Electrical Malfunction Causes Smoke in Airbus A320 Galley

Casualties unknown • Approximately 90 nm north of RCQC, TW

A B's Airways Airbus A320-200 experienced smoke and a burning odor in the aft galley during climb, caused by a manufacturing defect in a water heater power module.

What happened

On July 24, 2016, an Airbus A320-200, registration B-22317, operated by B's Airways, was performing a scheduled passenger flight from Taichung/Wuqi Airport to Macau International Airport. The flight was carrying 107 occupants, including 2 flight crew members, 6 cabin crew members, and 99 passengers.

During the climb phase, while passing over Magong, the crew reported smoke and a burning odor emanating from the aft galley (G5) water heater. The cabin crew responded immediately by switching off the relevant power sources, using a fire extinguisher to suppress the smoke, and pulling the circuit breakers. The flight crew monitored the situation and, after confirming that the smoke had dissipated and the source was controlled, decided to continue the flight to the destination. The aircraft landed safely in Macau at 16:04 without further incident.

The investigation

The investigation focused on the cause of the smoke and the adequacy of the crew's response. Investigators examined the water heater, a DR4101 model manufactured by B/E Aerospace, and reviewed maintenance records. The investigation found that the aircraft's maintenance history showed no prior issues with the galley equipment, and the water heater had no recent records of repair for malfunctions.

Technical analysis of the water heater's power module revealed that the failure was linked to the manufacturing process of the printed circuit board (PCB). The investigation also reviewed the flight crew's decision-making process and the cabin crew's emergency procedures, finding them to be in compliance with airline and flight manuals.

Probable cause

The smoke was caused by high temperatures and subsequent overheating of the water heater's power module PCB, resulting from high electrical resistance due to thin copper plating and contact defects caused by manual adjustment of the Faston connectors during manufacturing.

Frequently asked questions

What happened in the 2016-07-24 Airbus Industrie/A320-232 accident near Approximately 90 nm north of RCQC, TW?

A B's Airways Airbus A320-200 experienced smoke and a burning odor in the aft galley during climb, caused by a manufacturing defect in a water heater power module.

What aircraft was involved and where did it happen?

The accident on 2016-07-24 involved a Airbus Industrie/A320-232, registration B-22317, at Approximately 90 nm north of RCQC, TW.

What was the probable cause of the accident?

The smoke was caused by high temperatures and subsequent overheating of the water heater's power module PCB, resulting from high electrical resistance due to thin copper plating and contact defects caused by manual adjustment of the Faston connectors during manufacturing.

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