Boeing Design Manual 7126 Electrical Connections

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BOEING DESIGN MANUAL

BDM–7126 CONNECTIONS

REV

A

01–MAR–1999

QUICK REFERENCE HYPERLINK LIST 1

INTRODUCTION

29 MAR 1996

2

CONNECTION METHODS COMPARISON

29 MAR 1996

3

CRIMP METHOD AND PARTS

29 MAR 1996

4

WRAPPED–WIRE CONNECTIONS

29 MAR 1996

5

DRAWING REQUIREMENTS AND INFORMATION

29 MAR 1996

THE ABOVE INCORPORATES THE LAST TECHNICAL REVIEW DATE FOR THIS STANDARD.

BDM–7126 PAGE 1 OF 43

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BOEING DESIGN MANUAL

BDM–7126

TABLE OF CONTENTS Section

Title

Page

0

REVISION NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.1

Purpose and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.2

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.3

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2

CONNECTION METHODS COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

2.1

Performance Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

2.2

Reliability Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

2.3

Part Lead Materials Versus Connection Methods . . . . . . . . . . . . . . . . . . . . . . . .

11

3

CRIMP METHOD AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.1

Barrel Sizing For Multiple Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.2

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3.3

Splices and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

3.4

Cable Shield Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

4

WRAPPED–WIRE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

4.1

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

4.2

Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

4.3

Designing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

4.4

Dimensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

4.5

Commercial Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

4.6

Connection Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

4.7

Backpanel And Terminal Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

4.8

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

4.9

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

4.10

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

4.11

Quality Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

5

DRAWING REQUIREMENTS AND INFORMATION . . . . . . . . . . . . . . . . . . . . .

41

5.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

5.2

Crimp Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

5.3

Wrapped Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL

BDM–7126 LIST OF FIGURES

Figure

Title

FIGURE 1–1

WRAPPING LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

FIGURE 2–1

COMPARISON OF PERMANENT CONNECTION METHODS . . . . . . . . . . . .

9

FIGURE 2–2

CONNECTION METHOD RELIABILITY COMPARISON . . . . . . . . . . . . . . . . .

10

FIGURE 2–3

PART LEAD MATERIALS VERSUS CONNECTION METHODS . . . . . . . . . . .

11

FIGURE 2–4

PROCESS SPECIFICATION AND TOOLING DOCUMENT VS TERMINATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

FIGURE 3–1

CRIMP TERMINALS AND SELECTION DATA . . . . . . . . . . . . . . . . . . . . . . . . . .

13

FIGURE 3–2

CRIMP TERMINAL CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

FIGURE 3–3

CRIMP WIRE SPLICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

FIGURE 3–4

CRIMP WIRE SPLICE, SLEEVE, AND ADAPTER CONFIGURATIONS . . . .

16

FIGURE 3–5

BRAIDED CABLE SHIELD TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

FIGURE 4–1

WRAPPED–WIRE CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

FIGURE 4–2

COMPARISON OF WIRE WRAPPING METHODS . . . . . . . . . . . . . . . . . . . . . .

20

FIGURE 4–3

BACKPLANE WIRING DESIGN VS WIRING AND CABLING DESIGN PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

COMMERCIALLY AVAILABLE WRAPPED–WIRE CONNECTION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

FIGURE 4–5

CONNECTION STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

FIGURE 4–6

GENERAL BACKPANEL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . .

28

FIGURE 4–7

STANDARD PUNCHED PLATE DIMENSIONS AND TOLERANCES (INCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

FIGURE 4–8

RECOMMENDED DIMENSIONS FOR FORMED ALUMINUM PLATES . . . .

30

FIGURE 4–9

RECOMMENDED SEQUENCE OF PUNCHED PLATE TERMINAL GRID DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

FIGURE 4–10 GENERAL TERMINAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . .

34

FIGURE 4–11

TERMINAL MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

FIGURE 4–12 DETERMINATION OF MINIMUM TERMINAL LENGTH . . . . . . . . . . . . . . . . . .

36

FIGURE 4–13 EXAMPLE TERMINAL/SLEEVE CONFIGURATION AND SPECIFICATIONS

37

FIGURE 4–14 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

FIGURE 4–15 CHARACTERISTICS OF COMMONLY USED WIRE INSULATION . . . . . . . .

39

FIGURE 4–16 BOEING STANDARD CONNECTORS AVAILABLE WITH WIRE WRAP TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

FIGURE 5–1

SPECIFICATIONS USED FOR TERMINATION METHODS . . . . . . . . . . . . . .

41

FIGURE 5–2

SPECIFICATIONS RELATING TO WIRE INSULATION . . . . . . . . . . . . . . . . . .

42

FIGURE 5–3

TYPICAL INFORMATION ON CONNECTOR ASSEMBLY DRAWING . . . . . .

43

FIGURE 4–4

Page

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 0

BDM–7126

REVISION NOTICE This revision notice provides a brief description of the changes made within this standard. This standard should be reviewed in detail to determine the total extent of the revision. Areas that contain technical changes (changes in requirements) are noted in the margin of this standard with a revision bar.

Revision Synopsis:

Revision A expands coverage of computer aided design tools, such as ECAD and WICAD, and deletes the obsolete BMS13–11.

Revision Description:

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 1

INTRODUCTION

1.1

Purpose and Scope

BDM–7126

This BDM describes commonly used electrical connection methods (i.e.; crimp, and wrapped wire) and provides associated application information. A list of commonly used and standard parts, including selection data, is also given. Information presented herein is applicable to ground, aircraft, spacecraft, and marine electrical/electronic equipment. Closely associated information may be found in the following BDMs: BDM–7086

Insulating Materials

BDM–7124

Wiring Design, Assembly & Installation

BDM–7173

Electrical Bonding and Grounding

BDM–7504

Printed Wiring Boards & Assemblies

BDM–7505

Surface Mount Technology

1.2 a.

References GOVERNMENT MIL–F–21608; Ferrule, Shield Grounding, Insulated, Crimp Style, Brass. MIL–HDBK–454; Requirement 5, Soldering, Requirement 19, Terminal, Requirement 24. Resistance Welds; Requirement 59, Brazing. MIL–STD–1276, Leads, Weldable for Electronic Component Parts. MIL–T–7099; Terminals, Lug and Splice, Crimp Style Aluminum, for Aluminum Aircraft Wire. MIL–T–7928; Terminals, Lug and Splice, Crimp Style, Copper. MIL–T–22520; Tool, Crimp Type, for Contacts of Electric Connectors. MIL–W–5088; Wiring, Aircraft, Installation of MIL–W–8939; Welding, Resistance, Electronic Circuit Modules. MSFC–STD–271; Fabrication of Welded Electronic Modules. MSFC–SPEC–270; Component Lead and Interconnection Materials for Welded Modules. MIL–C–39029; Contacts, Electrical Connectors, General Specification for. MIL–HDBK–217; Reliability Prediction of Electronic Equipment.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 1.2 b.

BDM–7126

References (Continued) INDUSTRY STANDARDS American Welding Society Soldering Manual

c.

THE BOEING COMPANY D1–8275–1; The Boeing Company Preferred Electrical Crimp Tools. D2–AGM12101–1; Failure Rate, Mode of Failure, and Adjustment Factors, AGM–69A Parts and Components. D2–140040; Workmanship Manual for Advanced Electronic Hardware. D2–16495–1; Field Failure Rates of Minuteman Standard Parts (U). The following documents describe Electronic Computer Aided Engineering (ECAE) applications. D900–12083–4; ECAE Applications: WICAD User’s Handbook D900–12084–1; Wirewrap Functions User’s Guide

d.

VENDORS Mentor Idea Series System Overview Manual, 16729, V6.1

1.3

Definitions

Bond (electrical) – An electrically conductive union or joint between two or more adjoining surfaces. The union may be formed by fusion (welding, brazing), solid state diffusion (thermocompression, ultrasonic), soldering, or pressure contact (threaded fasteners rivets, pins, clamps, wirewrap, crimping). Connection (electrical) – A permanent or removable electrically conductive path between two adjoining or separated surfaces or points of an electrical circuit. Consists of an electrical bond alone, or, a conductor and/or termination(s) in combination with an electrical bond(s). Contact Area – Summation of all areas of contact between wire and terminal. Contact Resistance – Resistance between wire and terminal in a wrapped–wire connection. Crimp Connection – A conductive path formed from pressure contact obtained by cold deformation of a metal sleeve against enclosed wires. End Tail – Portion of last wire turn not wrapped against the terminal. End Turn – Last or top turn of wrapped wire around the terminal. Gun – Complete manual wire wrapping tool. Interconnection – A conductive path between two separated surfaces or points of an electrical circuit. Consists of an electrical conductor (wire, printed, deposited, etched) joined at each end to other circuit elements by electrical connections.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 1.3

Definitions

BDM–7126

(Continued)

Lead Turn – First turn of wrapped wire around the terminal. Modified Wrap – A wrapped–wire connection in which the first few turns are made with insulated wire. Overwrap – Piling up of a wire turn or turns on a previously made turn within the same wrapped–wire connection. Rewrap – Reinstall a wrapped–wire connection on a portion of a terminal that has been used previously. Solder Connection – A conductive path formed by linking two conductive surfaces with molten filler metal alloy (solder) at less than 800°F and without fusion of the conductive surface metals. Strip Force – Force, measured parallel to the longitudinal axis of a terminal, just sufficient to dislodge the complete wrapped–wire connection from the terminal. Termination – A circuit element device, such as terminal, splice, connector pin or post, to which the end of a conductor is bonded to form a permanent or removable electrical connection to another circuit element. Unwrap Test – Test to determine whether the wire has been overstressed during wrapping. Measures ability of a wire to be unwrapped and straightened out without breaking. Unwrap Tool – Tool designed to unwrap a wrapped–wire connection without disturbing other connections below it on the same terminal. Weld Connection – A conductive path formed by fusing the materials of two adjoining conductive surfaces. Wire Dressing – Layout of wiring within the mechanical assembly. Wire Turn – Turn of wire touching all edges of the terminal. To determine the number of wire turns on a terminal, count the wire turns crossing the first edge touched by the wire. The number of turns will be one less than this number. Wire Wrap Connection – A conductive path formed by pressure contact of solid bare wire wrapped under tension around a terminal of rectangular or square cross section. Wrapping Bit – Rotating member of the gun, which receives and wraps the wire around the terminal. Wrapping Level – Portion of terminal post occupied by a wrapped–wire connection. Levels are numbered from the baseline to the free end of the terminal as shown in FIGURE 1–1.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 1.3

Definitions

BDM–7126

(Continued) FIGURE 1–1 WRAPPING LEVELS

1

The third wrapping level is used for wiring changes only.

2

If only one level is to be occupied on a terminal, the wrap may be located on the first level.

2

CONNECTION METHODS COMPARISON

2.1

Performance Comparison

A guide to aid in the design selection of a connection method is presented in FIGURE 2–1.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 2.1

BDM–7126

Performance Comparison (Continued) FIGURE 2–1 COMPARISON OF PERMANENT CONNECTION METHODS Connection Method Rating Performance Category and Factor

Electrical Properties Mechanical Properties

Applicability To Conductors

Insulated Connections

Resistance To Environments

Cost Economy Accessibility Maintainability 1

2 3 4

Weld

Crimp

1

Solder

Braze

2

4

Low Resistance Resistance Stability Low Voltage Drop High Current Capacity

9 10 9 8

10 10 10 9

10 10 10 10

9 9 9 9

9 10 9

Pulloff Force Low Creep Strength Solid Wire Stranded Wire Insulated Wire Aluminum Wire Tinsel Wire Bus Bars Shield Braid Pre–Insulation Post–Insulation High Temperature Low Temperature Thermal Shock Vibration Salt and Humidity Aging Nuclear Radiation Tooling Process Automation Repeatability Operator Training Need for Space Ease of Repair

9 9 5 10 9 8 5 5 8 6 1 8 5 10 8 6 9 9 9 7 6 8 6 4 8 8

10 10 9 10 0 0 0 0 10 ––– ––– 8 10 10 10 9 9 10 9 6 5 4 8 4 8 6

10 10 10 10 0 0 0 0 9 ––– 0 8 10 10 10 9 10 10 9 7 5 4 8 6 8 6

10 10 9 1 10 10 8 8 0 9 10 10 9 9 8 10 9 8 9 8 9 8 10 9 9 9

9 9 9 10 1 10 1 0 ––– 0 0 8 9 9 8 8 8 9 9 7 9 10 9 7 7 8

2

Wrapped Wire

3

A rating value from 0 to 10 is assigned to each connection method for every applicable performance category. It is assumed that all types of connections are equally well made. A rating of 10 indicates the connection method is suitable for the category considered. Lower assigned values are less suitable, but values as low as 5 are sometimes acceptable. A rating of 0 implies that the connection method is totally unacceptable, while a dash means not applicable. Other design considerations being equal, crimp connections of stranded wire are preferred over solder connections because of approximately one fifth the cost. Wrapped connections are not recommended for high current applications. Brazing requires corrosive fluxes which must be completely removed/neutralized.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 2.2

BDM–7126

Reliability Comparison

Reliability of connnections for all assemblies except those using plated–through holes is listed in FIGURE 2–2. (Source: MIL–HBK–217D, 13 June 1983) FIGURE 2–2 CONNECTION METHOD RELIABILITY COMPARISON Connection Type

Failure Rate (10–6 Failure/Hr)

Hand Solder

0.0026

Crimp

0.00026

Weld

0.00005

Solderless Wrap

0.0000035

Wrapped and Soldered

0.00014

Clip Termination

0.00012

Reflow Solder

0.000069

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 2.3

BDM–7126

Part Lead Materials Versus Connection Methods

Part lead materials and their composition, common coating materials, and recommended connection methods are presented in FIGURE 2–3. FIGURE 2–3 PART LEAD MATERIALS VERSUS CONNECTION METHODS (CONTINUED ON NEXT PAGE) Base Material Designation

Composition

Common Coating Materials

MIL–STD–1276 Type

Connection Method Solder Braze

Weld

1

Crimp

Wire Wrap

2

Bare

Copper

Dumet

Kovar

Nickel

1

2

Oxygen Free High Conductivity Fully Annealed Copper

Core 58% Iron 42% Nickel Cladding Copper

54% Iron 29% Nickel 17% Cobalt

Commercially Pure Nickel (Grade A)

–––

7

10

8

–––

–––

C

10

10

7

–––

–––

Tin

–––

10

10

7

10

10

Nickel

–––

5

10

8

7

–––

Silver

–––

9

10

8

10

10

Gold

–––

8

10

9

–––

–––

Bare

–––

5

10

10

–––

–––

Tin–Lead

–––

10

10

9

–––

–––

Tin

–––

10

10

9

–––

–––

Gold Plate

D

8

10

10

–––

–––

Gold/Silver

–––

10

10

10

–––

–––

Gold/Alloy 45

–––

10

10

10

–––

–––

Bare

–––

2

8

5

–––

–––

Gold Plate

K

8

10

10

–––

–––

Tin–Lead

–––

10

10

9

–––

–––

Tin

–––

10

10

9

–––

–––

Silver

–––

9

10

9

–––

–––

Gold

–––

8

10

10

–––

–––

Gold/Nickel

–––

7

10

10

–––

–––

Bare

N–1

5

10

10

–––

–––

Gold Plate

N–2

8

10

10

–––

–––

Tin–Lead

N–3

9

10

9

–––

–––

Silver

–––

10

10

9

–––

–––

Tin

–––

10

10

9

–––

–––

Tin–Lead

A rating value from 0 to 10 is assigned to each connection for each material and coating. It is assumed that all types of connections are equally well made. A rating of 10 means that the connection method is suitable for the material considered. Lower assigned values are less suitable, but values as low as 5 are sometimes acceptable. A rating of 0 implies that the connection method is totally unacceptable, while a dash means not applicable. Welded to bare nickel wire/ribbon per MIL–STD–1276 or MIL–W–8939.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 2.3

BDM–7126

Part Lead Materials Versus Connection Methods (Continued) FIGURE 2–3 PART LEAD MATERIALS VERSUS CONNECTION METHODS (CONTINUED) Common Coating Materials

Base Material Designation

Composition

MIL–STD–1276 Type

Connection Method Solder Braze

Weld

1

Crimp

Wire Wrap

2

Advance

55% Copper 45% Nickel

Bare

–––

6

10

9

–––

–––

Kulgrid

Copper Core with Nickel Cladding

Bare

–––

5

10

9

–––

–––

Oxalloy

Copper Core with Stainless Steel Cladding

Bare

–––

5

10

10

–––

–––

Gold Plate

F

8

10

10

–––

–––

Tin–Lead

–––

10

10

9

–––

–––

Tin

–––

10

10

9

–––

–––

Bare

–––

3

10

10

–––

–––

Bare

–––

7

10

6

–––

–––

Tin

–––

10

10

6

–––

–––

Tin–Lead

–––

10

10

6

–––

–––

Bare

–––

8

10

5

–––

–––

Alloy 52

Brass Consil 1

2

51% Nickel 49% Iron

70% Copper 30% Zinc Silver Alloy

A rating value from 0 to 10 is assigned to each connection for each material and coating. It is assumed that all types of connections are equally well made. A rating of 10 means that the connection method is suitable for the material considered. Lower assigned values are less suitable, but values as low as 5 are sometimes acceptable. A rating of 0 implies that the connection method is totally unacceptable, while a dash means not applicable. Welded to bare nickel wire/ribbon per MIL–STD–1276 or MIL–W–8939.

Relationships between process specification tooling document and termination method are shown in FIGURE 2–4. FIGURE 2–4 PROCESS SPECIFICATION AND TOOLING DOCUMENT VS TERMINATION METHOD Termination Method

Crimp

Wire Wrapped

Process Specification

Tooling Document Coverage

BAC5120–1,

D2–6438

BAC5120–2,

D180–18754–1

BAC5120–3

D180–20156–1

BAC5153

BAC5153

BAC5110

D2–6438

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 3

BDM–7126

CRIMP METHOD AND PARTS

Electrical/electronic design and process engineers, in the course of product design, must select: (1) connectors suitable for the intended use (BDM–7013) and (2) appropriate wire termination techniques. In the case of wire termination, a criterion that must be considered is the availability and acceptability of terminating tools already in Boeing inventory. 3.1

Barrel Sizing For Multiple Wires

Terminals and splices are designed to terminate a single wire and performance specifications have been developed accordingly. However, where necessary to accommodate design, multiple combinations of wires may be terminated in a single barrel provided the circular mill area (CMA), current capacity and proper crimping tool have been verified. If wire combinations are required which are beyond those specified in the applicable process spec., approval shall be acquired from the applicable Technology Staff organization. 3.2

Terminals

Part and application selection data are presented in FIGURE 3–1 and FIGURE 3–2. FIGURE 3–1 CRIMP TERMINALS AND SELECTION DATA Part Family Title 2

Part Family Number 2

Wire Size

1

Process Specification

Min

Max

BACT12AA

22

18

BAC5120–1 D180–20156–1

MS20659

22

4/0

BAC5120–1 D180–20156–1

BACT12AC

26

4/0

BAC5120–1 D180–20156–1

BACT12AL

8

4

BAC5120–1 D180–20156–1

High Temperature Lug

BAC12AM

22

10

BAC5120–1 D180–20156–1

Lug for Aluminum Wire

MS25435

8

4/0

BAC5153

BACT12E

22

4/0

BAC5120–1 D180–20156–1

BACT12AB

22

8

BAC5120–1 D180–20156–1

Uninsulated Flag

BACT12G

22

4/0

BAC5120–1 D180–20156–1

Terminal for Junction Module

MIL–T–81714

Uninsulated Lug

Insulated Lug

Uninsulated Upright Lug

–––

–––

–––

1

Combinations of multiple wires may be possible. Designer must confirm that process covers his application, or request coverage from Technology Staff.

2

Other design considerations being equal, preinsulated terminals are preferred over uninsulated, due to lower manufacturing cost.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 3.2

BDM–7126

Terminals (Continued) FIGURE 3–2 CRIMP TERMINAL CONFIGURATIONS

A Ring Tongue

B Right Angle

C Flag Tongue

D Terminal for Juntion Module

E Ring Tongue

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 3.3

BDM–7126

Splices and Adapters

The most frequently used crimp wire splices and their basic part family numbers are depicted in FIGURE 3–3 with the item and parameters. Designers desiring additional detail are referred to the individual part standard contained in D–590. FIGURE 3–3 CRIMP WIRE SPLICES Part Family Title 2

Part Family Number 2

Wire Size

1

Process Specification

Min

Max

NAS 1387

22

10

BAC5120–1 D180–20156–1

BACT12C

22

4/0

BAC5120–1 D180–20156–1

NAS 1388

26

10

BAC5120–1 D180–20156–1

NAS 1389

8

0

BAC5120–1 D180–20156–1

High Temperature

BACT12C

22

10

BAC5120–1 D180–20156–1

Shielded Cable

BACT12X

22

14

BAC5120–1 D180–20156–1

Wire Terminal Splice Adapter

BACA14AN

22

14

BAC5153

Copper/Aluminum

AMP Copalum 277156 – 277162

8

3/0

BAC5153

MIL–S–81824/1–1

26

20

BAC5153

MIL–S–81824/1–2

20

16

BAC5153

MIL–S–81824/1–3

16

12

BAC5153

Uninsulated

Insulated

Moisture Sealed Splices 1

Combinations of multiple wire may be possible. Designer must confirm that process covers his application or request coverage from Technology Staff.

2

Other design considerations being equal, preinsulated splices are preferred over uninsulated because of lower manufacturing costs.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 3.3

BDM–7126

Splices and Adapters (Continued)

The commonly used splice, sleeve and adapter configurations are illustrated in FIGURE 3–4. FIGURE 3–4 CRIMP WIRE SPLICE, SLEEVE, AND ADAPTER CONFIGURATIONS

A

Uninsulated

B

Uninsulated

C

Preinsulated

D

Cable Shield and Center Conductor – Butt

E

Splice Adapter

1

Normally the wire and adapter are correctly sized so that the filler sleeve is unnecessary.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 3.4

BDM–7126

Cable Shield Terminations

The most frequently used cable–shield terminations and their part–family number are depicted in FIGURE 3–5. Quantified parameters providing additional detail may be obtained from the individual part standards in D–590. FIGURE 3–5 BRAIDED CABLE SHIELD TERMINATIONS Part Family Number

Part Family Title 1

BACS13S

Braided Shield Termination Inner Sleeve

BACS13BC BACS13S

Braided Shield Termination Outer Sleeve

BACS13BC

2

1

Cable shield termination configuration.

2

Uninsulated outer sleeve is less bulky than an insulated sleeve.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4

BDM–7126

WRAPPED–WIRE CONNECTIONS

This subsection contains design information on wrapped–wire connections for electrical and electronic airborne, ground support, and mobile wiring systems. A wrapped–wire connection consists of several turns of solid wire wrapped on a rectangular terminal post by means of a power–driven tool (gun) with a rotating bit designed for this purpose. The rotating bit winds the wire tightly around the terminal causing the sharp edges of the terminal to be pressed into the softer wire, crushing and shearing the oxide films from both terminal and wire. This action produces several intimate, metallically clean, gas tight electric junctions which are immune to the effects of corrosive atmosphere. Terminal–to–wire contact pressures are maintained at approximately 29,000 psi due to residual tension in the wire. As the connection ages at room temperature or higher, it becomes mechanically stronger due to solid state–diffusion between wire and terminal at the contact points. A wrapped–wire connection can withstand severe vibration because the bending stresses in the wire are not concentrated at the first point of contact with the terminal but tend to be distributed over the entire first turn of the connection. Stress distribution is further improved by wrapping the first few turns of wire with the insulation in place (see FIGURE 4–1). Repair of a wrapped–wire connection is accomplished by removing (unwrapping) the wire with an unwrap tool and rewrapping the terminal with a new length of wire. A terminal may be rewrapped many times without degradation of electrical or mechanical properties. In practice, a maximum of ten rewraps is standard. Wire to be used for wire–wrapped connections shall be selected from BMS13–46 and MIL–W–81822. Process information for wire–wrapped connectors is provided in BAC5110. FIGURE 4–1 WRAPPED–WIRE CONFIGURATION

1

1

This configuration, termed “modified wrap”, is the only configuration used at Boeing.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.1

BDM–7126

Packaging

Three types of panels are normally used. They are the punched plate panel, the connector–block panel, and the PWA motherboard. The punched plate panel is usually made of aluminum or plastic material. The panel size is determined by either customer’s application or the capability of the machine to accept the panel. Holes are punched or drilled on a grid to relatively close tolerances. Each terminal is inserted in its own insulated terminal then inserted into the punched holes in the panel. In the connector–block type panel, terminals are inserted or molded in connector blocks. The connector block is usually made of molded plastic. Each of these connector blocks is designed with some type of locating device since it must be located accurately within a frame of PWA backplane and assembled with other blocks to make a panel. Additional wiring not located on the backpanel should be designed in the form of subsidiary panels, such as printed circuit boards, module boards, side panels, or hinged panels. When designing to locate and mount components whose terminals are to be wire wrapped (such as integrated circuit sockets or modules on PC boards), the design guide lines given for connector blocks are applicable. Components are located by means of one or two holes, one of which becomes the reference point locating the component with respect to the datum. 4.2

Facilities

Designers must consider the resources and facilities available, such as; a.

Engineering Design Aids.

b.

Manufacturing Tooling & Processes

Electronic Computer Aided Design (ECAD) is one viable resource that the designer may use. A listing of computer programs developed to aid engineers in their design tasks are located in BDM–1740.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.2

BDM–7126

Facilities (Continued)

Comparison features between the semiautomatic and manual wire wrap methods are shown in FIGURE 4–2.

FIGURE 4–2 COMPARISON OF WIRE WRAPPING METHODS Feature

Semiautomatic

1

Manual

Description

Most operations controlled and executed by machine. Machine control tape identifies terminal to be wrapped. Operator inserts precut 5 and stripped wire in the wrapping bit and terminates the wire. Machine is indexed to position the bit at the next terminal in the connection sequence. Operator routes wires between terminals.

Operator performs all operations with hand–held gun. This method is used where quantity of connections is low. Drawing wire list is followed by operator to effect the proper wire routing.

Minimum Workload

May be justified for as few as 4 identical items having a minimum of 30 wires each, or for one item with 200 wires if a wire–book is required.

None

Wiring Rate (wires/hr/head)

100 to 400 (typically 150)

Less than 50 (typically 20)

Wiring Area (per head)

6

No limit

Wiring Sizes Capability (AWG)

20 to 30 (typ 26, 28, 30)

20 to 30 (typ 26, 28, 30)

Preferred Terminal Spacing (center to center)

Square, .100″

Minimum to allow for wrapping bit (see FIGURE 4–5)

Terminal Position Accuracy

.031″ PT

Not important

Minimum Programmable Increment 3

.001″

Not applicable

Machine Tolerance

± .003″

Not applicable

2

4

1

Standards for use of each method at Boeing are given in FIGURE 4–5.

2

PT = Position Tolerancing.

3

Ability of machine to go to a specific place.

4

Cumulative across board from reference datum.

5

Tape controlled automatic cutting and stripping (by means of a separate machine) is available.

6

A. Gardner Denver SP27A (34″ x 38″) B. Gardner Denver SP27B (37″ x 74″) C. Gardner Denver 14YA–1 (24″ x 36″)

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.3

BDM–7126

Designing

Computer–aided wrapped wiring design support is currently available for use by all Boeing Companies and Division. a.

b.

The capabilities of Electronic Computer Aided Design (ECAD) for wire wrap are as follows: (1)

Wire wrap, wiring and cabling and patchboard wire list documentation generated by computer.

(2)

Wire wrap, wiring and cabling and patchboard Numerical Control (NC) data for direct machine application (i.e., furnish NC tapes and/or files for wirewrap machine)

(3)

CAD generated wire wrap board outline currently unsupported in the existing board libraries.

(4)

CAD generated releasable detail drawing of wire wrap board dimensions.

(5)

CAD generated wire wrap board layout with component and pin placement and coordinates for wire length, NC data and geometric plot.

(6)

CAD generated releasable assembly drawing showing wire wrap board component placement, x, y component coordinate table and flag notes.

(7)

CAD generated wiring diagrams.

(8)

User conversational interface and remote access to ECAD capabilities Tools.

(9)

Full ECAD capabilities are identified in reference 1.2c.

Five software programs available are Backplane Wiring Design (BPWD), Wiring and Cabling Design (WICAD), Patchboard, Mentor Network Editor (Neted) and Symbol Editor (Symed). Consult the Electrical/Electronic Technology organization. These programs may be utilized at remote locations if compatible computer facilities are available. Some advantages of utilizing one or more of these programs are: (1)

NC machine locating accuracy in wire wrapping and in terminal location of crimp and patchboard contacts.

(2)

Computer–generated releaseable engineering documentation (wire book) of standardized format and nomenclature.

(3)

Shop–list documentation of NC data.

(4)

Significant reduction in manufacturing costs, through a variety of specialized manufacturing reports. See FIGURE 4–3 for a general description of WICAD programs.

(5)

CAD generated releasable detail and assembly drawings and wiring diagrams.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.3 c.

d.

BDM–7126

Designing (Continued) The types of input data required from users for these wire wrapped programs are: (1)

Electrical data – labeled in the form of logic or schematic diagram, part–pin–node data (a list which associates a node name with each pin), or connection list (a listing by node which identifies pins that are connected togeter to form each node.).

(2)

Mechanical data – such as dimensional description of the assembly, hardware location coordinates for connectors and terminal posts, specification sheets for contacts, connectors and/or other wiring termination and area available for routing wires. Most of this data is dependent on the kinds and quantity of parts to be interconnected.

(3)

Special design decisions – these include instructions if required, on wire routing, twisted pairs of wires and shield terminations.

The output data produced by the wrapped wiring design programs summarize the wiring and provide manufacturing documentation aids and NC data. A wiring design summary tabulates: (1)

Wiring parameters

(2)

Assembly layout

(3)

Connector types

(4)

Corner pins

(5)

Diagnostics from input data editing

(6)

A wire list

An optional output is a geometric plot of all pins on the assembly. The wirebook is a book form drawing available to manufacturing through normal program engineering release methods. The manufacturing aids provided are a numerical control (NC) machine tape and/or file, a shop list. All are referenced in the released engineering wirebook. The NC tapes are eight (8) track punched mylar and are identified, for configuraiton control, by part number and revision. Configuration and effectivity control of wiring changes is maintained by normal drawing ADCN and DCN changes to the released wirebook. Note that the first ADCN invalidates the shop NC data necessitating hand incorporation of the change. Both wiring design programs have the ability to track version and effectivity as a design is modified. When using the BPWD programs, only the pages necessary to update a wirebook need be generated or, as an option, the entire wirebook can be reprinted. When using the WICAD programs, the entire wirebook is reprinted every time an update is made, in order to maintain traceability with the shop NC data.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.3

BDM–7126

Designing (Continued) FIGURE 4–3 BACKPLANE WIRING DESIGN VS WIRING AND CABLING DESIGN PROGRAMS (CONTINUED ON NEXT PAGE)

Programs Backplane Wiring Design (BPWD)

Patch– board

Utilized To

Unique Advantages

• Build wrapped • Automatic computer checking wire circuit cards and printed diagnostics, i.e., for: • Build • missing parts (pin or wire) backplanes interconnecting • redundant wiring a series of circuit cards mounted in • Z–level conflicts a cardfile • specified wire too short

• Build Patchboards

1 • improper nodes • Automatic computer checking and printed diagnostics, i.e., for:

• No patch fits. • Specified patch doesn’t fit.

Upper Limits • 500 pins per node. • 8 characters maximum for node names. • 8 characters maximum for connector names. • 4 characters maximum for pin names. • 1000 connectors per assembly. • 2000 pins per connector. • 14 legged patchcord is maximum equipment–pin definition allowed. • 175 is maximum number of patchcord types allowed. • 2000 patchcord is maximum number allowed.

• Computer selection and sorting of patchboards by length in ascending order. • Ability to override computer selection of patchcords. • Sequencing of wiring to facilitate the optimum assembly of a unit. • Conversion of the patching chart to a WIring/CAbling Design WICAD wire list format. 1

“Node” comprises all wires, pins, etc., that form an electrically common path. Node names are a requirement for BPWD use and are included in WICAD for information purposes only.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.3

BDM–7126

Designing (Continued) FIGURE 4–3 BACKPLANE WIRING DESIGN VS WIRING AND CABLING DESIGN PROGRAMS (CONTINUED)

Programs Neted (Mentor NETwork EDitor)

Utilized To • Computer generate: • Wire wrap board outline. • Releasable detail drawing. • Wire wrap board layout. • Releasable assembly drawing. • Releasable wiring diagram.

Unique Advantages • Automatic computer checking and printed diagnostics, i.e., for:

Upper Limits Not Applicable

• Duplicate component reference designators on layout. • Matching component reference designators on layout and connection list. • Large component library resource. • Computer generate layout geometry and ATA (Assembly Termination Assignment) files for wire wrap applications. • Z clip power and ground pins per customer requirements. • Power and Ground nets can be routed per customer requirements. • Computer generate files for stitchwire applications.

Symed

• Create new components and symbols for wire wrap, layout and wiring diagram applications.

• Not restricted to 90% angles.

Not Applicable

• Checks for duplicate pin numbers.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.3

BDM–7126

Designing (Continued) FIGURE 4–3 BACKPLANE WIRING DESIGN VS WIRING AND CABLING DESIGN PROGRAMS (CONTINUED)

Programs

Utilized To

Wiring and • Build electronic Cabling racks Design (WICAD 2) • Drawers • Assemblies • Boxes using wrapped wiring, crimp, and patch–board techniques Wiring and Cabling Design (WICAD)

• Build electronic racks • Drawers • Assemblies • Boxes using wrapped wiring, crimp, and patch–board techniques

Unique Advantages • Documentation aids which help user enter and revise wiring data. • Automatic computer checking and printed diagnostics, i.e., for:

Upper Limits Not Applicable This WICAD 1 description is still valid for WICAD 2. No upper limits exist in the code.

• terminal too small or large for specified wire gauge

• Documentation aids which help user enter and revise wiring data.

• 5000 wires per wire list.

• Automatic computer checking and printed diagnostics, i.e., for:

• 100 wire termination types.

• terminal too small or large for specified wire gauge; • splice underfilled or overfilled for specified number of wires; • wire type not having correct number of conductors and associated wire colors; • Z–level conflict.

• 2000 wire storage bins.

• 100 wire types. • 25 wire colors. •1296 wire families. • 500 lines of text defining general notes. • 100 flagnotes. • 400 lines of text defining flagnotes. • 32 effectivity codes.

• 200 lines of text defining effectivity codes. • Generation of wire preparation list for independent wire prep • 8 characters maximum for node names. away from assembly process. • 10 characters maximum for connector • Sequencing of wiring to names. facilitate the optimum assembly of a unit. • 4 characters maximum for pin names.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.4

BDM–7126

Dimensioning

When designing for semiautomatic machine wrapping, use “Positioning Tolerancing” in accordance with BDS–1060 (see Drafting Standards Manual D–4900). Terminal holes must be located by specifying basic dimensions from datums X and Y as delineated in FIGURE 4–9 to provide clearance for the AWG size of wire being wrapped. 4.5

Commercial Components

Use components specifically designed for wrapped–wire connections whenever possible. Type of components commercially available are listed in FIGURE 4–4. FIGURE 4–4 COMMERCIALLY AVAILABLE WRAPPED–WIRE CONNECTION COMPONENTS Component

BAC Standard

Molded PC Boards headers and sockets

–––

Punched Plate PC board headers and sockets

–––

PC Card receptacles

BACC65T

Connectors and Connector Blocks

–––

Logic sockets

–––

Dual Inline Package (DIP) Sockets

–––

Diode Sockets

–––

Rack and panel receptacles

BACC66G & H

Rectangular Connectors

–––

Banana Jacks

–––

PC card guides

–––

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.6

BDM–7126

Connection Standards

Connection Standards are defined in FIGURE 4–5. FIGURE 4–5 CONNECTION STANDARDS Wire

Terminal

Size

Dimensions

(AWG)

(inches)

.025 x .025 30

Minimum

2

.035 x .035 .025 x .205

28

Minimum

Number of Number of

Minimum

Minimum Connections

Terminal

Terminal

per Square

Minimum

Typical

Turns

Post

Length for

Spacing

Inch per

Stripping

Terminal–

(stripped

Corners

3 Wrapping

(inches)

Wrapping

Force

to–Wire

wire)

Touched

Levels

Level

(lbs)

Contact

(insulated

(inches)

Resistance

wire)

1

(milliohms)

5

.625

7

2

.016 x .032

7

5

.625

.035 x .035 .025 x .025 26

2

.031 x .062

6

5

.641

.045 x .045 .025 x .025

2

.031 x .062

24

.045 x .045 .031 x .062

22

.045 x .045 .031 x .062

20

.045 x .045

.100

100

.100

100

.150

36

.100

100

.150

36

.140

36

.200

25

3

4

4

3

6

2

7

2

5

4

.668

5

4

.818

.200

25

8

2

4

4

.881

.200

25

9

2

2

1

Level 3 preferred left vacant to provide space for repair wrap.

2

Present capability for manual and semiautomatic wrapping.

4.7

Performance

Backpanel And Terminal Grid

The design considerations for backpanel and terminal grid wire wrap connections are reflected in backpanel recommendations in FIGURE 4–6, punched–plate dimensions and tolerances in FIGURE 4–7, recommended dimensions for formed aluminum plates in FIGURE 4–8 and a recommended sequence of plate design in FIGURE 4–9.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL

BDM–7126

4.7

Backpanel And Terminal Grid (Continued) FIGURE 4–6 GENERAL BACKPANEL RECOMMENDATIONS Datum Point The datum point is the master reference point on the backpanel from which all terminal locations, mounting holes and other features are dimensioned. To utilize computer backplane wiring (see 4.3) the datum point should be located so that, with the panel in position for wrapping and terminals facing upward, all terminals to be wrapped are in the 1st quadrant with respect to that datum. The datum point may also be used to locate the backpanel on the work table of the semiautomatic wire wrap machine. Punched Plate For punched plate type panels, design two .312″ or .375″ holes near the extremities of Panel with Single the panel diagonal as shown below. One of the holes is designated as the datum Terminal Grid point.

Connector–Block Panel, Multiple Grids

A backpanel may consist of more than one independent terminal grid, such as connectors, connector blocks or other wire wrap components mounted on the panel. In that case a system of additional reference points is required to dimension and locate the individual connector terminal grids with respect to the datum point. Each connector must have two locating holes or other features which are accurately defined with respect to the terminal grid on that connector, as shown below.

Assembly Fixture

In order to obtain the required dimensional reparoducibility for any number of panels, it may be necessary to design an assembly fixture. This fixture will have a number of locating pins, normally two per connector. One of the pins is designated the reference pin and will serve to locate the connector’s terminal grid in the proper relationship with respect to the datum point. While held in this position the connector will be fastened to the panel by its normal mounting hardware.

Panel Flatness Terminal Location Tolerance Z–Axis Range

Recommended tolerances for reference pins or holes are .001 TPD for size and .003 TPD for location with respect to datum. Whether the plate–type or connector–block type concept is used, the assembled panel should be flat and straight within .030 inch over its entire length. For consistent engagement of the terminals by automatic or semiautomatic wrapping tools, terminals must be located within .030 inch TPD of the datum point on the panel. The Z–axis range is the total vertical distance through which the wire wrap head of the semiautomatic machine operates. The preferred Z–axis arrangement from the programming and wiring viewpoint is to have a common baseline for all wire wrap terminals, and equal terminal lengths. However, if it is necessary to mount components of unequal height such as connectors and sockets, the difference in height from the baseline to the top of the longest terminal must not exceed 2.250 inches (see below).

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.7

BDM–7126

Backpanel And Terminal Grid (Continued) FIGURE 4–7 STANDARD PUNCHED PLATE DIMENSIONS AND TOLERANCES (INCHES) Terminal Size

Feature

.025 x .025

Size/Tolerance

Location Tolerance

Grid Holes

.072 dia ± .002

.008 TPD

Datum Holes

dia ± .0005

.006 TPD

Mounting Holes

dia ± .003

.010 TPD

Plate Periphery

± .005

N/A

Plate Thickness

.080 ± .005

N/A

Plate

2 x 6 Maximum

± .010

N/A

Flatness

24 x 24 Maximum

± .030

N/A

Grid Holes

.136 dia ± .002

.008 TPD

Datum Holes

dia ± .0005

.006 TPD

Mounting Holes

dia ± .003

.010 TPD

Plate Periphery

± .005

N/A

Plate Thickness

.125 ± .005

N/A

.045 x .045 Plate

2 x 6 Maximum

± .010

N/A

Flatness

24 x 24 Maximum

± .030

N/A

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.7

BDM–7126

Backpanel And Terminal Grid (Continued)

FIGURE 4–8 RECOMMENDED DIMENSIONS FOR FORMED ALUMINUM PLATES

Plate Thickness

Recommended Dimensions

(inches) .125 .080

A

B

C

D

N/A

.312 ± .005

Dim ± .010

Dim ± .010

less than 3

.170 min

Dim ± .010

Dim ± .010

over 3

.210 min

Dim ± .010

Dim ± .010

1

Minimum distance without distorting hole diameter (see note 3).

2

Minimum material needed for 90° sheet metal break (see note 3).

3

Shorter ribs on 90° breaks and less material from hole edge to inside plate edge are possible with a second operation cutoff.

4

To eliminate edge deformation.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.7

BDM–7126

Backpanel And Terminal Grid (Continued) FIGURE 4–9 RECOMMENDED SEQUENCE OF PUNCHED PLATE TERMINAL GRID DESIGN (CONTINUED ON NEXT PAGE) Step 1 Select terminal and grid pattern from examples shown at right.

Step 2 Determine desired configuration of the basic grid pattern, as shown.

Grid

Recommended A or B

.100

.100 or multiple of .100

.125

.125 or multiple of .125

.150

.150 or multiple of .150

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BOEING DESIGN MANUAL 4.7

BDM–7126

Backpanel And Terminal Grid (Continued) FIGURE 4–9 RECOMMENDED SEQUENCE OF PUNCHED PLATE TERMINAL GRID DESIGN (CONTINUED)

Step 3 Determine overall size of panel. Locate terminal grid configuration on the plate as shown.

Step 4 Locate mounting holes and optional peripheral holes. These holes will be dimensioned later from the true position datum.

Step 5 Locate datum holes on plate by “D” dimensions from terminal hole pattern to datum centerlines (X–Y coordinates), as shown. If computer–aided wrapping is to be used, see FIGURE 4–6, for Datum Point location.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.7

BDM–7126

Backpanel And Terminal Grid (Continued) FIGURE 4–9 RECOMMENDED SEQUENCE OF PUNCHED PLATE TERMINAL GRID DESIGN (CONTINUED)

Step 6 Mounting and peripheral holes (dimensions “C”) can now be indicated with reference to X–Y datum coordinates.

Step 7 Locate plate periphery from X–Y datum coordinates, and add tolerances for plate features and plate flatness as shown.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.8

BDM–7126

Terminals

Terminal design guidance is provided via general recommendations in FIGURE 4–10, material data in FIGURE 4–11, a procedure for determination of terminal length in FIGURE 4–12 and an example of terminal sleeve choice in FIGURE 4–13. FIGURE 4–10 GENERAL TERMINAL RECOMMENDATIONS Materials Cross–Section

Recommended materials are listed in FIGURE 4–11. Terminal material should have a high modulus of elasticity and a low rate of stress relaxation. Preferred cross–section is square, with a minimum of two sharp edges for contact. Top or free end of the terminal must have a radius or be pointed to facilitate entry into the wrapping bit. Opposite ends of the terminals may serve as connector pins attached to printed circuit cards, solder terminal lugs, or other terminals. Terminals must be small enough to fit into the wrapping bit, yet large enough to resist the torque developed by the wrapping process. In general, terminal width should be three times the diameter of the wire to be used and thickness two times the wire diameter. Commonly used and accepted standard size terminals are listed in FIGURE 4–5.

Length

For a given cross–sectional area, terminal length is limited by torsional resistance needed for the wrapping operation. Determining factors are wire size, number of turns required per connection, number of wrapping levels per terminal, and depth of the hole in the bit. Larger wire sizes require more space and greater wrapping force, with a resultant decrease in overall connection density. Beyond three wrapped–wire connections per terminal, repair or circuit changes become impractical. A connection board with three wraps (connections) per terminal requires removal of six to eight wraps to remove a bottom wrap while a connection board with four connections per terminal requires removal of 16 to 18 wraps to remove a bottom wrap. Recommended minimum terminal lengths for three wrapping levels per terminal are shown in FIGURE 4–5. Minimum length can be calculated as shown in FIGURE 4–12.

Edges

All terminals must have sharp edges for contact. The corner radius or chamfer must be .003 inch or less. Maximum edge burrs permitted are .0015 inch. Terminal edges must be parallel within .0015 inch. Tapered terminals tend to produce strip forces lower than the minimums listed in FIGURE 4–5.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.8

BDM–7126

Terminals (Continued) FIGURE 4–11 TERMINAL MATERIALS Material

Specification

Composition or Alloy

Hardness

Finish

3

Brass Wire (Drawn)

QQ–W–321

260

Hard

1

Brass Strip (Punched)

QQ–B–613

11

1/2 Hard

1

Punched

ASTM–B–103

A

1/2 Hard

1

Drawn Wire

ASTM–B–159

A

Hard

1

Chem–milled

QQ–B–750

A

2

1

Drawn Wire

ASTM–B–151

D

Extra Hard

None

Punched

ASTM–B–122

1, 4, 8

1/2 Hard

None

Phosphor Bronze

Nickel Silver

Beryllium Copper Alloy Wire

QQ–C–530

Not applicable

1/2 Hard

1

Strip

QQ–C–533

Not applicable

1/2 Hard

1

1

Specify gold plate per MIL–G–45204, or tin plate (electrodeposited) per MIL–T–10727 to 30 microinches minimum thickness.

2

Hardnesses from 1/2 hard to spring temper are acceptable. Use 1/2 hard when sharp bends are required.

3

See specification for chemical composition.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.8

BDM–7126

Terminals (Continued) FIGURE 4–12 DETERMINATION OF MINIMUM TERMINAL LENGTH

L + Nƪn 2d 2 ) d 1ǒ n 1 ) 1 Ǔ ) sǒn 1 ) n 2Ǔƫ ) Sǒ N * 1 Ǔ where

L

=

Minimum terminal length for the required number of connections (does not include tip or base configurations or tolerances on terminal length).

N

=

Number of connections the terminal is designed for.

n1

=

Maximum number of turns of uninsulated wire per connection.

n2

=

Maximum number of insulated turns per connection.

d1

=

Nominal diameter of uninsulated wire.

d2

=

Nominal diameter of insulated wire.

s

=

Space allowance between adjacent turns within a connection.

S

=

Space allowance between adjacent connections.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.8

BDM–7126

Terminals (Continued) FIGURE 4–13 EXAMPLE TERMINAL/SLEEVE CONFIGURATION AND SPECIFICATIONS

Configuration

Example Specifications Material: Brass 1/2 hard, QQ–B–613, Composition 11 Plating: Gold plate per MIL–G–45204 Contact Rating: 3 amperes .006 ohm resistance maximum Insulation Resistance: 5000 megohms minimum at 500 volts DC Dielectric Withstanding Voltage (52% Relative Humidity–Sea Level) and contact spacing 1350 Volts RMS .100 1600 Volts RMS .125 1800 Volts RMS .150 NOTE: Tolerance .005 unless otherwise specified.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.9

BDM–7126

Wiring

The characteristics of wire commonly used for wrapped connections and considerations for its use are presented in FIGURE 4–14 and the properties of common insulations are described in FIGURE 4–15. Additional data on these subjects may be found in BDM–7032.

FIGURE 4–14 GENERAL INFORMATION Insulated or Uninsulated

Insulated wire only is recommended.

Wire Size

Base wire size on electrical and mechanical requirements. Current carrying capacity is limited by wire size rather than connection. The net cross–section of the connection contact area exceeds that of the cross–section of the wire. Standard size for semiautomatic wrapping is AWG 30 (see FIGURE 4–5).

Wire Conductor

The most commonly used conductor material for wire sizes up to AWG 26 is oxygen free high conductivity type copper (OFHC) with a tin or silver coating. This type copper is preferred because it can withstand more abuse and movement without work hardening than regular tough pitch copper. This means that OFHC type copper will more readily meet unwrap test requirements. Various high strength alloys are in use for miniature wire sizes, AWG 28 and smaller. Desirable properties of the conductor are tensile strength 30,000 to 40,000 psi, elongation 15 to 25%, dimensional uniformity of diameter. The preferred wire finishes are tin and silver. Tin coated wire is often used for hand wrapping applications and where one end of the wire may require soldering. Silver coatings because of their lubricating property are reported to reduce bit wear in high speed automatic wire wrap applications.

Wire Density

When the quantity of wires per set of terminals used is high, problems of wire routing and redressing increase. Studies have shown that the optimum amount of wires in a panel is approximately half that of the number of terminals used.

Layout and Routing Provisions of BAC5110

(1) Wire routing between any two wrapped connections shall be point to point wiring. (2) Wires shall have slack so as to prevent stress on both the wire and the posts. (3) The wires shall be so dressed that the routing of the wire or any applied tension on the wire will not unwrap the connection. (4) Wire shall be dressed down so that it does not extend above the plane of the post tips. (5) Wires shall not be routed outside of or along the outer periphery of the terminal posts assembly; except when wraps are installed with a Universal machine, wire loops may extend beyond the periphery of the bottom row of terminals. (6) Wires lying between the terminal posts of any terminal post array shall not be tied together.

Insulation

See FIGURE 4–15 and BDM–7032.

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BOEING DESIGN MANUAL 4.9

BDM–7126

Wiring (Continued) FIGURE 4–15 CHARACTERISTICS OF COMMONLY USED WIRE INSULATION

Insulation 1

Dielectric Cut– Stripping Memory Heat Temperature Concentricity Cost Common Constant Through Consistency Resistance Resistance Range Consistency Usage 2 3 @ 1 MHz Resistance (°C)

Kynar

6.4 Nom.

Good

Excell.

Good

Good

–65 to 130

Excell.

5

1

PVC/ Mylar

3.5 Max

Excell.

Good

Fair

Fair

–55 to 105

Excell.

8

4

FEP/ Kynar

2.5 Nom.

Good

Good

Good

Good

–65 to 130

Good

10

13

FEP/ Nylon

2.2 Nom.

Good

Good

Good

Good

–55 to 115

Good

7

6

Poly– sulfone

3.1 Nom.

Good

Excell.

Excell.

Excell.

–65 to 130

Excell.

3

5

CTFE

2.4 Nom.

Good

Excell.

Excell.

Excell.

–80 to 200

Good

9

7

Irr–PVC

3.2 Nom.

Excell.

Good

Excell.

Excell.

–55 to 105

Good

4

14

Semirigid PVC

4–5

Fair

Fair

Excell.

Good

–55 to 80

Fair

1

12

FEP/ Kapton

2.2 Max

Excell.

Fair

Good

Good

–80 to 200

Good

12

8

FEP/H

2.2 Max

Good

Good

Good

Good

–80 to 200

Good

11

9

TFE/H

2.2 Max

Good

Excell.

Excell.

Excell.

–80 to 260

Good

14

10

PVC/ Nylon

4.0 Nom.

Fair

Fair

Good

Fair

–55 to 105

Fair

2

11

TFE

2.0 Max

Fair

Excell.

Excell.

Excell.

–80 to 260

Good

13

3

Irr/ETFE

2.2 Max

Good

Excell.

Excell.

Excell.

–65 to 150

Good

6

2

1

See FIGURE 5–2 for chemical name.

2

Ranked 1 to 14 with increasing cost.

3

Ranked 1 to 14 with decreasing usage.

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 4.10

BDM–7126

Connectors

Standard connectors for wire–wrap termination are identified in FIGURE 4–16. FIGURE 4–16 BOEING STANDARD CONNECTORS AVAILABLE WITH WIRE WRAP TERMINATIONS Item

BAC Standard

Circuit Board Receptacle

BACC65T

Rack and Panel Receptacle Shell Size 2 (ARINC 600)

BACC66G

Rack and Panel Receptacle Shell Size 3 (ARINC 600)

BACC66J

4.11

Quality Control

The integrity of a wrapped–wire connection is evaluated indirectly by performing tests on a number of sample connections. Wrapped connections on the production item are never subjected to tests or disturbed for any reason. On these, visual inspection is performed to ensure compliance with the process requirements. Normal tests performed on sample connections are strip force and unwrap tests which are adequate to certify tools and operator and are useful in qualifying wire and terminals. Other tests occasionally specified are millivolt drop and gas–tight–area tests. These tests are normally limited to qualification of new parts, materials, or finishes. It has been found that the strip force and unwrap tests normally ensure proper electrical and gas–tight contacts.

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BOEING DESIGN MANUAL 5

DRAWING REQUIREMENTS AND INFORMATION

5.1

General

BDM–7126

The information required for connection callout consists of process, part and material specification identities and assembly drawings. a.

b.

Drawing callout of process specifications should take the following form: CONNECT PER MANDATORY FOR BOEING INTERNAL USE)

1

(

2

1

If compliance with MIL–STD–143 is required, enter the appropriate government or industry specification. If such compliance is not required, or there is no appropriate government/industry specification, enter the Boeing process specification and omit the parenthetical callout.

2

Enter the Boeing process specification.

Applicability of a Boeing process or material specification to a design objective and company may be established from D–18888–1, Boeing Process Specification Numerical Index or D–18888–3, Boeing Material Specification Numerical Index. This applicability must be confirmed by the designer. When coverage for a process or material does not exist it should be requested through the designer’s company focal point. FIGURE 5–1 identifies the process specifications applicable to the standard modes of connection. FIGURE 5–1 SPECIFICATIONS USED FOR TERMINATION METHODS Assembly Process Subject

5.2 a.

b.

BAC

Lugs, splices, end caps, adapters

5153 5120

Dead ends, pigtails

5157 5118

Coaxial connections

5169 5122

Electrical connectors

5162 5121

Wrapped–wire connections

5110

Crimp Connections The Engineering drawing must specify. (1)

Part number to identify type, barrel size and stud size.

(2)

Process specification.

Applicable process specifications are presented in FIGURE 5–1. Example of typical callout is: INSTALL CRIMP WIRE LUGS, SPLICES, AND END CAPS PER BAC XXXX

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 5.3 a.

b.

BDM–7126

Wrapped Wire Connections REQUIREMENTS. The following information is normally required on drawings for equipment utilizing wrapped–wire connections: (1)

A note specifying the wirewrap process to be used. For either manual or semiautomatic method, specify BAC5110. Final choice of method resides with Manufacturing.

(2)

A wire list showing:

•

Material, size, approximate length and color of each wire.

•

Terminal numbers and levels to which each wire is to be connected.

•

Routing between terminals, if required to be other than process specification controlled (see FIGURE 4–14).

EXAMPLE ASSEMBLY DRAWING. Information normally shown on a connector assembly drawing (terminals installed in a plate) is given in FIGURE 5–3. FIGURE 5–2 SPECIFICATIONS RELATING TO WIRE INSULATION Trade Name

Chemical Name

Federal or Military Spec.

BMS

Semirigid PVC

–––

MIL–W–5086

–––

PVC/Nylon

–––

MIL–W–5086

–––

Polysulfone

–––

MIL–W–16787

–––

Irr.–PVC

–––

MIL–W–5086

–––

Kynar

Polyvinylidene fluoride

MIL–W–5086

13–46

Irr.–ETFE

Ethylene–tetrafluoroethylene Copolymer

MIL–C–22759

13–48

FEP/Nylon

Fluorinated ethylene propylene/(Nylon)

MIL–C–17

–––

PVC/Mylar

Laminated tape with oriented polyethylene terepthalate & polyester or PVC adhesive

MIL–W–5086

–––

CTFE

Polymonochlorotrifluoroethylene

MIL–W–81822

–––

FEP/Kynar

Fluorinated ethylene propylene/(Kynar)

MIL–W–81822

13–46

FEP/H

–––

FEP/Kapton

–––

TFE TFE/H

Polytetrafluoroethylene –––

–––

13–51

MIL–W–81381

13–46 13–51

MIL–C–22759

13–10 13–16

–––

13–46

CONNECTIONS BDM–7126 REV A

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BOEING DESIGN MANUAL 5.3

BDM–7126

Wrapped Wire Connections (Continued)

FIGURE 5–3 TYPICAL INFORMATION ON CONNECTOR ASSEMBLY DRAWING Notes

Example

After completion of the plate drawing, the connector assembly drawing should be constructed using X–Y true position coordinates The following data is normally required: 1. Terminal and sleeve (insulator or ground) part numbers, location, orientation and quantities on drawing. 2. True position tolerance of wire– wrap terminal tips. 3. Optional plate hardware and location.

CONNECTIONS BDM–7126 REV A

PAGE 43