Testing aircraft cableforms/looms
Overview
This standard identifies the competences you need to test aircraft cableforms/looms, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to use appropriate drawings, specifications and test documentation to test the various types of equipment.
You will be expected to carry out the appropriate testing procedures on cableforms/looms and associated components, including aircraft system cable assemblies, heavy duty cable assemblies, aircraft lighting cables, co-axial cables, fibre- optic cables, secure speech cables, headset leads, AFCS (Automatic Flying Control System) cable assemblies, databus looms and amalgamated looms, circuit breaker/switch panels, distribution panels, relay panels, control panels, transformers, aerials and data recorders.
Your responsibilities will require you to comply with organisational policy and procedures for the tests undertaken and to report any problems with the testing activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying test techniques and procedures. You will understand the aircraft cableforms/looms being tested, and their application, and will know about the test equipment and methods, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is to the required specification.
You will understand the safety precautions required when carrying out the testing operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the appropriate procedures for use of tools and equipment to carry out the required tests
- set up and carry out the tests using the correct procedures and within agreed timescales
- record the results of the tests in the appropriate format
- review the results and carry out further tests if necessary
- leave the work area in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when testing aircraft cableforms/looms (such as any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area where you are carrying out the activities and the responsibility these requirements place on you
- the safety procedures that must be carried out before work is started on the aircraft
- the hazards associated with testing cableforms and looms, and with the tools and equipment used, and how to minimise them and reduce any risks
the protective clothing and equipment (PPE) to be worn and where it can be obtained
the precautions to be taken to prevent electrostatic discharge (ESD) damage to circuits and sensitive components (such as use of earthed wrist straps)
what constitutes a hazardous voltage and how to recognise victims of electric shock
how to reduce the risks of a phase to earth shock (such as insulated tools, rubber matting and isolating transformers)
the correct operating procedures for the system being tested
- electrical bonding specifications and their importance
- how to obtain the required test specifications of the systems you are working on; how to interpret them and how to carry out currency/issue checks on them
- who can provide guidance to clarify the specifications and who can provide assistance in applying test methods and techniques
- what test equipment is to be used and its selection for particular tests
- the testing techniques, methods and procedures to be used during the tests
- the calibration of test equipment (where applicable) and the currency/issue checks that need to be carried out
- the fault finding techniques to be used if the system fails the tests
- how to analyse test results
- how to display/record the test results and the documentation to be used for this
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the authorisation procedures for changes to test procedures
- the problems or errors that may affect test results
- any environmental controls required relating to the testing
- what documentation needs to be used on completion of all tests
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the testing activities:
- obtain and use the appropriate documentation (such as job instructions, aircraft cable form/loom test procedures, quality control documentation, history sheets, flight logbook, aircraft standards and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the testing activities
- obtain the correct tools and equipment for the activity and check that they are in a safe, tested and usable condition and within current calibration date
- obtain clearance to work on the aircraft and observe all relevant safety procedures (where appropriate)
- ensure that isolation procedures are followed and that safe working distance procedures are set up (where appropriate)
- carry out the tests using the specified techniques and procedures
- return all tools and equipment to the correct location on completion of the testing activities
Test four of the following aircraft cableforms/looms:
- co-axial cable assemblies
- fibre-optic cables/assemblies
- AFCS (Automatic Flying Control System) cable assemblies
- heavy duty cable assemblies
- aircraft lighting cable assemblies
- databus looms
- aircraft system cable assemblies
- amalgamated system looms
- secure speech cable assemblies
- headset leads (mic-tel leads)
- other specific cable assembly
Test the cableform/loom components, to include four from the following:
- relay panels
- circuit breaker/switch panels
- control panels
- distribution panels
- terminal blocks
- transformers
- cable protection
- cockpit/flightdeck equipment
- module blocks
- data recorders
- line replacement units external to cockpit/flightdeck
- aerials
- avionic trays
- batteries
- fuel content/quantity probes
- formation/internal lighting
- other specific components
Use four of the following types of test equipment:
- multimeters
- time domain reflectometer (TDR) equipment
- wiring test analysers
- continuity testers
- voltage standing wave ratio (VSWR) equipment
- databus tester
- battery discharge tester
- optical light source and power meter kit
- automated test equipment
- other specific test equipment
Carry out three of the following types of test:
- voltage checks
- continuity checks
- VSWR checks
- TDR checks
Deal with two of the following levels of complexity during the testing activities:
- equipment with no faults
- equipment with faults
- equipment with intermittent faults
During tests use two of the following fault finding techniques:
- six point
- input-to-output
- equipment self-diagnostics
- injection and sampling
- half-split
- function testing
- emergent problem sequence
- unit substitution
Review and record fault symptoms and history of problems, using four of the following:
- data sheets
- log cards/history sheet
- fault records
- calibration records
- aircraft documentation
- maintenance records
- other specific recording method
Carry out tests in compliance with one of the following standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- Federal Aviation Authority (FAA)
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- manufacturers standards and procedures
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment