\

AEffi
ESA PSS-01-301 lssue 1

December 1982

Ci\ §uÉMo
ÚeW '

i_ Derating re_qu¡ rgmenl§_anel

aPplL-qatr-q.@
parere

Prepared by:
Product Assurance Division
\- European Space Research and Technology Centre
Noordwijk, The Netherlands

european space agency / agence spatiale euro¡Éenne

8-10, rue Mario-Nikis, 75738 PABIS CEDEX 15, France

I rrt
 1 , Issue '1 (Decernber 198 1 )

ABSTRACT

This document defines the ninimum derating requirements and

application rules for electronic, electrical , and electro-
mechanical components used in flight standard eguipment'
Parameter degradations to be crcnsidered in performing !áprst case
analyses are g iven.
ESA PSs-0 1-30 1, Issue 'I (December 1982 )

TABLE OF CONTENTS

1.

2. GENERAL
2
2,1 Introduction 2
2.1.1 Derating )
2.1.2 Vtorst Case Analysis 2
2. I .3 Appli.cability ¿
2.2 Related Documents 3
2.3 Def inir ions 3

1 TABLES 4
Resistors 4
3.2 Capacitors 1
Transformers, Chokes, Coi1s, ¡lotor windings 8
3.4 Relays 9
3.5 Swit ches 10
3.6 connect,ors 11
Wires and Cables 12
to Thermistors 13
3.9 CrystaIs 14
3.10 Fuses 15
, rl Diodes 16
3.12 Trans istors 17
Li.near Integrated Circuit,s 19
3. 14 Digital htegratd Circuits 20
3.15 Opto-Electronics Devices 21

ANNEX A _- Def in it ions 22

 AAsTNACT

Thl¡ b¡¡dbok l¡ l¡tadcd u ¡ 8u1d6 b thc delp of cr^bt¿

h-aii}¡e¡, thr ouph¡.t! bcbg cn dcatgD rl¡hc ih.ñ frlrlc.tloo.
Tbe dl.¡ct¡¡¡lo , vbtch bcludea me¡¡cd rñ'l ulr''.ñ''cd mrrlia6t,
alms at provldbg e cll¿lc8l gurde to thG v8¡lou! docum€ats td
tp€cülc¿ttcDs r¡¡h€r t!¡¡ ttytDg to rub.tlhrle tbeE Empb¡sl¡
tE thercfore gtvco io the bollc realoor for g1rrco d6rlg! or
manufacturtag réqu¡¡eE€üts ¡.!d relatl¡¡g tbcm !o sch¡¡l erp€rt€acé.

Tbe haadbook ts orgrals€d l¡r fou¡ s€ctLn6.

S€ctfo¡ I
cont¡b.s I llst of useñ¡l refereacee ,'..1 a sel€ctfo of
speculcatl6E Eort coE:raooly used h c8bl. haneea deatgn.

Sectlo! 2 contalDr guldell¡es for the de!rg¡ aDd brtsllattcn of

power, stgnal 'ñd p¡yotechDlc ha¡¡eseee. Tte erophssis ls otr .
rou¡d wlre ha¡¡¡eeeea slth aoEe l¡ for r'.. tlcn of flst cot¡dl¡cto!
cablbg (FCC). Refereoces 9. 10, 11, 12, 13 8sd l5 coat¡h
det¿lled dellgB, f¡brtcatlcD a¡d hstallstloa tech¡lques for FCC
hÁrDe6 s de!lgr.

Section 3 cotahs parametrlc d8ts for tbe EoiectloD of wl¡e/cable

and coDnector! and c llgt of aoEre of the m8luf,ach¡rers.

SectloD 4 -ontabs soEe a.sp€cta of cable heEesr fablicatlon.

Referace I t¡ recom¡neuded {or detslled Érbrlcatlco of cable
h¿ttega dl,ecu¡¡ed la thls he¡dbook.

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ESRO CR(P)' 0 5g

otcaxtllTrox gunoPÉtxxe D€ 8EC}IEBCHES SPATIAIEI

EUROPEAX SPACE ñESEANCH ORGANISANOT

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FOWER A}'D SICII{AT CAELTIIO
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h.Fs.d br E§O u¡&r EEfEc coltlrct No. 36!/?3

b, EAWKER EDDELEY DTNAECS L¡ETED

EPACE DIYI&}I
ITlryENAGE
EEAfFOBDE¡IAE
' Jr¡¡rrY fe?ll

IIR¡PI¡r SPlcg ñ!¡r¡rc8 0FcilllrTEt

Ib r¡l J.¡¡§ri L dA r rrl '¡ Ja ro{* [!10
*, l¡e¡¡¡¡Ir¡ L úr ¡¡r¡¡r¡ ii¡. b i. *
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FOWn, A}ID IIO}IAI CASL¡I{¡ EA¡¡D8q)K

Coqlld fo¡:
ESNOPEAN SPACD TECENOI¡G? CE}TT3I,
Ho()BDWTJX, NRTE EBIJ¡{I}E

cot¡rct lib. 2063,/73Ax

Eorét M¡Drg!$ G Jo¡¡

Cñtrtbúo!!! D. B. EsEbloto¡
P. E- Whlt¡he.d

J¡¡usry 197 3

EPACE DIV¡IEN
EATKEB EDDI¡JY DTXAX¡CE T..Düf E
grEvD{Aot
EIRTFOBBEAA, TNOLA¡{D.
¡

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(
OVERALL COI¡TEI*TE

SECTION 1 REFIRENCES AND DOCU }TE¡¡TATION

1. bttoductlcn
1.1 Bsflrcac6 Lllt
G¡üe to S €c tflcstlcn!
i l. ., $ececraG t¡terf¡ccs
I
¡ §ECTION 2 HAANESS DESIGN
I
a1 HaraGA .bg Sy!t6E!
aa Electromapeüc CoEFébtUty (EtlC)
+ on ryrotlchtcg
2.4 ll¡¡¡e¡¡ bttslbttc
EECTION 3 COIIPONENT SELECTION

3. 1 lblcct¡ca C¡lterte
,, Wtre D8t8
e., Co¡€ctor Dat¿
3.4 PottrDS CoBpoudr

SECTION 4 HAENES§¡ Má,NUFACTI'BE

4. I HaEeas Clea,Elng
4.2 H¡t¡eaa HaDd¡trg, Packlag sad Se¿llog
4.3 llaEesr !d6tul,c8ttoo
4.4 Repalr Metbode
4.5 mrc Stlrppl¡g
4.8 T.!tbg

(r)
 C tEtEx I
BAIIBT¡{C EI A¡{D DOCUUEITATDT

i
I @ttTBrrt
I
1. btsoü¡.tt D
1. I Bd.rao. ¡&t
1.2 Odd. to +.ot!!rd6r
1.3. 1 D¡l¡D
L.2.2 C@.ctoí
L.2.3 Ftrc ¡¡d C¡blo
-1. 1.3
1.3. I
L.3.2
Sroan! bt ¡¡3..
btrodr¡H-'
llab¡slo¡l bLttó.
1.3.3 ElÉtttorl htrrto.

&¡E¡o¡IY

Thb .ccth aetrbr . lrrt of rcfcrrocc¡ ¡d r aclGd¡o ol

l
I rpaol.0cstl6! t¡o.t coEEoÉly u¡ed b C¡blc Eltr¡a Dcrtga.
Equl¡cEcot! b¡ Eeb¡nl,csl r¡d cl6rtllrl bt r¡ca. ¡ta
I
Fa.a!€d rlt! r forB lo! btar!¡cr D!.r.¡g¡tb.
r
{

c
 ¡-
,

!
i
f'lt \
I INTBODUCTDN
.
Thl¡ lcctlca coatrbr r lra! of rsferaccs e¡d a ¡clcolt¡m of ¡p.curc.tt6t
mort com¡noD¡y urad l¡ lbo dea tgn of ¡n¡¡nod sad s¡nr¡n¡t rDroacstt'
crbl6 hs¡!o.!6a. Thr Blt lrlports.Dt raf6!6cGa st. Bu.EbGlr
f , 19, 23, .t{, 4t, 49, §5 ¡¡rd 56. Tbe re¡dor f.! ¡dú¡rd to trolllart¡c
hlmself wl¡b tha cñtéEt! of thcsc refar6c€! r! thGy cút¡tD thc bsrlc
raqutrér¡rat! of csbl6 l¡a¡nera dsstF, r¡¡gr srfoty ra'r crllcal¡ ror tbG
reloctloo ol cabl€ h¡,¡tera cotlpoo ertr¡.

Also l¡cluded t¡ thtr lGctloa ts a g€aGr.¡ dber¡leto¡ of thc n€cdr fDr

clear and coaclse pleleDt¿tloa of the rpac€cr8i meh¡¡tc¡l a¡d
eléctrlc8l llterface! sld prnm€terr.

l.l Refer¿nce Ll¡t

* (1) ¡t48Dufscü¡rc rd q¡dlty Cont ol of ht€rcon¡.cü¡g HerEr.er
NASA TM-X-646t5

t¡ St¡¡d¿rd for ¡n¡Drd¡ cü¡re, l¡rt8ll¡üon ald Qusüty Cootsol

! of lBta!@ññecüng hasneslea.
{
i-
(2',t Electroír¡gt¡eüc l¡telcrence Bdd Comprüblllty Volume 3
Don¡ld R.J. Whlt€, II§EE.EE
L
E fteoreüc¡l a¡d hrcücal sppro¿ch to EMI.
t (3) R¡dlo F ragucnc¡r lnterfercnce He¡du¡ok. NASA SP 306?

Pracüc¡l rpproac]¡ tnd To.hnrquc! for EMI cotnpsüblll§.

({) Al rer¡It Stn¡cü¡al Electrtc¡l Boaüag l¡d croundtDs.
Huglra Atr*aft t)onpe¡V - Febnnry 1972 - AD ?39356
(ñ2-n037)
Bot¡dl¡g, g¡ouodlr{ for llghblng protrstlo¡ d.q¡.rloD rDd
compr.h.nrlvr ll¡t d rCcn¡cc¡.
(5) A rrrtgr of Ug!6t!8 P¡oblca¡ b rught vchtclcr rlá rug¡cotcd
¡oh¡üoDa ¡Dd ralrtad lDtrr{elGDcr ral osüoE ?cchat¡tcr.
H. M. B.rtm¡n. Al. Force AvloDlc. L¡bnlor7 - ADt93135

tdaÉIf¡caüon oi h¡¿rrd¡ ¡d EMI dr¡c b U¡lrEl¡g ¡'.rüc¡.

l-l
(6) Etcctlc¡t Bod¡g ol rdya¡cGd rlrlr¡na .tñ¡eü¡rc.
L. E. thort. Prpc la ArEC Ll¡bt¡la8 sDd EtrÉc E¡ódrrclv
Codcrcnoo, ¡l¡t 1¡69 p, 12b{ll, AD 693 136

BodlDg for UÉü1 rd ¡trüc cl.cñctty o¡ ¡lrf¡¡oo¡

FI 8trü cEllct¡lct§ on Fllgbt Vchlalcr
J.E. Nrúlcz r¡d E. F. V¡DG. Ppc lD AIgC Ll8hEl,ry end
§t¡üc ElecHcú§¡ Codcr6Bce. It!¡y 1909, p. 15?-167. !{,o-f 9039
Paper ou t¡Éc rlecñclty aBd .S¡lb lE¡tÉoo.
(8) Llghtntng ¡rl §t¡üc Elecñctf @de¡euc¿, P.pcr. Msy 1969
AFAL-TB-66-290-PÍ-2. AD693135.

(e) Developmer¡t of ?rrnlDatlon ald Utlllzaüon CoDc€pt! of FCC

Volume 3. Colt Sü¡ü CompsrtroD. July 1g?2
Boetng Corrpa4r, Scattlc, WalhlDg-bn. }fl 3-202,t3

A @!t ra¡dy couperlDg FCC wtth ¡msll wlre gr¡¡8e aDd coD-
veuüo¡¡l BWC, Co.t elementg t¡cluded, fabrlc¿tlon, mat¿rl¡I
A¡T

(10) Derrelemeut of Terurllaüotr s¡d UüllzaüoD Cot¡c€pts of FCC

Volume 2. Uüüzaüon of ¡mall gEugÉ wlle roud conó¡stor
cable. July 1y72. Boetng Co¡rp¡¡y, Se8üIe, w¡abtEgbn.
lf,v20242.
Sürdy of wlre co¡rsEucüon, hlnecl coDccpts, fabrlceüon.
Eecult! of lrbontory evaluatloa r¡e tncluded.

(11) Dw.icpmo¡¡t of Tormi¡¡tton and Uüllzation @nc.ptr of FCC

Volume 1, Dlvo¡oprDc[t of low proflle F]¡t Codus'tor conDGct-
lr¡g dErrtc€ r¡d p¿¡r¡r¡.ut. Boelng Compuy, Saüle,
W¡.ht¡glotr, lir,3-20241.

D."al*mcú ol FCC, coEEcüng dsvtcar, ¡pllclnS End tá!ng.

tc¡t rcault¡ hclud.d.
(12) Fl¡t Conductor Ceble de¡tgn, ms.utdact¡rc rnd In¡Elbtsoa
W, AngGh. ¡{ EA Ap¡U 1973. }.I?3-2&86.

Idorm¡üotr oo h¡rrirrrc aalccüo[, m¡m¡l¡c!¡rc, QA lttd

colt eElprrlron, olcctrlcd cü¡rrct riaüe. ¡¡d EMC.
(13) Thc l¡rd C¡rrytra .!d Íl¡.rrtt¡¡ Cb¡ssc¡lrüo ol PCC
Georgc C. lñr¡hrll gf C 1966

t-?
 I
(1{) 8¡!¡r¡ rvB/V AIt Sktrt Mock-up. FI¡t C¡ble Devclopment
i
Progrrm. McDo¡¡eil Douglae Corporsioa SM531?5 Mry f966
Dllcr¡lrtou oD AppllcaüoD ol FCC on L¡u¡ch Veblcle¡
i
(15) Flat Cond¡ctor Cabl6 Tech¡ob$r N^8A-EP- sO{C. N68-28f 9
;
i F¡brlc¿ion procedurea, lystenr coat, olectrtc¡l chr.t:r,ctarlrñct
aad suggected eppll catlon.
I
(16) Ju¡cdoD a¡d Juncüon Delrlces, ElecElcsl dlstrltu§on 8d
I Buealng. IV§IF C Speclflcaóon 40M39589
I (1?) Wlring Harra!, Space Vehlcie, Dellp 8nd Teaüug
I ltrL-w83573

l¡ General deslp and t€Eüng requllements for ham€r! er

installed ln spsce vehlciee.

(19) WtrfDg, Alrcrslt, Selesüon 8rd l¡stal!¡tlon of, MIL-W-5088

I
Covers ttre aelecüoo Eud installeüon of wlring aod wirlng devicea
I lor atrcraf t lntercormectlng harr¡e¡aes,

I (19) Har¡ess, Electslcal DeEtgrt St¡Bdsrd IBFC Specifica6on

{0M39582.
I Eatablighes t¡e r.-'nimum derlg¡ lequtrcment! for the delign
!ñ of apace vehlcle electrlcal h¡nec¡er

(201 Bondlng Strengür of Encaparlrüng lúaterlsl b Hook up Wlre

I B.R. Crockett, Bendlx Cor?or.üon, K¿!rs! Clty. BDX-613-135
Evalr¡tt€r bond rtrenglb of v8rlous PotüDg compounds to
vtrlour wlre l¡¡ulrtlo¡¡.
(2tl Proccdura for Potüng Electtc¡I Cable As¡embly Termtnaüonr
l,r,AEA TM-X-68690. ¡n2-28230

Procedurca lo¡ ¡rfe cleanrag 8!d Potü!3 of c¡blc ¡¡aembllel

¡16 81v6n, prlEler aEPllcaüon ald i¡IaV p¡scauüon¡ are ll¡tod'

lz2l culdellne! lor ¡prce m¡tlrlsb acleeüo¡ ESBO PgE O?/QRM 0l

Crlterlr (o¡ ¡cleclloo of r&o.lvcú, tsP€! 8d potüag compouarlr '

(
1-3

11i'
l

- (231 the Eclecüoo d Iirlra LúuhEoEr

Crltsrli lor for Ure ln Eprce
Afllcrtlorr. N EA TN-D-{563.
Dtro¡atlotr oa rrdrüou, q¡t¡EarlDg, ¡16¡ho¡{6El ¡¡d clcctrt-
crl properüce of rnrlou¡ l¡¡ulrüoa¡.
(24) E¡octrt csl D.toDsbr! slrd Squlbo ¡¡d Tbalr A!.o c1¡téd
Idü¡üon ¡nd IEüüoD TtstDr. S. H. R¡¡¡b NA§A-SR-81250
N67-15986

tz3) Elcctrlcel Co.ñ-stor Potürg Procedrre, IME 701-73-003

D€Jl¡e! potüug procedule.

(26) Potflng Ceble ¡{¡¡emblies, u.tng Epoxy Rr.la @Dpq¡Ddr

I ItÍlF C Specllicaüon 196

De{lnee potüDg m8t€rlels aad proceraea,

(nt Space Shuttle CoDnector DeveloprneEt NASA-1Í71- 350.11

(28 ) Cabling 8!d Connecto¡! for UBe oD a LlDear Stage

NáSA CB 103056 N7l-198?5

r Cable and @nnector daE are deatled. E5/llolmeDtsl 8nd

functlonal requirements end mat€rl8,l dleoraeed. Wirtng
I
B.
concePts lncluded.

B
(29) Flat Conductor Csble Applf csÉotu for Alrplane Power Fee&re
! J. Morrls. The Boelng Aircraft ComPe[y.
130) Engtneerlng Dertgrr Handbook for ElecEtcal wlre lnd Cable
AMCP-?06-125. US Army Mstertei Comm¡nd

(31 ) E Co ¡r¡re cüo¡u f or Alumi¡lum CoDdr¡ ctor!

lectrl cal
T'tmotñy Lerüe. AMP l¡cor?oratéd

(32) NASA NHB 5300. {(3A) Requlrement¡ for Soldering Elecñcal

Co¡Decüon!

(33) Da-ratlng Baqulrement! ld Appüc¡üoa Rules for Elsctronic

P¡rr¡ ESRO QRA-ro
Ddl¡c¡ voltrge td c¡rrartt deratlog of wtreü aod con¡ector¡
u¡ed !¡. ¡ lpacc GrIvt¡ontnenL

(3r) MIL-B-45?43 Solder M¿m¡¡l TlDc HlEh Rellablll§ Elact¡lcel

connectlont for Ml¡alle s)'tt m., Proecdr¡¡e¡ for

l-{
 :
?.

