOR QUESTIONS REGARDING
RESPONSIBLE AIRCRAFT CERTIFICATION SERVICE OFFICES C.1 For questions concerning Aircraft Certification Service (AIR) offices, contact Suzanne Masterson, Product Policy Management: Transport Airplanes and Engines Section (AIR-62A), Aircraft Certification Service, Federal Aviation Administration, 2200 South 216th St., Des Moines, WA 98189; telephone: 206-231-3211 or 425-227-1855; email: suzanne.masterson@faa.gov.
Advisory Circular Feedback Form If you find an error in this AC, have recommendations for improving it, or have suggestions for new items/subjects to be added, you may let us know by contacting the Flight Standards Directives Management Officer at 9-AWA-AFB-120-Directives@faa.gov.
Subject: AC 120-102B, Incorporation of Electrical Wiring Interconnection Systems Instructions for Continued Airworthiness into an Operator’s Maintenance Program Date: _____________________ Please check all appropriate line items:
An e rror ( proc edural or typographical) has been noted in paragraph ____________ on page _______.
Recommend paragraph _____________ on page __________ be changed as follows:
______________________________________________________________________ ______________________________________________________________________ In a future change to this AC, please cover the following subject:
(Briefly describe what you want added.)
______________________________________________________________________ ______________________________________________________________________ Other comments:
______________________________________________________________________ ______________________________________________________________________ I would like to discuss the above. Please contact me.
Submitted by: Date: ______________________