TECHNICAL REQUIREMENTS FOR CABLE AND

WIRING HARNESSES
7-31k Wire Harness Design Task Group

Working Draft

Revision 2
(Design version)

07/24/2012
TABLE OF CONTENTS

1. PURPOSE ................................................................................................................................. 6
1.1 SCOPE ...................................................................................................................................... 6
1.2 CLASSIFICATION ..................................................................................................................... 6
1.3 DEFINITION OF REQUIREMENTS .......................................................................................... 6
1.3.1 HARDWARE DEFECTS AND PROCESS INDICATORS ......................................................... 7
1.3.2 MATERIAL AND PROCESS NONCONFORMANCE................................................................ 7
1.4 MEASUREMENT UNITS AND APPLICATIONS ....................................................................... 8
1.4.1 VERIFICATION OF DIMENSIONS ........................................................................................... 8
1.5 ENGINEERING DOCUMENTATION ........................................................................................ 8
1.6 ORDER OF PRECEDENCE...................................................................................................... 8
1.6.1 CONFLICT ................................................................................................................................. 8
1.6.2 CLAUSE REFERENCES........................................................................................................... 8
1.6.3 APPENDICES............................................................................................................................ 8
1.7 APPROVAL OF DEPARTURES FROM STANDARDS AND REQUIREMENTS...................... 8
1.8 MODIFICATION, REWORK AND REPAIR ............................................................................... 8
1.8.1 MODIFICATION ........................................................................................................................ 9
1.8.2 REWORK................................................................................................................................... 9
1.8.3 REPAIR ..................................................................................................................................... 9

2. APPLICABLE DOCUMENTS .................................................................................................. 10

2.1 SPECIFICATIONS ................................................................................................................... 10

3. DESIGN PHILOSOPHY .......................................................................................................... 12

3.1 GENERAL DESIGN CONSIDERATIONS ............................................................................... 12

4. GENERAL DESIGN REQUIREMENTS .................................................................................. 13

4.1 SELECTION OF PARTS, MATERIALS AND PROCESSES .................................................. 13
4.1.1 PROCUREMENT - WIRE & CABLE ....................................................................................... 13
4.1.2 MATERIALS AND PROCESSES ............................................................................................ 14
4.1.2.1 FLAMMABILITY ....................................................................................................................... 14
4.1.2.2 OUTGASSING ......................................................................................................................... 14
4.1.2.3 FOREIGN OBJECT DEBRIS (FOD) ....................................................................................... 14
4.1.2.4 TIME-CRITICAL OR LIMITED-LIFE ........................................................................................ 14
4.1.2.5 RESTRICTED MATERIALS / PROCESSES........................................................................... 14
4.1.2.5.1 FLUORINE ATTACK (WHITE PLAGUE) ................................................................................ 15
4.1.2.5.2 CRIMPING OF SOLDER-TINNED AND SOLID CONDUCTORS........................................... 15
4.1.2.5.3 PYROTECHNIC CIRCUITS - WIRE SPLICING ...................................................................... 15

5. ELECTRICAL CHARACTERISTICS ....................................................................................... 16

5.1 CIRCUIT CATEGORIES ......................................................................................................... 16
5.1.1 CATEGORY I (POWER AND CONTROL) .............................................................................. 17
5.1.2 CATEGORY II (HIGH LEVEL SIGNALS) ................................................................................ 17
5.1.3 CATEGORY III (LOW-LEVEL SIGNALS)................................................................................ 17
5.1.4 CATEGORY IV (ELECTRO EXPLOSIVE DEVICE CIRCUITS).............................................. 17
5.1.5 CATEGORY V (HIGH-FREQUENCY SIGNALS) .................................................................... 17
5.2 SHIELDING REQUIREMENTS ............................................................................................... 17
5.2.1 CATEGORY I CIRCUITS ........................................................................................................ 17
5.2.2 CATEGORY II CIRCUITS ....................................................................................................... 17
5.2.3 CATEGORY III CIRCUITS ...................................................................................................... 17
5.2.4 CATEGORY IV CIRCUITS ...................................................................................................... 18
5.2.5 CATEGORY V CIRCUITS ....................................................................................................... 18
5.2.6 BOND CLASSIFICATION........................................................................................................ 18
5.2.7 ADDITIONAL SHIELDING....................................................................................................... 18
5.3 SHIELD TERMINATION AND SHIELD GROUNDING............................................................ 19
5.3.1 METALLIC BRAID SHIELDING............................................................................................... 20
5.3.2 ELECTROMAGNETIC PULSE (EMP) .................................................................................... 20
5.3.3 CATEGORY IV CIRCUITS ...................................................................................................... 20
5.3.4 CATEGORY I, II, III, AND V CIRCUITS (NO EMP)................................................................. 21
5.3.5 UNGROUNDED / FLOATING SHIELD TERMINATIONS (NO EMP) ..................................... 21
5.3.6 MAGNETIC SHIELDS ............................................................................................................. 21
5.3.7 CIRCUIT ISOLATION .............................................................................................................. 21
5.3.8 GROUP-GROUNDING OF INDIVIDUAL SHIELD TERMINATIONS ...................................... 22

6. DESIGN REQUIREMENTS ..................................................................................................... 23

6.1 RELIABILITY ........................................................................................................................... 23
6.2 INTERCHANGEABILITY ......................................................................................................... 23
6.3 SERVICE LIFE ........................................................................................................................ 23
6.4 ERGONOMIC DESIGN ........................................................................................................... 23
6.5 CABLE / HARNESS LENGTH ................................................................................................. 23
6.5.1 DATUM .................................................................................................................................... 23
6.5.2 BREAKOUTS........................................................................................................................... 23
6.5.3 TOLERANCE ........................................................................................................................... 23
6.6 ACCESSIBILITY FOR MAINTENANCE .................................................................................. 24
6.7 CABLE / HARNESS MANAGEMENT (ROUTING) ................................................................. 24
6.8 BEND RADIUS ........................................................................................................................ 25
6.8.1 MINIMUM BEND RADIUS ....................................................................................................... 25
6.9 BREAKOUTS........................................................................................................................... 26
6.10 PROTECTION AND SUPPORT .............................................................................................. 26
6.11 FORMING WIRES INTO CABLES AND HARNESSES .......................................................... 27
6.12 SEPARATION OF REDUNDANT SYSTEMS ......................................................................... 27
6.13 CORONA SUPPRESSION ...................................................................................................... 28
6.14 ELECTRICAL DESIGN............................................................................................................ 28
6.15 WIRE AND CABLE .................................................................................................................. 28
6.15.1 DERATING .............................................................................................................................. 29
6.15.2 PROCUREMENT AND ACCEPTANCE TEST ........................................................................ 30
6.16 CONNECTORS ....................................................................................................................... 30
6.16.1 MATING PROVISIONS ........................................................................................................... 31
6.16.2 MOISTURE PROTECTION ..................................................................................................... 31
6.16.3 PIN ASSIGNMENT .................................................................................................................. 32
6.16.4 PROTECTIVE COVERS OR CAPS ........................................................................................ 32
6.17 PROTECTION OF SEVERED ELECTRICAL CIRCUITS ....................................................... 32
6.18 WIRE TERMINATIONS ........................................................................................................... 32
6.18.1 SPLICES.................................................................................................................................. 33
6.18.2 DEAD-ENDING ....................................................................................................................... 33
6.19 INSULATION COMPATIBILITY WITH SEALING AND SERVICING ...................................... 34
6.20 IDENTIFICATION AND MARKING.......................................................................................... 34
6.20.1 WIRING DATA ......................................................................................................................... 34
6.20.2 IDENTIFICATION OF INDIVIDUAL CONDUCTORS .............................................................. 34
6.20.3 IDENTIFICATION OF HARNESSES ....................................................................................... 35
6.20.4 IDENTIFICATION OF CONNECTORS ................................................................................... 35
6.20.5 TEMPORARY IDENTIFICATION ............................................................................................ 35
6.20.6 CLAMP LOCATING MARKS ................................................................................................... 36

7. ASSEMBLY AND FABRICATION REQUIREMENTS ............................................................. 37

7.1 MOCKUP / FORM LAYOUT BOARD ...................................................................................... 37
7.2 WIRE LAY................................................................................................................................ 37
7.3 ETCHING FLUOROCARBON-INSULATED ELECTRICAL WIRE.......................................... 38
7.4 INTERIM STORAGE AND PROTECTION .............................................................................. 38
7.5 STORAGE AND TRANSPORTABILITY .................................................................................. 38
8. WORKMANSHIP ..................................................................................................................... 40
8.1 ELECTRICAL ACCEPTANCE TESTING ................................................................................ 40
8.2 ELECTRICAL TEST (POST INSTALLATION) ........................................................................ 40

9. DEFINITIONS AND ACRONYMS ........................................................................................... 41

9.1 DEFINITIONS .......................................................................................................................... 41
9.2 ACRONYMS AND ABBREVIATIONS ..................................................................................... 48

APPENDIX A - RED PLAGUE CONTROL PLAN ....................................................................................... 50

APPENDIX B - PROHIBITED MATERIALS ................................................................................................. 57

APPENDIX C - FOREIGN OBJECT DEBRIS (FOD) CONTROL ............................................................... 63

APPENDIX D - ELECTRICAL WIRE AND CABLE ACCEPTANCE TESTS .............................................. 65

1. PURPOSE
“Technical Requirements For Cable And Wiring Harnesses” is the design requirements companion to
IPC/WHMA-A-620A, “Requirements and Acceptance for Cable and Wire Harness Assemblies”, and
IPC/WHMA-A-620AS, “Space Applications Electronic Hardware Addendum to IPC/WHMA-A-620A”. With
the present transition from prescriptive ‘‘how to’’ specifications to performance-based standards, much of
the design requirements were removed from IPC/WHMA-A-620A and IPC/WHMA-A-620AS. The intent of
this document is to set forth the general design requirements for electrical wiring harnesses and cable
assemblies.
The target reader of this document is a design or manufacturing engineer, and is responsible for the
tailoring of specific requirements of this document to the applicable performance class.

1.1 SCOPE
This document is intended to provide design requirements and technical insight that has been removed
from the acceptance standards for cable and wire harness assemblies. Reference materials listed in this
text are among those considered as required reading. The design engineer is encouraged to obtain
materials referenced in this text, as this text is by no means a comprehensive coverage of design
considerations for all possible end item use application.

1.2 CLASSIFICATION
This document recognizes that electrical wiring harnesses and cable assemblies are subject to
classifications by intended end-item use. Three general end-product classes have been established to
reflect differences in producibility, complexity, functional performance requirements, and verification
(inspection/test) frequency. It should be recognized that there may be requirement overlaps between
classes.

The USER is responsible for defining the product class. The product class should be stated in the
procurement documentation package.

CLASS 1 General Electronic Products

Includes products suitable for applications where the major requirement is function of the completed
assembly.

CLASS 2 Dedicated Service Electronic Products

Includes products where continued performance and extended life is required, and for which
uninterrupted service is desired but not critical. Typically the end-use environment would not cause
failures.

CLASS 3 High Performance Electronic Products

Includes products where continued high performance or performance-on-demand is critical, equipment
downtime cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must
function when required, such as life support or other critical systems.

Though not officially recognized as a separate performance classification, a specialized classification for
spaceflight is levied by IPC/WHMA-A-620AS, “Space Applications Electronic Hardware Addendum to
IPC/WHMA-A-620A”. This classification includes products where continued high performance or
performance-on-demand is critical, equipment downtime cannot be tolerated, end-use environment may
be uncommonly harsh, and the equipment must survive the vibration and thermal cyclic environments
getting to and operating in spaceflight.

1.3 DEFINITION OF REQUIREMENTS

The phrase “shall [D1D2D3]” or “shall not [D1D2D3]” is used in the text of this document wherever
there is a requirement for materials, preparation, process control or acceptance of a soldered connection.
Where the phrase “shall [D1D2D3DS]” or “shall not [D1D2D3DS]” leads to a hardware defect for at
least one class, the requirements for each class are in brackets next to the shall [D1D2D3DS] / shall not
[D1D2D3DS] requirement.
N = No requirement has been established for this Class
A = Acceptable
P = Process Indicator
D = Defect

Examples:
[A1P2D3] is Acceptable Class 1, Process Indicator Class 2, and Defect Class 3
[N1D2D3] is Requirement Not Establish Class 1, and Defect Classes 2 and 3
[A1A2D3] is Acceptable Classes 1 and 2, and Defect Class 3
[D1D2D3] is Defect for all Classes
A defect for a Class 1 product means that the characteristic is also a defect for Class 2 and 3. A
defect for a Class 2 product means that the characteristic is also a defect for a Class 3 product, but
may not be a defect for a Class 1 product where less demanding criteria may apply.

The word ‘‘should’’ reflects recommendations and is used to reflect general industry practices and
procedures for guidance only.

Line drawings and illustrations are depicted herein to assist in the interpretation of the written
requirements of this standard.

The written requirement always takes precedence over the drawings and illustrations.

1.3.1 HARDWARE DEFECTS AND PROCESS INDICATORS

When the word “shall” is used it expresses a requirement that is mandatory. Hardware characteristics or
conditions that do not conform to the requirements of this specification that are detectable by inspection
or analysis shall [D1D2D3] be classified as hardware defects. Hardware defects shall [D1D2D3] be
identified, documented and dispositioned, e.g., rework, scrap, use-as-is, or repair.

It is the responsibility of the USER to define additional or unique defect categories applicable to the
product. It is the responsibility of the SUPPLIER to identify defects that are unique to the assembly
process.

1.3.2 MATERIAL AND PROCESS NONCONFORMANCE

Hardware found to be produced using either materials or processes that do not conform to the
requirements of this standard shall [D1D2D3] be dispositioned when the condition is a defect. This
disposition shall [D1D2D3] address the potential effect of the nonconformance on functional capability of
the hardware such as reliability and design life (longevity).

Note: Material and process nonconformance differs from hardware defects or hardware process
indicators in that the material/process nonconformance often does not result in an obvious change in the
hardware’s appearance but can impact the hardware’s performance; e.g., contaminated solder, incorrect
solder alloy (per drawing/procedure).
1.4 MEASUREMENT UNITS AND APPLICATIONS
All dimensions and tolerances, as well as other forms of measurement (temperature, weight, etc.) in this
standard are expressed in SI (System International) units (with Imperial English equivalent dimensions
provided in brackets). Dimensions and tolerances use millimeters as the main form of dimensional
expression; micrometers are used when the precision required makes millimeters too cumbersome.
Celsius is used to express temperature. Weight is expressed in grams.

1.4.1 VERIFICATION OF DIMENSIONS

Actual measurement of specific part mounting and solder fillet dimensions and determination of
percentages are not required except for referee purposes. For the purposes of determining conformance
to this specification, all specified limits in this standard are absolute limits as defined in ASTM E29.

1.5 ENGINEERING DOCUMENTATION

The design engineer is responsible for ensuring that all applicable design details are clearly and
completely depicted on the engineering documentation (drawings). The USER (customer) has the
responsibility to specify acceptance criteria.

1.6 ORDER OF PRECEDENCE

The contract always takes precedence over this document, referenced standards and drawings.

1.6.1 CONFLICT
a. In the event of conflict between the requirements of this document and the approved assembly
drawing(s)/documentation, the USER approved assembly drawing(s) / documentation shall
[D1D2D3] govern.
b. In the event of a conflict between the text of this document and the applicable documents cited
herein, the text of this document shall [D1D2D3] take precedence.
c. In the event of conflict between the requirements of this document and an assembly drawing(s)/
documentation that has not been USER approved, this document shall [D1D2D3] govern.
d. If no criteria is specified, required, or cited, criteria shall [D1D2D3] be established and agreed upon
between the Manufacturer and USER.

1.6.2 CLAUSE REFERENCES

When a clause in this document is referenced, its subordinate clauses shall [D1D2D3] also apply.

1.6.3 APPENDICES
Appendices to this document shall [D1D2D3] be binding, unless separately and specifically excluded by
the applicable contract, approved drawing(s), or purchase order.

1.7 APPROVAL OF DEPARTURES FROM STANDARDS AND REQUIREMENTS

Special requirements may exist which are not covered by, or do not comply with, the visual examples
depicted in this handbook, and which are in conflict with program-specific documents, and/or the
program-specified workmanship requirements. Engineering documentation shall [D1D2D3] contain the
details for such instances, and shall [D1D2D3] take precedence over appropriate sections of this
handbook and the applicable requirements document(s).

1.8 MODIFICATION, REWORK AND REPAIR

The modification, rework, and repair of high reliability electronics demands the highest level of technician
skill and attention to detail, and shall [D1D2D3] only be conducted by trained and certified operators.
The goal of all rework, repair, or modification activity is to correct, restore, or change functionality in a
manner that closely approximates the original “designed” condition.

1.8.1 MODIFICATION
Modification changes the functional capability of the affected hardware. Modifications require written
approval from USER and shall [D1D2D3] be fully detailed in the engineering documentation. The
modification of a cable or wire harness assembly shall [D1D2D3] be limited to the revision / rerouting of
circuit interconnections by the interrupting of conductors, the addition and deletion of conductors,
correction of pin-out errors, correction of keying errors, addition of staking, and the addition or deletion of
components in the cable or wire harness assembly (i.e.: a connector, addition / removal of contacts, etc.).
The maximum number of modifications shall not [D1D2D3] exceed six (6) per electrical wiring harness or
cable assembly.

1.8.2 REWORK
Rework corrects minor assembly and workmanship non-conformances to bring the affected hardware into
conformance to the engineering documentation / drawing. Though rework is usually permissible without
Material Review Board (MRB) involvement, or notification and approval from the USER, it is
recommended that all rework be documented to provide an opportunity for development of corrective
action to reduce future rework and production costs.

All rework shall [D1D2D3] meet the workmanship requirements of the applicable design specifications.

1.8.3 REPAIR
Repair restores the functional capability of the affected hardware. However, depending on the severity of
the damage, the repair may (or may not) return the affected hardware to full conformance to the
engineering documentation / drawing. Repairs are only permitted following review and disposition by a
Material Review Board (MRB), and authorization to repair shall [D1D2D3] require approval from the
USER prior to the start of actual repair procedures.

Solder Thermal Cycles. The maximum number of solder repairs to any one joint shall not [D1D2D3]
exceed three (3) complete cycles (desolder and resolder).
The maximum number of repairs shall not [D1D2D3] exceed three (3) per electrical wiring harness or
cable assembly.
2. APPLICABLE DOCUMENTS
The following documents form a part of this standard to the extent specified herein.

2.1 SPECIFICATIONS
Aerospace
AIR1329B ........................... Compatibility of Electrical Connectors and Wiring
AIR4487A .......................... Investigation of Silver Plated Conductor Corrosion (Red Plague)
AIR4789B .......................... Evaluating Corrosion Testing of Electrical Connectors and Accessories for
the Purpose of Qualification
AIR5468B .......................... Ultraviolet (UV) Lasers for Aerospace Wire Marking
AIR5558 ............................ Ultraviolet (UV) Laser Marking Performance of Aerospace Wire
Constructions
AIR5575 ............................. Hot Stamp Wire Marking Concerns for Aerospace Vehicle Applications
AIR5717 ............................ Mitigating Wire Insulation Damage During Processing and Handling
AMS2491D ........................ Surface Treatment of Polytetrafluoroethylene, Preparation for Bonding
AS4373E ........................... Test Methods for Insulated Electric Wire
AS5382 .............................. Aerospace Cable, Fiber Optic
AS5649 .............................. Wire and Cable Marking Process, UV Laser
AS7928B ........................... Terminals, Lug: Splices, Conductor: Crimp Style, Copper, General
Specification For
AS22759.............................. Wire, Electric, Fluoropolymer-Insulated Copper or Copper Alloy (/11, /89B,
/90B, 91B, /92B)
AS83519B ......................... Shield Termination, Solder Style, Insulated, Heat-Shrinkable, Environment
Resistant, General Specification For (/1, /2)
AS9100C ........................... Quality Management Systems - Requirements for Aviation, Space and
Defense Organizations

Commercial
A-A-52083C ...................... Commercial Item Description, Tape, Lacing and Tying, Glass
A-A-59569B ....................... Commercial Item Description, Braid, Wire (Copper, Tin-Coated, Silver-
Coated, or Nickel Coated, Tubular or Flat)
IPC/WHMA-A-620AS ........ Space Applications Electronic Hardware Addendum to IPC/WHMA-A-620A
J-STD-001ES .................... Space Applications Electronic Hardware Addendum to IPC J-STD-001E
Requirements for Soldered Electrical and Electronic Assemblies
J-STD-004A ...................... Requirements for Soldering Fluxes
J-STD-006B ...................... Requirements for Electronic Grade Solder Alloys and Fluxed and Non-
Fluxed Solid Solders for Electronic Soldering Applications
ANSI/NEMA WC 27500 .... Standard for Aerospace and Industrial Electrical Cable
ASTM B-174 ...................... Bunch Strand
ASTM B 8 .......................... Concentric Strand
ASTM B 172-01a ............... Standard Specification for Rope-Lay-Stranded Copper Conductors Having
Bunch- Stranded Members, for Electrical Conductors
ASTM B 173-01a ............... Standard Specification for Rope-Lay-Stranded Copper Conductors Having
Concentric-Stranded Members, for Electrical Conductors
ASTM B 263-04 ................. Standard Test Method for Determination of Cross-Sectional Area of
Stranded Conductors
ASTM B 738-03 ................. Standard Specification for Fine-Wire Bunch-Stranded and Rope-Lay
Bunch-Stranded Copper Conductors for Use as Electrical Conductors

Federal
NASA PUBLICATION 1124 Outgassing Data for Selecting Spacecraft Materials
(http://outgassing.nasa.gov)
NASA-STD-6001 ............... Flammability, Odor, Offgassing, and Compatibility Requirements and Test
Procedures for Materials in Environments That Support Combustion
QQ-B-575 ........................... Braid, Wire Copper, Tin-Coated Tubular

Military
MIL-A-46146B ................... Adhesives-Sealants, Silicone, RTV, Noncorrosive (For Use With Sensitive
Metals and Equipment)
MIL-C-17G .......................... Cables, Radio-Frequency, Coaxial, Dual Coaxial, Twin Conductor, and
Twin Lead
MIL-C-27500 ....................... Cable, Electrical Shielded and Unshielded, Aerospace
MIL-C-39012 ....................... Connector, Coaxial, Radio-Frequency, General Specification for
MIL-DTL-17 ....................... Detail Specification, Cables, Radio Frequency, Flexible And Semi-rigid.
General Specification For
MIL-I-631D ........................ Insulation, Electrical, Synthetic-Resin Composition, Non-Rigid
MIL-I-22129 ......................... Insulation Tubing, Electrical, Polytetrafluorethylene (PTFE) Resin, Non-
Rigid
MIL-I-23053 ......................... Insulation Sleeving, Electrical, Heat Shrinkable, General Specification for
MIL-STD-202G .................. Test Method Standard, Electronic and Electrical Component Parts (Method
107, Test Condition B)
MIL-T-43435 ........................ Tape, Impregnated, Lacing, and Tying
MIL-W-22759 ...................... Wire, Electric, Fluoropolymer-Insulated Copper or Copper Alloy
3. DESIGN PHILOSOPHY
Cables and wiring harnesses are equivalent to the
human circulatory and nervous system. They deliver
energy, transmit command and control instructions,
and collect and distribute sensory data describing not
only the environment external to the system, but the
health and status of the system itself.

Often the most overlooked, ignored, and “taken for

granted” component in a design, high quality cables
and wiring harnesses are essential to the
performance and reliability of any electrical / Fig. 3.1
Wire, Cables, and Harnesses
electronic hardware.

It is the SUPPLIER’s responsibility to ensure that the

technical issues associated with the design and manufacture of cable assemblies and wiring harnesses
are conveyed to the USER, and that a dialogue is established, so that appropriate and timely decisions
are made commensurate with realistic expectations and reality. After all, it doesn’t matter how elegant or
innovative the design is if the cable assembly or wiring harness cannot be built, doesn’t fit, or won’t
perform as required during use.

3.1 GENERAL DESIGN CONSIDERATIONS

The basic design considerations to assure reliable interconnecting cable and wire assemblies include, but
are not limited to:
a. The physical and electrical properties of the wire and cable, including gauge/size; base metal;
coatings; strand count and construction; weight; tensile strength; current and voltage derating; etc.
b. The physical and electrical properties of the cable and harness assembly, including active and spare
wire count; connectors; EMI / RFI / magnetic shielding; ionizing / non-ionizing radiation; construction
(coaxial, discrete wire, hybrid, multi-conductor; optical fiber); redundancy; voltage drop; identification /
marking; etc.
c. Material properties, including arc tracking resistance; chemical / material compatibility; flammability;
odor, outgassing; low-pressure / vacuum stability; ultra-violet stability; resistance / reactance to
corrosives, solvents, oxidizers, chemicals, etc.; resistance to heat / cold; resistance to abrasion
damage and cold flow; etc.
d. Application issues, including acoustic, mechanical, thermal shock; acceleration (g-load); environment
(condensing / corrosive / explosive atmosphere), electric field density (high voltage / lightning)
e. Non-metallic components - insulation jackets, potting materials, lacing tapes, braid sleeving, plastic
straps, wrap sleeving, and plastic tubing
f. Special handling, storage, and processing requirements that may contribute to degradation of
performance and/or reliability of hardware in service (i.e.: Red Plague / White Plague control)
g. Foreign Object Debris (FOD)
h. Unique testing requirements
4. GENERAL DESIGN REQUIREMENTS
The design of electrical wiring harnesses and cable assemblies shall [D1D2D3] be based on the worst-
case operational requirements and expected use. These include, but are not limited to: assembly
processes; shipping and storage; installation; test; service environment (operational temperature limits,
mechanical, thermal, and vibration stress; contamination; corrosives; EMC/EMI/RFI, ionizing / non-
ionizing radiation, moisture or other fluid media exposure); post-use test and data recovery; and, life
expectancy.

Conditions that contribute to degradation of performance and/or reliability of hardware in service shall
[D1D2D3] require special consideration.

4.1 SELECTION OF PARTS, MATERIALS AND PROCESSES

Parts, materials, and processes covered by documents listed herein are classified as “standard” and
shall [D1D2D3] be used whenever they are suitable for the purpose. Unless otherwise specified in the
contract, the parts, materials, and processes shall [D1D2D3]:
a. Comply with the approved Materials and Processes Plan / Requirements
b. Be selected based on the worst-case operational requirements and the design engineering properties
of the candidate materials. Conditions that contribute to the deterioration of hardware in service shall
[D1D2D3] receive special consideration.
c. Be controlled in accordance with the SUPPLIER’s established and documented procedures
d. Satisfy the specified performance and reliability requirements of the design.
e. Be procured from qualified manufacturers and QPL sources as much as possible. A Certificate of
Conformance should be requested for delivery with the order.

The selection and control procedures shall [D1D2D3] emphasize quality and reliability to meet the
mission requirements and to minimize total life-cycle costs. An additional objective in the selection of
parts, materials, and processes shall [D1D2D3] be to maximize commonality and thereby minimize the
variety of parts, related tools, and test equipment required in the fabrication, installation, and maintenance
of the hardware.

Whenever a selected specification provides more than one (1) characteristic or tolerance for an item, the
SUPPLIER shall [D1D2D3] use items of broadest characteristics in the equipment and of the greatest
allowable tolerances that will fulfill the performance and reliability requirements of the design. When
acceptable items of higher than minimum quality are readily available, the utilization of which would not
increase the life cycle costs, may be used. When maximum physical dimensions of an item are indicated
in the selected specification for the item, all new equipment shall [D1D2D3] be designed to
accommodate the maximum physical size specified, so that all parts having the same type designation
will be physically interchangeable in the hardware.

4.1.1 PROCUREMENT - WIRE & CABLE

Wire and cable shall [D1D2D3] be procured to military specifications from qualified manufacturers and
QPL sources as much as possible. A Certificate of Conformance should be requested for delivery with
the order. Each cable / wire spool shall [D1D2D3] be permanently and legibly identified with
manufacturer’s cage code or manufacturer’s name, military part number, length, size (AWG) and lot or
date code of manufacture that can be used for traceability and age control.
4.1.2 MATERIALS AND PROCESSES

4.1.2.1 FLAMMABILITY
Insulation materials shall [D1D2D3] be non-combustible or self extinguishing. Selection and use shall
[D1D2D3] be traceable to acceptable flammability test reports. When no test report exists, flammability
testing shall [D1D2D3] be performed using the procedure of NASA-STD-6001, previously NHB 8060.1C
(Flammability, Odor, Offgassing, and Compatibility Requirements and Test Procedures for Materials in
Environments that Support Combustion), or as otherwise specified by the USER.

4.1.2.2 OUTGASSING
Nonmetallic materials shall not [D1D2D3] exceed 1% Total Mass Loss (TLM) or 0.1% Collected Volatile
Condensable Material (CVCM), when tested in accordance with ASTM-E595 (Test Method, Outgassing).

4.1.2.3 FOREIGN OBJECT DEBRIS (FOD)

A Foreign Object Debris (FOD) prevention program shall [D1D2D3] be established for the design,
development, manufacturing, assembly, repair, processing, testing, maintenance, operation, and check
out to prevent immediate and latent damage and to ensure the highest practical level of cleanliness.

Cleanliness shall [D1D2D3] be an ongoing effort. Practices shall [D1D2D3] include assembly in a clean
environment and the use of protective plastic sheeting or other coverings over cables and harness
assemblies not undergoing active assembly.

Interconnecting cable and harness assemblies shall [D1D2D3] be clean and free of contamination prior
to installation.

4.1.2.4 TIME-CRITICAL OR LIMITED-LIFE

Cables, harness assemblies, and hardware which are time-critical and/or cycle-critical or which have
limited storage life shall [D1D2D3] be subject to the following controls:
a. Each time-critical or limited-life assembly, subassembly, component, and spare shall [D1D2D3] be
clearly and indelibly marked with a serial number.
b. Appropriate documentation shall [D1D2D3] accompany all time-critical and limited-life items and
shall include the date of manufacture of the item and of its most time-critical component. Realistic life
limits shall [D1D2D3] be assigned and documented for each item and shall [D1D2D3] be suitably
altered as new data and new evidence are obtained.
c. Status records shall [D1D2D3] be maintained on all such items after installation.
d. Operating-time logs shall [D1D2D3] be maintained for all items having limited operating lives.
e. Components shall [D1D2D3] have sufficient life remaining to adequately support mission
requirements.
f. Special storage requirements shall [D1D2D3] be carefully defined and strictly observed.
g. A time-age-life cycle database shall [D1D2D3] be maintained for verification (and notification) of
time-age-life component status.

4.1.2.5 RESTRICTED MATERIALS / PROCESSES

All materials used in electrical connectors, cables, and wiring harness assemblies shall [D1D2D3] be
compatible with each other and have acceptable life. For a list of prohibited materials, see Appendix B.
4.1.2.5.1 FLUORINE ATTACK (WHITE PLAGUE)
To reduce the risk of fluorine attack (White Plague), when fluoropolymer-insulated silver-coated copper
wiring is either stored in sealed packaging (e.g.: vapor-proof bagging, MBB) or used in enclosed
environments / compartments, the fluorine evolution rate shall not [N1D2D3] exceed 20 PPM when
tested in accordance with SAE AS4373E Method 608, Fluoride Offgassing. Bulk wiring and harness
assemblies exhibiting fluorine attack shall [N1D2D3] be rejected.

4.1.2.5.2 CRIMPING OF SOLDER-TINNED AND SOLID CONDUCTORS

Stranded wire shall [D1D2D3] be used for crimping. Crimping of solid wire, or solder-tinned stranded
wire, is prohibited [D1D2D3].

4.1.2.5.3 PYROTECHNIC CIRCUITS - WIRE SPLICING

Splicing of wiring in pyrotechnic circuits is prohibited [D1D2D3] on both hardware firing circuits and
ground test firing circuits.
5. ELECTRICAL CHARACTERISTICS

5.1 CIRCUIT CATEGORIES

The electrical characteristics required for interconnecting wiring are the first considerations to be
established in designing electrical wiring harness for space vehicles. In particular, the cable / wire type
required depends upon the voltage, current capacity, and frequency of the circuits. The five major
categories and the various subcategories of circuits are defined in the following subparagraphs and
summarized in Table 5.1. Each circuit in each wiring harness or cable assembly shall [D1D2D3] be
categorized in accordance with these definitions.

Table 5.1 Summary of Circuit Categories and Shielding Requirements

Signal Level
Circuit Character Category Shielding
Volts (V) or Amperes (A)

Shielded as a group from other

< 10 V and < 5 A IIIa
categories
Direct Current (DC) < 10 V and > 5A Ib None

≥ 10 V Ia None

Shielded as a group from other

< 5V RMS IIIc
categories
Alternating Current (AC)
< 0.1 MHz 5V to 25 V RMS IIc Each pair shielded

> 25 V RMS Ic None

< 1 V RMS IIIb Each pair shielded

Alternating Current (AC) 1 V to 10 V RMS IId Each pair shielded

0.1 MHz to 1 MHz
Coax or balanced shielded
> 10 V RMS Vc
cable

Alternating Current (AC) Wave guide, coax, or balanced

All Va
> 1 MHz shielded cable

< 5 V peak IIIe Each pair shielded

Pulse with rise or fall time
5V to 25V peak IIa Each pair shielded
> 1 microsecond
> 25V peak Id None

< 1 V peak IIId Each pair shielded

Pulse with rise or fall time
1 V to 10 V peak IIb Each pair shielded
< 1 microsecond
> 10 V peak Vb Coax or balanced shielded cable

Electro-explosive (EED)
Bridge Wire Activated All IV Each pair double-shielded
Device (BWAD)
5.1.1 CATEGORY I (POWER AND CONTROL)
Includes (a) DC circuits over 10V; (b) DC circuits below 10V and over 5 A; (c) AC circuits below 0.1 MHz
with voltages above 25 Vrms; and, (d) pulse circuits with maximum voltages above 25V with rise and fall
times greater than 1 microsecond.

5.1.2 CATEGORY II (HIGH LEVEL SIGNALS)

Includes (a) digital circuits with voltage levels from 5 to 25V maximum and rise and fall times greater than
1 microsecond; (b) digital circuits with maximum voltage levels from 1V to 10V and rise and fall times less
than 1 microsecond; (c) AC circuits below 0.1 MHz with voltages between 5V and 25V, and (d) AC circuits
between 0.1 MHz and 1.0 MHz with voltage levels between 1V to 10V and rise or fall times less than 1
microsecond; (c) AC circuits below 0.1 MHz with voltages between 5V and 25V; and, (d) AC circuits
between 0.1 MHz and 1.0 MHz with voltage levels between 1V and 10V.

5.1.3 CATEGORY III (LOW-LEVEL SIGNALS)

Includes (a) DC circuits below 10V and less than 5A; (b) AC circuits between 0.1 MHz and 1.0 MHz with
voltage levels less than 1V; (c) AC circuits below 0.1 MHz with voltages less than 5V; (d) digital circuits
with maximum voltages less than 1V with rise times less than 1 microsecond; and, (e) digital circuits with
maximum voltages less than 5V and rise and fall times greater than 1 microsecond.

5.1.4 CATEGORY IV (ELECTRO EXPLOSIVE DEVICE CIRCUITS)

Includes all electro explosive device (EED) circuits.

5.1.5 CATEGORY V (HIGH-FREQUENCY SIGNALS)

Includes (a) all AC circuits above 1 MHz; (b) high level digital circuits with maximum voltages above 10V
and with rise or fall times less than 1 microsecond; and, (c) AC circuits between 0.1 MHz and 1.0 MHz
with voltages levels above 10 V.

5.2 SHIELDING REQUIREMENTS

Shielding shall [D1D2D3] be provided as indicated in the following sub-paragraphs. All shielding shall
[D1D2D3] be insulated to prevent uncontrolled grounding / ground loops.

5.2.1 CATEGORY I CIRCUITS

Wiring for category I circuits shall [D1D2D3] have the power or signal wire(s) twisted with the return wire.
The wiring may be unshielded.

5.2.2 CATEGORY II CIRCUITS

Wiring for category II circuits shall [D1D2D3] have twisted signal and return wires with each pair, or
circuit, shielded.

5.2.3 CATEGORY III CIRCUITS

a. Wiring for category IIIa shall [D1D2D3] have twisted signal and return wires. Category IIIa wiring
shall [D1D2D3] be shielded as a group from category IIIb and other categories.
b. Wiring for category IIIb shall [D1D2D3] have twisted signal and return wires with each pair, or circuit,
shielded.
c. Wiring for category IIIc shall [D1D2D3] have twisted signal and return wires. Category IIIc wiring
shall [D1D2D3] be shielded as a group from category IIIa, IIIb, and other categories.
d. Wiring for category IIId and category IIIe shall [D1D2D3] have twisted signal and return wires with
each pair, or circuit, shielded.

5.2.4 CATEGORY IV CIRCUITS

Wiring shall [D1D2D3] be twisted pairs, each pair shielded. with multipoint grounding of shields at source
and load. The method of shield termination shall [D1D2D3] be via full-peripheral (360 degree)
termination at all connector backshells. Wiring for Electro-Explosive (EED) / Bridge Wire Activated
Device (BWAD) circuits shall [D1D2D3] be double-shielded.

5.2.5 CATEGORY V CIRCUITS

Wiring interconnections, other than waveguide, shall [D1D2D3] be shielded coaxial cable, balanced
shielded cable, or balanced cabled with a characteristic impedance of 100 ohms or less.

5.2.6 BOND CLASSIFICATION

Bond design shall [D1D2D3] prevent intentional electrical current from flowing in ground references
except under fault conditions. Cable and harness assemblies (which include the electrical wiring and
connectors, tie and protective materials and installation hardware) shall [D1D2D3] be designed and
routed such that adequate protection is afforded per applicable shielding and EMI/RFI/EMC criteria. See
Table 5.2.6.
a. Electrical bonds, particularly those intended to be semi-permanent or permanent, shall [D1D2D3] be
sealed to mitigate the intrusion of electrolyte or FOD into the interstitial space between the two
materials. Bonds which are intended to be opened and re-connected during planned or contingency
maintenance shall [D1D2D3] be designed to accommodate re-establishing an acceptable bond using
techniques and materials that are suitable for the application and the environment.
b. Harness shields external to the equipment, requiring grounding at the equipment, shall [D1D2D3]
have provisions for grounding the shields to the equipment chassis through the harness connector
backshell. Equipment or element internal secondary power supplies and signal and shield networks
may utilize those grounding techniques most appropriate for the application as long as the isolation
specified above is maintained.
c. Class L bonds shall not [D1D2D3] be terminated by solder process.

Notes:
1. Grounding is designed to ensure USER safety, proper operation of electrical fault avoidance /
detection systems, and electromagnetic interference reduction by establishing a minimum series
impedance path between the electrical equipment and the ground plane.
2. A ground is used to establish a zero signal reference for any equipment or other item required to be
grounded.

5.2.7 ADDITIONAL SHIELDING

Shielding can be added over that specified for the category of each circuit to prevent excessive radiation
from, or excessive pickup on, the circuit. Coax or balanced shielded cable may be used instead of
twisted shielded pairs, particularly in applications where the capacitance per meter is critical.

Shielding shall [D1D2D3] be added over that specified for the category of each to the extent required
when an electromagnetic pulse (EMP) environment is specified. Shielded circuits may be routed together
in a bundle with a common secondary (overbraid) shield.
 TABLE 5.2.6 BOND CLASSIFICATION

CLASS FUNCTION TYPICAL RESISTANCE (ohms)

≤ 2.5 milliohm* (2.5mΩ) at the frequencies ≤ 2.5 milliohm* (2.5mΩ) at the frequencies
of interest, Z=R+iωL of interest, Z=R+iωL
A • May be any low impedance value deemed • May be any low impedance value deemed
appropriate by engineering design for the appropriate by engineering design for the
particular application. particular application.

Max. Resistance = Max Voltage Drop / Max Max. Resistance = Max Voltage Drop / Max
Current Current
• Max. Voltage Drop: <3.5% (28V system, ≤ • Max. Voltage Drop: <3.5% (28V system, ≤
1V; 120V system, ≤ 4V) 1V; 120V system, ≤ 4V)
• Not allowed in most NASA programs to • Not allowed in most NASA programs to
C prevent structural damage / galvanic prevent structural damage / galvanic
corrosion to vehicle structure, unintentional corrosion to vehicle structure, unintentional
heating, electrical interference, potential heating, electrical interference, potential
shock hazards to crew. shock hazards to crew.
• Cable / harness shield shall not be used as • Cable / harness shield shall not be used as
the intentional power return path. the intentional power return path.

0.1 ohm max from exposed equipment 0.1 ohm max from exposed equipment
chassis or cable tray to structure chassis or cable tray to structure
H • The fault current return path through • The fault current return path through
structure: 500% overload current , 0.5s structure: 500% overload current , 0.5s
• Cable / harness shields • Cable / harness shields

≤ 2.5 milliohm (≤2.5mΩ) at 200,000 Amperes ≤ 2.5 milliohm (≤2.5mΩ) at 200,000 Amperes
• Design to route lightning across outer • Design to route lightning across outer
surface – not penetrate. surface – not penetrate.
L • Bond strap / conductor terminations shall • Bond strap / conductor terminations shall
not be soldered not be soldered
• Bond straps will withstand the magnetic • Bond straps will withstand the magnetic
forces from the current they conduct. forces from the current they conduct.

≤ 2.5 milliohm (2.5mΩ) at the frequencies of ≤ 2.5 milliohm (2.5mΩ) at the frequencies of
interest, Z=R+iωL interest, Z=R+iωL
R • Bond straps should be flat with length to • Bond straps should be flat with length to
width ratio less than 5:1 width ratio less than 5:1
• Covers wide frequency ranges. • Covers wide frequency ranges.

< 1 Ohm: Conducting Structural Items < 1 Ohm: Conducting Structural Items
(>100cm2) (>100cm2)
S • < 1000 Ohm: Conductive Mechanical • < 1000 Ohm: Conductive Mechanical
Subassemblies / Parts (>100cm2) Subassemblies / Parts (>100cm2)
• < 1000 Ohm: Non-metallic / Composite • < 1000 Ohm: Non-metallic / Composite
Structural Items Structural Items

5.3 SHIELD TERMINATION AND SHIELD GROUNDING

Shielding shall [D1D2D3] provide maximum EMI/RFI coverage in the intended application and
environment, with a minimum cover limit of 85 percent, or as specified by USER.
a. Multiple point shield grounding shall [D1D2D3] be used on high-frequency circuits (above 0.1 MHz),
on digital circuits with rise or fall times less than 1 microseconds, and on all EED firing circuits
(category IV).
b. Single and shield grounding shall [D1D2D3] be maintained on all other circuits, expect that when
multiple shields are used to prevent induced interference, the outer shield shall [D1D2D3] be
multipoint grounded.
c. When single and shield grounding is used to protect a circuit against induced radiation, the ground
shall [D1D2D3] be at the receiver or high impedance end.
d. When single and shield grounding is used to minimize radiation from a circuit, the ground shall
[D1D2D3] be at the signal source end.
e. Magnetic shielding shall [D1D2D3] be terminated to ground at the signal source end.
f. Shields for Class L bonds shall not [D1D2D3] be terminated by solder process.

5.3.1 METALLIC BRAID SHIELDING

Metal braid shielding shall [D1D2D3] either be woven directly over a core or obtained in prebraided form
and installed by sliding it over the wire bundle. Copper braid is the most effective RF shielding. Copper-
clad steel-core wire, woven into a flat braid, is also an effective shielding material. Nickel and nickel
coated copper should be considered for wiring subjected to high heat environments. A magnetic survey
shall [D1D2D3] be conducted if project requirements indicate a sensitivity to magnetic interference.
a. Prewoven metallic braid shall [D1D2D3] be cleaned in a suitable solvent to remove contamination,
and dried to ensure all solvent residue is removed, prior to installation over the harness. Aqueous
(water-based) solvents shall not [D1D2D3] be used, as this may promote Red Plague if the braid is
silver-coated copper.
b. Prewoven metallic braid tubing shall [D1D2D3] be tightened down to contact the wire bundle to
present a smooth continuous finish (i.e.: without lumps, puffed areas, kinks, etc.)
c. To prevent mechanical abrasion during installation and mitigate potential long-term damage (cold
flow) of the underlying wire insulation jackets, a separator layer (e.g., a tape wrap) shall [D1D2D3] be
applied over the wire bundle to give the wire continuous protection.
d. Metal braid shielding shall [D1D2D3] be mechanically and electrically terminated as specified by the
engineering documentation. All harness assembly external braid shields shall [D1D2D3] be covered
with an insulating cover (i.e.: fabric braid sleeving, shrink tubing, etc.). Exception: Harness
assemblies to be installed in high heat environments shall not [D1D2D3] be covered with an
insulation sleeving unless specified by drawing.

5.3.2 ELECTROMAGNETIC PULSE (EMP)

Wire shields in all categories shall [D1D2D3] be bonded around the circumference (360 degrees), and
preferably within the backshell of the connectors. Inner shields that are designed to be ungrounded at
one end shall [D1D2D3] be terminated within the connector shell and the ends secured against fraying.
Ungrounded inner shield terminations (floating shields) shall [D1D2D3] be insulated from the connector
pins, the backshell of the connector, and from adjacent shields.

5.3.3 CATEGORY IV CIRCUITS

Wire shields in category IV circuits (EEDS) shall [D1D2D3] be bonded around the circumference, and
preferably within the backshell of the connectors. Circuits such as pyrotechnic event instrumentation
circuits that make a direct connection to the electro explosive device circuit shall [D1D2D3] employ
shields which are bonded around the circumference (360 degrees), and preferably with the backshell at
the pyro junction or relay box connector. If an EMP environment is not specified, the shield ground at the
other instrumentation circuit connector may be grounded through a pigtail to a pin in the connector or
directly to the structure.
5.3.4 CATEGORY I, II, III, AND V CIRCUITS (NO EMP)
Wire shields in these categories of circuits that require grounding and are not subjected to an EMP
environment, shall [D1D2D3] be grounded to the vehicle structure by the shortest feasible route. The
length of the pigtail or connection wire between the shield and the ground shall [D1D2D3] be as short as
practicable, but shall not [D1D2D3] exceed 100 millimeters (mm) for harnesses containing less than 20
shielded wires. The length of unshielded, insulated wire that may show in back to the connector shell
shall [D1D2D3] be as short as practicable, but shall [D1D2D3] not exceed 20 mm. For these circuits, the
following methods of grounding the shields are acceptable, in order of preference:
a. On, and preferably within, the electrical connector to provide a low impedance path to structure when
joined to the mating connector.
b. By a pigtail to a pin in the electrical connector.
c. By a pigtail directly to structure.

5.3.5 UNGROUNDED / FLOATING SHIELD TERMINATIONS (NO EMP)

Wire shield terminations that are to be ungrounded, and are not subjected to an EMP environment, shall
[D1D2D3] be secured against fraying and insulated from the back shell of the connector and from
adjacent shields. Where practicable, the ungrounded end of the shield should be terminated by a pigtail to
a connector pin to facilitate making shield continuity and resistance measurements. The length of
unshielded, insulated wire that may show in back of the connector shell shall [D1D2D3] be as short as
practicable but shall not [D1D2D3] exceed 20 mm (in.).

5.3.6 MAGNETIC SHIELDS

Magnetic shields (i.e.: mu-metal) shall [D1D2D3] be electrically isolated from the EMI/RFI and over-braid
shields (if specified) by protective insulation overwrap / separator over the length of the cable / harness
assembly and mechanically and electrically connected to the chassis / structure, either (a) by pig-tail /
ground-lead to a chassis-mounted bonding post or (b) through the connector backshell at the source end
of the cable / harness assembly.

5.3.7 CIRCUIT ISOLATION

Interconnect wiring in each of the five categories shall [D1D2D3] be isolated from wiring in other
categories by maintaining, to the extent practicable, a minimum separation of 30 mm between wires and
wire bundles of the different categories. When wires from circuits in different categories use the same
connector, the pin assignments and layout shall [D1D2D3] stress isolation between different categories,
and grounded spare pins shall [D1D2D3] be fully utilized to provide such isolation.
a. Category IV circuits (electro-explosive devices) shall [D1D2D3] maintain a minimum distance of 30
mm from other category circuits and shall not [D1D2D3] share the same connector with other
category circuits.
b. High impedance circuits above 1000 ohms, or sensitive circuits, below 5 V, shall [D1D2D3] be
isolated by routing or shielding or both from other circuits even in the same category.
c. Antenna cables shall [D1D2D3] be separated from each other and from other wiring.
d. Where practicable, wiring to redundant subsystems or equipment shall [D1D2D3] be run in separate
harnesses or cable assemblies to prevent damage to one subsystem affecting the other.
e. Safety ground wire (if specified) shall [D1D2D3] be routed through the connector to the chassis /
structure.
f. EMI/RFI and over-braid shields (if specified) shall [D1D2D3] be mechanically and electrically
connected to the chassis / structure, either by pig-tail / ground-lead to chassis-mounted bonding post
or through the connector backshell(s).
g. EMI/RFI and over-braid shield circuits shall not [D1D2D3] be routed through connector contacts,
unless specifically specified by drawing.
h. Current shall not [D1D2D3] intentionally flow through the shield(s) or chassis / structure.

5.3.8 GROUP-GROUNDING OF INDIVIDUAL SHIELD TERMINATIONS

When grounding wires of individual cable shields are grounded to one point, they shall [D1D2D3] be
spliced to a common bond grounding wire.
a. No more than four (4) shield conductors plus one (1) common bond wire shall [D1D2D3] be
terminated in one splice.
b. The common bond wire shall [D1D2D3] be derated for the combined maximum short circuit / fault
current of the shielded circuits.
c. For ordinary RFI/EMI protection, the shield shall [D1D2D3] be terminated within 100mm (4 inches) of
the center conductor termination for the x-distance, and the combined length of shield grounding
wires shall not [D1D2D3] exceed 190mm (7.5 inches).
d. For interference sensitive circuits, the shield shall [D1D2D3] be terminated within 20 mm (0.75 in.) of
the center conductor termination, and the combined length of shield grounding wires shall not
[D1D2D3] exceed 115mm (4.5 in.). When this does not provide adequate isolation, RFI/EMI
connector backshells may be necessary.
6. DESIGN REQUIREMENTS
The design of electrical wiring harnesses and cable assemblies shall [D1D2D3] be based on the worst-
case operational requirements and expected use. These include, but are not limited to: assembly
processes; shipping and storage; installation; test; service environment (operational temperature limits,
mechanical, thermal, and vibration stress; contamination; corrosives; EMC/EMI/RFI, ionizing / non-
ionizing radiation, moisture or other fluid media exposure); post-use test and data recovery; and, life
expectancy.

Conditions that contribute to degradation of performance and/or reliability of hardware in service shall
[D1D2D3] require special consideration.

6.1 RELIABILITY
The reliability design requirements shall [D1D2D3] assure that the overall reliability requirements are met
under the most severe extremes of acceptance testing, storage, transportation, testing, and operational
environments.

6.2 INTERCHANGEABILITY
Any two (2) or more wiring harnesses or cable assemblies bearing the same part number shall [D1D2D3]
possess such functional and physical characteristics as to be equivalent in performance, durability, and
connectivity; and, shall [D1D2D3] be capable of being changed, one for another, without alteration of the
items themselves or of adjoining items.

6.3 SERVICE LIFE

Unless specified by USER, the service life of the wiring harnesses shall [D1D2D3] be specified as one
year in addition to the service life of the hardware / system for which it has been designed.

6.4 ERGONOMIC DESIGN

Hardware designed for use or deployment by humans shall [D1D2D3] be designed to work with the
human body in the intended environment and application.

6.5 CABLE / HARNESS LENGTH

Harness length shall [D1D2D3] provide enough additional wire length for reworking the entire connection
at least one (1) time. Conductors connecting contacts within the same connector shall [D1D2D3] extend
25-50 mm [1-2 in.] from the rear of the connector.

6.5.1 DATUM
Wire harness length and/or breakout length, shall [D1D2D3] be measured from the connector face at one
end of the wire harness (datum) to its final termination and/or breakout point. (i.e. connector face,
terminals, splice, etc.).

6.5.2 BREAKOUTS
Dimensions for breakouts shall [D1D2D3] be referenced from the approximate center-line of the harness
/ breakout.

6.5.3 TOLERANCE
Cable length measurement tolerance shall be as specified in IPC/WHMA-A-620A, Table 11-1 “Cable
Length Measurement Tolerance”, unless otherwise on the drawing / documentation. If the engineering
drawing has multiple dimensions called out between a connector and termination, breakout, or overall
length, the tolerances shall [D1D2D3] be considered noncumulative and will be applied to the sum of the
dimensions (entire length to the termination point), not each individual dimension.

For the purposes of form layout board layout only, the recommended acute angle of the breakouts from
the main body of the harness is 45 +/-15 degrees, unless shown otherwise on the drawing. For the
purposes of form board layout, breakouts that branch away from the main body of the harness do not
have to be routed straight but may be curved, provided the curves do not exceed the minimum bend
radius requirements.

6.6 ACCESSIBILITY FOR MAINTENANCE

Cable and wiring harness assemblies shall [D1D2D3] be designed with features that contribute to the
ease and rapidity of maintenance without removal of other equipment, interconnections, wire bundles,
and / or fluid lines. All wiring shall [D1D2D3] be accessible, repairable, and replaceable at the
maintenance level specified by the USER.
a. Access - Cable and wiring harness assemblies shall [D1D2D3] be designed with sufficient flexibility,
length, and protection to permit disconnection and reconnection without damage to wiring or
connectors.
b. Ease of Connect / Disconnect - Electrical connections and cable installations shall [D1D2D3] require
no more than one (1) turn to disconnect and reconnect without damage to wiring or connectors.
c. Hand Access - Electrical connections and cable installations shall [D1D2D3] be designed with
sufficient clearance so that they can be grasped firmly by hand (bare or gloved) for connecting and
disconnecting.
d. Adjacent Connectors or Obstructions - Space between a connector and any adjacent obstruction
shall [D1D2D3] be compatible with the size and shape of the plugs.
e. Single Rows - Connectors in a single row which require removal and replacement shall [D1D2D3]
be spaced a minimum of 25 mm (1 in.) apart (edge-to-edge) for bare hand access during alignment
and mating. A separation of 41 mm (1.6 in.) shall [D1D2D3] be required for gloved hand access and
is preferred for bare hand access.
f. Staggered Rows - Staggered rows of connectors shall [D1D2D3] be a minimum of 64 mm (2.5 in.)
apart (edge-to-edge) for bare-hand / gloved-hand access.
g. Test Points. Electrical systems and subsystems shall [D1D2D3] be designed to permit checkout
tests and shall [D1D2D3] include provisions (e.g., test points) that permit these checkout tests to be
conducted without disconnecting mated connectors. Test points shall [D1D2D3] allow checkout of
the system without loss of integrity (e.g., loss of signal, loss of continuity, etc.).
h. Tools - If a tool is to be used for mate / demate, the edge-to-edge clearance shall [D1D2D3] facilitate
initial access and alignment by hand (bare or gloved).

6.7 CABLE / HARNESS MANAGEMENT (ROUTING)

System reliability shall [D1D2D3] be a primary consideration in selecting the routing for wiring harnesses
or cable assemblies. Cables and harnesses should be routed along flat surfaces (either vertical or
horizontal) whenever possible, shall [D1D2D3] be properly supported and secured by cable clamps, and
shall not [D1D2D3] be routed near high electrical noise, heat, or vibration sources.
a. Where practicable, routing shall [D1D2D3] provide accessibility for easy removal and replacement of
attached equipment as well as the wire harness.
b. Routing through small structural openings shall [D1D2D3] be avoided where practicable to minimize
flexing and handling of the harness during installation.
c. Flat and ribbon cables shall not [D1D2D3] be routed so as to interfere with air ventilation flow
patterns.
d. To prevent possible damage from fumes and fluids, a 50 mm [1.97 in.] minimum clearance shall
[D1D2D3] be maintained, where practicable, between the harnesses and lines or equipment
containing oxygen, flammable liquids or gases, corrosive liquids or gases, or cryogenic liquids or
gases. The clearance between wires or cables and heat generating devices shall [D1D2D3] be such
as to avoid deterioration of wires or cable from the heat dissipated by the devices.
e. Cable and harness assemblies shall [N1D2D3] have slack lengths or maintenance loops sufficient
for the removal of the connectors after the component / hardware has been extracted from its
installed location / position, unless adequate internal access (physical and visual) is provided.
Additional slack shall [D1D2D3] be provided in the area of terminations to allow the replacement of
terminations three (3) times; however, excessive slack shall not [D1D2D3] be provided.
f. Wiring installations where relative movement occurs (such as at hinges, rotating pieces, vibration-
isolated hardware, etc.) shall [D1D2D3] be installed or protected in such manner as to prevent
deterioration of the wiring by the relative movement of the assembly parts. This deterioration includes
abrasion of one wire or cable upon another, cold flow, and excess twisting, bending, and pinching.
Cables and harnesses should be installed to twist instead of bend across hinges. Cables and
harness assemblies in the vicinity of equipment expected to be routinely serviced or replaced shall
[D1D2D3] be protected against damage caused by flexing, pulling, abrasion and other handling
stress.
g. Cables or wire harnesses crossing a moving or rotating interface shall not [D1D2D3] contain strain-
energy elements to assist deployment. Where cables or wire harnesses must cross a moving or
rotating interface, the installation drawings shall [D1D2D3] define dimensions including loop sizes
and distances to attachments. Attachment clamps shall [D1D2D3] be provided sufficiently close to
any loops so that movement into the path of motion of the moving mechanical assembly cannot occur
under any conditions.
h. Connectors shall [D1D2D3] be provided at each end of the loop where practicable to permit
assembly and disassembly without disturbing the harness configuration in the area of the interface.
i. Cable and harness assemblies shall [D1D2D3] be routed so that they:
(1) Cannot be pinched by doors, lids, or slides.
(2) Will not be used as a translation device (i.e.: a hand hold, step, anchor point, etc.).
(3) Will not be bent sharply when connected or disconnected.
(4) Are readily accessible for inspection and repair.
(5) Do not infringe into the operational envelope nor constitute a safety hazard (i.e.:, sagging,
hooking, etc.).
(6) Are not external to the face of the equipment rack.

6.8 BEND RADIUS

The bend radius for cables and harness assemblies shall not [D1D2D3] not be less than ten times (10X)
the outside diameter of the largest included wire or cable. At the point where wiring breaks out from a
group, harness or bundle, the minimum bend radius shall [D1D2D3] be ten times the diameter of the
largest Included wire or cable. If wires used as shield terminators or jumpers are required to reverse
direction in a harness, the minimum bend radius of the wire shall [D1D2D3] be three times (3X) the
diameter at the point of reversal providing the wire Is adequately protected.

6.8.1 MINIMUM BEND RADIUS

a. Coaxial cable. The minimum bend radius for coaxial radio frequency cable or harness assemblies
containing such cable shall not be less than six times the OD of the cable or harness.
b. Wire size larger than 10. The minimum bend radius for harness assemblies containing wire larger
than size 10 shall not be less than six times the OD of the harness.
c. Wire size 10 or smaller. The minimum bend radius for harness assemblies containing only wire size
10 or smaller shall not be less than 3 times the OD of the harness.

TABLE 6.8.1 Minimum Bend Radius Requirements

Cable Type

Coaxial Fixed Cable, Note 2 6X OD

Coaxial Flexible Cable, Note 3 10X OD

Shielded and Unshielded ≤10 AWG: 3X OD

Wires and Cables >10 AWG: 5X OD
Polyimide Insulated Wire 10X OD

Composite, (AS 2759/80-/92) 6X OD

Semi-rigid Coax Not less than Manufacturer’s stated minimum bend radius

Harness assembly Minimum bend radius of largest gauge individual wire/cable within the
harness.
Breakouts Minimum bend radius of largest gauge individual wire/cable within the
harness.
Note 1: OD is the outer diameter of the wire or cable, including insulation.
Note 2: Coaxial Fixed Cable: Coaxial cable that is secured to prevent movement; not expected to have the cable repeatedly
flexed during operation of the equipment.
Note 3: Coaxial Flexible Cable: Coaxial cable that is or may be flexed during operation of the equipment.

6.9 BREAKOUTS
The location of breakouts shall [D1D2D3] be specified on the design documentation.
a. Bend radius at breakout. Breakouts shall [D1D2D3] meet the bend radius requirements as specified
in Table 6.8.1.
b. Forming and Support. Breakouts shall [D1D2D3] be formed into a twisted or parallel lay bundle, and
secured with spot tie, plastic strap, or stitch lacing within two harness diameters (2d) immediately
following their emergence from the main bundle. and within 2 breakout harness diameters (2d) after
emergence from the trunk bundle.

6.10 PROTECTION AND SUPPORT

Installed wiring harnesses and cable assemblies shall [D1D2D3] be protected and supported in
accordance with SAE AS50881 paragraph 3.11, and the following:
a. Support devices specified by the engineering drawing (i.e.: cable clamps, etc.) shall [D1D2D3] hold
the wiring harnesses and cable assemblies in place without deforming or damaging the wire or cable
insulation, or without causing undue mechanical strain on the connections.
b. Main Bundle Support. The main bundle shall [D1D2D3] be secured within two harness diameters
(2d) of the emergence of the breakout from the main bundle, within two harness diameters (2d)
following the emergence of the breakout, and at intervals not to exceed 24 inches.
c. Breakout Support. Breakouts shall [D1D2D3] be long enough to provide proper support at
installation. Breakouts shall [D1D2D3] be secured by connector backshells or clamps as close to the
connector as practical but shall not [D1D2D3] violate stress relief.

6.11 FORMING WIRES INTO CABLES AND HARNESSES

Wiring shall [D1D2D3] be assembled into interconnecting cables or harnesses using fabrication methods
and assembly techniques that assure the production of high quality interconnecting cables and
harnesses. Wiring terminated in connectors shall [D1D2D3] have the first tie located such that the wires
are not stressed and do not distort the resilient wire sealing grommet of the connector (if installed).
Spacing dimensions for spot tie, plastic strap, and stitch lacing for trunk, branches, and breakouts shall
[D1D2D3] comply with Table 6.11, and the following:
a. Ties shall [D1D2D3] be spaced at intervals required to maintain bundle configuration.
b. Spot ties shall [D1D2D3] consist of a clove hitch followed by a surgeon’s square knot or other non-
slip knot.
c. Spot tie ends shall [D1D2D3] be trimmed.
d. When knots are staked, the necessary compounds, as well as any special design requirements, shall
[D1D2D3] be specified on the engineering documentation.

Minimum bend radius of any individual wire/cable within the

TABLE 6.11
harness.Spacing Dimensions
Distance From Back Edge of Connector
Harness Diameter Maximum Distance Between Harness
or Connector Accessory to Start of First
mm (inches) Ties mm (Inches)
Tie mm (inches)

6.4 (0.25) or less 19.1 (0.75)

25.4 - 50.8 (1 - 2)
6.4 (0.25) - 12.7 (.5) 38.1 (1.50)

12.7 - 25.4 (.5 to 1) 50.8 - 76.2 (2 - 3) 50.8 (2.00)

25.4 (1) or larger 76.2 - 101.6 (3 - 4) 76.2 (3.00)

6.12 SEPARATION OF REDUNDANT SYSTEMS

In cases where wiring redundancy is a requirement, separate cable bundles shall [D1D2D3] be formed.
Exclusion: This requirement is not applicable to cable and wiring harness assemblies mounted in
common housings within a redundant system, sub-system, or sub-system element.
a. Cable and wiring harness assemblies of redundant systems, redundant sub-systems, or redundant
major elements of sub-systems, having different circuit classifications or redundancy codes and
routed in the same area, shall not [D1D2D3] be commonly bundled or routed in the same wire
bundle, but may be routed through a common connector if a 20 dB coupling margin is maintained.
b. Verification. Cable and wiring harness assemblies shall [D1D2D3] be designed to permit verification
of redundant functions or operational modes any time the system, subsystem, or equipment requires
testing prior to use.
c. Coding. Each bundle shall [D1D2D3] be coded with a bundle code which is the same as the circuit
classification of the circuits which it contains.
d. Classification. Each bundle classification shall [D1D2D3] be designated on drawings in which the
bundle appears. Such bundles shall [D1D2D3] be coded with the circuit classification code, plus a
numeric designator code to identify the redundancy classification.

6.13 CORONA SUPPRESSION

Installed cable and wiring harness assemblies susceptible to corona as dictated by the Paschen Curve
shall [D1D2D3] be designed such that detrimental corona discharge will not occur under any operating
conditions. Test(s) or analysis shall [D1D2D3] be performed to demonstrate that the cable and wiring
harness assemblies will remain protected for the intended length of the mission.
Note: For purposes of this standard, the term "corona" is defined as an electrical discharge caused by
ionization of gas in the vicinity of an energized conductor. Ionization can occur on the surface of an
insulated or uninsulated conductor, as well as in voids and cracks within the insulation jacket.

6.14 ELECTRICAL DESIGN

The electrical design shall [D1D2D3] provide a two-wire power distribution system in which one wire
serves as a return path for load currents.
a. Safety ground wire (if specified) shall [D1D2D3] be routed through the connector to the chassis /
structure.
b. EMI/RFI and over-braid shields (if specified) shall [D1D2D3] be mechanically and electrically
connected to the chassis / structure, either by pig-tail / ground-lead to chassis-mounted bonding post
or through the connector backshell(s).
c. EMI/RFI and over-braid shield circuits shall not [D1D2D3] be routed through connector contacts,
unless specifically specified by drawing.
d. Magnetic shields (i.e.: mu-metal) shall [D1D2D3] be electrically isolated from the EMI/RFI and over-
braid shields (if specified) by protective insulation overwrap / separator over the length of the cable /
harness assembly and mechanically and electrically connected to the chassis / structure, either (a) by
pig-tail / ground-lead to a chassis-mounted bonding post or (b) through the connector backshell at the
source end of the cable / harness assembly ONLY.
e. Current shall not [D1D2D3] intentionally flow through the shield(s) or chassis / structure.

6.15 WIRE AND CABLE

Interconnecting wire, cable conductors, and shield braid shall [D1D2D3] be high conductive, stranded
copper, copper alloy, silver-coated copper, or silver-coated copper alloy. The size of individual wires
shall [D1D2D3] be a minimum of 22 AWG. Exceptions include power harnesses where the size of
individual wires shall [D1D2D3] be a minimum of 18 AWG, and thermistor wiring where wire sizes
smaller that 24 AWG may be considered for use. Wire size 24 AWG and smaller shall [D1D2D3] be high
strength copper alloy (HSC), for adequate termination strength and flex life. HSC wire should be
checked for magnetic cleanliness. A magnetic survey shall [D1D2D3] be conducted if project
requirements indicate a design or system sensitivity to magnetic interference.
a. Silver-Coated Copper. Silver-coated copper, or silver-coated copper alloy should be considered for
wiring carrying higher frequency circuits, and may be terminated by solder or crimp processes. Due
to potential fire hazard, silver-coated conductors shall not [D1D2D3] be used in areas where they
are subject to contamination by ethylene glycol solutions. Use of silver-coated copper or silver-
coated copper alloy shall [D1D2D3] require use of a Red Plague Control Plan (RPCP). See
Appendix A.
b. Aluminum. The use of aluminum wire (including copper-clad variants) shall [D1D2D3] require prior
USER approval. Aluminum wire shall [D1D2D3] be terminated only by terminations specifically
approved for this application.
c. Nickel / Nickel-Coated Copper. Nickel and nickel-coated copper should be considered for use in low
frequency circuits (i.e.: dc and ac power circuits), corrosive, and high heat applications, and should be
terminated by crimp processes.
d. Solid conductors. The use of solid conductor in wiring harness design shall [D1D2D3] require prior
USER approval.
e. Selection of wire and cable shall [D1D2D3] take into account all requirements of this specification
and the following design considerations:
 conductor material and coating
 strand count and construction
 circuit characteristics (nominal and maximum voltage, allowable voltage drop, steady-state and
intermittent current load, derating, frequency)
 temperature (operational and storage)
 mechanical (tensile strength, vibration, flexure, etc.)
 insulation (dielectric rating, abrasion / cold-flow / cut-through resistance, arc-tracking resistance,
flammability / smoke rating, outgassing, ionizing / non-ionizing radiation resistance, etc.)
 shielding (EMI / RFI, EMP, magnetic)
 pressure / partial-pressure / vacuum requirements
 aging effects
 extreme environments (corrosive, Severe Wind and Moisture Problem - SWAMP areas, fluid /
moisture contact / submersion, etc.)

Exceptions:
1. Power harnesses where the size of individual wires shall [D1D2D3] be a minimum of 18 AWG.
2. Thermistor wiring where wire sizes smaller that 24 AWG may be considered for use.

6.15.1 DERATING
Wire and cable shall [D1D2D3] be of a type suitable for the intended application, and shall [D1D2D3] be
selected so that the rated maximum conductor temperature is not exceeded for any combination of
electrical loading, ambient temperature, and heating effects of bundles, conduit and other enclosures.

Degradation of conductors when exposed to environmental conditions and/or continuous operation at

temperatures beyond their upper continuous rating shall [D1D2D3] be taken into account in the selection
and application of wiring and cable.
a. The selection of wire size shall [D1D2D3] be based upon circuit current and cable size in accordance
with the derating requirements of SAE AS50881 paragraph 3.8.8.1, thermal math model, or USER
specification.
b. Electrical Wire Current Carrying Capacity. Wires shall [D1D2D3] be of such cross section as to
provide ample and safe current carrying capacity. The maximum design current in any wire shall
[D1D2D3] be limited so that "wire total temperature" will never exceed the rated wire temperature.
"Wire Total Temperature" is defined as maximum ambient temperature plus temperature rise.
c. Voltage Drop. The total impedance of wires and ground return paths shall [D1D2D3] be such that the
maximum voltage drop between the power supply bus and the load does not exceed the limits under
maximum continuous load conditions.
Note: Published wire temperature ratings are short term ratings. Operating wire in excess of 50 percent
of rated temperature requires engineering evaluation.

6.15.2 PROCUREMENT AND ACCEPTANCE TEST

Electrical wire and cable, including wiring used within electrical / electronic assemblies ("black boxes")
shall (N1D2D3) be procured and acceptance tested to the appropriate cable specifications listed below:
a. Cable specification: ANSI/NEMA WC27500-2012, “Standard for Aerospace and Industrial Electrical
Cable”
b. Cable specification: MIL-DTL-17H, “Cables, Radio Frequency, Flexible And Semi-rigid, General
Specification For”
c. Wire specification: AS22759B, “Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy”
d. Thermocouple applications: MIL-DTL-5846D, “Detail Specification Chromel and Alumel
Thermocouple Electric Wire”
e. Other wire procurement specifications authorized by the USER.
f. Wire and cable shall (N1D2D3) also comply with applicable Materials and Process (M&P)
requirements.

If the wiring used in any application is unknown, as it may be in the case of off-the-shelf equipment, pig-
tailed components, heater strips, etc. and if the application is non-critical, the assembly is required only to
meet applicable program materials and process requirements.

Two methods for certifying wire are:

a. As required by the procurement specification, Government Source Inspection (GSI) shall certify that
the tests specified in Appendix xxx been performed by the wire manufacturer on the length of wire
procured. In addition to meeting the requirements of the appropriate procurement specification, each
shipment shall be accompanied by the manufacturer’s test report.
b. Wire certification can also be performed by a USER-approved test facility.

6.16 CONNECTORS
Connectors used in the fabrication of wire harnesses and cable assemblies shall [D1D2D3] be suitable
for the application. Connectors shall [D1D2D3] be specifically designed and approved for mating and
demating in the existing environment under the loads being carried, or connectors must not be mated or
demated until voltages have been removed (dead-faced) from the powered side(s) of the connectors.
a. Wire harness connectors shall [D1D2D3] be of the rear insertable / removable crimp contact and
quick disconnect type, where feasible.
b. Connector Pins/Sockets. The powered side of a connector pair shall [D1D2D3] be terminated in
sockets rather than pins and shall [D1D2D3] have a grounded backshell.
c. When mating/demating recessed / blind connectors (e.g., connectors that will be hidden from sight
during mate/demate), the connector design shall [D1D2D3] be scoop-proof and maintain grounding
during mating/demating.
d. Designs that are reconfigured such that their fault bond circuit is disturbed during mate/demate
operations, shall [D1D2D3] require either redundant fault bonds to grounded structure or a post-
installation test to verify a good fault bond has been established prior to power activation.
e. Connectors to be used in an EMP or high-level RF environment shall [D1D2D3] be capable of
incorporating RF finger stock at the connector-receptacle interface to provide for shield continuity and
shall [D1D2D3] be mechanically capable of being subjected to the coupling nut torque.
f. Connectors that are not self-locking shall [D1D2D3] be safety wired.
g. High Voltage. Circuits carrying potentials in excess of 200VAC rms, or 300VDC through critical
pressure environments shall [D1D2D3] be terminated in single-contact, high voltage connectors. If
the design requires that high voltage circuits be terminated in multi-contact connectors, contacts shall
[D1D2D3] be selected which are the most distant from ground potentials. Shielded wire should not
be used in high voltage circuits unless required by special designs. High voltage connectors must be
kept free of any contamination which would decrease the voltage flashover characteristics.
h. High Power. Connector interfaces categorized as high-power shall [D1D2D3] have one verifiable
upstream inhibit which removes voltage from the connector prior to mate/demate. The design shall
[D1D2D3] provide for verification of the inhibit status at the time the inhibit is initiated.
Note: High-power connector interfaces are those that do not limit the short circuit outputs to 16 W or
less, or have an open-circuit output voltage of greater than 32 V.

6.16.1 MATING PROVISIONS

Electrical connectors, plugs, and receptacles shall [D1D2D3] be designed to prevent incorrect
connection with other accessible connectors, plugs, or receptacles; pin damage; and/or, inadvertent pin
connections due to misalignment.
a. Electrical systems shall [D1D2D3] be designed so that all necessary mating and demating of
connectors can be accomplished without producing electrical arcs that will damage connector pins or
ignite surrounding materials or vapors. Unless connectors are specifically designed and approved for
mating or demating in the existing environment under the loads being carried, they shall not
[D1D2D3] be mated or demated until voltages have been removed from the powered side(s) of the
connector.
b. Equipment, wire harnesses, and connectors shall [D1D2D3] be designed such that blind connections
or disconnections are not required to be made during installation, operation, removal, or maintenance
unless the design includes scoop-proof or other protective features.
c. Connectors used for acceptance test shall [D1D2D3] comply with this requirement when mated with
product connectors.
d. The selection of the technique used shall [D1D2D3] be at the highest level of precedence in the
following order:
(1) Use of physical constraints (i.e.: bends, differing branch lengths, etc.) built into a cable or harness
that locate similar connectors so they cannot be interchanged.
(2) Selection of different sizes or types of connectors to be located adjacent to each other.
(3) Selection of alternative polarization, keying, and/or clocking of adjacent, similar connectors only if
this requirement cannot be met with either method (1) or (2) above.
(4) Permanent identification of mating connectors provided on each side of each connector pair.
(5) Unique labels on each end of the cable / harness assembly identifying the connector name /
number and mating connections.
(6) A label located approximately in the center of the cable / harness assembly length identifying
cable / harness assembly name / number and purpose.
Note: Although identification markings, labels, or color coding are required, the use of these identification
methods alone have been shown to not be insufficient to preclude mismating.

6.16.2 MOISTURE PROTECTION

Electrical connectors and wiring junctions to connectors shall [D1D2D3] be protected from moisture by
methods which are demonstrated by test or analysis to provide adequate protection to prevent open and
short circuits or a harmful unintended conductive current path. This requirement shall [D1D2D3] include
test conditions (except for environmental qualification test articles) and all operating conditions, including
flight, wherein condensation of moisture can occur either during equipment operation before equipment is
brought up to operating temperature or after equipment is shut down.

Shrink boots are not acceptable as moisture barriers.

Electrical connectors and wiring junctions to connectors which are not hermetically sealed or otherwise
positively protected against moisture shall not [D1D2D3] be cooled below the dew point of the
surrounding atmosphere.

6.16.3 PIN ASSIGNMENT

Electrical circuits shall not [D1D2D3] be routed through adjacent pins of an electrical connector if a short
circuit between them would constitute a single failure that would cause injury to the USER; cause
emission of arcs, sparks, molten metal; cause ignition of surrounding materials or vapors; or cause loss or
degradation of a critical system.
Note: For purposes of this standard, the term "adjacent" includes pins within reach of a bent pin.

6.16.4 PROTECTIVE COVERS OR CAPS

Electrical plugs and receptacles shall [D1D2D3] be protected at all times to prevent contamination and/or
damage. Protective covers or caps shall [D1D2D3] be placed over electrical plugs and receptacles
whenever they are not connected to the mating part.

The protective covers or caps shall [D1D2D3] have the following characteristics:
a. Provide protection from moisture for the plugs and receptacles
b. Provide protection against damage to sealing surfaces, threads, and pins
c. Be made of conductive or dissipative materials that provide electrostatic discharge (ESD) protection
of components.
d. Be resistant to abrasion, chipping, or flaking.
e. Be positively marked by bright colors or streamers if they are to be removed prior to flight / launch.
f. Be maintained at a level of cleanliness equivalent to the plugs or receptacles on which they are used.
g. Be made of material that is compatible with the connector material.
h. Be made of a material that does not contaminate the connector (i.e.: outgassing / offgassing, etc.).
i. Be provided with restraining devices or suitable storage areas if required for on-orbit activities.
Pressure-sensitive tape shall not be used to satisfy this requirement.

6.17 PROTECTION OF SEVERED ELECTRICAL CIRCUITS

Cables and harness assemblies which are to be severed in the normal course of operation (e.g., vehicle
separation) shall [D1D2D3] be protected against short circuiting or compromising other circuits during the
remaining phases of the mission by dead-facing to remove all voltages.
Note: For purposes of this standard, the term “severed” is defined as permanently separated by cutting
conductors using guillotine devices.

6.18 WIRE TERMINATIONS

Wire terminations to connectors or terminal shall [D1D2D3] be made with a crimp device where
practicable. Not more than one wire (conductor) shall [D1D2D3] be terminated to any contact of
environmentally sealed connectors. Not more than one wire (conductor) shall [D1D2D3] be terminated in
an individual terminal lug. For screw type terminal boards, the harness design shall [D1D2D3] be such
that the maximum number of lugs to be connected to any one terminal on a terminal board shall
[D1D2D3] be four (4) for ring type lugs, or two (2) for spade type lugs.

6.18.1 SPLICES
The use of splices shall [D1D2D3] be minimized as much as possible, and should only be considered
where the use of a connector is not practicable or would reduce reliability; and/or, where the use of a
splice can optimize complicated wiring when the harness must support branch circuits or parallel-
connected devices, or where use of a splice facilities installation (i.e.: joining harness sections /
branches).
a. The splice termination shall not [D1D2D3] be located in a flexure zone and shall [D1D2D3] be
provided acceptable stress relief. Splices shall not [D1D2D3] be located in breakout / branch areas.
b. Extra care should be exercised with harnesses and cables that have splices so that they are
protected from abrasion, cold flow, cut through, vibration, chafing, flexing, sharp edges and excessive
handling.
c. For applications involving the mass splicing of conductors in a harness, the splices shall [D1D2D3]
be staggered along the length of the harness to minimize the final cross-sectional profile.
d. Splices shall [D1D2D3] be completed with conductors that are properly sized to safely accommodate
the power load expected, at the recommended derating.
e. The completed splice termination and any exposed metallization shall [D1D2D3] be over-sleeved
with transparent / translucent heat shrink tubing extending a minimum of 5.1mm (0.2 inch) beyond
any exposed metal. For mission critical harnesses incorporating splices, two layers of shrink sleeving
shall [D1D2D3] be used over the splice area. Splices shall [D1D2D3] be wrapped with protective
tape to prevent cold flow of adjacent wiring and possible abrasion of shrink sleeving over the splice
area.
Examples of splices demonstrated to be acceptable for high-reliability and space flight applications
designs are listed in Table xxxxx. It is the engineer’s responsibility to choose the splice most suitable to a
specific application.

TABLE xxxxx TYPES OF SPLICES

Assembly Termination Method

Splice Description Classification Difficulty
Level Discrete Solder
Crimp
Solder Sleeve

Butt Mechanical Easy X

End Mechanical Easy X

Lap Non-Mechanical Easy X X

Lash Mechanical Moderate X X

Modified Pin Terminal (MTP) Mechanical Moderate X

Parallel Mechanical Moderate X

Jiffy Junction Mechanical Easy X

Western Union / Lineman Mechanical Difficult X X

6.18.2 DEAD-ENDING
Undesignated wires shall [D1D2D3] be dead-ended with AS25274 caps or with insulation sleeving in
compliance with IPC/WHAM-A-620, and in a manner acceptable to the USER. Dead-ending shall
[D1D2D3] be located within 101-152 mm [4-6 in.] of connectors, breakouts, or bulkhead feed-through
bushings. Dead-ending shall not [D1D2D3] be located under mounting clamps.

6.19 INSULATION COMPATIBILITY WITH SEALING AND SERVICING

Wiring terminations in devices where the wiring must be sealed to provide an environment resistant joint,
shall [D1D2D3] have insulation compatible with the sealing feature of the device.
a. When the diameter of the wire is smaller than the minimum allowable diameter, a length of shrink
AMS-DTL-23053/5 Class 1 & 3, /8, /11, /12 Class 3, 4, & 5, or /18 Class 2 & 3 sleeving shall
[D1D2D3] be installed in back of the contact and shall [D1D2D3] protrude through the
environmental seal a minimum of two (2) insulated wire diameters.
b. Elastomer grommets are generally qualified to seal on wires and electrical/optical cables having
smooth extruded insulations. Only one wire/optical cable per grommet hole is permitted.
c. Sealing on tape wrapped, braided, striped, or other than smooth circular insulations shall [D1D2D3]
be specifically tested for compatibility and shall [D1D2D3] be subject to USER approval, unless
compatibility has been demonstrated in the qualification of the terminating device.
d. Post Installation. After installation into the hardware, the integrity of the sealing features of all such
devices shall [D1D2D3] be intact, and able to perform their function. A device shall [D1D2D3] be
considered as sealed if the outermost sealing feature (web) is in full contact with the device when
visually inspected.
e. Wiring shall [D1D2D3] be installed and mechanically secured to prevent transverse (angular) loading
that will degrade or compromise the integrity of the sealing feature.
Note: For technical guidance on wire to connector sealing grommet compatibility see SAE AIR1329B,
“Compatibility of Electrical Connectors and Wiring”.

6.20 IDENTIFICATION AND MARKING

To facilitate the rapid identification, isolation, and repair of circuits, each wire, cable, and connector in
interconnecting cables and wiring harnesses should be permanently marked with a unique identification
code.

6.20.1 WIRING DATA

The preparation of wiring data shall [D1D2D3] be in accordance with MIL-HDBK-863, or an equivalent
format agreed upon by the SUPPLIER and USER.

6.20.2 IDENTIFICATION OF INDIVIDUAL CONDUCTORS

When specified, interconnecting harnesses shall [D1D2D3] have each wire and electrical / optical cable
permanently marked with a unique identification code, throughout its length, at intervals not longer than
7.62 cm [3 in.], as measured from the centerline of a mark to the centerline of the next mark.

Exception: Individual wires or electrical / optical cables in a jacketed / shielded-jacketed cable.

a. The identification code should be printed to read horizontally from left to right or vertically from top to
bottom. The characters shall [D1D2D3] be legible and permanent and the method of identification
shall [D1D2D3] not impair the electrical or mechanical characteristics of the wiring.
b. When it is not possible to print directly upon a wire or electrical / optical cable, an identification marker
(i.e.: heat shrinkable sleeving, tape, etc.) shall be placed on the external surface, at each end within
12 inches or before the first clamp (whichever is less), and at intervals not greater than 3 feet. The
marker shall [D1D2D3] not be used as an electrical insulating device.
c. Short electrical wires and electrical / optical cables less than 6 inches in length need not be identified,
but shall [D1D2D3] be completely identified on the drawing.
d. Wire(s) for which the identifications are reassigned after installation may be re-identified by markers
at each termination, but do not need to be re-identified throughout its length.
e. Optical Cable. Optical cable shall [D1D2D3] be uniquely color coded to facilitate identification.

6.20.3 IDENTIFICATION OF HARNESSES

Each cable and harness assembly shall [D1D2D3] be permanently marked with a unique identification
code identifying the cable / harness assembly, the function, and the mating equipment nomenclature, per
the detailed wire and cable specification.
a. The identification code should be printed to read horizontally from left to right or vertically from top to
bottom. The characters shall [D1D2D3] be legible and permanent and the method of identification
shall [D1D2D3] not impair the electrical or mechanical characteristics of the wiring.
b. When it is not possible to print directly upon a cable / harness assembly, an identification marker (i.e.:
heat shrinkable sleeving, tape, etc.) should be used. The marker shall not [D1D2D3] be used as an
electrical insulating device or clamp locator mark.
c. For repairable, protected harnesses, the marker shall [D1D2D3] be visible during maintenance within
the accessible area at the rear of the connector.
d. Hot stamp marking shall not [D1D2D3] not be used for wire used in aerospace applications.

6.20.4 IDENTIFICATION OF CONNECTORS

Each connector shall [D1D2D3] be identified by a permanent label / marking device affixed directly to the
connector body or to the cable adjacent to the connector, identifying both the connector and mating
receptacle, the function, and the equipment nomenclature.
The identification device / marker may be placed directly on the connector or on the cable / harness
assembly within 15 cm [6 in.] of the connector. In all cases, the identification device shall [D1D2D3] be
of a material, either as applied or with the aid of a protective overcoat (i.e.: tape, clear shrink tubing, etc.),
that will resist damage or degradation that would obscure or make the identification information illegible.
a. The identification code should be printed to read horizontally from left to right or vertically from top to
bottom. The characters shall [D1D2D3] be legible and permanent and the method of identification
shall [D1D2D3] not impair the electrical or mechanical characteristics of the wiring.
b. All plugs shall [D1D2D3] be identified with a “P” designation.
c. Mating connectors / receptacles shall [D1D2D3] be Identified with a “J” designation.
d. All bulkhead / structure mounted receptacles shall [D1D2D3] be Identified with a “J” number on both
sides of the structure, adjacent to the receptacle.
e. Receptacles, such as test and power, to which a mating plug Is not normally attached, shall
[D1D2D3] have, in addition, the function of the receptacle identified on the plug side of the structure.

6.20.5 TEMPORARY IDENTIFICATION

Temporary identification markers may be used for in-process identification requirements.
a. All temporary markers shall [D1D2D3] be removed from the completed cable / harness assembly.
b. The markers shall not [D1D2D3] leave a contaminating residue and shall not [D1D2D3] damage or
degrade the insulation jacket(s).
c. All temporary identification shall [D1D2D3] be removed from each completed harness by the end of
the fabrication process.
6.20.6 CLAMP LOCATING MARKS
Marking tape used to position and locate harnesses and cables may be either permanent or temporary in
nature. Permanent type marking tapes shall [D1D2D3] meet M&P and environmental requirements.
7. ASSEMBLY AND FABRICATION REQUIREMENTS

7.1 MOCKUP / FORM LAYOUT BOARD

A full-sized, three-dimensional (3-D) mockup (i.e.: wiring boards, mockups, fixturing, etc.) shall [D1D2D3]
be provided for all complex interconnecting cables and harnesses to ensure proper routing, wire lengths,
connector configurations, support requirements, and access requirements of the wiring harnesses. The
mockup may be limited to partial installations which contain the more complex wiring harnesses.

a. The mockup shall [D1D2D3]:

(1) Incorporate all electrical terminations, with position, tilt, and index identical to the final installation.
(2) Incorporate all permanent bends, offsets, and physical restraints the interconnecting cable or
harness assembly will encounter upon final installation.
(3) Be designed to limit the amount of bending, pulling, and other handling a harness will receive
during installation.
(4) Be capable of supporting design reviews, electrical acceptance test, and implementing design
changes.
b. Connector shells with inserts shall [D1D2D3] be used to reproduce the mating interface and facilitate
testing.
c. The default acute angle of breakouts from the main body (trunk) of the harness shall [D1D2D3] be 45
+/-15 degrees, unless specified otherwise on the drawing. Breakouts that branch away from the main
body (trunk) of the harness do not have to be routed straight, but may be curved. Curves shall not
[D1D2D3] violate minimum bend radius requirements.
d. When approved by the USER, development test, qualification test, or actual hardware may be used
for harness mockups instead of creating a separate mockup, provided adequate time is scheduled to
support the wiring harness mockup activities.

7.2 WIRE LAY

Harness assemblies consisting of more than four (4) discrete wires or cables that are expected to be
flexed during use or connector mating / demating operations shall [D1D2D3] be fabricated with a
unidirectional or helical wire twist (lay), with the direction of twist (lay) either right or left to produce an
essentially circular cross section for that portion of the wire harness or cable assembly that is subject to
movement. Contra-helical or unidirectional twisting of successive layers is optional. Winding should
prevent the introduction of residual twist from individual conductors. The length of lay for each layer shall
[D1D2D3] be between 8 and 16 times (8X-16X) the outer diameter of the harness cross-section. A twist
is defined as one complete 360 degree rotation of a conductor around the cable bundle.

When unidirectional or helical wire twist (lay) is not required, discrete wires or cables may be laid parallel
to each other with minimal cross-over before tying into bundles. Harness assemblies requiring preformed
bends using this assembly technique shall [D1D2D3] be constructed on a 3-D form board. Minimum
bend radius requirements shall [D1D2D3] be observed when constructing preformed bends.
a. Constructing Twisted Pair. When constructing twisted pairs by the twisting of single conductors is
specified by engineering drawings, the twist operation should produce a uniform twist pattern. The
single conductors defined for twisting by the engineering drawing shall [D1D2D3] be twisted in pairs
only and the twist shall [D1D2D3] run throughout the length of the harness or the length of the signal
run in the harness (i.e., from connector to connector, to splice, etc....).
b. Twisted Pair. Wires that are twisted by design, such as twisted wire pairs or triplets, shall [D1D2D3]
be treated as a single cable (do not untwist). Run all wires and cable in parallel when routing under a
backshell clamp.
c. Parallel or Straight Wire Lay. A wiring harness or cable assembly may be fabricated with a parallel or
straight wire lay for that portion of the wiring harness or cable assembly which is permanently
installed, and which is not subject to movement after installation.

7.3 ETCHING FLUOROCARBON-INSULATED ELECTRICAL WIRE

Electrical wire or cable insulated or coated with polytetrafluoroethylene (TFE) or fluorinated-ethylene-
propylene (FEP) shall [D1D2D3] be etched per SAE AMS2491D, “Surface Treatment of
Polytetrafluoroethylene, Preparation for Bonding”, prior to potting to ensure mechanical bond strength and
environmental seal.
a. Etched surfaces shall [D1D2D3] be processed within 24 hours, or packaged per SAE AMS2491.
b. Etched surfaces packaged per AMS 2491 shall [D1D2D3] be processed within one (1) year.
c. Potting shall [D1D2D3] be accomplished within 1 year of etching, provided the etched wires have
been protected from ultraviolet light and contamination.
d. When etching of wire insulation is required to provide satisfactory bonding to potting materials, the
end of the wire to be stripped and terminated shall not [D1D2D3] be exposed to the etchant. The
preferred process is to form the wire into a U-shape, immersing only the bent portion in the etchant
with the open end of the wire above the etchant level. The un-etched end of the wire shall not
[D1D2D3] be cut off prior to neutralization of the etchant.

7.4 INTERIM STORAGE AND PROTECTION

The Supplier shall [D1D2D3] establish and implement procedures to protect interconnecting cables and
harnesses from damage, Foreign Object Debris (FOD) contamination, and degradation during assembly
and test.
a. Connectors not being actively assembled shall [D1D2D3] be individually protected by wrapping them
in clean bubble wrap, water-vapor-proof packaging, or covered by a clean ESD-rated dust cap.
b. At the end of the work shift, protective covering shall [D1D2D3] be spread over the harnesses in
fabrication.
c. Wiring, cable, and harness assemblies that are not being actively worked on shall [D1D2D3] be stored
in water-vapor-proof packaging, or in an environmentally-controlled and monitored area where dew
point is not attained and the relative humidity is less than 70%RH.
d. Protective coverings and packaging shall [D1D2D3] be compliant with ANSI/ESD S20.20 if
Electrostatic Discharge Sensitive (ESDS) parts are utilized.

7.5 STORAGE AND TRANSPORTABILITY

Completed cable and wire harnesses assembled on three-dimensional forming boards should not be
removed until all quality assurance (QA) requirements have been verified. Clean, ESD-rated dust caps
shall [D1D2D3] be installed on all connectors.
a. Installation. The completed cable and wire harnesses assembly shall [N1D2D3] be moved from the
fabrication forming board directly to installation, without intermediate storage to avoid unnecessary
handling.
b. Storage. Whenever production schedules, alternate practices, or other considerations, require
harness storage, the wire harness shall [N1D2D3] be packaged, handled, and transported in a
manner that minimizes possible damage or environmental degradation. When a wiring harness is
removed from the fabrication forming board for storage, clean ESD-rated dust caps shall [D1D2D3]
be installed on all connector and the entire harness placed in a sealed, vapor-proof, protective bag,
with desiccant and a humidity indicator card (HIC).
c. Handling. Unsupported handling should be avoided. Minimum bend radii requirements shall
[D1D2D3] be observed.
d. Re-verification. When a harness has been in storage for longer than 6 months, the quality assurance
requirements shall [D1D2D3] be re-verified by test or retest immediately prior to installation.
8. WORKMANSHIP
All details of workmanship concerned with the fabrication and installation of wiring harnesses shall be
controlled such that the finished item is of sufficient quality to ensure proper operation, safety, reliability,
and service life.

8.1 ELECTRICAL ACCEPTANCE TESTING

As a minimum, testing shall [D1D2D3] be performed on cables and wire harnesses as defined in IPC-
WHMA-A-620AS, Paragraph 19.4.1:
a. Following fabrication and prior to installation
b. Post installation, but prior to connection or reconnection to components, devices, or systems
c. Prior to each use for non-permanently installed cables.
d. Prior to performing dielectric withstanding testing, the dielectric strength of all connectors, wire,
components, or devices attached to the harness shall [D1D2D3] be verified to be greater than the
applied test voltage. The test voltage level shall [D1D2D3] be adjusted to prevent damage to the
lowest rated item in the cable.
e. The individual leakage current readings shall [D1D2D3] be read and recorded for each test
performed. Measurement shall have resolution to the nano (10-9) range. The data shall [D1D2D3] be
maintained and available for comparison as long as the subject cable is in service.
f. Initial and periodic testing for shorting and dielectric failures shall [D1D2D3] be performed on support
and test cables that interface with production hardware, using the test criteria described above.
g. Any trend in dielectric strength degradation / fluctuation greater than one order of magnitude shall
[D1D2D3] be evaluated to determine the cause and worst case effect.
h. Electrical test potentials shall not [D1D2D3] exceed the dielectric and/or current rating of the most
sensitive component in the cable / harness assembly.

8.2 ELECTRICAL TEST (POST INSTALLATION)

Post installation testing shall [D1D2D3] be performed to assure that individual wire conditions have not
been degraded by installation operations. The post installation test requirements shall [D1D2D3] be
those identified in this clause. The tests shall [D1D2D3] be performed after installing the cables or wire
harnesses in place, but before mating connectors.

The required tests shall [D1D2D3] be conducted in this order:

a. Continuity
b. Shorts
c. Dielectric Withstand Voltage (DWV)
d. Insulation Resistance (IR)
9. DEFINITIONS AND ACRONYMS
For purposes of this document, the following additional acronyms, abbreviations, and terms are listed in
addition to those listed in IPC-T-50H, “Terms and Definitions for Interconnecting and Packaging
Electronic Circuits”. Specialized definitions and acronyms related to “Red Plague” are listed in Appendix
A.

9.1 DEFINITIONS
Accessories Mechanical devices, such as cable clamps or backshells, added to
connector bodies.
Adapter An intermediate device to provide for attaching special accessories or
to provide special mounting means.
Barrel (Contact Wire Barrel) The section of contact that accommodates the stripped conductor.
The radius of a formed bend, either temporary or permanent,
Bend Radius measured in multiples of cross-sectional diameters, to which a
component lead, conductor, cable (metallic, fiber, hybrid), harness
(metallic, fiber, hybrid), optical fiber, or wire, can be bent without
inducing permanent damage or reduction in performance, power, or
reliability.

The radius of a formed bend in a component lead, conductor, cable

Bend Radius, Long-term (metallic, fiber, hybrid), harness (metallic, fiber, hybrid), optical fiber, or
wire, in the permanently installed configuration.
The radius of a formed bend in a component lead, conductor, cable
Bend Radius, Short-term (metallic, fiber, hybrid), harness (metallic, fiber, hybrid), optical fiber, or
wire, during assembly, installation, or storage.
Birdcaging The radial expansion of individual strands in a stranded conductor
(bowing outward) that can occur in the exposed portion of the
conductor between the insulation strip and termination point.
Braid A fibrous or metallic group of filaments interwoven toform a protective
covering over one or more wires.
Breakout The designed separation of a conductor or group of conductors from
the main body of wires in a harness assembly toform a branch .
Bubble Pack A laminated plastic sheet that is formed with patterned air entrapment
("bubbles"). The bubbles provide excellent cushioning for anything
enclosed between layers of the material.
Cable An engineered wiring product, consisting of a single insulated and
shielded wire, or consisting or multiple insulated wires contained within
a common insulating jacket. A cable may be shielded or unshielded.
Cable, Biaxial (twin-lead) An engineered wiring product, consisting of two individually insulated
50 Ω coaxial cables, bonded together to resemble a lamp or speaker
wire.
Cable, Coaxial An engineered wiring product, typically supplied in the form of a central
solid or stranded conductor insulated by a dielectric material, held in
 concentric orientation to a conductive tubing or braided sheathing that
serves both as an EMI/RFI shield and as a return circuit path. Coaxial
systems are available in different technologies, ranging from flexible,
insulated cable, formable, and semi-rigid metallic sheathed.
Cable, Coaxial, Flexible Flexible coaxial cable is constructed of a central solid or stranded
conductor surrounded by a flexible low loss r-f dielectric core material,
which holds the inner conductor in concentric orientation to a braided
metal outer conductor(s), and covered by a protective outer jacket /
covering.
Cable, Coaxial, Formable / Formable / hand-formable coaxial cables are constructed of a central
Hand-formable solid conductor surrounded by a flexible low-loss r-f dielectric core
material, which holds the inner conductor in concentric orientation to a
a tin-dipped and fused metallic braid as the outer conductor. This
offers the advantage of being capable of being bent and formed
without the use of tools or bending jigs, while providing the electrical
signal performance of semi-rigid coaxial.
Cable, Coaxial, Semi-rigid Semi-rigid, coaxial cables are constructed of a central solid conductor
surrounded by a flexible low-loss r-f dielectric core material, which
holds the inner conductor in concentric orientation to a solid,
continuous, metal outer conductor (tube).
Cable, Flat An engineered wiring product, consisting of two or more individually
insulated, round or flat solid conductors that are mechanically bonded
in a parallel alignment, to a flat insulating base material to form a
planar composite construction.
Cable, Hybrid An engineered wiring product consisting of two or more wiring
technologies (i.e.: multi-conductor, coaxial, and / or fiber optic) bound
together by an overall insulation jacket (unshielded); or, bound and
wrapped with an overall metallic covering (braid or foil), and covered
by an overall insulation jacket (shielded).
Cable, Multiconductor An engineered wiring product, typically constructed of two (2) or more
individually insulated conductors, bound together by an overall
insulation jacket (unshielded); or, bound and wrapped with an overall
metallic covering (braid or foil), and covered by an overall insulation
jacket (shielded).
Cable, Shielded An engineered wiring product consisting of one or more insulated
conductors, wrapped with an overall metallic covering (braid or foil),
and covered by an outer insulation jacket.
Cable, Tri-axial An engineered wiring product consisting of three concentrically
oriented, electrically isolated conductors (a center conductor, inner
conductive shield, and outer conductive shield) covered by an overall
insulation jacket. In application, the outer shield is electrically
grounded, which protects the inner (floating) shield from
electromagnetic interference (EMI).
Cable, Twin-axial An engineered wiring product consisting of a balanced, twisted-pair of
insulated conductors, bound together by an overall insulation jacket or
dielectric core and held in concentric orientation to a overall conductive
metallic sheathing (braid or foil) that serves as an EMI/RFI shield, and
covered by an overall insulation jacket. Twinaxial cables are used
primarily for the transmission of control, data, or high frequency (HF)
 signals, offering a nearly perfect differential signal which is both
shielded and balanced.
Cable Clamp A mechanical clamp attached to the wire entrance of a connector to
support the cable or wire bundle, provide stress relief, and absorb
vibration and shock.
Certification The act of verifying and documenting that personnel have completed
required training, have demonstrated specified proficiency, and have
met other specified requirements.
Class 100,000 A clean room in which the particulate count does not exceed a total of
3500 particles per liter (100,000 particles per cubic foot) of a size 0.5
micron and larger, or 25 particles per liter (700 particles per cubic foot)
of a size 5.0 microns and larger.
Clean Area A general assembly area in which gross airborne particles and the
introduction of other contaminants (i.e.: aerosols, dusts, tobacco
smoke, food, beverages, cosmetics, etc.) are controlled through
exercise of routine “housekeeping” discipline. This area may be open
(i.e.: enclosed by visible perimeter markers / tape stripe, islanding by
aisle separation), or enclosed by physical barrier (i.e.: partitions, walls);
with limited pass-through access, ESD-protected, and environmentally
controlled (i.e.: temperature, humidity, and positive-pressure). Most
manual electronics assembly and soldering and cable / harness
assembly is conducted in areas described as Clean Areas, with entire
sections of an assembly facility designated as “Clean Areas”.
Clean Room A dedicated, isolated physical structure / room in which the
concentration of airborne particles is precisely controlled, and which is
designed, constructed and used in a manner to minimize the
introduction, generation, and retention of particles inside the room, and
in which other relevant parameters (i.e.: temperature, humidity, and
pressure) are controlled as necessary
Clean Zone A dedicated space in a Clean Room in which the concentration of
airborne particles is precisely controlled, and which is constructed and
used in a manner to minimize the introduction, generation, and
retention of particles inside the zone, and in which other relevant
parameters, e.g. temperature, humidity, and pressure, are controlled
as necessary. This zone may be open or enclosed and there may be
multiple Clean Zones located within a Clean Room.
Coldflow / Cold Flow The permanent, non-recoverable distortion, deformation, or
displacement of an insulation jacket resulting from application of
intermittent and/or constant mechanical stress below the polymer’s
elastic limit at temperatures within the polymer’s working range.
Conductor A lead or wire, solid, stranded, or printed wiring path serving as an
electrical connection.
Connector, Backshell
Connector, Body The main portion of a connector to which contacts and other
accessories are attached.
Connector, Grommet An elastomeric seal used on the cable side of a connector body to seal
the connector against contamination and to provide stress relief.
Connector, Insert The part of a connector that holds the contacts in position and
electrically insulates them from each other and the shell.
Contact The conductive element in a connector or other terminal device that
mates with a corresponding element for the purpose of transferring
electrical energy.
Contact, Crimp A contact whose crimp barrel is a hollow cylinder that accepts the
conductor. After a conductor has been inserted, a tool is used to crimp
the contact metal firmly onto the conductor.
Contact, Insertable/Removable A contact that can be mechanically joined to or removed from an
insert. Usually, special tools are used to insert (lock) the contact into
place or to remove it.
Contact, Pin Male-type contact designed to slip inside a socket contact.
Contact Retention The axial load in either direction that a contact can withstand without
being dislodged from its normal position within an insert or body.
Contact, Socket A female-type contact designed to slip over a pin contact.
Contaminant An impurity or foreign substance present in a material that affects one
or more properties of the material. A contaminant may be either ionic
or nonionic.

An ionic, or polar compound, forms free ions when dissolved in water,

making the water a more conductive path.

A nonionic substance does not form free ions, nor increase the water's
conductivity. Ionic contaminants are usually processing residue such
as flux activators, finger prints, and etching or plating salts.
Crimp The physical compression (deformation) of a contact barrel around a
conductor to make an electrical and mechanical connection to the
conductor.
Crimping A method of mechanically compressing or securing a terminal, splice,
or contact to a conductor.
Drain Wire A wire that runs linearly along a foil shield wire or cable and is used to
make contact with the shield. Grounding of foil shields is done with
drain wires.
Electromagnetic Interference The unwanted intrusion of electromagnetic radiation energy
(EMI) whose frequency spectrum extends from subsonic frequency to X-rays.
Ferrule A short metal tube used to make crimp connections to shielded or
coaxial cables.
Grommet An insulator that covers sharp edges of holes through panels and
partitions to protect wire insulation from cut-through damage.
Harness One or more insulated wires or cables, with or without helical twist;
with or without common covering, jacket, or braid; with or without
breakouts; assembled with two or more electrical termination devices;
and so arranged that as a unit it can be assembled and handled as
one assembly.
Insertion Tool A device used to install contacts into a contact cavity in a connector
 insert.
Interfacial Seal A sealing of mated connectors over the whole area of the interface to
provide sealing around each contact.
Jacket The outermost layer of insulating material of a cable or harness.
Joint A termination.
Key A mechanical device or feature in addition to, or in lieu of, a
Keying polarization feature that ensures the coupling of identical connectors /
components can occur in only one orientation and only to similar keyed
connectors / components.
Lay The twist (helical) pattern of wire stands in a stranded wire, insulated
wires in a cable, or insulated wires and cables in a harness assembly.
Length of lay The axial length of one complete turn of the wiring helix.
Mate The mechanical and electrical joining of two connectors
Minimum Electrical Spacing The minimum allowable distance between adjacent non-common
conductors or conductive surfaces (i.e.: mounting hardware, brackets,
metal-cased components, etc.), at a given voltage and altitude, that is
sufficient to prevent dielectric breakdown, corona, or both, from
occurring between the conductors.
Mission Essential Support Equipment used in a closed loop within the system, where the failure of
Equipment this equipment would degrade the mission or imperil personnel. This
category includes items of ground support equipment whose functions
are necessary to support the pre-countdown and countdown phases,
whose failure can create a safety hazard, cause damage to flight
hardware, or create an inability to detect a problem in the flight
hardware.
Moisture Barrier Bag (MBB) A bag used to package moisture-sensitive devices (MSD) that is
electrostatic discharge (ESD) safe and is designed to restrict the
ingress of water vapor.
Molding The process of creating a defined shape or pattern by shaping pliable
raw material (i.e.: epoxy, plastic, etc.) using a reusable, rigid frame,
pattern, or mold/casting. Molding is typically used to create sealed and
environmentally resistant (ER) connector assemblies. The mold /
casting is removed, cleaned, and reused once the curing process is
complete.
Offgassing The release of a volatile part(s) from a substance when placed in a
vacuum environment that may affect crew members.
Orbital Replaceable Unit Hardware assemblies / sub-assemblies designed to allow removal and
(ORU) replacement during microgravity flight.
Outgassing The release of a volatile part(s) from a substance when placed in a
vacuum environment.
Potting The process of filling of a connector backshell, shape/shell with a
material that excludes moisture and provides stress relief. The
connector backshell or a potting shape/shell typically remains a part of
the assembly once the curing process is complete.
Protoflight A test program intended to combine the objectives of the qualification
and acceptance test programs; i.e. design confidence for use in the
service environments and adequate workmanship/quality. All
protoflight components, assemblies, and flight elements are intended
for subsequent flight use. The protoflight approach uses reduced test
levels, cycles, and/or duration from the standard qualification test
requirements, to allow the protoflight tested hardware to be used for
flight.

Protoflight carries a high level of technical risk in comparison to a full

qualification test program, due to there being no demonstrated flight
duration capability (i.e., number of cycles; or time of operation or
exposure to a service environment) and, in some cases, lower
demonstrated margins over the service environment extremes.
Protoflight Hardware Flight hardware utilized for qualification testing in lieu of a dedicated
test article. The approach includes the use of reduced test levels
and/or durations and post–test hardware refurbishment, where
required, to allow tested hardware to be used subsequently for flight.
Purple Plague AuAl2. One of five (5) brittle gold-aluminum intermetallics formed when
bonding gold directly to aluminum. Although highly conductive, the
appearance of Purple Plague (AuAl2) is coincident with development of
Tan Plague (Au2Al), which can cause Kirkendall voiding and failure in
interconnection bonds.
Typical MTTF: 15 – 25 years
Qualification Qualification is the process that proves the design, manufacturing, and
assembly of the hardware and software complies with the design
requirements when subjected to environmental conditions.
Qualification Test Article A qualification test article is a flight article modified to the extent
necessary to conduct the qualification test.
Radiofrequency The frequency spectrum from 15 kHz to 100 GHz. Cables are seldom
(RF) used above 18 GHz.
Radiofrequency Interference Electromagnetic radiation in the radiofrequency spectrum from 15 kHz
(RFI) to 100 GHz.
Red Plague (Cu2O). The sacrificial corrosion of copper in a galvanic interface comprised of
silver and copper, resulting in the formation of red cuprous oxide
(Cu2O) and black cupric oxide (CuO). Risk of developing Red Plague
in silver-plated copper wiring is relatively low, if the wire has a non-
porous silver plating with a uniform plating thickness of at least 2 µm (
0.078 mil), and is stored in a humidity-controlled environment.
Typical MTTF: 15 – 25 years
Sealing Plug A plug that is inserted tofill an unoccupied contact aperture in a
connector. Its function is to seal an unoccupied aperture in the
assembly, especially in environmental connectors.
Shield The metal covering surrounding one or more conductors in a circuit to
Shielding (v) prevent interference or signal radiation.
Shielded Cable Cable surrounded by a metallic covering intended to minimize the
effects of electrical crosstalk interference or signal radiation.
Solder Cup Terminal A hollow, cylindrical terminal designed to accommodate one or more
 conductors.
Solder Sleeve A heat-shrinkable solder termination device with meltable sealing
preforms at ends.
Splice The joining of two or more conductors to each other.
Spacecraft Devices, manned or unmanned, which are designed to be placed into
a suborbital trajectory, an orbit about the earth, or into a trajectory to
another celestial body.
Strain Relief A connector device that prevents the disturbance of the contact and
cable terminations.
Stranded Conductor A conductor composed of a group of smaller wires.
Stress Relief The formed portion of a conductor that provides sufficient length to
minimize stress between terminations.
Strip To remove insulation from a conductor.
Tab Terminal A flat-surface terminal that is broad compared to the metal thickness.
Wires are often soldered along the flat surface.
Tang (Connector Backshell) A backshell tang is a tapering metal projection (straight, 45°, or 90° to
the axis of the connector) designed to accommodate cable-tie
attachments. The cable-ties grip and hold harness wires exiting from
the connector, thus providing stress relief for the wires.
Tines Tines are the members of a contact retention system that capture or
"lock" removable crimp contacts into the contact cavities.
Tin Pest (a.k.a.: Tin Disease / The progressively destructive and irreversible allotropic transformation
Tin Plague) of pure tin from an electrically conductive metal (a.k.a.: beta-tin / β-tin),
to a crumbly, white, non-metallic, non-conductive powder (a.k.a.:
alpha-tin / α-tin / white tin), when exposed to temperatures below
+13°C (+56°F) for long periods of time. Alloying pure tin with at least
5% lead (Pb) or at least 0.5% antimony (Sb) or bismuth (Bi) is
considered to be effective at preventing tin pest.
Tinning The selective coating of a solderable surface with a uniform layer of
tin-lead (SnPb) solder.
Transfer Soldering A manual soldering process where solder terminations are completed
by the transfer of a molten ball of solder on the soldering iron tip to the
termination area. The application of a small amount of solder to the
soldering iron tip to facilitate thermal transfer during the manual
soldering process is not Transfer Soldering. Transfer soldering is
prohibited.
Wicking A flow of molten solder, flux, or cleaning solution by capillary action.
Wire A single metallic conductor of solid, stranded, or tinsel construction,
designed to carry currents in an electrical circuit. It may be bare or
insulated, but does not have a metallic covering, sheath, or shield.
Wire Dress The arrangement of wires and laced harnesses in an orderly manner.
9.2 ACRONYMS AND ABBREVIATIONS
ANSI ............ American National Standards Institute
ASTM .......... American Society for Testing and Materials
ATP ............. Acceptance Test Procedure
ATT .............. Acceptance Thermal Test
AVT ........... .. Acceptance Vibration Testing
CFR ............. Code of Federal Regulations
2
cm .............. Square Centimeters
COTS ......... Commercial Off-The-Shelf
CVCM .......... Collectable Volatile Condensable Material
dB ............. ... decibels
DOT ............. Department of Transportation
DWV ............ Dielectric Withstanding Voltage
EEE ............. Electrical, Electronic and Electromechanical
EIA ............... Electronic Industries Association
ENIG ........... Electroless Nickel Immersion Gold
EPA ............. Environmental Protection Agency
ESD ............. Electrostatic Discharge
EV ................ Exposure Value
EVA ............. Extravehicular Activity
FMEA .......... Failure Modes and Effects Analysis
FOTP ........... Fiber Optic Test Procedure
Ft ................. Feet
GFE ............. Government Furnished Equipment
Hrs ............... Hours
IEEE ............ Institute of Electrical and Electronics Engineers
IPC .............. Interconnecting and Packaging Electronic Circuits
IVA ............... Intravehicular Activity
lbf ................. Pounds force
LCC ............. Leaded Chip Carrier
LED ............. Light Emitting Diode
2
lm/m ........... Lumens per square meter
LO2 .............. Liquid Oxygen
MIL-STD ...... Military Standard
min ............... Minutes
mm ............. Millimeter
M/M ............ Multi-Mode
MSDS .......... Material Safety Data Sheet
NASA ........... National Aeronautics and Space Administration
NASA-STD .. NASA Standard
NIST ............ National Institute of Standards and Technology
ORU ............ Orbital Replacement Unit
OSHA .......... Occupational Safety and Health Administration
OTDR .......... Optical Time Domain Reflectometry
OTS ............. Off the Shelf
PSIA ............ Pounds per Square Inch Absolute
PWA ............ Printed Wiring Assembly
PWB ............ Printed Wiring Board
QPL ............. Qualified Products List
RH ............... Relative Humidity
RMS ............ Root Mean Square
SAC ............. Tin, Silver, Copper Alloy (See lead-free solder)
secs ............. Seconds
S/M ............. Single Mode
TIA ............... Telecommunications Industry Association
TML ............. Total Mass Loss
UUT .......... .. Upper Useful Temperature, °C
UV ............... Ultraviolet
VCS ............. Voluntary Consensus Standard
VDC ............. Volts Direct Charge
APPENDIX A - RED PLAGUE CONTROL PLAN

Number: Revision

A-1
RED PLAGUE CONTROL PLAN (RPCP)
Page Date:

1 of 1

STATEMENT OF STANDARD

Red Plague (cuprous / cupric oxide corrosion) can develop in silver-coated copper (SCC), silver-coated
copper-alloy (SCA), and silver-coated ultra-high strength copper alloy (SCU) wire and cable when a
galvanic cell forms between the copper base metal and the silver coating in the presence of moisture
(H2O) and oxygen (O2). Once initiated, the sacrificial corrosion of the copper base conductor can
continue indefinitely in the presence of oxygen (O2). The color of the corrosion by-product (cuprous oxide
crystals) may vary depending on the amount of oxygen available, but is commonly noted as a red /
reddish-brown discoloration on the silver plating surface – hence the term “Red Plague”.

A.1 RED PLAGUE CONTROL PLAN (RPCP)

The use of silver-coated copper (SCC/SCC1), silver-coated copper alloy (SCA/SCA1), and silver-coated
ultra-high-strength copper alloy (SCU) wire and cable shall [D1D2D3] require the implementation of a
Red Plague Control Plan (RPCP) to control exposure to environmental conditions and contamination that
may result in immediate or latent damage that may adversely impact performance or reliability.

A.1.1 QUALIFIED / APPROVED SUPPLIERS

Wire and cable shall [D1D2D3] be procured in accordance with the wire procurement specification, from
suppliers listed on the Qualified Manufacturers List (QML) or suppliers approved by the USER.

A.1.2 SILVER COATING REQUIREMENTS

SCC / SCA: Silver-Coated Copper (SCC) and Silver-Coated Copper-Alloy (SCA) primary and shield
conductors shall [D1D2D3] have a coating thickness of not less than 1 micron (~40 micro-inches) average,
when measured in accordance with ASTM B 298-07.

SCC1 / SCA1: Silver-Coated Copper (SCC1) and Silver-Coated Copper-Alloy (SCA1) primary and shield
conductors shall [D1D2D3] have a coating thickness of not less than 2 micron (~80 micro-inches) average,
when measured in accordance with ASTM B 298-07. After stranding, the coating thickness on each of the
individual conductor strands shall not [D1D2D3] be less than 1 micron (~40 micro-inches) when inspected
using micro-section analysis in accordance with ASTM B 961-08.

SCU: Silver-Coated Ultra-High-Strength Copper-Alloy (SCU) primary and shield conductors shall
[D1D2D3] have a coating thickness of not less than 1 micron (~40 micro-inches) when measured in
accordance with ASTM B 298-07.
1. The silver coating shall [D1D2D3] exhibit a non-porous, smooth, and continuous finish with no evidence
 of lumps, kinks, splits, scrapes, corrosion, contamination, or exposed base material after stranding. The
continuity (non-porosity) of the coating shall [D1D2D3] be determined on representative samples by the
sodium polysulfide test, in accordance with ASTM B 298–07.
2. Micro-section inspections shall [D1D2D3] be in accordance with ASTM-B961 except that the coating
thicknesses specified herein shall [D1D2D3] be in effect. When required by the USER, photographs
shall [D1D2D3] be captured and saved as proof of inspection. The magnification scale of photographs
shall [D1D2D3] be identified.
3. Micro-section analysis shall [D1D2D3] be performed by a lab certified to IPC-QL-653A, or as agreed
upon by the USER.
4. All wire and cable shall [D1D2D3] have full lot traceability and manufacturer’s test reports, certified by
the Government Source Inspector (GSI). Test reports, and all tested and untested micro-section
analysis coupons, shall [D1D2D3] be delivered to the USER as part of the procurement.

A.1.3 FLUORINE ATTACK (WHITE PLAGUE)

To reduce the risk of fluorine attack (White Plague), when fluoropolymer-insulated silver-coated copper
wiring is either stored in sealed packaging (e.g.: vapor-proof bagging, MBB) or used in enclosed
environments / compartments, the fluorine evolution rate shall not [N1D2D3] exceed 20 PPM when
tested in accordance with SAE AS4373E Method 608, Fluoride Offgassing. Bulk wiring and harness
assemblies exhibiting fluorine attack shall [N1D2D3] be rejected.

A.1.4 LIMITED LIFE ARTICLE

SCC/SCC1, SCA/SCA1, and SCU wire and cable with a shelf life exceeding 10 years from manufacturing
date shall [D1D2D3] be segregated and shall [D1D2D3] not be used in harness assemblies and hardware
fabricated to this standard. Completed cable, harness assemblies, and hardware incorporating
SCC/SCC1, SCA/SCA1, and SCU wire and cable, with a combined storage and use life exceeding 10
years from date of assembly shall [D1D2D3] be identified, periodically inspected and tested, and tracked
as a “Limited-Life Article”.

A.1.5 ENVIRONMENTAL REQUIREMENTS

SCC/SCA, SCC1/SCA1, and SCU wire and cable shall [D1D2D3] be protected to reduce and control
exposure to environmental conditions and contamination that promote the development of cuprous / cupric
oxide corrosion (Red Plague).

A.1.5.1. SHIPPING AND STORAGE

Wire and cable shall [D1D2D3] be shipped and stored in sealed water-vapor-proof packaging (i.e.: Moisture
Barrier Bag, dry pack, etc.), with capped ends, activated desiccant, and an irreversible humidity indicator
card (i-HIC).
1. Water-vapor-proof packaging shall [D1D2D3] meet MIL-STD-2073-1E Method 51. Moisture Barrier
Bags (MBB) shall [D1D2D3] meet MIL-PRF-81705, TYPE 1.
2. Capping. Wire and cable ends shall [D1D2D3] be capped with heat shrinkable end-caps conforming to
SAE-AMS-DTL-23053/4, or dipped in Red “GLPT” Insulating Varnish (10-9002-A / 10-9008 / N.S.N.
5970-00-901-5331) for a length of approximately 2.5 cm (1 in).
3. Desiccant (Activated). The bagged, activated desiccant shall [D1D2D3] conform to MIL-D-3464 Type
2. The minimum quantity of desiccant to be used (unit packs) shall [D1D2D3] be based on the
protective package’s interior exposed surface area, in accordance with MIL-STD-2073-1E, Method 50,
Formula 1.
4. Irreversible Humidity Indicator Card (i-HIC). Irreversible Indication (50-60-70-80-90% RH). A
combination Irreversible / Reversible Humidity Indicator (50-60-70-80-90% RH) conforming to MIL-I-
8835 is allowable.
5. Wire and cable shall not [D1D2D3] be stored in paper wrapping materials or cardboard boxes.

Note:
Silver is highly susceptible to attack by contaminants present in the atmosphere and common “green”
packaging materials. Paper wrapping materials, rubber bands, and cardboard boxes should be avoided
because such materials contain and outgas small amounts of sulfur.
(ref.: MIL-HDBK-338B [11.4.1])

A.1.5.2. ASSEMBLY
All assembly processes, including Receiving Inspection and Kitting, shall [D1D2D3] be conducted in an
environmentally-controlled and monitored area where dew point is not attained and the relative humidity is
less than 70%RH.
1. Wire and cable shall [D1D2D3] not be removed from its protective packaging until it has reached
thermal equilibrium with the assembly environment to reduce the risk of condensation formation.
2. Unused Wire. Prior to returning wire back to storage, wire ends shall [D1D2D3] be capped to prevent
diffusion of air and water vapor into the wire through open ends, and stored in water-vapor-proof
packaging per 4.4.1, or in an environmentally-controlled and monitored area where dew point is not
attained and the relative humidity is less than 70%RH.
3. Wiring, cable, and harness assemblies that are not being actively worked on shall [D1D2D3] be stored
in water-vapor-proof packaging per 4.4.1, or in an environmentally-controlled and monitored area where
dew point is not attained and the relative humidity is less than 70%RH.
4. Completed cable and harness assemblies shall [D1D2D3] be stored in water-vapor-proof packaging
per 4.4.1, or stored in an environmentally-controlled and monitored area where dew point is not attained
and the relative humidity is less than 70%RH, until ready for installation.
5. Aqueous solvents and cleaning systems shall [D1D2D3] not be used.

A.1.5.3. 70%RH INDICATION

Wire and cable shall [D1D2D3] be quarantined and dispositioned by the appropriate Material Review Board
when the humidity indicator card (HIC) registers 70%RH exposure.

A.2 RECEIVING INSPECTION

Receiving Inspection shall [D1D2D3] confirm conformance to the requirements of this RPCP and the wire
procurement specification. The following verifications and tests shall [D1D2D3] be performed on each lot of
wire / cable received:
1. Verification of compliance with GSI certification / documentation requirements (4.1).
2. Verification of compliance with minimum silver coating thickness and quality requirements (4.2).
3. Verification of compliance with shelf life requirements (4.3).
4. Verification of compliance with environmental protection requirements (4.4).
5. One (1) test specimen, approximately 30 cm (12 in) in length (including the capped end), to perform the
required inspection(s) shall [D1D2D3] be required:
a. From each end of each continuous, unspliced length reel or spool.
b. From each end of reeled or spooled wire sections (non-continuous lengths).
c. From each end of coiled lengths.

A.2.1 VISUAL INSPECTION

Primary and shield conductors shall [D1D2D3] be visually inspected for mechanical damage and cuprous /
cupric oxide corrosion (Red Plague). The silver coating shall [D1D2D3] exhibit a non-porous, smooth, and
continuous finish with no evidence of lumps, kinks, splits, scrapes, corrosion, contamination, or exposed
base material.

1. Magnification. Magnification power for visual inspection shall [D1D2D3] be based on the inspection
activity or conductor size, per J-STD-001E. For wire and cable with mixed conductor sizes, the greater
magnification may be used for the entire inspection. The tolerance for magnification aids is ± 15% of the
selected magnification power. Magnification aids should be maintained and calibrated as appropriate
(see IPC-OI-645).

2. Illumination. Illumination intensity on the surface being inspected shall [D1D2D3] be at least 1000
lm/m2 (~93 foot-candles). The light source type shall [D1D2D3] be as specified by engineering
documentation.

A.2.2 ACCEPTANCE
Wire and cable that has been accepted shall [D1D2D3] be stored in water-vapor-proof packaging per 4.4.1,
or stored in an environmentally-controlled and monitored area where dew point is not attained and the
relative humidity is less than 70%RH.

A.3 ASSEMBLY REQUIREMENTS

The following controls shall [D1D2D3] be imposed during the assembly of hardware incorporating
SCC/SCC1, SCA/SCA1, and SCU wire and cable:

A.3.1 PRE-PRODUCTION SAMPLE

Prior to material take off for assembly or kitting, a pre-production sample of the wire / cable shall [D1D2D3]
be visually inspected for mechanical damage and cuprous oxide corrosion. Any evidence of non-
conformance shall [D1D2D3] require quarantine of the entire spool and disposition by the appropriate
Material Review Board (MRB).

A.3.2 WIRE STRIPPING

To reduce exposure to moisture and oxygen, wire insulation shall [D1D2D3] be stripped just prior to
termination.
1. Solder terminations. The insulation shall [D1D2D3] be left on the wire until assembly, at which time the
wire shall [D1D2D3] be stripped and immediately solder tinned to minimize the exposure time of the
silver-copper endface to atmospheric moisture and oxygen.
2. Crimped terminations. The crimp termination of silver-coated cooper wire is not recommended, unless
additional mitigation (i.e.: heavier plating thickness, environmentally rated connector, conformal coating,
shrink sleeving, etc.) is implemented to protect the exposed end of the conductor(s).

A.3.3 BEND RADIUS

Wire and cable shall not [D1D2D3] be bent less than minimum bend radius requirements to avoid cracking
of the insulation and/or silver coating.

A.3.4 CLEANING SOLVENTS

Aqueous solvents and cleaning systems shall not [D1D2D3] be used for cleaning and flux removal.

A.4 NON-CONFORMANCE
Non-conformance to any of the above requirements shall [D1D2D3] require:
1. Immediate rejection and segregation of the wire, cable and/or harness assemblies from stock and
 production.
2. Relocation to a dry area or otherwise protected (i.e.: placed in a nitrogen-purged dry box, MBB, etc.) to
prevent continued environmental damage.
3. Disposition by the appropriate Material Review Board (MRB).
4. Non-conformances dispositioned other than scrap shall [D1D2D3] be approved by the USER.

A.5 CAPPING
Capping provides a simple and effective environmental barrier to oxygen and moisture contamination of the
cut / exposed ends of silver-coated copper wire and cable by sealing the cut / exposed ends of the wire /
cable with double-wall (melt-liner) heat shrinkable tubing or preformed end cap, or by dip coating with Red
“GLPT” Insulating Varnish.

A.5.1 SHRINK TUBING METHOD

This method uses double-wall (melt-liner) shrink tubing conforming to SAE-AMS-DTL-23053/4D to create a
crimped-end “cap” to environmentally seal the exposed end of the wire / cable. If a preformed double-wall
(melt-liner) heat shrinkable end cap is used, the crimping of the “tail” (step e) is not required.
1. Clean the wire / cable end and approximately 5 cm (2 in) of the insulation jacket with IPA. The wire /
cable shall [D1D2D3] be positioned with the cut end pointed downward to minimize wicking of cleaning
solvent. Do not use aqueous cleaners.
2. Cut shrink tubing sections approximately 5 - 8 cm (2 to 3 in) in length.
3. Insert approximately 2.5 cm (1 in) of the open-end silver-plated copper wire / cable into one end of the
shrink tubing, with the remaining shrink tubing forming an open “tail”.
4. Use a heat gun to shrink the tubing down over the wire / cable and to shrink the “tail”.
5. When the inner wall of the shrink tubing has melted, crimp the “tail” (only) with smooth-jaw pliers
toflatten and close the tubing. Hold pressure on the “tail” for 20 to 40 seconds until the inner liner cools
and solidifies.
6. Visually inspect to verify that the tubing has been shrink tightly, that the melt liner has adhered to the
wire / cable insulation, and that the crimped “tail” is sealed. The sleeving shall [D1D2D3] not exhibit
damage (i.e.: blisters, lumps, dents, tears, pinholes, seams, cracks, foreign matter, or other defect) that
would compromise the environmental seal.

A.5.2 DIP COATING METHOD

This method creates an environmental seal by coating and saturating the exposed end of the wire / cable
with Red “GLPT” Insulating Varnish (or other approved sealant). Though the basic process involves dipping
the wire / cable end into the varnish / sealant, the process could be modified to use brush or swab
applicators, if approved by the USER.
1. Clean the wire / cable end and approximately 5 cm (2 in.) of the insulation jacket with IPA. The wire /
cable shall [D1D2D3] be positioned with the cut end pointed downward to minimize wicking of cleaning
solvent. Do not use aqueous cleaners.
2. Allow to dry and visually inspect for cleanliness.
3. Slowly dip the end of the cable / harness into the varnish to a depth of approximately 2.5 cm (1 in). A
slow dip speed is recommended to prevent bubbles forming on wire / cable end and to prevent
splashing of the varnish.
4. Slowly remove the wire / cable from the varnish and allow to dry. The wire / cable shall [D1D2D3] be
positioned with the coated end pointed downward to minimize wicking of varnish and to allow excess
material to drip.
5. Visually inspect to verify that the coating is cured (non tacky) and that coverage is continuous and of
uniform thickness. The coating shall not [D1D2D3] exhibit defects (i.e.: incomplete coverage, exposed
 conductor surfaces. pinholes, cracks, foreign matter, etc.) that would compromise the environmental
seal.

A.6 ACRONYMS AND ABBREVIATIONS AND GLOSSARY OF TERMS

For purposes of this document, the following additional acronyms, abbreviations, and terms are listed in
addition to those listed in IPC-T-50H, “Terms and Definitions for Interconnecting and Packaging Electronic
Circuits”.

ACRONYMS AND ABBREVIATIONS

Acronym Definition
GSI Government Source Inspector
i-HIC Irreversible Humidity Indicator Card
SCA Silver-Coated Copper-Alloy, 1 micron (~40 micro-inches)
SCA1 Silver-Coated Copper-Alloy, 2 micron (~80 micro-inches)
SCC Silver-Coated Copper, 1 micron (~40 micro-inches)
SCC1 Silver-Coated Copper, 2 micron (~80 micro-inches)
SCU Silver-Coated Ultra-High Strength Copper Alloy

GLOSSARY OF TERMS

Term Description

Cable An engineered wiring product, typically constructed of one

(1) or more individually insulated conductors, bound
together by an overall insulation jacket (unshielded); or,
bound and wrapped with an overall metallic covering (braid
or foil), and covered by an overall insulation jacket
(shielded).

Capping A process involving the sealing of the cut / exposed ends

of the wire / cable with a double-wall (melt-liner) heat
shrinkable tubing or preformed end cap, or by dip coating
with Red “GLPT” Insulating Varnish, to create an
environmental barrier to oxygen and moisture
contamination.

Conductor A material capable of carrying an electrical current, and

formed into a wire exhibiting a flat, round, square, or
braided cross-sectional profile.

Dew Point The temperature at which a volume of air at a given

atmospheric pressure reaches saturation and the entrained
water vapor precipitates and condenses.

Dry Pack An environmental protection system consisting of activated

 desiccant material, a Humidity Indicator Card (HIC), and
water-vapor-proof packaging (i.e.: Moisture Barrier Bag –
MBB).

Electrical / Electronic Assembly Any configuration of discrete and/or integrated electrical,

electronic, and/or electro-mechanical components; sub-
assemblies; Printed Wiring Assemblies (PWA); discrete
wiring, cabling, or harnesses; fiber optic components, or
combinations thereof, that are joined together to perform a
control or processing function (i.e.: measurement, sensing,
or transmission of data or power).

Red Plague (Cu2O) The sacrificial corrosion of copper in a galvanic interface

comprised of silver and copper, resulting in the formation of
red cuprous oxide (Cu2O) and black cupric oxide (CuO).
Galvanic corrosion is promoted by the presence of moisture
(H2O) and oxygen (O2) at an exposed copper-silver
interface (i.e.: conductor end, pin-hole, scratch, nick, etc.).

Supplier Contractors and sub-tier contractors.

Unit Pack (Desiccant) The standardized unit of desiccant material, which at

thermal equilibrium with air at +77°F (+25°C), will adsorb at
least 3 gm (~0.1 oz) of water vapor at 20% relative humidity
(RH) and at least 6 gm (~0.2 oz) of water vapor at 40%RH.

Wire A single, bare or insulated, conductor of solid, stranded, or

tinsel construction, designed to carry current in an electrical
circuit.

REMARKS
APPENDIX B - PROHIBITED MATERIALS

Beryllium (Be) Beryllium shall not [D1D2D3] not be used for primary structural applications or
as an alloying constituent exceeding 4% (percent) by weight. Beryllium is
allowed as an alloying constituent up to a maximum of 4% (percent) by weight.
Cadmium (Cd) Cadmium and cadmium plating in electrical connectors, cables, wiring harness
assemblies, and mechanical fasteners shall not [D1D2D3] be used where
exposure to elevated temperatures and reduce atmospheric pressures could
cause sublimation (vaporization) and deposition of cadmium on optical or
electrically energized surfaces.

Rationale
There are several reasons for prohibiting the use of Cadmium plating in space
flight electronic systems.
1. Cadmium has the ability to sublimate (vaporize), if exposed to temperatures
in excess of +75 °C (+167 °F), and reduced atmospheric pressure or
vacuum. This temperature is well under the rated temperatures of
approved wire insulations thereby reinforcing the need for a cadmium
prohibition as today’s wire gauge selections often take advantage of
insulation temperature tolerances. The resulting toxic, heavy-metal vapor
can be inhaled by crewmembers, or condense onto surfaces as a thin,
electrically conductive layer, impacting the performance of electrical circuits
and optical systems.
2. Cadmium plating on tool surfaces can be transferred to the surfaces of
hardware and fasteners.
3. Cadmium is subject to the spontaneous growth of Cadmium whiskers. The
propensity of Cadmium to grow whiskers appears to be lower than that of
zinc and especially tin. Cadmium whiskers (like tin whiskers) grow
spontaneously and are capable of causing electrical failures ranging from
parametric deviations to sustained plasma arcing that can result in
catastrophic short circuits.

Recommendations
Cadmium plating is commonly used on connectors, connector hardware and
mechanical hardware such as fasteners. It provides excellent resistance to salt
corrosion and is therefore offered in many military specifications predominantly
for use in naval applications. However, most applications are not concerned
with salt corrosion and the risks associated with use of Cadmium plating noted
above outweigh the benefits of its use.

There are several alternatives to Cadmium plating that are suited for spaceflight
use:
1. For connectors, electroless nickel plating is preferred. Gold plating is
preferred when the application requires additional shielding effectiveness,
improved electrical conductivity in RF applications, or where low residual
magnetism is desired.
2. Passivated stainless steel is the preferred material for hardware items such
as fasteners.

Consult your materials or parts specialists for suggested alternatives to Cadmium

plating.
Glass The breakage / shattering of glass presents an acute eye and laceration injury
and Foreign Object Debris (FOD) hazard. Glass is prohibited unless it is suitably
contained.
Glycol When solutions containing ethylene glycol and propylene glycol are used in
Ethylene Glycol hardware which have electrical or electronic circuits containing silver or silver-
Propylene Glycol coated copper, a silver chelating agent such as benzotriazole (BZT) shall
[D1D2D3] be added to the solution to prevent spontaneous ignition from the
reaction of silver with ethylene glycol and propylene glycol.

When solutions containing other glycols (aliphatic dihydric alcohols) are used in
these conditions, testing shall [D1D2D3] be conducted to determine if the same
spontaneous ignition reaction can occur as with ethylene glycol and propylene
glycol, and a silver chelating agent shall [D1D2D3] be added to the solution if
ignition can occur.
Magnesium (Mg) Magnesium alloys shall [D1D2D3] not be used except in areas where minimal
exposure to corrosive environments can be expected and protection systems can
be maintained with ease and high reliability. Magnesium alloys shall [D1D2D3]
not be used in the primary structure or in other areas subject to wear, abuse,
foreign object damage, abrasion, erosion, or at any location where fluid or
moisture entrapment is possible.
Mercury (Hg) Equipment containing mercury shall not [D1D2D3] be used where the mercury
could come in contact with electrical connectors, cables, and wiring harness
assemblies during manufacturing, assembly, test, checkout, and use.

Rationale
Mercury (Hg) is a particularly hazardous material because of its toxicity and
tendency to penetrate joints and amalgamate structure materials. Metal
contaminated while under high stress will receive greater penetration of mercury
and degradation of ability to withstand stress than will metals under relatively low
stress. Aluminum contaminated by contact with mercury will rapidly corrode, as
the mercury prevents formation of the protective oxide layer on the aluminum’s
surface.

An environment containing mercury vapor in concentrations of 0.005 mg/m3 () or

greater is not acceptable for continuous human occupancy.

Coronal discharge can occur at low voltage potentials in the presence of mercury
vapor.

Recommendations
1. Well-protected lamps containing mercury, including those used in the
fluorescent die-penetrant inspection are exempt from this requirement.
2. Mercury must not be removed from metal surfaces with any abrasive
cleaning method. The removal of oxide films on the metal will cause
immediate mercury penetration.
Polyvinyl Chloride The use of polyvinylchloride (PVC) insulated wire or cable shall [D1D2D3] be
(PVC) limited to applications where temperatures do not exceed +49°C (+120°F).
Non-lead stabilized PVC (classified as RoHS compatible) shall not [D1D2D3]
be used without USER approval. Polyvinylchloride (PVC) insulation shall not
[D1D2D3] be used in vacuum environments.
 Rationale

Recommendations

Silver (Au) Silver-plated hardware and finishes shall not [D1D2D3] be used in applications
where condensing moisture, salt fog, sulfur compounds, or atomic oxygen are
present. Use of electroplated silver is prohibited as a plated surface on printed
wiring boards, terminal boards and bus bars.

Bare or defectively insulated silver or silver-coated copper components such as

wire, pins, sockets, or connectors impressed with a direct current potential can
spontaneously ignite and burn when exposed to ethylene glycol solutions that do
not contain a silver chelating agent.

Silver underplate on gold connector contacts (Exception: movable contacts inside

hermetically sealed relays). Porosity in the gold plating can cause exposed silver
and oxidation, which can cause increased electrical resistance. The exposed
silver can also migrate.

Rationale

Recommendations
Tin (Sn) Pure tin plating containing less than 3% lead (Pb) by weight as a finish coat on
mechanical, EEE, electromechanical, or electro-optical parts or devices is
prohibited.

Rationale
Pure tin finishes are susceptible to the spontaneous growth of electrically
conductive single crystal structures known as tin whiskers. Over time these
whiskers may grow to be several millimeters (mm) long. Tin whiskers are capable
of causing electrical failures ranging from parametric deviations to sustained
plasma arcing (in vacuum) that can result in catastrophic short circuits.

The problem with tin whiskers has been known since the 1940 – 1950s, and was
solved over 30 years ago by prohibiting the use of pure tin plating on component
leads, component bodies, connectors, and mechanical components. Tin whisker
is considered an electronics reliability concern and whisker FOD in the habitable
section of the vehicle may present a possible health risk to the crew.

Tin whiskers are electrically conductive, crystalline structures of tin that grow as a
result of mechanical stress in the tin crystal lattice, from surfaces where tin
(especially bright electroplated tin) is used as a final finish. Whisker growth does
not require moisture or ionic contamination as an activator, and growth rates from
0.03 to 0.9 mm/yr have been reported, with lengths of several millimeters (mm)
and in rare instances to lengths up to 10 mm. Because they are crystalline
structures they are very strong, and capable of conducting significant amounts of
power before melting or vaporizing.

Recommendations
1. Growth of whiskers has been shown to be controllable by tinning with tin-lead
(SnPb) solder, and as little as 2 %Pb (lead) in the alloy or tin plating will
significantly reduce whisker growth.
2. Conformal coatings will not stop whisker development. Preliminary results
 from various NASA and industry-sponsored studies indicate that resilient
conformal coatings (i.e.: urethanes (UR), silicones (SR), etc.) appear to only
slow whisker growth.
3. Rigid coatings such as acrylics (AR), epoxies (ER), and paraxylene (XY) may
offer some whisker protection, but present additional reliability and rework
issues that must be taken into consideration by the design engineer.
Titanium (Ti) Titanium shall not [D1D2D3] be used with Liquid Oxygen (LOX) or Gaseous
Oxygen (GOX) at any pressure or with air at oxygen partial pressures above 34.5
kPa (5 psia).

Rationale
With a few exceptions, common structural metallic materials are flammable in
oxygen at modest pressures. However, most metals can be used safely in
oxygen, provided that the system is designed to eliminate potential ignition
sources.

Recommendation(s):
1. Titanium alloys are extremely flammable and should be used only in
exceptional circumstances.
2. In some applications, use of Titanium (Ti) may be acceptable via a Project
approved waiver process that includes review and approval by both
Materials and Parts Engineering disciplines.
3. Care shall [D1D2D3] be exercised to ensure that cleaning fluids and other
chemicals used on titanium are not detrimental to performance or reliability.
Surface contaminants which can induce stress corrosion, hydrogen
embrittlement, or reduce fracture toughness include the following:
hydrochloric acid, cadmium, silver, chlorinated cutting oils and solvents,
methyl alcohol, fluorinated hydrocarbons, and components containing
mercury.
Zinc (Zn) Zinc plating is prohibited on EEE parts and connector hardware.

Rationale:
There are several reasons for prohibiting the use of zinc in space flight electronic
systems:
1. Zinc is known to sublimate in a vacuum environment, especially at elevated
temperatures. The sublimation products are conductive and can result in
short circuits.
2. Electrically-deposited zinc (Zn) coatings have been shown to exhibit
spontaneous metallic whisker growth that appears to be more aggressive
than that observed with electrically-deposited bright tin (Sn).
3. The propensity for whisker growth and the possibility of microscopic metallic
fiber FOD in an IVA environment presents a serious reliability and health
concern.
4. Zinc whiskers are capable of causing electrical failures ranging from
parametric deviations to sustained plasma arcing that can result in
catastrophic short circuits. See prohibition against pure tin plating for
additional insight regarding the risks of metal whiskers.
5. The use of zinc chromate coatings in the habitable section of the vehicle is
considered a crew health risk.
 Recommendation(s):
In some applications use of Zinc plating may be acceptable via a Project
approved waiver process that includes review and approval by both Materials and
Parts Engineering disciplines.
1. Zinc (galvanized) plating is occasionally used on mechanical hardware such
as fasteners for its corrosion resistant properties. By using alternative plating
materials most designs can avoid the risks associated with the use of Zinc
plating while still achieving suitable corrosion resistance.
2. Consult your materials or parts specialists for suggested alternatives to Zinc
plating.
Radiation Cross-
Linked Tefzel (XL- Rationale:
TEFZEL, XL-ETFE)
Recommendation(s):

Lock Washers (Star Lock washers with a “star” or “tooth” locking feature have a potential to create
and Tooth Type) foreign object damage (FOD).

Rationale:

Recommendation(s):
Fasteners requiring a lock washer should use a split washer design.
Silver-Coated Copper Rationale:
Wire With Less Than
40 Micro-Inches of Recommendation(s):
Silver Coating

Use of Silver-Coated Inadequate silver plating thickness results in wire corrosion, known as “Red
Copper Wire Without a Plague.”
Red Plague Control
Plan (RPCP). Rationale:

Recommendation(s):

Parylene (Paraxylene) Chlorine may corrode metals or form undesirable electrically conductive
Coatings Containing substances.
Chlorine
Rationale:

Recommendation(s):

Natural Rubber Natural rubber materials outgas sulfur when subjected to heat, low pressure, or
Materials vacuum conditions; have limited resistance to extreme temperatures, sunlight, or
ozone; are fungus nutrients; and, exhibit significant compositional variation from
batch to batch.

Rationale:

Recommendation(s):
Acetic Acid Cure RTV
Silicone Sealants,
Adhesives, and Rationale: Release of acetic acid during cure of Room Temperature Vulcanizing
Coatings (RTV) silicones creates potential corrosion and contamination.

Recommendation(s):

Soldering Of Solid
Gold Ribbon Leads
and Wires With Tin- Rationale: Unlike gold-plated leads or wires from which the gold can be stripped
Lead Solder prior to soldering, solid gold ribbon leads and wires cannot be stripped, and
soldering with tin-lead eutectic solder can result in the failure of the solder joint
due to gold embrittlement.

Recommendation(s): Use either

Ultrasonic Cleaning Ultrasonic cleaning systems shall not [D1D2D3] not be used to clean electronic
parts and assemblies.

Rationale: The high acoustic energy levels used in ultrasonic cleaning systems
can damage sensitive parts inside electronic parts and overstress solder joints.

Recommendation(s):

MIL-DTL-16878 WIRE - KAPTON INSULATED (ALL SLASH SHEETS)

Aromatic Kapton- MIL-HDBK-454 states that MIL-DTL-16878 wire shall not [D1D2D3] be used for
Insulated Wiring Air Force or Navy aerospace or NASA applications. In addition, the ordering
requirements for these specifications are inadequate to ensure that the wire,
plating, and insulation will satisfy flight requirements.

Rationale:

Recommendation(s):

Immersion Cleaning of
Connectors and
Harness Assemblies Rationale:

Recommendation(s):

Sulfides or Free Sulfur Materials containing or coated with substances known to be detrimental to
metals used in electrical connectors or optics shall not [D1D2D3] be used
adjacent to exposed electrical contact or optical surfaces. The use of materials
containing or coated with sulfides or free sulfur is prohibited [D1D2D3].
APPENDIX C - FOREIGN OBJECT DEBRIS (FOD) CONTROL

Number: Revision

F-1
PROTECTION FROM FOREIGN OBJECT
DEBRIS (FOD)
Page Date:

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STATEMENT OF STANDARD

A Foreign Object Debris (FOD) prevention program shall [D1D2D3] be established for the design,
development, manufacturing, assembly, repair, processing, testing, maintenance, operation, and
check out of the equipment to prevent immediate and latent damage and to ensure the highest
practical level of cleanliness.
a. Cable and wiring harness assemblies shall [D1D2D3] be designed with debris-proof covers,
shrouds, containers, housings, potting, or conformal coatings that protect the entire system prior to
use, or that prevent debris from entering into critical areas of the mechanism where the debris
could cause arcing, binding, jamming, seizing, or unwanted current paths.
b. Connectors not being actively assembled shall [D1D2D3] be individually protected by wrapping
them in bubble pack or other physical covering (i.e.: clean, ESD-rated dust caps, etc.).
c. Clean, ESD-rated dust caps shall [D1D2D3] be installed on all unmated connectors.
d. Interim Assembly / Temporary Storage - Wiring, cable, connectors, and harness assemblies that
are not being actively worked on shall [D1D2D3] be stored in water-vapor-proof packaging, or
covered by Electrostatic Discharge (ESD) protective covering in accordance with ANSI/ESD
S20.20 and stored in an environmentally-controlled and monitored area where dew point is not
attained and the relative humidity is less than 70%RH.
If necessary, connectors that were subjected to frequent mating and demating operations during
fabrication and test shall [D1D2D3] receive additional cleaning prior to the final mating. Visual
examination of the contact surfaces of connectors shall [D1D2D3] not reveal the presence of
contaminants such as metal flakes or large dust particles. If required, additional cleaning should
be performed by vacuum removal methods and solvent-brushing.
e. After harness fabrication is complete and certified, the complete harness shall [D1D2D3] be
cleaned with an approved solvent, inspected with both black and white light and then vacuum
baked (bakeout) at a temperature of +20°C above the maximum environmental test temperature.
The bakeout will continue until a chamber pressure of 1X10-6 Torr is reached and the QCM
requirements have been fulfilled.
f. Completed Assemblies - Completed cable and harness assemblies shall [D1D2D3] be placed in a
sealed, vapor-proof, protective bag, with desiccant and a humidity indicator card (HIC). Clean,
ESD-rated dust caps shall [D1D2D3] be installed on all unmated connectors.
g. Cleaning The Harness Assembly - Particles and debris shall [D1D2D3] be cleaned from the
 harness or cable assembly by vacuum-removal methods. Solvent brushing with solvent, or wiping
with a clean lint free cloth and an approved solvent may be used as required to remove other
contamination. Under no circumstances should the harness assembly be submersion cleaned,
and aqueous solvents (water-based) should not be used in instances where the wiring is silver-
coated copper.
h. Cleaning Harness Connectors - The following cleaning procedures shall [D1D2D3] be used with
connectors:
(1) For solder-type connectors, flux rundown into the mating part of socket contacts shall
[D1D2D3] be removed (Requirement). Solvent cleaning by brushing may be used. Contact
surfaces of pins, sockets, and connector bodies shall [D1D2D3] be free of flux residue (see
Figure 15-1), solder splash, metal flakes, moisture, and other contaminants that may
jeopardize the integrity of the connector system.
(2) Crimp-type multi-pin and coaxial electrical connectors should be solvent-cleaned by brushing
before assembly to the harness or unit cable. Contact surfaces of pins and sockets and the
interior surfaces of the connector shall [D1D2D3] be free of contaminants.
i. Cleaning Connector Covers - The internal surfaces of dust covers and connector covers shall
[D1D2D3] be cleaned by solvent brushing and allowed to air dry before the covers are fitted onto
cleaned connectors.
j. Cleaning Coaxial Connectors (Assembled) - Coaxial connectors shall [D1D2D3] not have
accumulated contaminants such as metal flakes, dirt, moisture, and other foreign materials. The
connector interface shall [D1D2D3] be cleaned by brushing with solvent, vacuum procedures, or
a combination thereof until the contaminants have been removed.
k. Metallic Braid - All tubular metallic braid shall [D1D2D3] be cleaned with an approved solvent
before being incorporated into the harness. Aqueous (water-based) solvents shall not [D1D2D3]
be used.
l. The FOD prevention program shall [D1D2D3] conform to NAS 412 "Foreign Object Damage/
Foreign Object Debris (FOD) Prevention".

REMARKS

Overbraid / metallic tubular braid shielding must be cleaned to remove the oils and the tarnish
inhibiters used during the weaving process. While use of an ultrasonic cleaning process is
recommended, a manual process of three immersion-removal-drain cycles (with a gentle agitation by
hand while immersed) with room temperature isopropyl alcohol (IPA) should be sufficient. The third
cycle should be clean IPA and used as a final rinse. Once dried, the braid should be visibly inspected
at 4X-10X magnification to verify it is clean, particulate free, and should not have a sticky / tacky feel
when touched.
Silver-coated copper braid should not exhibit visible indications of Red Plague (a dusty reddish / pink
tint at the intersections of braid weave).
Aqueous (water-based) solvents / cleaning processes shall not be used if the braid is silver-coated
copper (commonly used for flight hardware), as this may promote Red Plague.
APPENDIX D - ELECTRICAL WIRE AND CABLE ACCEPTANCE TESTS

Number: Revision

APPENDIX D
ELECTRICAL WIRE AND CABLE
ACCEPTANCE TESTS
Page Date:

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STATEMENT OF STANDARD

Electrical wire and cable, including wiring used within containerized electrical / electronic assemblies
("black boxes") shall [D1D2D3] be procured and acceptance tested to the appropriate cable
specifications listed below:
• Cable specification ANSI/NEMA WC27500, Standard for Aerospace and Industrial Electrical
Cable.
• Cable specification MIL-C-17, Cables, Radio Frequency, Flexible and Semi-rigid.
• Wire specification AS22759, Wire, Electrical, Fluoropolymer Insulated Copper or Copper Alloy
• Other wire procurement specifications may be authorized by the USER.
• Wire and cable shall [D1D2D3] also comply with applicable Materials and Process (M&P)
requirements.

If the wiring used in any application is unknown, as it may be in the case of off-the-shelf equipment,
pig-tailed components, heater strips, etc. and if the application is non-critical, the assembly is required
only to meet applicable program materials and process requirements.

Two methods for certifying wire are:

a. As required by the procurement specification, Government Source Inspection (GSI) shall
[D1D2D3] certify that the test specified below has been performed by the wire manufacturer on
the length of wire procured. In addition to meeting the requirements of the appropriate
procurement specification, each shipment shall be accompanied by the manufacturer’s test report.
b. Wire certification can also be performed by a USER-approved test facility.

In either case, testing shall [D1D2D3] consist of the tests below. Testing for insulation flaws of
cable’s basic wires shall [D1D2D3] be done prior to cable assembly.

100-Percent Testing
a. Insulated single conductor wires and cable basic wires
(1) Impulse dielectric test (no greater than 80% of military specification)

b. Cable
(1) Dielectric withstand of component wires
(2) Jacket flaws for shielded cables

Sample Testing
As a minimum, a sample or samples of each lot of wire/cable shall [D1D2D3] be subjected to the
following applicable quality conformance inspections. (Applicability is determined by the specifications
cited above).

1. Insulated single-conductor wires and cable basic wires

a. Conductor resistance
b. Wrap test
c. Shrinkage (heat resistance)
d. Cold bend followed by wet dielectric
e. Visual and mechanical examination (finished wire O.D., identification of product, conductor
diameter, strand diameter, conductor stranding, wire base metal, and the plating material)
f. Polyimide cure test (applicable to modified aromatic polyimide coatings only)
g. Cross-link proof testing for cross-linked insulation materials

2. Cable
a. Shield coverage
b. Identification of product
c. Jacket wall thickness
d. Cold bend
e. Thermal shock
f. Stress-Crack Resistance testing (MIL-C-17 Cable only)

Any failure during sample testing shall [D1D2D3] be cause for immediate rejection of the entire lot.

Certification Processes
Certification of a USER-approved test facility is done by an audit team with representatives from the
USER, or their representatives. The team shall [D1D2D3] assure the test lab is qualified to perform
the test methods referenced in this standard.

At the using installation, before placing wire/cable into bonded storage, representatives from the
Engineering team and/or receiving inspection function shall [D1D2D3] verify that the test report
indicating conformance with all applicable procurement specification requirements accompanies each
lot shipped.

Storage shelf life: Silver plated wire and cable that has exceeded a shelf life of 10 years from its
manufacturing date shall [D1D2D3] be downgraded to non-flight status and not be used on flight
hardware.

REMARKS

The primary reason for downgrading silver-coated wire after ten (10) years of age is to control
increased solderability problems with silver and the potential for Red Plague for wire stored in a high
moisture environment. See Red Plague Control Plan (RPCP), Appendix A.