(35 ) ESRO PPBU,/QRMO8P lvfsr!¡I Solderrrg o( Hlgn ReIt¡brUR

:\ Cou¡Gcüooa.
t
tt (36) I¡rulrtsd Wlre 8elscdon on ihc Apollo Spacccraft tad tle
I,tr¡¡r Excr¡rrloa }6¡lc, J, ![. D¡vlc¡. Fcbnrery 1986
r NASA CB 11007{. N?035866

t.¡ 8!¡dy oD lD¡ul¡tsd q¿tre colrlttl.rsüona lor rprce rppllceüon,

! (37 ) Flrt Co!á¡ctor Cable Symporlum
t,
J.D. Hawldlr. NASA TM-X-6{716. }{?3 23294 to }fI323318
t
Detsiled s¡¡dy of FCC eppllcstloE, E¡!a.¡fac¡¡!e, EMC sDd @rt
I coDpsrtlon

(36) Product Clcaullne¡s levels a¡d CoBtalolDaüoD Coatrol Progrra

I
p (3el
MIL.STD.I2,I6

Te¡t on FCC cro!.tEg 8 hinge llr. ESRO TN-11{ (ESTEC)

F Augutt I Yl2
!
r (40) Llfe va Voltege Pcrformance of FCC a¡d Ltgrlt?eight BwC
i. N. Cotter¡, J, P. Perklne. A.D69E 606. N70 234{8
T
t S!¡dy i¡to l¡¡ulaüon thickn€r!, delectlc co¡rtEDt, coroE¡
t dlrch8rge tEd voltage raüng cf FCC srrd BWC
i'
(41) Proce€ding! of the Sec.ond tfforkahop on Voltate Breakdowo ln
Electro¡üc EguipmeDt gt Los Alr Pregaure
E, R. Bemker. ¡IIABA CR ll61?3. M1-r66{3
CorcD¿ lerl6 on FCC, RWC aDd coD.Bctort, tryl8t€d palrt s¡d
elfect of f¡¡ul¡üoa thlckoer¡ dotsnñtEéd.

(121 Electrlcs¡ Coron¡a, L. B. Locb, UDlv€r.tty of C¡IlÍortls her!'

BGrkoby ¡Dd l¡! Aagelce 1985

(43) coroÉ ooaGt voltstc ol I¡¡ubt¿d ¡¡d Borc ElGcEod6 lD

R¡reflcd rnd ot}er grrct
r¡V. G. Du¡b¡r AFAPL-18-65-L22. Nt Forca Acroproprlrlou

L¡b., Re¡e¡rch a¡d ?echalc¡l üvl¡lon, Wrlglrt P¡lt raon

Att{o¡c. Br¡. Ohlo

- ({r) Co¡oo¡ Ev8Iu¡Eoa of Specccreft wlrct ¡Dd Conrc'tor!

w. G. Duab§ :fI0-23{49.

Prc¡cota rarultr ol @ron¡ taatr odr¡ct¿d to oHlD cll Ert¡

for eclccllng vlre for u.c la u.Qrr.aurl a ed P.cúsr¡ft
coEpstl¡nGtrta.

I
r-ó
:
 (46) Hlgh VoltrSc Brcd¡doro Plc blcm¡ l¡ 6docül1c Ert lltrt
!{AEA X-30f Be-{I. F 6b¡r¡¡rY 1966

Bayla cl ¡Focnlt nr.llütrctloú .ü¡lbt d to coron d¡drr¡:c

I r¡d lo¡lz¡ÉoB.
I
¡ (48) AFW:? MrE¡¡l lZ7-1. Eugo Sdcty llrurl
Vrndeoburg Alrlorce Br¡c, CeltforDle
I
CoEt¡lrl! ra¡g! aslGty raqulrcm€nt! cour¡noD to all l¡undl
cper¡üons et th. We.t8¡ñ Tctt R¡D8B'

(47 ) AFEIA MaE¡¡t 127. R¡rye S¡loty ll¡n¡¡l

Cod¡i¡! raagc lsrety r€rplremcnta contnoa to ¡ll lcu¡c¡
op€reüoDr at the E8lt¿ro Test B¡Dge

(48) Elcctro-Exploelvc¡ H¡¡dbok. Hol.r IscotTorstcd, HolllgEn'

Callfornla

Compttsüou of glorearT of term!, dcllp formulee and hsndllng

p¡e (3uüonr,

({9) Ali¡A B¡lletln No. 400. Alrborne Elecfonlc and A!8oc1et€d EquiP-
meut, ApPiicsble Dod¡metrt!.
(50) TOR-1001(230?)-{ Electromagnettc Compatlbtllty Requtrcments
for apace !y!tem6 -
Aerolpsce Corporatlon, ClllfornlÁ.
P¡.ovldea EMC requlremenls for sp¿ce vehlcle system 3'

(51) Technlqu€a fot ihe r€ductlon ol Elcctromaglellc l¡r¡erference

oo !¿tell¡te (GEOS) ¡vfAB Prolect 6.48?. I. November 19?0'

(s2) The concept of tiagle-polat Grot¡¡d¡¡8. M' Hoff¡rt'

Proce€dl¡B! of the rpacecraf! EMI Work¡hop. Februsry 968'
r

N69-25445.

(s) El6clromagDGllc comPellb¡llly, prlaclpler snd prlctlceE

Af¡lo progr¡tü NHB 5320.3. Octobcr 1965.
(t) S:rleldl¡8 Dc!lgD C,t¡idcllDcc. GEOS Tech. Note TNE 21' f 0/028'

_ ( 5s) A comptl¡tlo of O¡tgrr.lng Datr for a¡cccralt mrllrLalr'

NASA TN-D 736:¿. SePt€ñb.r 1973.
complhlton of rp¡cccr¡ft mrt.rhl. bcludlng uGlgh! lotr
VCM, cuto tlfnc! and ¡Fllcttloo.
_ (55) A rcreoobg t..t melhod lmPloyl¡8 ¡ tharmr¡ v¡'üu m lor th'
lel€ctbn ol m¡rcrl¡l¡ to bc u¡cd ln rp'ce - IIIRO PSSI-09/
QRM.O2T (F.sTEC).
l-6
( L'. 2 cutd. to SD6elfl atloar

tn thc (ollowtag n¡bocGlon¡ ¡rc Urt¿rd th. FcclrlctüoDt Erott omnraly

urcd l¡ tbc dotp d 4ecccralt c¡blo b¡ru¡¡c¡.

Tho r6vitl,o[ rts¡d¡rd aDd l.au. d¡tc ¡ha¡ld bc vcrlflcd; tbl¡ lr mo¡t
Gellly doDG by chccld¡g AlitA400 (n lotcucG ,19) o¡ t¡. rpcclllcedon
l!dq, E¡meric or e§hsbe üc.
Ep.df I csüour ¡rc ü¡ted for Dcrlgl. cor.clon a¡d rlrc,/c¡ble.
Spe cill ceÉone for procedrree ¡¡¡d accc.aorler are omlttadi thaac c¡!
bc tdeEtlrled by rrilarrlng to the a¡pllcer,le apeclfl crüoor ¡ccüon o(
the D€.lgn rlgullrErcrIt!.

l-?
 UrFrrEaE rr ¡¡,&r¡ ,
,,(n

Dcslgn

M¡L-W-50AI 70 Bonding. Electrical and Llghtning Covcrs the charactcrisücs appltcaüon

protcction, For Aeroapae aystems and testing of electrlcal Boxling. For
instal lation tnd ¡niercor¡nectlon of
eicctrical/electronlc equipment and
lightnlng prot€ction.

l,flI-W-5088 73 f,llrlng, Alrcrafl Selection ¡nd Covers the selectlon ¡nd lnst¡llaüon
lmtrll¡üon of of wlrlnB rf¡d w¡rlng devlcoa for lho
lntercon¡ncdon clechonl c,/Gtectrl c
equ¡pment ln ¡ircraft.

NIL.W.E35?5 wlrlDg HtrD€eB, Space Vehlclo. Covers the Beneral deslgn snr laüng UIL-W-Í086 forma r pr.rt
Dee lgr and Tesüng requlnementa for eleclrlcal wt ng of thla epeclfloüou
he rnesgea ¡¡d c¡blea tlut are be
installed ln epece vehl cles.

toM39582 ?t Harrreas. Etectri cal Dealgn standard Est¡bliehcs the minimum rcqui rements Mo.t W b &tG, bot hlrly
for the design of space vehlcle gEf¡orrl
elecHcal h¡rrpes

ESRO PPST I/ Manu¡I §o¡derlr¡g of lllgh Reltablllty f,stabll,Bh mlnlmum aolderll;g

QnHosP Solder JoLot¡ requlrem€rita
 +lcrtttrlrrrti!;¡Utllcr
----.e.!
-.2.2 c.onnectors
o) o
a a
SFctltc¡tloo ¡o o Tltlo Cont€ota Comlnc¡lt

¡,ü L- C- 501 s D 70 Con¡rctor Electrical AN Type Descriptlon of clrcul¡r c'onnectora Thle eec{f lcaüon h¡¡ becn
suitable for power/sigrul, operating euperaeded bt MII- C- 85? 23.
withln the t€mperahrre range -55 to
r 200oC. working voltage 300 min.

l,trL-C-22992 D 73 Conmcbr, Plugs snd Re -cptaclee, Covers heavy d¡ty, qu¡ck dlsco rect
Elect¡lc¡l Wst¿rproof , Qulck Dlo- waterproof connectora for power and
@n¡¡€ct, Ileavy Du§ control ciror i ts.

tau,- c- 259 55 60 C-rrnrrcctor. Elect¡lcal, Envlron¡nent DescrlpUon of miniaü¡re clrorlar

Reoletlng, Mlbl&h¡re wl th Snap ln envlronmental @nnector sultable for
Crontrctg power/elgnata, opcraüng wtthin the
t€mperrürre range -55 to ' l2f C-
Worktng voltage 600V.

I
(o üI-IC-? 82 E 69 CoüEctor, Electrlc, Clrorlar, Dcscrlption o[ miniature conn€ck)r
ltrnlaü,rre, Quick fra únrrect, eultable for power/eignals, operuüng
Envl ronm eot¡! Reeladng at 20@C maxlmum. Worldng voltage
l- 300

xII- C- 265{X} E 73 C-on¡nctor C eneral Purpose, E lectrl cal I¡r¡cüvo repl¡cod by

Itllnl.iü¡re Cl rcrrlar, Envlronmental MrL- C- 857 33
nartBUnS

taIL- c- z7 5 99 A 7l Conrrecbr, Electrlc¡I, Mlntlü¡re,

Qulck DlaoorEct. Eetabllshed
ReUabtllty
 (
o o
$.ctftÉt16 e ¿ Ttil c CoDttat! Oor¡@t
: o
xIl,- c- 3E99t) D 72 Conrcbr, Elecblcal. C'lrorlar, Connoctor capable of 6nü loüB Aprovod for 4eco rPll-
Mlnhture, HlBh Dengl§, Qulck dle- operaüon wllhln the ter¡perah¡re crüon- Rel. UII-W-
cúnlEct, Xwlronment R€slsünB, rargo -65 to r 2o0oc auplled to 835'1 5
Remov¡ble Crlmp (bntrcts lll L-STD-? 90 Relirblll§ Asaura¡co
Pro8ramme

xII-C-Er 5ll D ?l Conmctor, Electrlc¡1, Clrculer,

lllBh Densltf , Qul ck Dls@nrEct"
Envlrom¡e¡td nealsüng

rlr-?-6r?tt B 'to Termlml Juncdon Syater..rr, Ger¡cral

Sp€c lcrüon

x¡I-c- &n 23 B 72 Co¡rEcbr, Elec'lrlc, Clrorl¡r, Apprsvod for ry.e ¡!Pll-

Euvlm¡¡mental RealsHr.g. Ge¡eral caüon Rd. llIL-W- 8ll5?5
I Sectllcaüon
I
xII-C- EyI 3¡l I 7Z Coutcior, ElecEtcal, Mlnl.at¡re, Apprt Yéd lor apaoe lPll-
Hectrngutar Tlpe. Rad< b Paml, caüon Ref . tdI-W-E3575
Eovlrooment Realadng 2üPC
@nurr¡d¡a Qeretlry Temperaü.¡ re.
General $peclftcadon

xrL c-55sat A 7r Cr,nrectora, Electrlcal, Envlronrnent Detlno th¿ dea tgn reqrlromenta of en Amrovod for q¡eoo rPll-
(xflFc Se. Rcrldng r..;; lrse wtll¡ Fle¡lble Flat FCC con Ector capuble of cperaüng caüon Rel. MII- w- 8J5? 5
2r9) C¡¡rxl¡ ctnr wlthln the t€mp€r¡b¡r€ ringe -65 to
t t 25oC

l0lt395a0 B 72 Cou.mctor. Electrl cal Z ero-G Deflno requlrem"nt" to" o+loslvos Spcolflc¡lly dol Srrad lor urc
Spedfl c¡üon for proof coruroctor i*ht.ü c.n be opemted ln m¡n¡od ¡p¡ cacralt
by an sBtromut tcmpcrobüre ratlng onvlronmont R€í. {0M39582
-65 b +lslto(j I

.,
 -.¡tilmr -
^r t!:'rx n?rrErrP=
Co¡EtDrr - oonünuod

&.ctltc.t h
a¡
t
a ! Tttlo Co,ntcnts Commari!
e o
10u382?? A 72 Conmcbr, Elecblcal. Clrqrl¡r Define a crlmp removable connector I¡tended for use ln a apro6
l,llnlsture , Hlgü Denel§, E¡wlronmont capablo of conlm¡ous operauon wl thln vehlcle. Av¡lhble ln
Roclaury $oclf lceüon for the rango -loo to l2ooÓC llermeUc or Envlronmontal
form. llermeüc conr¡edora
l¡ave goldor potú. AIprov od
{0 t!Í:r9582

{0tf,39569 B 68 Conccbra. ElecHcal, Il,Ilrilsbre,
Clrorhr, Ewlronment" Realaüng
zoooc. 8p€ctflcrdon for
Deflne a crlmp romovable @nnector
capable d @ndDuoua op€r¡Uon $,lthln
the range -fls b 20PC
lntentled for uae ln i apaoe
vehlcle. Avallable ln
llermeüc or Eüvlronment¡l
form. llermedc @Dnec.tora
h¡ve aoldor potr-
.t0M39582. ^Sprovod

uII- c- ?r s08 A T2 Co¡¡Dctor, ElecElc, Rec'tangular, Rectanguler, fnn envlronmental crlmp

I
lñnl¡ülre Pol¡rlzed §hell, Ra c-k and or solder ph couEctor capable ol
P¡nel. Genorel Speclftcsüon operaüng wlthln the temperature range
-55 to r l2ooc

NA8 r s99 66 C.onrrcctora, Gerrcr¡l hrrpoae, Envlronment resl8ung, crlmp cont¡ct Suporaeded b,y MIL-C-EYIz3
Electrlcal. Mlnlaü¡re Clrcular, connector capable of operatlng wlthln and l,l§¡F C {01á:19 569
E¡vlronme¡t Reclaüng zfi)oc M¡xl the temperature rango'-55 to + 20@C
Temper¡t¡re.

GSPC 69 ConEc.torú ¡nd Contacts, Elect¡lcal Rectangular, rnn-envlronmental crtmp

8-3lr -P-t0 Rectrngglar for Space tr'llgbt UB€, or solder pln @nnocbr c¡pable of
Gener¡l Sp€cú¡caUon operadng wlthln the t¿inperature range
i
I
GSrC 69 CoBEctor! ed Contaota, ElecElcal Rectangular envlronmental crlmp pln
8-!l r-P-{ nosbnguh¡ for Spaco Fllght Uae connector c¡pable of opera§ng wlthln
tl¡c temperaürre ratgel
.|,
'
 iwlir" ¡r¡¿ c"u¡c
o t,
1 t
Sp.cUlc¡tlon Tttle Conteatg CoEr)adtl

M¡L-W- 5086 B Wlre, Eloctrlc lloo& r.9 &ul lnter- Nor alitabte for ape ce
conrncüng PVC, Copper or Coppcr I
appl I caUon
Alloy Condr ctor
I

M¡L-C- r 3??7 F 72 Crbl,e Speclal hrrpoae, Electrical Multiwlre cable, 34 to 78 condrctors t.nsulatlon rnt 4cclf led.
Obtalmble wlth PolYes tcr
insulatfon

úLS-r6878 D Wlre Electricrl, hrsu b ted lligh Det¡ll8 cablee for uae at 25oV, 6O0v, Insul¡tlon rr¡t @e clf led.
Teripemb¡re 1000V, 300W. Wor}lng lemperature (I¡ttlrnble
wl tñ P\¡C, Telloo
tos b 2000c FEP lnsuliuon

lflL-w- 22159 C 69 Wlre. Elect¡lc. Fluorocarbon 00OV ood 600V cable, lneul¡don
Imulatcd, Copper or Coper Alloy rlals: TFE, FEP-Pt/FZ, ellver,
Conó'.i,rrB ckel a¡rd dn plated cor¡d¡ctora,
I and llglrtwclgtrt
§¡
l,{¡L-W-8r0,H A 73 Wlre, Electric, Cmeeltnkc(l Mcdium and llBhtweight 135 to 26ooc Approvcd for ryeoe rPll-
Polyalkeoe Insulat¿d Copper or t¡ng temp€ratute. lnsulatlon caüon Re{. MIL- 835?5
Copper Alloy ¡t€rl¡l : t¡olyalkone, alkene-l mlde
§mer, polyoryleno. C,onductora
tlver. ¡ückel or ün plated

MIL-W-813{tl A 72 Wlre, Electrlc, Polylmlde lr¡sutated, nickel or sl lver plat€d cr)ndrcüor, Approved for sp¡ca rppll-
@pe r and Copper Alloy and Ughtwetght caüon RGf. Mn-W-&¡575

MIL- C-555{3 A 7t C¡bl,c, Elecblc, Fl¡t Multl onductor, , cable, lneulaüon

20OoC
( !§¡E C Spcc. Flelble, Uo¡hleld¿d mlde/fluorl nat¿d othylene
22ol rqylene, polyooter, 'ITE, FEP

I
 r-\
!.2.3 It/lre rnd Cable - ontln¡ed
t¡¡ (¡¡
a
Sp6clftc¡tl@ Tlüc Conte¡ts CoDmdrt!
c¡ o
{0M395t 3 B 7l Wlre. Elechlcal. llook-t4. Ceneral Covers lnaulated, urshleldcd, sb-a¡ded Approved for epace a¡pll-
Speclflceüon copper and oppcr elloy wlre. Suit¡ble caüon Rel. 10It139582
for uae ln epace vehiclee. Voltage
raüng 600V temperaürre ratlng -125
to r26@C, Insulaüon FEP end 'ITE

,t 0l(395 ?6 Cable, ElecHcal, Shlelded, Covere lnaulat€d, shlelded, etranded
J¡cketed Gonor¡l Seclf lc¡don for coper ¡nd opper alloy wlrea. Sult-
¡ble for use ln opace vehlcle. Volhge
r¡Ung -125 !o +26ooc. Insul¡tlon
FEP a¡d TFE
Wlroa of the c¡ble ¡re
oaaenurl to apectfl cauoo
10M39513. Apjiroved for
Bprco rppll6üon. Ref.
{0M39582.

I
4.,
r
1,,
I
r.s. I
Soacccrglt htarfrco¡

bt!'oductlca
J

Tto oGtfol ¡ lyi lrrG¡cot¡tloo ol 6lcctlfc¡l t¡t¡r'f¡cc¡ are lEports¡t sDd

late gr.el psrte of csblo h¡llesa der t{D. Elcctrlc¡l bt€rt¡cc caD
oeclly bo ccotrolled, ¡¡d th€ btErlroo h¡w boco dc&cd, by me.us
of üo airtllg chaDg8 Dotlco ryltcm. kla.Btrtloa, on thc otb6r
hand . lr ull¡8uy p@r, wtth irale or Do ltrad¡rdltstlca.

Ttls r6ctloD dlacus¡ea the lD l€rlso€! whtcb tb€ deelgler roqulres and
¡ method of pres€o!8tloo.

L.3.2 Mecha¡¡tcal Ipt erfrce

Tbe perameters required are: -

(a) Pbysl,cal dlI!€nrtñ8 ad locetlott of co!¡etors oo the electrontcg
lalt - there ere requlred very early oE l¡ the destS! so thst
efectlve opttmlrgtlor¡ of ¿he u¡ll t¡st8l¡stloo 8.¡¡d h8¡!e!8 routl¡g
ceo be perfor mcd.

(b) Pbyatcai loca¿ldr of ptD 1/A o¡ each ccD¡ector - thrr dstr tE

requlred for harness fabrlcatloB. C¡re muat be exercl¡ed l¡
deffalng the pb 1/A posltl6, thele b€b8 !.ucoDslsteocy lD the
nrr¡D€r h whlch ma¡ufBctu¡et s def,¡e the pb co¡ñgutadcn.
llcEe are defhed by looklDg oE the froot of tho conDector alrd
Eomc by looldl g Eom the rear; cleesly tf the localloo l8
rElsl¡terpreled the haE¡ess wül ¡ot mgle wtth the u¡¡lt oE
lntegrstlm.

1.3.3 Electrl,cel Erterlsces

DelrDlDt the €Iectrtcsl hterfac66 ln I sta¡drtd form ln o¡e document

tervea tvo purFoseú, DaEoelY:

l. g¡rrér e csaeldereble em ou¡r ! of ttme eDd elfort - Bll the

necorra¡y t¡forrñatioD ls l¡ one Plsce end oot bu¡led Er a maas
of ryrtem 8¡d sub.yrlem doo¡men¡¡tlou.

2. Tt€ h6,rne8r deslgner, EMC a¡d t¡tégrstlcn €oglle€rt ell e'ork

lrom one docu melDt whtch le¿d¡ to hlgñer efflclsrcy,

T¿blc l. 3. 1 Ls olercd s! a¡ lDterhc€ de!¡lttJotr form. I! co¡t¡l¡! el¡

th€ p¿¡rra€iors the har!6r! dé.§ncr rqullet ead r l'rrgc ¡mtr¡Dt of
d¡t¡ for the EMC saSrDeGr.

I -1{ .,

I
 I
I
t_
I Da0¡l!lc¡¡

CoEÉlor l)pc - t!rr.rrs6¡re!!r d6llEBrdco ol lal! EolEtad @!.Doc.to!.

SIEúI Typ€ - ltgD¡I c1r¡llñcatlco. Trb¡G 2. 2. 5. 1 reLrr.

8e6rtÉvtty - tbrG.bo¡d volt¡F.
The reD¡r.l¡tDg hcadbg! o! the Ebl6 are geu eplaaatoty.

Who coaptLlo g !b6 d.8t8 oEly üe p¡¡su¡etor! wbbb sFply to the

fiactb ale to bé cotered.
To suF¡eE¡q¡t tle €léctrlcal l¡t¿- face dst8 ed h o¡d€r to brtEulate
a z610 t/olt coBltgt¡¡rtioD i8€€ rectlo! 2.2. f. q e d¡8wbg rbovlDg lhe
2610 volt coú8¡¡rstim t¡f eacb elect¡cnlc ultt ls requlrcd. Es¡ü
loopc , via r6h¡¡n llDks, caD b€ ld@tlfled 8t 8¡r early 8t!gÉ of the detlF
sDd tho E*erlary correctlvs ¿ctloD t8kso.

t
I
:!
'.

1-l E
I
II
a
:

i
t
I
;
I
a

-
--

rori¡t TAaLE 1, 3. r
FoRMAT FoR INTERFACE DETIMTIox
l-r6
t;
ESA PSS-o1-10'l , Issue ( Decetnber 1 98 2 )

'l . SCOPE

This documen¿defines the minimum derating requirements and

appl i cat ion rules for e1e*ronic, electrical . and
e Iectro-mechani caI cotlrPonents used in f1ight standard equipment.

Pararneter degradations to be clcnsidered in perforrning $orst case

analyses are given.
 ESA PSS-01-301 , Issue 1 (DeceÍber 1982)

2- GENERAL

¿. t IMTRODUCTION

2.1.1 Derating
Derating is the reduction of eLectrical and thermal stress
co a component in order to increase its useful Iifetime. The
derating factor is usually grven as a percentage of the maxi¡nu¡n
value of the considered parameter. These maximum rated values are
defined in the procurerient specifications.

Derating factors shall be applied under the worst case

conditj.ons anticipated during the nission. These derating factors
do not preclude further derating by the designer. It is even
reconrnended to derate as nuch as Possible.

\f, in particular cases and for important reasons, the

requiremenLs of this specification cannot be implemented, a waj,ver
request shall be issued.

2.1 .2 worst-case analysis

The pararneter degradations given for the vrorst-case
analysis are valid for mission times uP to ten (10) years. The
drift values have to be added to the initial tolerance and to the
temperature-coefficient effect. Parameter degradations caused by
the space radiation environnent are not included and shall be
added to these figures accordi.ng to the mission.

2.1.3 Applicability
It¡e derating reguirements given in this specification must
be achieved for flight-standard equiPment for use on ESA
spacecraft and associated equiprnent unless the contract states
otherr, rse.
ESA PSS-01-301, Issue I ( Decenber 1982)

2.2 REIATED DOCUTIENTS

sotreor alr, of the contenc of the docurnents listed bel0w

i.s directry related to this specification. The applicability of
these specifications is defined in the contract.
ESA pSS-01-30 Reliabirity Assurance of ESA spacecraft and
Associated Equip[Ent
ESA pSS-01-60 Seleetion, kocuretnent and Control
Components
for ESA Spacecraft .nd Associated Eguipnrnt
ESA PSS-01-603' ESA preferred parts List

2.3 DEFINITIOIS
The defini.rions in Annex A shall apply.
 (

3. O TABT,ES

3.I RESISTORS

Deratlr¡9 Derat ir¡9 Al lowed max. Zero porer VTSRST CASE A}¡ALYSIS
factor factor teíp. at ¡nax. á R to be dded to the initial
of nEx. rated of ¡rar. rated max derated te!¡p. tolerance ard to t]¡e tenp. coeff.
volt4e p(,íer por'rer limit ef f ect at mx. derated porer

Carbon olposit ion 75t 50r 70'c t00'c 115

(RCR) FI
an

lletal film (Fotr ) 75t s0t r 25'C 150'C !2 t fo

(,,
Hetal oxide film 751 50c 70'c 125'C t4 t an

(RI,R}
oI
I

t{ire round poler 75r 50r 25'C 175'C l.5t o

including drassis
( RWR, RER )
a
Wire rcurd p,recislon 75t 25t r 25'C 130'c r 0.{t
U¡
G
o
(R8R )

Chips 75r 50t 25'C 100'c t2 t I

o
metat fitm tr igtr 75r 50t 70'c 125'C i 0. lr o
a
ú
lrecrs ron o
n
llmgo-nssz¡
I
I

l, i
(o
@
^-,
 3.1 RESISIDRS (con't ) rt)
U\

!
a
th
I
(>

80 WIRE 9UJ¡¡D nESISIOnft (lncludlng 80 I"ETAL FILU

I

crtASSTS-{Oo![ED) NESISIORS
o
60 60
¡-t
o
40 {0 UI
c
o
20 20

0 0 c,
ó
20 40 60 80 100 120 t{0 160 180 20 40 60 80 100 120 140 160 180 200 o
o
arblent teÍperalure anbient te,rperature
,TD ú
ñ
@
co
N

t00 100

80 80

60 60

40 40

20 20

0 l)' 0
40 60 80 100 120 r40 160 t80 200 20 40 60 80 100 r20 't40 t60 180 200
a¡ülent te[perature anülent Ee[perature
 ( (

(^

3.¡ RESIS'IORS (con 't )

E'
UI
v
20 40 60 80 ¡00 120 140 160 180 200 €
(r!
a¡bienc te[perature tn
oI
I
o

H
a
o
o
MEÍAL FIL¡'I HIGH PRECISIO\¡ RESISI0RS
ME'TAL OXIDE FILI4 RESISIOR
o
o
o
o
tf
a
rl
ro
co
40 60 80 100 120 140 160 r80 200 N
arlblent tefiperature
 ( (

rr,
3.2 CAPACIIOR^S U1

rt
'a aI
Deratlrq l¡laximum Rennrks hORST-{}SE A¡IAI,YSIS
O
factor operat irrg
of teíperature A C to be alded to tie int ial I

rnax. rated toleranc-e arid to the terperature O

voltage coefficient effect.

tefiperaLure 50r 85'C inrush olrrent ir.sr a

a
I imited to 75t 50t drop in initial minimtun c:
o
Ceramic, fixed cqrpensatd insulation res istanc-e to te
of n¿xirnum
Discrete ard general 50t 85'C specified Iimit +25t, -208 mnsidered.
p(lrpo6e (,
ch ips o
o
GIass, ¡xrrc.'elain 50t 85'C *0.2t or to.SpF rtrichever is greater. o
7
o
o
50s 85'C f0. 5t rt
Mica

Hetallised plasLic f ilm 50t 85'C *2r lsot ¿rop in inltial \o

(D

(t) (2) Iinsulation res istance - N

Sbl id tar¡tahxn 40t 50"c 0. l<R<3 effect ive l00t increase of the iniLial
(2)
fiN circuit tl ot max inr.¡m leakage current to he
55{ ---E5'- R>3 n/v
im@ance cons ldered .

llor¡-sol id tantalurn (2) 50r 75'C surge voltage i15t dissipation factor: l00t increase
(t{et-Slt¡g ) rated tr 'Joltale of the initial rux i¡num limit.
E leakage Glrrent: 50t increase
of the initial nnximum limit.
feed-throtrgh attenuation @radat ion of 2 dB-
E.M. I . filters 50r 85'C
current to be
derated to 5Ot

Variables 501 85'C t5t

¡rctes :(I ) Reconnended minim.¡n enerqy afid voltage to be -or¡s iderea !9: @rrect self -heal inq
of the max' rate values'
(2) R¡§ .ippre .ui."ni =nuif-L derated Éo ?5t
 (

3.3 TRANSFORIERS, CIIOKES, MII§, I'UIOR !{I¡¡DI¡GS

o

6xim¡m +lted voltage: 5()t of the mxlm¡m rated dlaleetlc strength between wlndlrgs dd between wlndlrqs
ard case.
Wire l¡rsulat lor¡ grade: Higher than 130'C.
!{axim¡n hot spot
teíperature in the
orponent: At least 30'C beloh, t}te rated t€!¡perature of the wire lnsulation grrade.
Degradat iqr to be
q¡s idered in rorst §,
@
case analysis: l'lo @rdatict. >
t
an
I
c)
I
o

l'{
a
o
É
i o

U
o
o
o
ú
o
rl
ro
(D
N
 (

]. 4 RETAYS
t"
o
io
ln
tfl
I
contact ,,/oltage tb derat. im o
I
CoiI votEage tlo derat irq o

Nr.urü)er of eerat ions ( I ) : 50t of qual i f icat ion nunber

,o H
o
Contact qurrent (2): t¡uer tlan 75t of specified nrax imun raLd olrrent (resistive load ) C
o
ConLact cl¡rrent transients (3): Shall be limited such that I2E .-< l6(Imax¡Z 16-5 1ek¡
o
o
Degradat. ion to be considered o
foi f¡e rórst{ase analysis: An increase of 4 Lires üe limit specified for contact resistance shall be o
used for rore than 1000 sritchirlg opratior¡s (4) o
rl
(t,
l) If the nunber of operat ions is belo* l0 cycles, the specified r¡axinf,m ratd cllrrent can be used. co
2) It. is rDt recormerxled to use a relay with a contact GlrrenE below 20t of the max imum rated N
clrrrenE, exc.ept for lor-level aFplicatim (\<l mA)
3) In tie case rñere the prlse duration is lor¡, ór equal to l0 microseconds, the transient olrrent shall
be limited to 4 (In¿¡).
4) For a nu¡ber of srviEdtr ing cperat.ions of less t¡an 1000 an increase of tr+ice the contact resistance
will be used.
 ( (

3.5 S{ITCHES o

Cq¡tact voltagb: lb derat irE

Cdttact current: 50t of +ecified mxim¡m rated orrent

Nurüer of cperations: 50t of guallfication nu¡rber

a!,
UT

\,
UI
(,¡
oI
I
t¡J
o
H
a
a
c
o

to
o
o
á
(J
o
r1

(o
o
N
 ( (

3.6 CONNECIORS
r'
a
'0
a
lt)
I
Maximum afpl ied voltage: 50t of specifled nnxim¡m rated vDltage (pin to pin - pin to shell ). O
I

i4ax imlm tenperat.ure: 30'C belcry the specified nux imum temperature. o
Max i¡r¡n c\rrrent: 50t of tlre specified ¡rax i¡¡mm ratd Pln cltrrent. H
o
a
Haxim¡m nating ard c
o
denatirg cycles: 50

Degradat ion to be
considered during F
o
the horst case analys is l lto @radat ion . o
á
ú
o
,rl
(o
@
:
 ( (

3.'l WIRES A¡¡D CAAI,AS

a\)

Hax im¡n appl ied roltage: 50S of tj¡e spect f led max imt¡n insulation voltage.
!{ire size 30 28 26 24 22 20 l8 16 't4 12 l0 I 6 4
Max im"rm ied cllrrent
appf A¡Ñ
versus the wire size ( I )
in a max inr¡n ant¡ient tlax. orrrent
terrperature of 85'C (single wire ) 't.3 1.8 2.5 3.3 4.5 6.5 9.2 13.0 17.0 23.O 33. 0 44.0 60.0 8t.0
in an¡:eres

l¡cte (l) ¡l¡en *ir"" are h¡ndled, the ¡nax im.m deslgn c'urrent for eadr ir¡dividual wire shall be derated tr'
a
arording to the form¡la
}U
a
- N for 1(N-(15.
Ib¿ = rsw x 29 a¡
7E- oI
or Ibr, . l Isw for N)15. I
c)
Ihr = maxlm¡m Glrrent for individual wire in a bur¡dte.
Is;w = maxim¡n currenE for a slngle wire as given in the table above.
N = núrüer of rrires in the bundle. o
H
o
c
o

t
rD
o
o
4
u
ñ
¡l

\o
@
N)
 PAGE 5
ESA/scc D€raj,I sp€ctflcatlon
SPECIFICATION rssuE I
No. l9ot /006
Sept. '81

I. GE¡ERAL
1.1 Siob€
Tt¡ls spoclflcatlon det¿lLs the ratlngs, physical a¡d elcctrical characteristlcs
t€Bt af¡d j.nspecLton data for PoLyilolde Insulated TJlres and Cables (light-
weight), Lo!¡ Frequency, 6OOv - 15Oo C. It shall be read j.n conjunctlon with
cSA/SCC Generj"c Spcclfj.catlon No. 3901, ¿he regul'reDents of rrhlch are supple-
EenLed herein -

wires anC cables shall not be used in the presence or vj-cinity of

NCrI'E: These
hydrazlne or n i trooen tetroxj.de.

r- 2 99PP9191!-in9-Y-arli!!:
vatrianre of the baslc types of Hlres and cables specifieC herej.n and al-so
coverei by thl,s speclflcatlon are listed ln Ta-ble 1(a) . o
i . i Y-lg:I-31!119:
The maximuE ratlngs agPllca.bte ¿o the flnished wires anC cables speci¡j-ed
hereLn, vhich sha.L1 not be exc.eded at any tlE¡e during use or storage in
controllai space envllonmont, are 3cheduled ln Table 1(b) .
1.4 !3!119!9:-!:r3!l!9-1!!9r9r!19!
The deraclnq lnfo:-rnarlon applj-cable to the finlshed uires and cables sPecified
herelr: 1: as :oilowg: -
- ::1É ¡!a)::iiun currant lor each wire used in a bundle shall be:-
20 - N
r Snax=t nax x-#(for1<N<15);
ló
r
roax (for N > 15),
r tsmax= "=-
¿

where N = nuDbar of wlres in ¿he bundle;

o
- The te¡DPerature deratlnq lnforroatj'on is shov¡ in Fj'gure I wllh naxi'nuro
currant I-El¿)(-- for a sl¡¡gle vlre and ,"rux fot a wire incor'-Dorated in a bundle;
- T'hB dera¿lng factorg contatned herein lndtcate lDaxlr¡uE stress values and
do not preclude furt¡¡or derati'ng'
1 .5 Phvstcal DloonllonB
Tha physical dlEenclons of tt¡e finished wires and cables specified
herei¡ are
shown in I'igxrres 2la) , 2 (b) , 2 (c) and Table 1(a) '

1.6 I9t9!r9!31-9]19r1-D
Not aPPllcabLe.
 PAGE 9
ESA,/SCC Detail sp€cif lcatl.on rssuE 1
SPECIFICATION No. 3901,/006 Sept- '8 1

1@

|\
I 'l I P I I ,-" I

I I I I ¡.s
i.ó
I o I ;- "" 24
I , | *"*'.,.,* currentt L I I l" 22

lI lI l*. 1 ,;:: II l:::

l "'
20
18

Il --1.
I oo"t".trrg r.np.r.- | - I -,nn ¿,q. I o. l-too, *zoo ro,

¡ | ..o"ne reEpara- I r o
:
o
| --wt Range s9t I -,oo
I |
-1s0 || ". l-,00, -roo ,o,
lunsni.taea ca¡tes

r The abovg specj.fied current wi:] oenorate a temPeraEure rj.se of aPProxiE-

aLelv soe C a.bove aJBblent te¡¡perature !n a vacuum envlronment, Precautions
snal'l be taken to prevent that Lhá Lotal ternperature of the vlrc (atr¡bj.enL
pfus r!se) exceeds ¿he continuous op€ratlng tefllperature of the wlre.

FfGUÉT 1- BE}'EEN,qTURE DERA"TNC INFORHATION

r-a.¡m:--T--
rl lll\,-, 1

j :ll ; \I :\. II -,/unshielded cables

j;ll r r
ñ Ell

L \
\
r{ 0
a ¡'ll

rl¡r
rlll ' I

\ l,
ii
I

-l t'l i | \ ,:
Itt r \ ,1

t-- i , \ ,¡
l

ll!o'".o.!cl¡:'
I I ',- , ; r r -f--L "a
Al lor¿able cur-ant üoliiii-teooe ra tu re
 ( (

] - 8 TIIERT,IISIORS
fí
a
rJ
a
a
For"rcr derating: 50t of the po.rer nec.essary to give ar) error of res istance value equal to the oI
initial toleranc,e. I

o
Voltage derat ing
between thermistor H
elerent. arrl rn:unt ing a
o
base: 50t of the specified n¡ax imum rate<i dielectric witistarding voltage. c
o

@radat. ion to be
cons idered for rorst
case analysis: t 5t of tie resisLance value to be dded to t}le initial [olerance. fD
o
o
a
o
rl

ro
o
N
 ( (

3.9 CRYSTAI'S

P*rcr drlve level: t¿ss than the maxim¡n speci f ied rated value.

QperaEirq tenperature: + lo'C hÍgher than the ¡ninim.un specified rated value.
- lO'C lc*ler than the maxim¡m specified ratd ualue.
gbrsE case aralysis: Frequency $ift to be qrsidered dependinq of type and applicat.ion.

F'
¡n

E
an

oI
I
c,

H
o
o
É
o

t,
rD
o
o
á
tf
o
rt

ro
co
3
 ( (

3. r0 rq
(n

ú
U)
a
I
l. Fuses shall he avoided r*rerever possible. c)
I

2. l*¡ere fuses are needed, cennet fuses are preferred. 3

3. the largest f use rat ing orpatible with the source cl¡rrenL shal I be used . H
o
t.r)

4. Absolute nraximm al Iowed ratings: c

o
65t of the rsninal speci f ied current .
l00t of t}re nnximum specifleri w)ltage after blow.
6
o
o
¡¡ote: Wire link fuses c¡cr-¡ld only be envisaged for short tire appl ication ard or special reguest. o
3
ú
a
r-l

\o
@
N
 (

l.l I DIODES o\

Deratirg factor of ü¡e ¡mxim¡n speclfted reverse

rrol t a9e 55t

tEratirg factor for Ta = 25'

of the max imurn spectfied current 60 t {rpEe l)
l,laxim¡¡ junction teflperature lls'c (mre t,
T€RSrcASE A¡¡ALYSIS : Drifr to be cor¡s idered.
G'
Leakage ca¡rrenLs: 5 tines t}le specified nnxira. ln
Breakdor¡n volt4es: 5t dec.rease of the specified rnxinn.
Forvrard \¡olt4es: 10t increase of the specified maxima. U
an
(n
I
zeñer volt4e regulators arrl reference dlodes shal I be used at t¡e,naxim¡m olrrent orpatlble with c)
stable cperatiqB. I
o
lt¡te l: The value of the Grrrent shall be calculated with the follo^rim formula:
!.a
Tt-T2 t
o
Io(derated ) = 0.60 Io(nax ) t I - ----- I E
o
ll5{2
glt¡ere: Io(nax ) = nraximun specified qrrrent
Ta = aüient teÍperature U
ó
o
operat irq rrithor¡t heat sink: T2 = 25'C o
!t
T1 = Ta for Ta> 25'c or 25'C for T"d 25'C ú
o
ñ
For diodes operatlng ¡rith heat sink: T2 = 0.6 (Tm + 25'C'
rm = maximt¡n case terq)erature at nt¡lc*t rmnufacturer ro
@
allol,s max. rated o¡rrenB N
T1 = Tcase for T."". 2TZ q T2 for T."". ¿l T2
 I (

3. I2 TTIANSISIOTIS
rr)
(-r)

.ú
LN
LN
Deratirq factor oI
of the minimtrm speci f ied reverse rrclt.age: 65 t I

Derat ing factor

of the nix imurn specified cltrrent 75 t H
a
Fovrcr deratirg (Ta = a¡rbient telperature t¡
) É
Lhe ¡rexi¡ru.¡m speci f ied value : 60C ( note I) ID

Maximum junction ternperature: ll5'C (noLe l) t

6
9ORSr{ASE A}¡ALYSIS: Drift Lo be considered ó
o
3
,ñ ú
L¿ak4e clrrrenLs: 5 LiIrEs the specified maximum.
Breakdo¿n r.rcIt.ages: 5t decrease of the specified ninimu¡n-
Forward voltages: l0B increase of the specified nnximun. \o
Gain: 258 decrease of t-tre specified minim¡n.
:
@

25t increase of the specified naximum.

Saturat ion r,tcl tages
(Vcesat, Vbesat)! 108 increase of the specified ¡raxi¡m¡n.
Currents afd voltages shall be naintained at ]evels coÍpaLible with the safe operat ing area.

ilote l: Detailed calorlat.ions permittirg cofipl ianc€ with these trrc reguirements are given crr the next paqe.

-l
 ( (

3.12 IRAII¡SIS'IORS (con rt )

@

For transistor eeratirq ulthor¡t heat slnk: Pderated 0. 6 [tl5 - ra I P¡¡ax Ta > 25'C
--3Ú-
Pderated 0. 6 P¡rux ra( 25'c
For transistors operat ing ritJr heat sink: Pderated 0. 6 Pntax if Tc < fiS'c - 0, 6t 17S-Tml 'c( rbt e 2l
Pderated 1t5 Tc Pmax if IE > ils'c - 0, 6f 175-Tm I 'c( rDte 2l

l{here P¡nar = ¡na¡¡im.¡m rated power ar 25'c

llhere Tc tr car¡e teÍPerature GI
fm = rnax. sPecifled case te[perature for max. rated poter a
v
¡d
a
a¡
I
o
Pmax Plrax I
o
0. 6Pnax 0. 6Pmax H
a
o
É
o

25'c 't
I 5'c 175'C T Tm ils'C 175.C U
ó
o
vriLhout heat sink uith heat sink o
á
(T = tt5'c - 0.51t75"C-{rml (r¡ore 2l t
fi
¡.l

\D
llcte 2: is fixed to '175'C for the calo:latiqr of the derated ¡r er. For lcñ,er
-junetion terperaturetsrperátures
Hax. @
sPecified N
rrEr. ,unctlon 'Uitionat deratirE shall be foreseen.
 ( (

3.13 LINEAR INTEGRATIID CIRCU I'IS

E'
(Tarnax < 85"C) (n
),
¡o
(n
It
I
o
Stply \Dltqe of maximm specif ied raLed value. 80t I

O
Ir¡pr¡t rnltqe of noxim¡m specif ied rat«l value- 70t

O¡tput orrrerit of nax lm¡m specified raLed value. B0S U)

(/)
C
a

CASE AI.¡ALYSIS
(]
the follorirg cñange wiII be onsidered: a
o
o
á
I of input offset t/oltage (operational anpllfiers
mV and corparators ) U
o
25t of lrcltage gain (operaEional anpllfiers) ñ
0.25t in cuEput volEage (voltage regulators ) (o
0.201 load regulation (voltaqe regulators). @
N)

(o
 ( (

3.14 DIGITAL INIEGNATED CIRCUIIS

AJ
o

Tanax. < 85'C

slply rcltqe greater than ¡ninint¡n rectr¡¡e¡rded rcltage

less tj¡an 801 of ¡mxi¡n¡n recq¡rerded voltage
ru lrgrt rolt4e less t¡an sulply \Dltqe, or
less t¡an 903 of ¡mximlm specified value¡ rtricJrever is loyer
q¡tpt¡t cilrreot less than 75t of mxlm¡n speclfied rated value.

sqply tDltqr greaEer thar¡ minirnu¡ recolnrer¡ded voltage tlt

(n
less than 75t of mxim¡m specified rated value ),
CT'G other rclt4ea greaEer than l}sS ¡(,
tn
less than derated vDD 6
ort¡rt oEr€r¡t Iess than 751 of ¡raxim.¡n speclfied rated value. oI
I
o
VORST. CASE AMLYSIS: l¡o deqradat ion beyorrl tlre minimt¡n specified input and ottrlt rJoltage rarge H
to be cpnsidered. o
o
E
a

G
o
o
o
ú
o
ñ
r¡)
6
3
 ( (

l.15 OPIOEI,ESTÑI\¡ I CS DS\ICES r¡j

(/)

a
fh
I
o
Light anlttirg dio<ie Current of maxlmxn sfreclfled values 20t I

()

H
o
Ilroto trans {stor Ib be derated as other translstors (3.12) a
E
o

Qtocouplers Ele¡¡ents Lo be derated as above F

o
o
I
tb
VDRS'T C,\SE AMLYSIS: 'ñ
\o
@
N

t)
 22 ESA PSS-o1-30 I, Issue I ( Decenber 1982)

ANNEX A

DEFINITIONS

DERATING
Derating is the reduction of electrical and thermaL stress to a
.- cofnponent in order to increase its useful lifetitne. The derating
factor is usually given as a Percentage of the maximun value of the
considered parameter. These naximum rated values are defined in the
procurement sPec i,f icat ions.
 ESA PSS-01-301 tssue 1

December 1982

Deratin g requ irements and

appticati on rules for
:eléctronic
-E---=---
com penent§

Prepared by:
Product Assurance Division
European Space Research and Technology.Centre
Noordwijk, The Netherlands
 'a

MINIATURE C¡RCULAR CONNECTORS

ruIEiiJ,'.T' KJL/KJ CONNECTORS
STANOARD DATA t49ll!!¡!-9114.
MlrtRr¡ts lxo flxtsxts Contaci S¡re 220. 20 and !6
coñr¡.t R,¡,rt ¡nd wir€ sL?. Áccoññod¿lron
a¡rt..t n¡. ¡nd trtt ¡ñor
20 15

50
't5
Mtc[tNtc¡t fttrutts t8 t0 a
ShelL Sly les 0 Wall mounting r!ceptabie I3 0
2
- 8or mounlrnB rec¿ptacle'
3
- W¿ll mountrng receDlacle {b¡ci Danal)
5
- 8or mounting recapl¿cle {b¿ck p¿nel}'
6
- SlrarSht plug SerYrce R¿l ng
-
7 -- l¿m nut raceplacle
lt00
Shell Si¡es KJL. 9 thru ?5. Xl S lhru 24 24 ll0.o00,r 2@
Cougling 3 po¡nt b¿yo!!al, qurck.rel€ase
Polári¡¿tior Shell 5 kay3 ¿nd l¿yways '^opl,c¡Dl. lo ¡(l onlr. Conlact Ternrln¿lron cnñ9 (c,¡¡tB t t, P l, ¡ {
 :C tEcttoN 2

EARXEEI DEAOI
t.

I CONTEÑTA
I
2.1 E¡¡!...l!¡ Eyrbr
2.1. r Ix¡trttnt¡a 6trü@.
2.L,2 LúDbS ffiror
2.1.3 Erruaa lltar-.ü¡o l.üod¡
2.L.1 ElEtdcsf C@6to!.
2.1.a. r C@6s t¡t¡¡frl¡
2.L.4.2 Coator C@faurattot
2.L.1.1 Eür1¡oat¡l C6!.GÉo!a
2.L.1,t Pl¡./&*.t br.rt¡
2. 1.4.5 CdÁt¡
2.L.1.8 CouD¡r¡S Xebt¡t¡u
2.L.4.7 Caao F¡¡¡lt¡ t! Coñsrt.t!
2. r.a.t C@étor A¡DUcr6.E

2.1.5 El¡cilrtc¡l WI¡¡ ¡rrd Crbl'

2.1.5.1 Co&cto! l¡stlr¡f
2.t.t,2 I!!¡¡rtf!¡ ü¡t¡r,¡l¡
2.1.5.S Wtr. r¡d C¡blc Cco¡Eutlo¡
2.L.r.t Wlra ..,1 C¡bL T.rEb.tlÉ¡
2.r.6.3 ci¡rlut C§r/ry Crfoll, Ed D.rúba
2. 1.6.6 Volt¡t. D¡op
2.t.6.7 Porrr Ceblc Elri4
2.L.C.t Ylr¡ I¡¡r EttlE¡üo
2.1.r ffiS
2.L.7 B&óroy
¡. 1.t SÉtorls
2.t.4 CcbrzTtn e$oÉ.
,.2 tlrtrur¡lrÉo Copto¿tlty FraC)
¡.t. t bE.rT
,.2,' ElrEfuÉc.
¡. ¡.! .Étto!.
¡.t.a Cql¡¡ I¡bla¡

3
i ¡.3.t. t i¡r¡ Cl¡¡¡llor¡o
I 2,r,6.7 n¡nl Grogb¡
t.¡.6. t üf .U Xrt rl¡¡lO¡md¡¡
2.2,O.4 Cbor¡ft OrqadEl
8.2.6.3 E¡r¡¡¡¡ Bd¡lrDl
2.2.6.6 ?ütorr

2,2.Q EIC Alrlyrl¡

2.2.7 bEdtD¡

2,5 Pyrotaoblcr

,,1 E¡r!..r l¡¡lrllrtloa

2.t.L Protetloo B.qulrülott
2.4.2 &¡pFrt ud Cbupbg
2,t.3 Plotétlv. O¡oE¡ct¡
2.1.1 E¡r! .. 8q¡tb8
2,1,6 E¡¡r!.a. Frbrloe§o

St X}I/I¡Y
ItL.-tb oÉrb. tü. prbbL. tbr tL d..ra¡ of ¡ orbl. h¡¡¡c¡¡.
Dt,e[¡.d r¡r tü¡ vrrlor¡¡ b¡¡!..ata8 rt¡!G., úrr,/o¡bb,/mbr¡.
ua¡rl¡f¡ Ed ¡f¡!o.t5tr. 1t¡ ü¡d¡a¡trl¡ of tIC lr. tlol¡td.d.

J
 t
r
i
¡
I
Ir BARNrqS DESON
I
t. I Htr¡arrlDc *ltrmr
2. l.l Dl!trltr¡tloD 3vltrl!!
.
Thore ¡ra o dtstbct typ!¡ ol hrmGa.tag ryttcmr, urrroly
. Fk6d
o Flexlble

Defl¡ttlc'D of ca¡rdldrto syrteEr:

Ft¡ed ¡ygtem - l¡ dcü¡ed ac barnecahg dlrcct¡y bel rea t¡t¿rhcht

qrlta.

Fle¡lble - Le defl¡ed a8 herielrh¡g b€twoco llterfsclDg l¡atts vl¡ .¡

lDtermedlate fl.Ect¡abg or patchl¡g laculty.

J¡DsttoE/Ftcbtlg
factlüy

F t¡Gd wtrl¡g Flqtb¡. wlrt¡g

Thr cr¡dtd¡t€ .yct út ¡rG rDllcsblo to both ltrgB ¡ad rm¡ll

dl,.tttb¡tlc,¡ .yrtc nu.

Fl¡.d Wlttp8

i. .'t Fl¡.d ?lrl¡¡t t¡ ¡ pobt-to -FtDt rl¡b3 coEcpt. rth caly tro bt rft G.,
oG ¡t tbr .ourcG co¡ccttra, tüo otlcr rt thG r.cGtrd¡g ca@.ctl.[,
l¡rtGlmadLlr cco¡ccttm¡ bclag rcrtrtctod to ¡ n¡bl¡¡um.

llodl!¡ülca¡ to tür c¡.ctlbrl coaSu!¡lL¡ rro ur.rrlly IDP¡.E¡Gt d by

rO{rlat¡tbt üc pb c:@ettaEr r! t¡. .o¡¡c. or rorlrt3 l¡lt. 3üü-
¡lly ú !h. rc¡r of thc b¡EG., oE¡éto8. ltt L ¡¡ rco?t¡blr mchod
rha urbg RWC b¡t lr ¡ c(D.tt¡b! rbo urb¡ FCC (br fu'ii.r d.t¡lt
... t¡tloL 2. 1. 6).

I( 2-l-l-l
I
I¡ rDy !y!t6m olóctltcs¡ rellsbtllty c8D bG q!.G!¡Gd b lclrtrr ol th.
nurr¡bGr ol ccn!.ct16! rcqulred !o corng¡do tbc clccfl,cal cl¡cult¡,
tba f. cr thc co¡¡cctli¡oa thc htghcr th. r.ltsbt Uty, b ¡ flr¡d ry.t6m '
tblr€ r!6 craatlrlly cB ly trro cGo.ctlo¡r , ola rt ¡cb u¡lt. lharclore
thc rellrbtllty tr htrly hlgb.

Lov c¡bl,a r¡^¡.a by r¡¡tcbbg lhc rl¡c llrca t¡ lhc

ca¡r bc ¡chlcr¿cd
cl.clltc¡l lcqul¡cmd¡, t!€rr b.ht oo euperfluour crblb& Thc
rortlag lr ¡uaerelly more dl¡ect rorultbg t¡ ¡horter crblo lendhr.

AdveDt¡gEr Dls¡dvrnt¡ ga.

1. Grastc! rcUsblUty b€csrs€ Not rdry¡ble to Fcc r;rt¡g

of fsr€r pbllock t rlthq¡t btrlface cqrt¡o¡ at
ccDetioB!, coaD€ctora.

2, Tot¡l m¡!. tcDd! to b€ lcr. Modlll,crt! ! cu oaly be

rhrn lhat of ¡ lledblc pcrformcd st re¡r ol
ryatrt¡. or by rc*trtag.

Sotrv¡re c8a oaly b€ L!!u6d !o

m¡¡ul¡cture occ the b¡t€rfeccú
h¡vc bcea E¡s¡lzrd.

Complcr h8¡¡e!a/c6f ltu rlttoo .

!r a fl¡ed systerñ. the wtres/cable ¡¡¡embllea are r¡!¡ polat-to-potDt,

wllh br8¡cheE tc completr lhe lntcrlace r6qul¡et[at8. HamesE
compllcrtlcri reru¡t! from the ht€rf¡ces on cnc coa¡cctor matbg vlth
several other conDeclor!. It ,¡ thL! compllcrtlcD whlch le.d8 to
m¡out¡ctt¡r bg rnd lDlt¡¡l¡tloD prohlems wlth thal! lttcnds¡! co!!.
Th¡r typo ol h¡¡¡elr!¡B te uaurlly u¡ed fo¡ prcdr¡ctlon of ¡ow mod€l
protrrmme. , c. g. rfcecratt, En gla eerlag, Qr¡slttlcut¡ca eud Fllgüt
modcl¡. Thc¡c r¡dcl¡ b€ta8 er.rotr¡lly ldartb¡l €lGctrlcil conftSrr-
rlloDa, raodulcstla a bGlD8 ml¡lm¡¡.

Flrltblü ttv.tcm
A Ocdblc .ytttm L¡ tbc llmp¡crt ¡¡d cbo.pcrt form of h¡rnü!.hg bi¡t,
ó¡c to bc!c...d num.bor ol cqrDGctld¡r, .Bot ¡¡ r.¡.1¡bl€ ¡¡ üc flr¡d
ryrtcD.
WtsÉ./cabb ¡¡¡c¡nbllc¡ ür nE to 6c or rüor. ,uactlo/parchh¡
¡ctlltL. xhGrc th6 cl¡cr¡lt rrc compl.tad. FIB¡rc 2-f lllu¡t¡rtc¡ r
t}fplc¡l l!lctl,6 modulc. Coula$¡otly th. m¡b h¡tnG..bt c¡a b.
l¡rt¡llcd h tb6 ¡lly prductto rt¡¡t rDd th. fb¡l conetloE of thG
clrcult¡ ¡t ¡ l¡t. at¡fr b tbc p:,r8r¡rn]rra, by ñtthf of ¡ p.tchhrt cer¡ -
ccror or bdlvfdu¡¡ p.tchhg llDk¡.

2-l-l -t
Iudutcstlols !o tbG rlcotrlcrl cco nSurall 8 ..ñ b. r...llly trBptomraled
by ,aodlltc¡!¡ot! of thc vlrbg rt lbo ,u¡ctt6,/p.tchbg frctllly.

Adnatrgrr r Dlredv:auglr;

1,. llodllc¡úar pcrforñod l. B¡drrccd rell,¡blllty duc to

rt tbc ,roctLD /prt4hb8 rddttlolrl coEGstlm¡.
f.ülty. bcro¡cd rlrbg mrrr.
2. Eotvrr. cr! b€ blu¿d prlor at
Dt¡alutlhet EMC.
3. Elnplc hencar/ccaf§untloo {. ,iddlttoasl Psrchtng
t. ld¡Érblo to ¡¡l bDes ol docr¡rnat¡t¡cD.
glr¿¡.

Ururlly u¡cd for hlgh nodcl nu¡nbcr proarünñ r! *tcr! tbGactl.s

rlG ¡o¡t r¡d ccn¡ldc¡rbl. vrt ¡tldr b.txc.D rouad¡ l¡ to ba a*Pctcd
órrtag dcrrcloprcct.
Tlraút¡tlon/Ju¡.tbo dGv tcea
TlrtalDrtloo devtce¡ tü..tbg MI¡FC Sp.clflcstloD 401ú:¡'1t89 for
dlrt¡th¡ttoo, buaab3, ¡¡rd bt.rcoBectlon rre u¡ed qr fky lrb. These
dc],lccr ¡rc a temadou, lrDprovemcnt over thc term!¡rs¡ ltrlps, solder
terElDr¡r , ¡sd ,Ect!.,n boree forrnerly uscd and offer:

Eaclo¡od, €n vlr qr m€nt a lly protcctcd bu¡ se¡ ¡od,[actlon!.

Bsmovrble crtflrg cdrtac!!.

S¡¡rd¡td cqrt¡ct crlmP dt'trGtulms cotnrnon rtth {0M39569

(Mod. NASf 599) conncctor.

!t8Dd¡!d crlmD tool¡.

i¡d¡rd c6t¡cl b!.rtlon srd r.movrl tools.

E¡¡y ¡a!.t!b¡y rlth frr.r toolr.

XaGa¡.ncodGd lrmp.r¡lurc r¡¡t8E comrnon yltb {OM39369

Gt¡ECCtOl.

¡l.Gi¡ llrlD¡Ét S<y l¡b vlcuum or¡t8¡s. b I rGqulremat!.

Nl¡trabGd ryrtom rel3trt.

E¡¡y b.t¡llrtlo l¡ crn!¡d rrcu.

a Ct¡rE¡s d.. taD ttrodttlc¡llcDr .¡. lly rcco n¡P I !. h Gd.

2-t-l-3
 EARfHI¡{6 SIUO

CAB.E ENfñ
CABLE E\IRY 'c'
A

CABLE ENIñ
'D'
CABLE EMRY
'B'

CABLE CTAMP

\ fHERMAL
c¡aLE cLAUPS

''l
o
¡r,

(-t
ss
2. L,2 Looml¡¡F flyst.nr!

The typo ol henreralag ryrteE to bc der tg¡Gd bto th6 ,paacñG t, r

fulctl,cn olr-

Spa¡ocnft avl¡@.sr6ot

Spacecraü dloa¡lou¡
S¡oecreft cc,E !8ur't tJoD

Type ol dr! t¡lbutlo! sylt€ra

r Model phlloaopby (1. e. number of developn.at !,rbtcl6r)

There are earartl,ally 7 type3 of looma, crch wltb ¡ speclttc t!!trll¡t16

requlromeDt. A spsc.craft may emgloy Eoro th¡¡r oae looro type,
dependeot cn tbo \,r!lor¡! envlroDments rDd phylic¡l relatloeblp bct*eeo
l¡lercoD¡ectl¡g electronl,c/electrtcal uolt¡.

Loom wrr (R6forsEcc 1)

Tvp€ I
Conatn¡ctlorl e¡cioaed l¡ Fluorocarbon Elsstomer coa'rolute EblDg

Appllcatlo¡r rn8y be used lI] all aleas a'lthlD cre* coEpartrD@t8

OperattDg 4oc to.66oc

Temp€raü¡re

Tvgc 2

Coastructlo¡ eacloaed l¡ TFE coavolute tubtng lt¡ed *lt! Obrc

ghee breld

Afltcrtlo mey be ucd ln ¡ll rre¡! wltht¡ the crsP comP.¡t !¡at!
Opü,lu¡g -?3oc to *28ooc
TrEprrstura
Tvoc 3

CoD!tn¡ctl6 acloccd b TFI coaroluto h¡bl¡g

Apuc¡th !!¡y b6 ulcd b ¡ll rr.u a¡t¡lde thc c¡r coBFrt-

mat, bcludlaf ro¡bc beya, rb¡rc rbrl¡tco frotétlo
tr rcqulrcd ¡¡d rhcra th6 looa t¡ mrl¡d r*ly horn
l@¡¡l¡Gd hot lpott

¡ -1-2-l
OD.t.tbg - -?soc !o +26ooc
Tcogonarrc
Tvp. a

CoDr tfi¡ctl,ca opa h¡dlc - not aaclo¡¡d

ApD¡to¡ilG rary br urcd h dl rrc¡¡ 6¡t¡td6 thG crar coraD8rt -
ms¡t, l¡ u¡¡¡ hca Eo¡a ¡br¡¡ tm dragcr rd local
hot rpot!

Op.r¡tlDg -á6oc ¡o * t25oc

Te rapa!¡tr¡86

Tvm i
cmrt¡lctlco oclo¡od b TFE hs¡t .b!bk E¡bbt
Appllorticn ruy bc rucd !r ¡ll ¡rea¡ out! ld€ th6 crsr compart-
tErot ?hGrc ¡br¡¡lcn relllt¡¡ce protoctloE l,! r€qr¡tred
ud r*ry f¡om loc¿l hot rpot!

Opsr¡teg -65oc to .loooc

Trr¡pa:ü¡rG
Tvp6 6

Co!!tlr¡ctto fl;¡lble ¡rmou¡d

Amllc¡t16 ured b caglnc con p8rtmeDtr snd other troaa where
thG harrrGlr mry be 34o.€d ro locrlls€d ll¡me rnd
hot g¡t tmpl¡gprrlont

w.3-
Coort$3ttcD - flrt coDductor crbll¡8

AFItc¡ttG - gaarll u!€ outatd! üe crcv comP¡rtmat, bcludlag

sDgllr comPrrt8tntr b(¡t excludhg locrl hot tPotr ¡Dd
. a!6¡r ptrñc to ebrr¡lo drmrge

op.¡rtb3 - -6trc to +l25oc

?€Epar¡¡¡tt
Co¡abh¡tba¡ of tho lr¡8loi¡¡ l@m typ€! rrc poertblc' T'hc¡c co¡nbla-
rttqra r¡a u¡cd e¡ch Port&D mu.t bo br¡Ud ÜlthtD tt! t'rnPClru¡rc
r.¡d.DvlñEÉat.

2-L-2-Z
¡-era^ typár I , 2, 3 in.l 6 c¡! b€ Bdttlod to bch¡dc ¡ E.rslllc E ldl
lblcld. Tbo ¡ddlllo of ¡uch ¡ .btcld do€ü Eot, bo;cwr, Eodüy ttr
rpDllc¡tlco or op€rtthg tstBp€r¡ü¡ra. Il ¡b¡r¡ld bc bor¡c l! El¡d tb¿t
tbc laclu!1(D of a¡ EMI ¡hlcld dccra¡cr the Oclblllg ol tbc IooE,
tborcfor! ¡! El(I Bblald ebanld oly bc u¡d vharo EMC roqul¡co.ltá
cr¡ad bo ñot sith.i¡t ¡¡ EMI ¡bl¡ld.
EMC rcqrtremoEts arc rpclñ6d l¡ dctatl ta lhcttoa 2.21te vlaior¡a
loom typca sre tlluEEat d ts Ftgurss 2-Zto 2-5.
CoEEtor lrclttm cn Elastrcntc_Upttr
All tm o!t€!E the c¡ble hr¡¡€rr Ir th€ ltrt lter! of qutpo¡at to b€
co¡¡ldered b üe deaign of the ape.cacralt cGÁgurülcn, rblcb h¡¡ led
to tb€ sd8pt¡t16 of 8 c.c,Dñtulattcn tb¡t h¡¡ abt beeo fuUy optl¡nle€d.

If th€ spla eraft l3 to be co¡?octly optlrñr.€d tt l,B ti!¡p€rüteG th.i the

h¡r¡eae Éaglno€r ps¡ttctpüer b th€ loc¿tloD of electloDtc /€l€ct¡lcsl
r¡alt¡ oD tle epececrei. Eqr¡¡lly lnDortr¡t lr the coBslderatlo gtvE,
§ the heneea €agl¡¡e€r, to tb€ dorlg! of tbe rFc€crút cúAgu¡ü16.
to lntr¡1lnls6 rD¡¡ufrcturlEg rsd AI ad T &ctlvlltes. The rDolt corrnx)D
f¡ult here l¡ the loc¿tlca of ccEDetors such thst acccssfblllty t¡ dlfEcult.

Tbe poaltlmlag of caDectorr ou electroalc /electric¡l u¡lr8 1r h!'eri.8bly

a luactl6 of packaglag the uDlt. Thls ca¡ result h comectora bebg
posltl@ed wttbcr¡t duo regard to the rFcecr¿ft btorf¡c6. ltcrefore
tbe h¡r?ea6 eDgl¡eer ahcr¡ld endearrot¡¡ to ,Df,u€¡ce tb€ loc¿tlcD of
co¡.uectore oD th€ r¡¡tts; €Emples of tba preferred locatk)D ccE¡ector8
are llluatr¡t¿d h Flgure 2-6.

Ideally coonectors sbould be locatod ¡s clo€ 6 to the rDouDthg plaae as

poealble vlth ád€qu¡to apectog to allcrr cler.ra¡ce betseea 8dr!c€!t
coE€tctola ¡Dd th6 rlot¡¡tl¡g Pl¡a€ fo! antbg aad d6m¡tü¡t of the
conooctos!. Recomaadcd apeclaSr are glveu l¡ üc t¡ble belos.

C@6ctor Typa B A

Roct¡D gul¡r -R€ct¡¡ 8ul¡r L + zOEE IV + 20mm

Ecctragulu-Bourd l1t+o¡zomm l(g*ol'zo-,o

no¡Dd-Rot¡ld D + 20Era D + 2omñ

Wh6rG L = ¡agl¡ ol corEcctor

w= wldtb ol c(E¡.cto!
D= dLE tr! of @Dastor.

z-1-2-il
 !/
I ^
I

lDhlHtr
CoDloetors ghcr¡ld oot b€ clo6
cr tho 20mm to tb' b're r^r tH..
of tho €qub¡oat.
;ol,übll;braachs' rcroBs ttle frtnt

2-L-r1
 FIG.2.2

< F-sEE TABLE I

llI
l.2SMAxltYP)-i F
llll_
I

TY. RAPS

FtG. t,3
 ,
{

FIG.2.4

r¡G. 2.5
 LONG UNISUPPORIEO
CABLING - UNDESIREABLE

OIFFICUTI ACCESS FOR AI.I.

OVERCOME BY SIAGGERING
Iil }IORIZONIAL PLANE

EASY ACCESS
FOR A.t.l

I
-rT -/ -,/--T--7'7-V V-V-- i FT-r-v'/-
l
o
t9 NOIE LOW PROFILE OF
o! BONDIiIG SIUO
t
2.r.3
fhl¡ [¡ 6¿ of thG Eoat trEport8t ¡rpcctr ol cablc br¡!c..bg. D l¡ d¡o
thc mot n¡ber¡bla to d¡E¡gr by tbo bcvlt¡blc hrodlhg thG e(n!6cü6.
recalvr durbg hrtroe ¡^brlc¡tlo, tD¡rt¡llrtto .¡d tEt, ¡od r!dr' thc
coDdlácnr of thc l¡¡,uch GavltcaEat.

h aDy elecrrtcal coofuuruton tt l¡ dc¡l¡¡ble to btve tll ccBductora

cod¡uous bGtwG.o l¡t6lc6DoctlDg clGctr6lc/olcclstc.I ulttr. To
¿chlev€ tlü8 cctbuous ctrorlt prth ¡ hl'arly rcll¡blc cooDcctlcn, ba!€d
on hlgi mectunlcal rttra8th ¿¡rd tood cloctrtcrl ccdr.Etlvtty, la r€qr¡lrGd.

Thare ¡re thr* baltc c(n¡octloD ryltor!!, uroaly:-

. CooDeetora - clrcr¡lsr sDd rec,t¡lgul¡r xl¡ü eltb€r crtEp o¡
so¡der pl¡r
. ConDectorle.! - r€ct¡¡tuler wltü z€ro-tos€rtlc,D fo¡c€ vltb h18b
p!6saure sprbg sctl6 force to Erke th€
coBncctloa

PermgeDt - solderbg, braziag, we¡dhg rDd cr1¡Dph8.

'.- ! -¡,.,a'-': -

Co¡Eector!

RectsDgulrr a¡¡d cl¡o¡ls¡ c(D¡€ctor8 offer corDplete Oedblllty tD l¡tüal

destgn wh€|D uscd wltb c6rIlntiousl a¡d ra¡domly orlat$ed nWC SyBtem'
o"datl- of üe wlielscuE ac'ilmlÑhe¿ u tu'a co¡ector srpport
cl¡op, or, wh6 r lupport c4glP_t! Dd u!€d, !063 7 qrlgt Eom $e
.'¡eg S! the cq¡!cfo!- e¿f¡ráñ=¡¡fEa-pu co¡¡etiool ta s&r4üt-
Effid, ftú;'a by ¡ccrléBtrt¡¡¡g crlmp rGoov¡ble c(Dt¡cts or by
raEolri¡g r¡¡d rsro¡dstbE vlrc! to ccD¡rctor rolder pot!.
q/ho trrlilñalbg FCC tB dtbet clrc'ul¡r or r.¿t¡Dúul¿! c(D¡ecto!
Ocrtblllty lr ü tt¡ le.rt, pb rtttgDm€at cbraga b€r¡g ll¡ltted to
lclcülDg r¡d rcortat¡tlDg thc crble eagmatt. Fleübtüty cu bc
l¡crc..cd by rdoptf¡g r flodble h¡¡:rall IDB lystsm (BGG Élsctlou 2 ' 1)
.:r by ¡ trrarltlo hoa FCC to BWC.
Who t!¡¡c c68Étola rrc blck poücd thay lo.G thalr rdvu¡8c ol
ptr rG-..3ltr¡¡aat Pot othl. I¡ üt¡ cr¡c th. m¡.xlm q.¡l rmor¡Dt of
t..tt¡g .bd¡Id b. dooa prtor b bck pÉlDg (for ptt'rDg teh¡.lqr¡..
t c S.ctloo 5.6 ).

2 -1-3-l
Cmectorleg¡

Cco¡octoll€!! torml¡¡tlcr¡! h¡vc Ii¡ult¡d u¡c !¡ c¡blc hrrnc!! d..lg!,

tb6 c.Dcet bebg ooro rd¡pr¡ble to l¡tlrD8l wtr!3g ol cle¡rtrl/
á¡6clralc E¡tt¡. Ttey hrw tie ¡¡¡rc Ocxlbllity ¡¡ d¡culer lld
rrst¡Egul8r coDoctor! *ie¡ u¡cd rüh rudomly brr¡c¡¡ed RWC ¡!d
tho ¡arac ll¡lolt¡tlo whau u¡od wltb ECC.

Co¡¡ectorles¡ t€lEl¡tdoDr rhca correctly ¡r¡cmblod ad ¡ec¡¡rd ¡re

equrlly re rcll¡bl e ¡! ccnv€Étloarl coucctor¡.

Ccooctorleea termlDstloDs ca¡ld b.rt bc u¡d l¡ ¡ ,llc*lblc ylrl.og lyltrr¡.

(r€€ SeclloB 2. 1) wherG ¡Il clrcults ¡¡e c{mp¡rt6d 8t s ,u¡ett6t¡g,/
p.tcbl¡rg fecüty. Tbl! ryrtca tr eurr.Dtly uadcr dcvclopmcat,

Peruac¡t
b geaerel p€rmr¡¡eDt co!!éctloD! heve 8 hlgü degree of OeÉblllty whea
uld wtlb ra¡dom R\trC vtltag but llEtt€d tt rswork wheo u¡cd *lth
rt¡eked or sbgle layer FCC.

Tblr type of cooDectlcrr la usuelly u¡ed for the t€rrn ¡aüca of RIIC
wl.rl¡goD to el ectrlcal/elect!úrlc compone¡E ¡ñlch ¿¡e to sta¿¡l to
hou¡e e conlector, e. g. aHa mourted l¡strumeateüo, dlodes, etc.

C6peeti6 Svstem Trade <ff

?he most trnportant crlterla ts that of retlablllty, mass belag e secondary
cona ldertlo. The moet rellable rystem ls whcrc the elcctrc¡lc ualts
l8d wirhg ¡rre coor¡ected by the rDrDlEum aumber of ,otnts.

lta t¿ble belqr ahos8 th6 Durfüer of rol¡ts requlred to tllercolDect oae
yl¡e betsaen €léctroalc cl¡cults.

Perma¡clat ¡ad coD, €ctor lar! tortü¡¡sloDs h¡vo the I€aEt numb€r of
JolDtr r¡td crD therefore be cooeldered the moEt rell¡ble. Both of thcse
.yrt6rD! h¡vG dlr.dv¡atrgee whtch ¡¡o ¡ot ¡ h¡r¡d by th6 c6¡é:or method:
dt!¡d,r¡Dt¡g!! arc the l¡apr¡ctlcrbtUty of tortlDg, lrbltcstlq¡. m¡lDt'rñ-
¡btuty ¡Dd üG UElt¿üor lr¡poacd o .yB!66 lnt!tr.t16.

ConDector termt¡rt!,o¡ rellabtllty cea ba grcrüy tr¡lprovcd by thé ¡dAtt D

of a pla roduadeacy phlloaophy , whoro the numb€r of Jo!¡tE l¡G bcrcalcd,
requlrb g thc opea cttcultlag of trro Johtr bcbrc tbc stEDll l,i lo.t.
(Se€ §€ctlcD 2.L.7 oi Bcd¡¡¡dscy).

2-L-3-2
 NO OF
CONNE Cf IONS
TERMINAIING MEIHOO

CONNECfORLESS

PER}'*NENI

2-1-3-I
2.1.4

MtDy Gl.clrlcrl cca¡ctor¡ uc anrratly rvrll¡blc lor hsb -

pcrbroraco hlSü-rou¡bt¡lty rpllcrttru. &¡oc tbc co¡a:tor¡ phy
lucl¡ e tEpolt¡.st f¡.ñ l¡¡ th6 btalc(!¡Elhg rt¡bg ba¡tdrc., l! [r
very t¡lport ¡t :hÁt fear corEarrtro ba É.rto E üG b¡¡artll¡,
ñ¡rt¡hcs , ¡¡d c(ó¡ccto! c6trgrErll,.ar.

A brl.l lDtroductla t¡ dva b.lorr. For aorc d.trUGd dt cur.lo

the rader l,! dlrcct€d t rcfeaatcc! 9, 10, 11, 16, 18, 28, 31, {l ¡Dd
u. PrrrE.trlc drt¡ l,r glvca lD sccttO 3.
2. 1.4. 1 Ccn¡elo! M¡t¿rlrlr
Sretl¡ Materlal¡

Ccn retor ¿hell¡ a¡e uaurlly mrde ÉoB htgrr grade aluabtua rtloy,
bra¡¡ ¡nd fo¡ loEe aF¡t!8llqis st¡b¡€a rtlel.
Il¡e permesHt{} of thc ¡trlú ,¡¡tli¡¡ -¿ ¡-Á*f . p"Ur.
l! of lnterelt b a Dco-t!¡glctlc enrá¡o¡aaat. Co@actor .bGllr
to MIL rcrr'rl¡em6t! ap.clly per me¡blllty of 2 ¡¡d re¡tdrnl
Ei¡EBetls ra r¡D dsg tor! 2OOO to 2 g¡¡¡!r.

Df¡gtaúl¡r Ddrl¡ ¡re norma,lly aot a problera, MIL rp.ctic¡llor6

of ccrrDcctors prohlblt the u8c of dbrtmll¡r met¡Is whtch ¡te
subrect to eloctrolytlc r-.1 g¡lve¡lc corro€ !(¡. Ncw¡tbcla¡e
thlr Pobt ¡hq¡ld bc ke,t b ,orDd' "j:.-n-.
::!- :.-'. -.--- -..
-.1
tpsul¡ttcB M¡t€rl¡l8 )¿ . . ', ¿ .

Tte t¡rul¡tor bodt6! of ht8ñ p€rlorm¡ace c6D.ctor! are geaerall¡,

mrdc from d[flyl pbth¡I¡t: rad epory nroldlag co¡oporod¡ rhlcb h¡ve
¿rccllat phyr tcel s¡d cl€ctrl,crl chú¡ctorutlc.. Ra.Uleot E¡¡lrr¡lr
of hlgñ pcrforrnrace tier¡¡o¡ct Gl¡rtoraar! ¡!d rUlc(Dc coflporsd! rrG
u¡¡d for ¡atl¡ ¡¡d othar BoallEld lDtrllotor r.qul¡rBcotr.

lrl¡tertrl Dt.. C6rt. D[!r. Faetor

Phaoltc tf.laenl Ftllcd 9-15 o7- .n

Mclr¡nbc Gt¡¡r Flbrc Ftll¡d 6.5 - 7.5 013 - .015
AllV D Cb¡¡ Ftlld 6.2 - 6.t 00t - .023
Dl¡¡¡yl Pbth.r.tc Glu¡ Fllld 3.{-{.5 009 -.01{
lillcoa Gh¡¡ Ftbra Fllled 3.2 - 1.7 002 - . o,¿0
Polycertoeta Glu¡ Flllcd 3.0 -3.{ 007 - . 00&
r0-.{¡%

&l{-t
 fhcl I Fl¡l¡ho¡

Cqr¡etor abcll flal¡hcr ¡re both cúducllvG ¡¡rd Decadr5tlyc.

Elactlol,¡r llckal 1,. oc of lbc b.o€r cood¡Ettw o¡l¡ba fLtlr l¡¡rd
r¡dtra pto!ád.. r dr¡r¡blc noBod¡¡cuv. 6lrb. Go¡d fbtrb provHae
e 3wd dunble coducllvr fht¡h. CoEeto! fblrb6. rrC SlyGa b
Tr.b¡c 2. I . a. 2.
$tcldhc Proú! loa

Two typea ol ehtaldbg provtrloD! rre pror¡ldGd by c<uetor ry.tañr.

fhe trtrt provldce a lw tmpcd¡¡ee path bctvca üe ccn¡e¡or b¡lvcc.
Oft¿¡r, the cqr&Gc¿or l,r dectgncd to aalule tbst thtr rhell ro-rheU
cc¡rt¡c! wül bc r¡¡do prfor to the clrcult ccnt¡st¡ GD rastbg ¿.d yül
be broka rtle¡ the cfreult cot8crs on dtacolcctlag.

Tbe ¡ecod t¡ ¡n BF perlpherel shleld whtch ts mde arol6d t¡e atire

rútbs aurfrcc ¡¡rd at erch c¡ble+und¡e c¡tly tnto tbe b¡ck of tbc
coa¡ccüJla.

Adcgr¡úc rhleldhg p¡ot lrtor¡! h¡rrc beca aupglled or¡ both cyltadrlcal
¡!d recErgul¡r cqr¡ectoE for both BWC aDd FCC.'

2.t.1.2 Coopetor Cooftn¡rett6t

Rcr¡pd Coúgt¡ratlon!

Round co¡¡ectora provlde the most eficl€at form factor for meha¡rtcel
psck¿glsg, rnrnufrcñlrllg, reqrber sy8ter:a ¡ad mech¡a lcal btegrlty,
Ttey ere s\,¡thble l¡ rneDy dlüereat MIL-SPEC cot¡llgu¡¿tlcE! as shotrtr
l¡ Table Z.l,ÁZT.he NAS-1599 acrte¡ la a¡r :rvlroomeot-relbtr¡g
lsmüy of mtnl8ü¡re cqrDector!, utül¡lDg lea¡ co[t3ct bser1loa ¡ttd
remoral,. dectgned to me€t th. mls! Ue r¡rd rFc€ htgi d!t!,¡de r6qulre-
m.,Dt!. c. EGGtOrr to MIL-C-83723 rl¡o urlll¡e r€ar blerllona. resr
renovrble coaú¡ct!, and provlde coltÁct rtu6! to'O" gaugE.
Tt¡¡ MIL-C-265O0 coDDector8, uaed b the p.!t, hrvc bcea lrrgely
rrplrced by tho MIL-C-8I511 lcltes, whtch hss v.¡f, htÉl contrct dcDrtty
a¡ wcll r¡ hlgh pcrforruac. ch¡nctcrtstlca.

@
Rcctoguhr c(Dnéctor¿ ¡rc u¡d (or a ¡umbor of spect¡IÍ¡ed rrquEe-
metttt. They do provldc. raorc Glflclent forru f¡ctor for mury prck-
sgrns probl€E!; tücy c¡¡r bc urcd.rcrd§ for ¡¡ck ¡¡d p¡¡cl tpp¡lc¡tidr,
r¡d thcy p€r rnltl terrulD¡tloar o¡ ¡'hycr'brrb whfch tr ro lmpoat ¡t
to slbbc Erd FCC tGsñl!¡tlGa.

a
2-L-r-2
 ?. t. {.3 EcvlroEEacattl Co6 e!or!
A¡l rhG cclGctorr ltrtGd b 'I¡blc 3-I9 h¡v. o vtroa¡Dear¡ I ec¡b yü!
thr Grcrpatc of MIL-2{308. A¡ hvlro¡¡ar¡!¡l S¿rt !s dei¡d ¡¡ r
caaetor c¡fb¡a of rlthroadbg üc hgfoea of ¡rol¡n¡¡e she¡
b¡t¡l¡d b ¡ hunt,r avlr6a6t.
byl¡EDracDarl aalla3 tr ¡cbtcval by h¡reS s! l¡ErÉ.ctsl ¡c¿l a¡d
8!oEr!Gt ¡orl¡ lor üo y{rr! , tce F§urc.r belo*. bt¿rácl¡l te¡le
ceu bc elt"bcr b thG brE ol ra O rlng vlth hsrrc l¡6ert! or h¡rd BockÉt
b¡ert ¡ad eolt pb brcr!.

"cí RrNci=
LIFTING SHOULOER

ENLARGEO HOLES
SEALING IVEB

SLIPPERY GROMMET

COMPRESSING SLEEVE
CLAMPING NUf

h ordar to fo¡l¡t¡b thc avl.rcoE€Bt¡l prcPcrtlG. of the cctrDG¿tor

¡ü ¡or¡¡cd pb po6lt1cE, riurt b€ É!¿cd Ttth !,ll¿rc.

2- r{-t
 2.1,1.1 PlD,/t¡oc k8t hrclt
fh6 toprt ¡t l¡¡Eü. of üe pblaookrt b..rt rF:-
l. brañ rútatloa brcc
2. Dto¡cctltc Ert6rt¡I
3. T¡p.r !!d clolGd otr? rooklt hol¡¡l¡g
i
ThG h.Grt rgtaattoG folcc r|!¡lt crcc¡d tüc o¡Lu¡t¡ coaH¡d
pln/lockGt retatl@ fbrcc, otherlac !h€ brer't cottld bc purhed
back á.rñag m8tt¡9, s condltlori whlch tt k u¡Ukely to b€
encq¡¡¡ler€d but cor¡ld rrr¡rlfelt ltrelf U the qrrllty of thG retattoB
ryrtoE were to bo dogrrded due to 'ábr8t¡m.
hrér! dtélectltc mrtertalr are giv€o t¡ T¡ble 2.1. {. r aad
gctlon 3. L

Flgussa 2- 1 tD 2-:l dGfrbt f tv€ co¡¡!¡oo .ekst hs€rt

c@Ilg¡¡ntlon!.

/ l-xeee en Tbt! LE tbe Pr€felréd h!e!t

cor¡ñgu¡8tlca. AIY EÚsUgEGd
pbs o! tbe taaÉ8g coDDcetor wll¡
6trlke th€ ch¡mfer, whlcb ¡cts

Wffi ar a locator, and corroct oatlng

stll be acbleved.

clored entry, h8¡d f8c!d

wltb ?n¡mf€r lgad h.
FIG. 2-?

b_ r4ALE PIN
I
b thlr coftguratton .aY mb.l-
I
l8Dm.Bt ol the m¡lo Pi¡r vtll rGlult
tn clthcr 8 b€ot Pt¡ or tbc Ptr
bebg prahd b¿ck t¡ ltt brcrt.
Tblr t Bot a P¡efcrrcd ccnflSl-
uratticn

opco s¡try, b¡8d f¡c€ htcrt

rtthout chrmler le¡d t¡.
F¡G. 2-6

2-t-t<
%g% Ttlr f! ¡¡ l¡grove¡o¿at o tho
coigu¡ltld ¡ho*¡ t¡ Ftg.2- e.
Ttc cb¡r¡Icr lcld b ..'Ut t6d to
ell¡a tüa ra¡i. ¡¡d teurle ptoa.
Thl¡ t¡ tbc accod prefer.rcd
coü,gurettm.
on€! coFy, hrad f8c€d blort
wtth chr¡nf€r lo.d tr.
FIG. 2-9

I PIN b thtr co!,guratlm, 'nr.atlFed

2,MALE Et.le pbs c8! eoter ae ebo*¡ ta
the Agu36. ltls ls.t6á'¡!ort '
dañgeFous coa f, grrrtlú. Poeelble

%nru leult! ¡rc cp€n ctrcldt or lDter-

rultt¡r¡t coüt¿ct (Daltl§r!¡rly Eder
vlb!¡t16). Not reconacoded.
op€n 6!try, ¡oft frced b¡e¡t
wlthq¡t ch¡Eler le¡d to.

FlG. 2-10

la thts couügu:atloB e¡¡y E,r8UE!-

mrDt of the tD¡l e Ph Ylll teluLt b
€lt¡e! the pt¡ bef¡g bs¡t or tr¡s hed
bsck tn lts Lo86rt. Ttlt cofgur-
atloE i3 :roi r €co Erra6l d€d.

clorcd atry, hr¡rl f¡c€d lDreñ

vttbq¡t l.¡d b.
FlG.2-11

Ccn¡étor! xüh loc h!€rt¡ !o! pb ¡¡d ¡ok¿ cúO.¡Ertt¡t

both
BuE¡c¡q¡¡ E¡lñ8ct'6t o¡r§
¡toEd ll 'L
¡nllrblc, thc¡c ¡bor¡.td b€
occulrcd rh.ta thc "'.lc ph t¡tac.d ol otl¡rss tüc rook¡t cEtlcr b¡'
lltd bct?Ga tho .olt lBr.rt .-l thc pb.

2-l-{-6
2.1.1.5 Ccntact!

Th6r€ ¡rG t?o cotsct tYP€3 , Damely:-

1. Tbc l¿msle co¡tact p¡ovldet th€ coot8ct prorsure.
2. The m¡le coDtsct provtd66 th6 cout8ct prGrruF!.

I¡ botb type¡ the mÁtl¡g co¡t8ct 16 p88slve.

Feraslé SDrlpg copt¿cts

I! thr! typ€ of conact the female preseuts e¡ orlflce of lesger dtametcr

thrD the n¡rle coatact. The stral¡r of ep8¡81@ of the sprbg device
producee the cont¿ct prelaure. The battc tyPe8 of female sprlEg:
cont¡ct! ¡re Ulustratcd lD flSrree 2-L2 to 2-L3.

Probsbly the moet rel lrble pla

PROO PROOFING coBsü:r¡ctlon. It's resfBta¡rce to
plobe damagE betog enhaaced bY
the prod prooñug rleeve. Most
MIL speclñcatton cot¿cts are cf
ülr patterE.
Dtsad DtagE - postib¡e point
coDtsct to matlDE Pl¡.

SplU s¡d tF¡¡t cout¿cl

FIG. 2-12

Tht! style tr cvat¡8ble wtth or

PROO PROOFING rrthout the prod Ploofbg, tD boü
csa€! the rBshtance to prove rlrm-
HALO SPRING rEE l! p@rr the b¡lo tlDg belDg
poalttonod too 8.8r thc úeck of the
rocket pt¡. O¡ rocket PlDs stth-
out prod proolbg thc lltt¡8tlc,l l,r
*ur!€, the ha¡o r1¡g c!¡ b€ dls -
p¡¡c€d rGlu¡tt[g ta cüher o/C or
btalEltt6t coEt¡cL
H¡¡o rl¡g rPrbS coat¡ct
F¡G.2-13

2-l-1-6
 O PROOFING prd pmobg rlcctl glver r
Tbc
SPRING
Eiáurr ol proteG¡/oa Éota probe
drorgs. hrt¡¡caú h¡w occr¡rred
ricrc thc aprtg h¡¡ bca debroed
rod t.ha agltg b¡¡ bcca omla¿d
rltoSlthGr, rcaultbg t¡ O/C or
btlrraltt.at coat8ct. cGtsstl¡8
¡¡r{rce¡ phlaockat t¡o.tar t¡s¡¡
th¡t .hñu h Ft8. 2-12.

LoaSrludl¡¡¡ .prbg
FrG. 2-1a

Thl¡l¡ ¡tolla¡ to tü. l68ltt¡dhal

rFúg tj'p€ c(Dt¿.t tYllh tbe l¡tro-
dr¡ctlGE of e Ooathg plrté wt¡lcb
asrvÉtr to bcrerlo tbc c6t¡cÉla
rr€e. lt rr Eot wbolly prod proof,
botb the sprbg ad Oo¡d¡g plste
ca¡ be deforad.

EIoirhB pl8to BprtDB

FIG. 2-15

Melo ptue ale Eot so Proao to Frob€ d¡E¡88. fasfe ar€ eólatlslly
tüo tyF!. Ftgurea 2-16¡Dd 2.f 7.

.qF
1.,

FlG. 2-16 FIC.2-r7

S!¡rgtt pb cGt¡ctr ¡¡¡ r¡¡ed rn! fcmrlc coct¡ct! of tbc tfp. aho¡! b
FlSr¡¡c¡ 2 -12 to 2-15 oc ! tbe c'mrttlad typo ' br¡rrt¡bly ¡Pclid
t ,z¡¡,. M8PC ¡!d GstrC tP.ctflcrtlc.. t[6 rr¡t6 Mtt PID lborü tD
Ftgu¡a 2-ls tD¡tr. vltL aa ,tñ'prtag Pt¡, ih{' tyF ,.. Ed r'corüEadGd
tor gpcrrl ur.. üry.r. i'rgf¡c Ed ted !o bad ¡t, pollt A' rt t¡6
lG..t E¡r.llaDBat.

¡'l*r -7
 Conü:ctor llf¡terl¿l¡

Con¡ector coot¡sts ¡¡E m¡de from ia&hb¡ble copper dloyr. Prqor

coaó¡ctlvlty mu¡t be provtded by tho loElpÉ¡g membcre. Ptorpbor
brmze ¡¡d beryllü¡ru copp€r ¡ro uaed for the !p!bg n¡Grob.rr. llr¡y
coDts.ct scb€n¡e! u¡¡e aprbg metobor¡ ¡hlch do Dot c.rry thc clrer¡ll
curr€a!, Thls permlta e very lor €loctllcal coBó¡cttvtty m-stGrld to
be uaed a¡d reduces the probablllty of loehg contlct p¡Balure dudag
s¡d sfter overload c@dltloD!.
Mthe"
Typlcel coDtect p¡atbgr ¡re rho*a l¡ Table 2.L.l2 Platbg t! uscd to
prevent mecba¡lcal, el€ctllcal, a¡¡d cheolc¡l d€tétlorsttcB ol tbs
matlng suráces of the cot8cts ¡trd m¡¡st be cqrstder€d lor e¡cb
p¿rtfcular a!¡pltcatlo.
Trble. 2. 1 .4. z
CONNE TOR A¡¡D CONTáCT DATA

Co¿nector Appilcab¡6 CoDtact Co¡tact Accept Coffact CoDt¡ct

Sect{lcatlon Coatá4t PlatlDg Slze Wlre TerEiDsl R¡UE8
§p€ctAca¡t6 Gsuge Typ€ (8qr)
(AwG)

MIL-C.501 5 Go¡d 16 Solder' 22.0

o9er L2 41.0
aüve¡ 8 73. 0
4 135.0
MIL-C-22992 @ld n 24S 0

MIL-C-26482 Go¡d 20 Solder LO

ovor l6 13. 0
sllve! L2

MIL-C-23216 Gold 20 24 Crtmp 3.0

ovel
sOver 20 7.5
l6 20 7,5
18
16 13.0
14 17.0
12 23.0

NAS 1599 NilS l5O0 C'old 20 24 Crlop 3.0

or 22 i0
rtlvar 20 7.S
or 16 20 7,5
D!ck¿t 1E 15.0
18 20.0
L2 l{ 25.0
t? 3&0

2-t{-8
 TABLE 2. l. 1. 2 Coüta¡¡.d

Connector Appllc¡ble CoDt¡ct Cootrct ¡t cGVl Cat¡^ct Coalact

Seclflcstto,r CoDt¡ct PlÁtbg $¿c Ptre Ts!ñ I ñr I R¡!l¡¡g
Séctlcstlqt G¡ugs Typ6 (rEp.)
(AwG)

MIL-C-2 5955 Gold 20 30 Cr'lmp

ovGr 24
aüver
20
MtL-C-27 599 Gold 20 Crlop l 7. 5
over l6
sOver
I 13..9
I

10M 38277 Gotd 28 28 crt¡ap I t. t

ovet 26 26 I z.o
coPper 24 24 I s.o
I ao
40 M 39569 Gold 20 20 Crlmp
ovea Lb 16 20.0
nlc kel L2 35.0
or
c.opP€r
40M 39 580 I
Crtmp 5.0
20 20 (. ¡
I6 16
L2 23.0
GSFC S-311 - Gold 26 26 C:1mp 2.0
P -.113 over
copp€ r
csFc-s-3u- 3.0
P -413
MrL-C-2430E Cold 26 2g Crlmp 2.0
cs¡rc -§-3rl - ovcr 20 20
P-10 coppaf

2-¡-{-0
2.r.{.6 Ca¡Dll¡E Mech¡¡ls Er

Thcrclrttvr !dv!,Dt¡g!. ÁEd dbrdvr¡tsgEa ol tü6 vrslo¡. ccr¡nlhg

E6cb¡¡tlr[r arc g:.v€! t¡ Trbh zJ.t3. '!h6 c.rdr¿..tr ryltrtlr r¡e
lcr , bryoosr, cea!¡¿ ,¡€k, tr¡rh/püll ud ¡¡h.

Table 2. 1. 4.3
Adve¡t8ge! /DbadvaDt¡EE! of Coupllug Mecha¡ls r!3

Conplbg Adwatege Dl,aadvaaage.

Mecbal¡m

Scrr,? Mccbralcally etrag. Dtftreult to tDate l¡ coafl¡ed spsce8.

E¡sy to loclc Good CoDtsct sar thr<,ugh rcp€et€d
elGctllcd coatbrüty m¡tes/dem¡tes. Col¡lectors [x¡at
betreen mrü¡8 br¡veE. b€ Erou¡ted far 8pa¡t.

BayoEet Mech¡a tcally strñg. Elect¡icsl ccDtr¡ulty b€treea netl¡g

Eaey to lock. E¡ly to halrna depradent oa 3 pobt coDiact.
ut8te I¡¡ coaftned !¡Fce8.
No d¡agpr from swarf.
Ccn¡ectorr ca¡ be
moutod cloae togetber.

CeDtle Jack Eaay to mate tD conüDed More dttflcult to lock. I¡v

spece. No danger bom e¡6ct¡lc8l contr¡ríty bet reen
8ra!f. coEfiectors caD E attag halves.
be r¡or¡rted cloee
to8üher.

Pr¡¡h/hll ' No drager Eom ¡*a¡f. Hlgh m¡tlng/demstb g force. l¡w

slectrlc¡l coltlDulry b€tween ma!l¡8
b¡Ive¡. Co¡¡ectolE ¡r!¡s! be mourted
trr apsrt. DüAcult to lek.
P1'¡!h No danger from assrf. Hlgh mrttag force.
Euy foaté b coD.6¡ed
,
aFcc!. Eaty to lock.
' Not covtrcd by ray epprovcd lpGclflcrtl E.

2-l {-10
'lhe DuErber of c6!6ctor m¡!e! r¡d d€Esle! pcrElt!€d bcbre
repLaceEent of tho c6neto! ls Dot rpacl8éd 18 ray of thc
rpelllca¡lcns lr, tsl l! lbctlcD 1.2. 1. Wberc tie Du Eb.r ol ¡lz¡a /
dem.a!e! t3 spectfl€d ll tl ua uelly l¡ tl¡e lorm '¡h¡ll be kapt !o a
m-btoum'.

CoDecto! ravels e¡e behg btroduced on rDo.t ESTEC plorects Eo

thst the number of mates/dem¡tes of the Olght corEectorr !r kept to a
Ial¡lmum. Tbls do€s add Blgdtaca¡tly to the cos¡ of c¡ble har¡esses.
The followlag l3 oüered ea a meana of porttlwly tdcatuybg th€
ma.xlrnum aumber of ma¡eá/demates p€rrDltt€d. If tB ba!€d oo the
level of teltbg shlch coooectors uadorgo durlag Qualflcatlo a¡d
koduct acceptaace testlDg (Doml¡rally 500 mateE sld demate! wllhou!
degrrdatloD).

MaxlrDum l{r¡mber of Mates /De nretes = Total EuEb.r of mateldemete cvc les
IO

The corplbg r¡echs¡l8m¡ ldeatlfled t¡ Table 2.1. {. 3 st! lot consfdered

to be lufEclenl to casu¡e ¿bat deEretbg do-'s Dot occu! r¡¡de! vlbratlqi
coodltlods whlch erlsts dulbg the larmch phase. Addftlcns¡ lockl¡:g ls
reco¡nmaded. The preferred Eethods ere e¡ iollows:-

¡. Wtre locklng flgu¡es 2. lg to 2.22.

Torque loadla g of fldn g screwa - recommended for sm¡ll scretv

!tze! arly.
Appllcatlon of screr*' lock medtEn - e. 8. I¡ctlte recommended
for sm¿ll scrars ouly - rtEk of da¡nagt¡g the scr* th¡ead wha
dematlng.

l-l -{-lt
2.1.1.1 CotrEoo F¡ultr tp CoEpEtort

Elcctrlcrl cco!.ctoa! prG!.at mor. tb¡! t¡elr rFroprr¡t rblrG ol

trcn¡bl6!. Thc Eo.t conroo f¡ult¡ t¡c:-
(i) Rece¡acd ccot¡ct¡ - coot¡ets Dt colrcct¡y r€t !t tlr hrert or
tD lhc c¡re ol rc¡aorrble pla colrEt¡, tbc pta rc6¡r'C lprbg
L mtrrbg.
(b) Recec¡ed heert - l¡sert uot corrcctly pocttlcnod la the
cco¡ector ebcll.

(c) B€at pbs - r¡¡Itle8lE(fit durbg hr¡¡¡lh,g e-¿ fla laaertb /

ext!¡ct!6.
(d) To¡¡ or crecked r¡ommets - whele dt¿Eete¡ te blg br the
gtotürnet, mr¡uf¡c§¡r{¡ g error.

(e) Colroded c6t8ct8 - ¡urface fhl¡b oa c.o¡trct! wola by te

r¡sDy m4t¡¡8,/deEat ¡g operatloEs i or, hsde$¡8tr or beñclat
pl¡d¡¡g. or excésrlve currents durGg EsttDg or drE¿t'l¡g.

(0 hterr¡ttterpt caEtacts - sprbg t! tockst ccat¡ct ELssi¡g or

socket dlaEeter overglze or ph u¡daElze.

(s) Cracked ccntacts - d¡€ to overcrloplag or use of hcortect tool.

o) Damared surface tleatmqrt - car¡sed by mlaheadlbg,

2-t-1-12
2. l.{,8 CqrEector ADD ll,cstlon

Sloel H¡¡¡c¡
Muluptn coE¡etors as€ lr¡ ur6 l¡ various forE8 lor Eultf -l¡telccDséclbg
dlgitsl clrcult boa¡da e¡d also !o lDt€rfrce hE¡dw¡re. Tbele coaDectorr
coDslst of the cylbdrtcsl. rccta¡guhr prlDted clrcult, r8ck aDd ps-pel,
flst cab¡e, dlp aocket, a¡d termlDal ,u¡ctloD ryltera tl¡peú. ¡úo8t have
appeared w lth oBe o¡ rnore coaxlal coDt¿ct€ lDEtslled b place of soEe
of thei! aorrnsl pb a¡d socket arra¡¡getr¡enls. Tbege bave be¿a
lntrodtrc€d at spectftc dlgltal user rquerta wherc certah cl¡cults
p8sllng tlrough s pertlcula¡ cootector Eust be coat¡olled for loa¡es
due to üe dlelectllc or lmpedaace tlllEatches. The coeÉal ayatea
also ml¡lñ¡Ees clrcutt to clrcult croslte¡k.

The loE8er la traDsrDl6sloD ll¡ee and €¡ectrtcal btercoD[ectlDg

mechanlsms ¡tlect the ñdellty of tr8o8El,!!ed pulaea, aad the¡e losao!
l¡clease with lDcreaa¡ng ftequency, b pertlculsr tt la evfd€ot tlat es
puke rlse tiBeE a¡d ¡rldths contl¡ue !o decre¿rs€, üe couveatloaal pb
and socket multlplD coD¡ectors wlll prcve to be too loeay to aeFre es
dlglt system lDt¿rcoEecta. (ReL 27).

Where connector losr a¡¡d lmpedance mlsmatch probleas have bes¡

severe, htgh qu¡ilty slDgle cl¡cuü co8.É¿l cc,oD*lors ale eoployed.

Power Haregs

Multlpln coDEectors are l¡r use for l¡¡lercoD¡recll¡g power lolerÉacea.

The ra¡ge of conDector dell¡eated lD Table 3.19 cater for tbe cu¡reat
a¡rd voll8ge requlreE€lrts of present day spacecrafr.

MSFC Seclgcatlon 40M39569 type corurectors a:e the maLDstre.¡a or

workhorse coD¡tectorg for the Skylab space vehtcle. Theee conetora
8re ¡¡ up8raded NAS1599 t¡Ae, selected eDd Edlfted by NA§A/}§IFC
to nract the raore 6lrlngrnt aad pecullar requl¡eErats of S§lab.

The Zero-G Electrtcs¡ CoDD€ctor [r a¡,t8o lJsed t¡ sddlüoD ro tbe

40M39569 (modtftad N.tS1599) typ€ 6 Skyt¡b. MSTFC Sp€cEc¿tlco
{0M39580 deflnee :hl! coBoeclor. The zero-G Co¡¡ector l! the ¿l¡st
electrlcal cotrn€clor of major usage apeclflcaUy deetgncd to mect
NASA'! needr. Ttre Zero-G Coo¡ector le ¡ hr¡dle oper¡led, owr-
ccatre lock, €Dvt¡oam6ulally ac¡lcd r¡¡l! wlt r removable crU¡P tyP€
coB!¡ctr. (R¡feroce 27).

?he GSFC S-311-P-4/3 sDd MILc-2430t €lcctrb¿¡ ccn¡ectorg hlve

bcsr u¡ed oÉollve¡y o .ataül!r8 for both po'wer rad rlgnrl
rF¡lc¡llca.

2-l -{-13
 -.;,.j:¡i
).

FtG" 2- lE FIC. 2-19 iYPlCAt LOCXING FOR rWO «»at{tcrG

ioc¡rlaa t f
xI
f^rÍ lt rlla
t
I
fcc

FtG. 2-20 FtG.2-2t tYPrcAl t-ocxrraG tr{stat tArrot¡

FtG. z-22
A¡t thc .¡€ctltcsl ccrrlelorr ltltrd b Tsbl,!- 2¡¡. úulE¡bl. br u¡e wtil
BWC c6ll8u!stl6r. El6ctll,crl cooDetor! for r¡¡c wlt! FCC ¡rc
¡polltod t! MIL-C-á6643.
A.llP bcorporamd b8v€ dcwlopcd r @!.!eto! lor tlrñrñrü¡g
¡l¡ñrt'ruu coduclor. (Eá¿ 3l).

2-1-{-15
2. 1.5 Eletrlcal Wtro ¡pd Cable

Therc are ma¡y hlgb performrace , blgi rell¡htllty wt¡ea a.d csblee
Evaflable for tpcocra0 aFll,catf([. S.uc€ th6 rtrc s¡d csble pláyg
such an lreport¡¡t ¡ p8ñ l¡ tho rpacocrr! oloctrtcs I c6ñgu¡ülco, tr l,s
very lmpoñ!D t that p¡.op€r attailou Ls glve¡ to tbe ccduct r tad
shoath mstertslr. A brtef d€rcr lpt¡an ta gtvcrr bciot. For ¡ more
det¡Ued dl6cu¡alm the r€ader l¡ dl¡ectod to ref€rcace8 9. 10, lf,
12, 13, 14, 15, 23, 28, 29, 31, {0, 41 ..á,tt. Per8m€rrtc d.srá ts
g{ven in S¿ctloD 3.

Power Cabll¡f

Power cable rf¿krg ts h"qed upon suoreble roltage drop, regu¡attoD,

po*er loea aad !s de¿lt wtth b! S€ctlon 2.L.17,

Mase LB ar¡ lmport¿Dt feah¡¡e ln power c¿ble stzl¡g. Th6 poser crb¡e
should be rlz€d to satlsfy the electrlcal parameters for E¡lDlrnu.E fD 8s.
The dealgner should real,lt any preg8u¡e to lDcrease ¡he comer c.anteDt
merely on the g¡or¡¡tdE that ' lt would be m¡¡ch bctter". It l,E edÉsable
to questlcn ¿¡ny strtlgE!t regulatlon requtremats as urera are apt to
overstáte thetr requl¡emqlts.

A mlniÍrum copper cootent of 24 AWG la recomhended, smaller

diameler coriductors do not have üe mech¡¡lcal strength regul¡ed for
power cebllDB.

SlEa t Cabllns

The load and source stgnal impedances are usually much larger than
the DC resl,sta¡ce of ihe wire l¡ter@Mectl¡8 them, consequenlly the
rmallert evallable wtre B8uge can be used, conal,Etent P tl}l adequate
mechs¡¡lcal protectlon a! the con¡ector to t lre JolDt 8Dd l¡ the routln8
of the cable loom.

The core to core and co¡e to Bhleld capactts¡rce cen have i slsElflcant
affec! on the stgnEl, p&ñtcularly on long cable routes, and shorld be
leko lnto accourit when atzing muitl-core cable. Capcltence flSrres
ere 8lv€n tn S€ctlcn 3. 2.2. Gt very loug cable routes or rrhere the
:equlred ftdeltty cannot be echleved mlDlalur€ RF c'o-8xla I crble
should be cqlrldered.
 *¡ .
DESI6H FOE EAhDOtl AN EXAÉPL:
bY 0tca9 X. robS i
fur!iñ lnt!¡tu!a of Tcchnology. Iñc. 5.n(¡ 6¿roara, C¿¡ifcrñi¡
9r. Hobbr ¡a ¡ Con¡ultiñ9 Engrneer ¡pccr¡l¡¡rñg tn an¿ z) S¿!aiaL -¡r!¡ ir¡¡ó Daeñ brok?ñ
r¿lór ot tl¡(¡c, oyñañ¡c ¡¡nd lnermoalá!trC aña¡y¡r: a crrcu¡ I ooaaé
!nvrroñm¿ñ!¡l t!¡tLñg ol ,yrtafñs l,o vatlry oct¡gñ
¡d qualray lnl!9rlty, Hc ¿llo ta¡cñat Coqraet for tolOCt to¡ñ(. T¡t ilra! raar 8l!o a?!lfarñ¿ó Oy tOC(
Tsr!rn lñat¡!u!. lñ VrDrattoó Testtng, S¡¡c¡¡ 5cteenrng boñdrño. tta rrraoo¡nQ 0t u/tth t¡crño coró ¡a ño ¡a3!
ád Oasrgn ol Ayrcnrc! end Eiactaoñtc! lo Survrvc !ñ6^ two tñch lñ¡atv¡la ovat tñctt anrrr! ¡r^atl\
VlDta!roa¡ ¡ ó Shcck. Prrvto,J! a!¡oc¡a!¡ona hay6
rr€luocd fRW 5yttaar! Cqr2or¡t¡oñ, Ftrgñer A¡tcr¿ft, cio0ñoñ tcl ñad cé óur iñg
At(ro R¿tcarch Corpoa¡!¡m, S¡ñ!t Esaoa¡¡ Rc!a¡rch vlbrattm, ¡ñó to ¡ll la¡O¡ from ht9ñ rrñpeasrc!
C¿naar, MfS 5y!tatña Corporatioñ; and lhc uñrvar¡lt¡!t 6av¡car yaara iog¡ bon&d or olhrrwrtc rc¡la¡¡¡lao ayary
of C¡lilorñ¡¡ ¡ o Mlrñc!o!¡. Frolst¡ton¡l regt!!ra!¡oft! oñr ioc[
tñC¡u<la coñt¡ol tv!taÍ!a angt¡alrrñ9, rnccñlnrC¡L rñgl.
ñaatlng ¡¡t(l ciyll eñ9¡ñG¿rrng. hc ¡t a ñarnocr ol I ltñt¡ wrre 9rc0¡É¡n w¡t _cualrñg - *nrrr tha_wrra.
' 'AA .ñó th. lEs. wcr! pu¡lro jMt_l-_99!-tgll. br.ck€r _.oE!. gl!9!
ASSfRACT
w_.J9
-rgIogilq P PI9Yeñ! Lng Jh!tP_!99!!_l! .lglalPgt
boñóGó rarll- ito.r tü ollvcñr mol¡o.!

Thrt papar rÉrraw¡ a caaa ¡n rñrch the mÚ¡.¡ltc!r.¡rÉt ,) fwo circuit boardt scra .lrquntld to !t!. !ié!t ol
c, ¡n ¡¡¡tomc porea s¡Dp¡y fai¡aó lo ¡ccqsn( lor r¡E tL hou¡ing .na !ñrGr w!¡G .t¡ckaC oo .tanóoll¡ trorn
.llcctt ol rsrl(,om v¡bta¡¡qL Ch¡ñgot rn.d! rñ o¡ó¿r rhc botlorñ 9l ttE hou¡ing. All cirs¡¡i! bo.¡da lcru
!o prr. qualilic.trgr ¡lat¡ w!!a tr¡óity sccofñp¡¡t¡tró r¡r¡ch 3oo tnln Jor lna .upPorSad weigñl .trd ro.ñ
cnc. prgpcr ó.!rgñ psroc¡plct w.r! followed. Tha brtwcrñ tugpoatr¡. Scvcf¡l boÚcr h¡d t¡¡n¡lo!¡ñc!¡
p¡par d..crlbrt thc la¡Jlr! uncov.rcd ürd thc rolutrql loc¡trd ,ñl6wry batvtan bollr rupDcra¡ñ9 ill. board¡.
to atctl. fha .ñr¡rfacluE¡ ¡ñd anó urat a¡! ño! fh! circu¡t boardr mountcd to inl tlér ol llrr hou¡¡ng
ditcloaad aa i¡ woulo latta no urcful gutporc. rG¡c I irEñlr loñg, 4 irEhat wi6c, .060 irichr! ¡h¡ck
¡nd u!rc mly .125 incha¡ trotn !h. wall. Co.rt¡ct
fNIROOUCTION bolwc!ñ llr wa.l.l üd ghc ¡a¡ü protrud¡ñg lhrosgñ lnc
bo¡rd wa¡ tvrocna lt ¿h! ttout¡ng wlt g.ancd lfi6 lh.
a pow.. *pgly lol ¡ c¡o.r! ¡itc lt wa¡ to b. lioirh wom arat Dy lha lc¡ó¡ fhcrc ur. ¡ntulf¡cltñr
eJrliliad u.¡ñ9 b¡ord bf¡ó iarldgñ vrorat¡on frorñ 20 .p¡c? rlrñiñ tñ. hor¡tlftg to lhickan tna §oat6+ ul.
n¡ to , e000 hz wrt¡ an oyal¡ll lcv.l ol t grtñ. rño!! ¡3t¡chrñall( potñtt ¡ ó/ol provida tñott !¡!!la
(.0t269'ihz). Th. r.tt urt $rcrfico lo lrtl for trro tp¡ca. Thcrllcrt, lh! bo¡rd! wcl! ¡tt¡cncd to tlE
¡!u¡! !ñ cach of lñc thftc ax?r. houarng in ¡i¡ ¡dd¡t¡ori¡l pt¡c"t by utlnq lilrrql.t!
afl.r livr mrrulct ol y¡O!¡tioo ¡ñ üE lirtr a¡r¡, u! tgacrr; Ültr..n ltE bo¡s6¡ ¡no aha houtlñg' fh!
tprcr t¡JP9iy lrrlaó alacú¡c¡lly OuC to uolfiorñ ro¡c!?r we!! búdad lo ttlG ñoullñg frd ¡o lnl Eo¡üo
rr¡¡on! Thr vlbt¡t¡t't ra! cont¡nu?ó in lrocct t¡¡t u!¡no ¡ollthañ! rnlch ia cotnañoñly saÉó fot cgnlolrn¡l
¡r! fa¡luÉ wouló l¡tlt proya !o ba ¡ ñoñra¡at¡ t co¡ting. Th. ¡ol¡rhaña grovtdct a gooC oyñ¡fn¡c boñd
f¡¡¡ul!. Altr¡ f¡lrasn n¡lnu!!¡ ol v¡bratlo.t, r¡ttliñ9 ¡ñd chr¡¡pallt Grialgy wñGñ lllxad, but c¡¡1 Da llrñov'¡o
r¡! ha¡lcl úld tñ€ ¡r.t tarrñ¡n¡t!é. Thr olu¡ hou.¡ñg Dy ¡ptyinq ¡.!lé, Prll !3!.lr
ra¡ ¡lrtLrvrd añ6 ¡ha rnum¡L artm¡ña(L Aclu¡l
f¡rlurlt ob.?rvao rumbcrtó 15 rna mrny no¡-9¡cci. fht thraa bor¡ór :r¡ckró oñ lt¡frd¡ol,¡ hac ñuliiol'
pr!¡lad fsiluÉr o.rlt llcrrd ücrt¿lion lim" and aurclt ptoblem¡. ftra Do¡¡d¡ ll!¡rd !o ñlcn lñ¡l comocncn(
loul(t h.y. occr¡rlrd ¡l fl! ¡¡¡t h¡ó DcÉn n¡ ,or rlla l.¡ó! anó ao¡dr¡ iointt wlra allñcr olok'll o¡ lmwtó
fuu ¡¡r iEufr ol v¡baattoa r-."j..ii r¡*t - i *,- t,gn ol co'n¡nq l¡t lure' ThG
whol! tlEk tlE ñovaó tiówayt .nougn to lmp'c( tñt
Tha l¡ilurtt gbaltytó ¡o h¡ta occulté añá ¡1.. lhoaa Doatot oñ tllt tl(llt €l arr ñgut¡ng whtcll cau¡46
ó.aiñ- cff!¡¡n ro occur il lñt a!¡t ta.. !o bt tavlt¡l tr¡¡!.¡¡!s¡a !o b! bañt ovct. fha llñi ¡ño
co¡hplataó a¡r .lo!aó balor aloñg rllh ll!. oall9ñ aacoÍtó bo¡¡é tlrf pl.cld t¡Jcñ l¡¡t !ñ' qt¡'t §cfn?dr'n'
cn¡ngaa rlptGítaltlaó !o otgv.flt rlx fa¡lu¡!& 5iñca
r l.¡ór tnrcuqh Ü'a Doa¡6r ,.c.d atcñ a
¡Doua !ycñ(y towcr ¡¡pPliat n¡d alrlloy b66n fibcto¡¡5 ¡gEt! oo¡to had baañ pt¡E'C bttr'cñ tn'
-o yqrtóplft¡
'htpg'ó
ñrva to Da ¡tcrllaó ¡nd mYo¡lcó' cn¡ngc! tñ oo¡rói lo gllrcnr clccl¡ictt cf¡ar!¡ci{ üJl tlL YlDr¡(ld1
rcr! to ¡vc¡dcd il cl ür. oo¡rdt crnad tha ta¡d tñdt to Donl tl¡¡o¡4n (ñ'
¡rut¡llad Da 9or¡¡bia.
bo¡rc A¡ ¡
L-ai .¡¡ m.&. cd'titct vlt,,l !fr' otlrrr
FAILURES FOUNO ANO FIXEO lir, tr bo¡¡tl¡ t!r!! Fltla¡ltac ¡n tñc l'ñ' lilm¡vv1¿' 0' tl
,,;,r,
.
tha aiCa bgr¡ét .pacatt ecft tr.dc lo
ño'¡ltt!9 t.ló 'ñd rñ!
I) Mfly l.d,ñ.rl rala tü,Író !o D. loo.." Tltia bgrdad . r¡t¡ Élilrrrna baSt'atñ t¡r
irElirdcé bolt¡ .nd .¡¿!¡ rma ol rñ¡ch h.d b..ñ uá'tto- Xato. ur Dollo,¡ bo.¡c rid ¡lr ¡'ccn¿ col¡ó
ir¡lallad uarñg ¡octr¡tt¡rr 5d ¡!¡¡ ratataat 5-["4 ¡ria .acqró Dot¡l Jtó' 3ha to9 board. 'frd t¡r' l¿p rl
Do¡r'
tt ir
Ear(rva vaail¡c¡tiqt ot bckino lt aBarñltalr a9o! bql -.na
-i¡at¡ !l, no,.,.ing. f hc ?tssrt Y'Ñ
Cl ¡ll lanarEra wl¡ uaaó añd ¡U ¡ock ra3ll.r lyPa ¡o ¡cctpt'bla '¡r"t9'6
lim¡u l¡r
L. 6-ricii-' ir¡¡- ¿¡t.Eé*R.torr.d untu iá?ñ-to- b.
oca"o ¿¡h¡crio¡r¡
t¡¡¡rrlonnrn t.rt prov¡dté wiih ' drrc' to¡c F'lñ l¡
'lc
ñtóiq-,ia*ira-rfót--Éúd.d t..v¡ng !¡. lock ./rd (¡r r¡caorl¡rr tttttt¡nt.
raaaara an placa.
L f}r. ñ¡¡iqrm óGflactidr ol ¡ cl-rc!i! oor¡d !¡ro-u¡
4g! .rcaaó .ü1, tima. ¡rr tCfr ol llr boat( )6
R.t.ra¡Ea L

11
,
i

2. 1.6. 1 C6du6tor l'í¡tei t! ls

Thc ¡¡o¡t com"úG a¡lcrl¡b r¡¡cd for cr¡ductorr ¡r ¡ aFcccr¿ft

¡ppllcatloo ¡re D6.! pu¡e a¡d copper alloyr, Alural¡lua le gradually
bGbg ln!¡oduc€d ¿¡ sa rltrta¡llve codr¡clor m¡tlrl¡l (fuí. 2E).
A brtcf dercrlpttm ts gfvúo b€lry. TbG rordGr !r dlrcctod lo
Ra!.roaco. 28 aad 29 for ¡ rnore det¡l¡Gd dl..cúrr!6.

Copp€r and Coop€r Allov

The high e¡ectrl,cai ¿¡¡d üermal cooducttvtty of c.opper , coupled wtlh

lts mechanlcaI strength and reslEL1nc€.to qp;¡oatoa-.,[gve ea{b!,a-t¡_q! __?_
com€r as the prlmsry cqrductor mat€rtáI. Untll rccqlt E€gul¡ementa--; 1.
for ml¡tmum wetght aDd rp.ce, the conductor ¡¡¡cd for fllSht appltcatton l
ve¡ llrnlted to 20 AWG eod lerger, glnerelly of ¡tra¡rded electrolysls-
lough-pltch copper. Wlth th€ use of wlre slzcs of 2{ AWG and em¡lier,
s hlgi{trength copp€r alloy l! used !o ret8in the rcqutred mecha¡lcet
strogth for terrnlnatloa rnd handllag. The t¡bl€ b€lü§ llrts the flex
llfe of co¡per veraue Alloy 63 wlth tho conductorg u¡rder vartor¡s tenstle
losdr. Irnprovemcota of an otder of rnsgnttude e:glalaa why the allo]'
co¡rductora ¡re uad la the ¡¡a¡ller vl¡e slre.. (Reforace 28).

Flex Llfe of Cooper Versua Allov 93

Load Materlal Soft Copper Alloy 6Í|

(psl)

1,500 160 cycrea 3000 + cycles

5, 000 36 cycles 249 cycles

t 0,000 t 6 cyc ¡er 30 cyeler

I 5.000 1 cycle 1{ cyclea

Alumtnlum

Trble 2.1. 5. !h€ eleclrlcll 8Dd mcchsnl,c¡l proP.rtlc! of

I cornp¡r€t
slumlDlum a¡d eopper ¡¡rd ¡hos¡ that ltumblum hr! t?lc. thc
ccn,Iucttüty lor thc ¡¡mc unlt ?6l8ht, a t.B.llG, t6¡d atraSth of ¡bol!
one-thlrd lh¡t of copper. and I coefflctcñt of llnear thcrmal e,9e¡! t'oo
(i'c) of about 1l ttn:ee thst of copP€r. The r.¡c ol rlurntnlum lD ¡ler¡
of c.opper wtll redrrce the ccrrductot s€tght by 50 P€rcat. h rddttlon .
the aluml¡Ium coEductor wltb Poiylmld. l¡rulatloo wlll fi¡¡e lnrtde the
l¡rul¡ttql prlor to bu¡nb8 throuEh the l¡¡ul¡ttm' Thlr provtdca e
sylteñ th¡t wlll m.Gt ¡tl tñoln fl¡mtn¡btllty rqrrlr.mats aa rell s!
pFovlle ctntrollsble fi¡le chrrecterbtlca. Thl,¡, a frult l¡ cnc
cooCr¡ctor sll¡ not !e.u¡t ln the d¡ma8c or dcrtn¡cll'oD ol sdrrcEt
cq'¡ductor¡ o r €qulPmcnt.
z-t-6-2
 Tbl¡ m¡kaa sluml¡rlurD r ñiaror conteader for the nuclcer rtagr.
HorrvGr, the reducGd yi6ld streagth wllh relult¡at cold flry
oh8¡act€rlEtlc! r lhc l¡cre¡rGd Tc, th6 tendearcy ¿o ox-ldl,re . rDd
3u¡oetlblltty to corrorloo r€qul¡e tb¡t atuml¡¡lum bc u¡ed h electrl,cal
clrculta wllh oÉreoe csutloo. Ter¡! IDrtruEEru h¡! dev€lop€d a
copcr cl¿d Eluml,nlum cooduclor for r¡¡e l¡ colvontl,ooal ltra¡ded
rou¡d wl¡e cable. TtrIE coDductor hs¡ much hiSher st¡Co gth 8! welt
rr hlghGr cGdrcitvtty than aluml¡lum aDd y€t !et¿b! tnolt of the
edrraalagee of alurülDlum lacludllg the fuzhg chssacterlBtlcE.
Il te allo clalmed thet thts conduclor system c¿! be crtmped a¡d
haadled the eame aa conveutionel csble with copp€r cooductors.

T8ble 2. 1.5. 1 - Prop€rtres of Alumlnlum ald Copp€r

Symbol AI Cu
_1
A¡omlc Welght 26. e8 63. r{
DeDrlty 2.7 0
I 8.8e
|
Meltl¡g Polnt (oC) 660 | rosa
Sp€cl0c Hoat 0.226 I o. osz

CoelflcteDt of Ltnear Thernral Expa¡r toD

24.7 rt.
(cm/cmFC)
Ttrermal CoDductivlty (Btu,4¡rlsq. fttrF /ft| t01 21I
Electrlcst Res istivtty (2ooC mtcro-ohm/cm) 2,8 1.7
E lectr tca I conducth'tty (%lr. Cs) (Eque t volu me) 62 101

Electrlcal Conductlvlty (Equal Welght) 204 100

Currer¡t Car¡yl¡g CaPec tty 80 100

Modulr¡s of Elalttctty 10 1?

Teltl€ Str€ogth (ADDe8l6d) (10! p€ t) L2 38

Yt€ld 8ü (10!
StreD P6 t) ,t l0
Hard¡ess (Brl¡éll) 50 103

§l,tutlon Potentlsl (b NaCl 3% H2O3 N/10 0.85 0.20

Catomel Scel€)

Ftlotex hsve devcloped ¿n slumlnlum ¡tloy coot¡l¡lng 0.75% m¡s¡e¡!¡m'

It ha! a much hlgher mechanlcal real¡t'a¡lc€ (l)¡;:tcul¡¡ly to fléxlD8) then
F¡rc alumlnlum. lt abo ha6 e lJw d€nrlty : 2. ?0. Thc mcch¡¡lc¿l
propGrtler degrrdc sbo vü lsOoC. lt 1,6 m:rkst€d uldcr th' tradaname
ALU F LEX(.

2-r -6-3
Coaduoior CoülpE

Tl¡Dl¡g - wtdoty u! €d úor teEparabtro. up to l50oC (r¡elttDg poLat

2320C). Ea¡r' to aolder. Not normally u¡ ed for HF cable
due to lt! higi r€rEttvtty (0, 114 ohm,/mmr/rD.[6):
s!!oc lBted wlrh rk1! €ffect.

Sllvor Platlng - wHely ured br ternperatu¡es >15OoC. It Buffera

hom oxldattoD and uader certal¡ €xtreme c@dttloDr t¡e
copper ccnductor corrode€ (a galvrDlc couple !s formed).

Ntckel Ptstlng - tdeal coatlDg where the teD¡erature exceedg 2oooc. -

, Solderng i¡ dlfficult. I! form¡ wlth copper a protectlve
galvan lc corple.

Stlver over nlcket platlug - ldeal coetlDg where operattag lemPera .re
lr < 2?0oC. Has good solderablllty a¡¡d forr¡s wtth copper a
protectlve gakar lc couple.

Wtcklng, the flsr, of eolder under the conductor l¡sulattcE [t dePendat

on lhe wettl¡g prop€rty of the conductor coallng. Solder wets better
on sllver thaD on tlJr, con8equently tLD !s preferred where tbe wile !B
¡o be soldered. Stlver piat¡ng [s propoeed Ior crlmpbg.

J' '- -:- )-' '': '--

2-1-ó-{
 2, r, 5.2 hrulettcn MÁterl,als

Coarldcr¡ble work h¡¡ beea doe l¡ the €vrlu¡ttotr of E¡t rl¡l! for
usc l¡ ¡ apece eppllcatton. REfer€oce3 23 rDd 35 ¡re rccooroeaded
(or detsl¡ed datÁ. Tb€ resultr of ar¡b.¡¡tlo¡ aro rhcnra l¡ T¿bles
3. 2 th¡ough 3. 10 (S€€ f¡€ctl,on 3).

Polyeater fll'nr provlde very g'rod mach¡alcal prop€rtle! st a relattvely

lou, cort.The tr8¡rlparent fllma ü3::'ue provlded ln a flame reterdaDl
conftg:rratton. For malmum atd mlDlmum op€rstLog temP€rstu¡e8
encour:tered on moat programmes the Polyerter syetem ls adequate.
The polytmide/FEP lnrulatlon system ts tbe mo6t popt¡lsr tod ay for
h18i! p€rformance operatlon. Polylmldet provlde excell€!¡L mechanlcal
propertles except for no¿ch sensitlvlly aad re8trte¡¡ce to ttroug alkalL,
and FEP provtdea the electrlcal che¡acterlstlcr.

Teflon ¡¡rrulattori rerD¡lla Ooxtble througtr very low operatlDg

"r,""-óly
tempera res and ca¡ be u¡ed at cryogralc temPer¿lurea. The all-
polylmide system provrdes a very hlgh +emperature syateD, above
zoooc. ;_. .
.

Polytmlde con8tructlons are easy to chemlcally 8frtP, a¡rd can provide

a h§hly rellable deoslty eable wtth 12 mll¡ or less bebye€n coDductor
ed ges.

Tefzel and Polyarylene provüe good flame res L8talce as well as

mechs¡ical a¡d electricat propertle8.

t(apton l¡sulallm rrsl¡¡lal¡8 tts physic¿I, eleclrlcal a¡d mechanlcal

characterlstlcs over a wtde r¿¡lge of temperatures, can b€ r¡s ed ai
cryogenlc temperaturea, lt ls alao llame reglst¡.Dt.

My!¡r bEulstla ha8 outstsldl¡lg m*haolcal tough¡ess 8¡d ls

partlculsrly resLsts¡rt to cold flow and lrr eapsble of oPeraths tn the
t€mperature ra¡r ge +250o lo -6oooc.

1.a

2-l { -6
2. t. 5.3 Wl¡e snd Cable Constructlcpt

The¡e are tE typ€E of ooaductor coalEl.rctlcn , lt¡aüd€d and ¡olld,

ra¡glD8 hom 30 to 00 AWG. !t€ DC rc6l6t8¡c€ of .oild ccnduc¿or8 is
lwer thsa thst of EtreDd€d ccaductora¡ lt tc ako Eochan lcally strongÉr
b.¡t ha8 lnferior mechautcal flexlbtllty. ln apaceerac ap?Ilcülou
flexlbillty Ls the overrtdhg factor a¡d for thls rea86 I traaded
cooductors are preferred to solld cmdlEtors , thls mly holde ttue for
rou¡d wt¡e coDduclors (RWC). flet ccDductor cables are htrzrlably
toud, flexlblllty befrxg provlded by tt8 cmttruetloD (wtdth much larger
th8¡ thicloes6).

Rou¡d 1{lrelCabIe

, The terms wtre,¡.od cablJ e¡e very oftea mlstoterPret€d;

*r"" i" ¿áiu"¿
aa a. c@duclor sheathed with a¡ l¡eulatl¡g mstertal, whllst cable ls
défued as a number of wl¡es twtsted tog€lher e¡td ocloEed wtth a¡
overall !¡tul,sttrg sleeve (s rúetaUlc shteld máy b€ l¡tterposed betwee!
the twtsted vrlree a¡d 8h€sth).

Slagle core ehietded a¡d sheathed cÉble ts often referred to as co-adai

wttl6 lt does lot exhlbtt the kupedaace characterlrtic a8soctat6d
wlth RF co-axlal ceble.

Wlre E av¿llable tn gauges 30 to 00 AWG, the moat commonly used

belng 30 to 16 AWG, and cable 30 to 20 AWG, fD 1, 2' 3' 4 cable'
Composlte cables are avalleble, these may be made up of rious wi¡e
a¡d cable typ€s, wtth or Y¡Ahout a¡ overall sheath- Greá¿ care II[Ist
b€ takgl whea uaiag compoalte cable coagtructiüts , EMC b€lng the
mrb problem.
The speclftcattcng for RWC wl're and cable a¡e giv€$ lD tábie 3' 9'
Spec tftc8tlcD t for aluinlDluo" sLr€ wtth apace aproved l¡BulatloE
m8t€rLal ar€ Eot at€Uable.

The mechaDl,cal rDd electltcsl perfotmance ls a fr¡rctlon of the

cc,nductor end l¡sulettoBsi theee ere glven ln S€ction 3'

Wlr€ 8Bd c8ble to sPect lcettons MIL-W-81381 cnd MIL-W-810{{ have

beeo extenslvely used on Europesn apececrall,.

Flat Copductor Cab¡e

Flat couducto:,' cable (FCC) ts mede up of eolü , flat, rocte¡8uhr

coodrrctor¡, ' u¡ually bere or P¡r¡ted copp€r, but other cmductor
' materlals iúth as alum.lnir- be used, lsml!¡ted betse€n lrysr8
"eo
or she€ts of hlgü+et-!úrlu¡¡cc l¡úulrtlDt mltorl¡lt'

2-1-5-6
Tbo raogt wldely wed ooostructtcñ l,B the symmGtrtcally lrmlaüed
form wllb t¡e ¡¡dlvtdusl coaductorg eaadvfchod betcrea üc pt¡sttc
bsulaücn lheets, Aa adh€stvo l,s r¡scd to keep the ccodr¡ tors properly
spaccd aad !o Íul8r¡rs the t¡tegltty of the FCC wb€u eryosGd to tbe
var Ious op€r8tlDg c@dlttoDs,

DetaU€d and exteDslt/€ *ork be¡ bsei¡ done oo the developtaelEt 8¡rd
uttll,ss¡too of FCC, aee refercncea 9 to 15 tocluatv€.

Rlbb.p Cable

Rtbbon cable ls a BerDeric n¿me for a numb€r of rouDd ccoductors fl.xed

by aa lasulaüm ByEteE lD e paretlel plaoe coaflguratlon. ..-,h. gEneral, .¡ - .- -
\r¿rlous types of Bl¡gle 8Dd multlcoDductor l¡ ¡hlelded and uahtelded
conflguratlons cao be used for rlbbcrr cable. '

Thls type ls notl¡ general spacecraft use, but could be u8€d where
orderlDg of cable conaS¡¡¡ation ls requlred for EMC rqr.aoa6,

!'l{-?
2. 1.5.{ Wlre aad Cable Ter'ñlYt.tlols

The Dat coE,Eo lerEl¡aUo ayrt€¡Dr srcr-

Soldcrhg
Crtñrpbg
WcHbg
Brerhg
The sroat c.omaonly ueed ale roiderr.g ervr crlEpbg. Weldbg aDd
brazlng a¡e ccaf,¡ed to thermeouple rl.rtt g wbre the ccductor
matertal l! not sulláble 6or eolderhg aad crtEpbg

Alua¡l¡lu¡ [a a rpécl¿l c¡se where D€sly dev€¡op€d t€chtqua8 are

requlred (Refer6c€ 31).

Solder Jr.Ectlops

Solder Ju¡ctlons are the oldest used for maay arrccesefuI appllcatfooa.
AD alloy, usually about 60% tln ald 40% le8d t8 usd flrst br trnll¡ g
and th€o ,ob wlth the proper Or¡x ead heat appllcülcB. Solder
JuDctloEs properly deelSE€d aDd ¡üade offer a hlgh deg¡ee of rell¡blllty
a¡d ca¡ b€ l8sp€cted. However, all solder ,lDct!6s have very lw
yield stre3aes lader cfitlDuoLls loads at rooE teEp€reü¡red 'rl ebove
aDd should tierefore be ue€d lD leer zero€treE8 apPllcatlos.

Solder eleeves are wldely used for wl¡e terEl¡atlcaa. Here, the
pretnsulated solder sleeve l,s placed over tbe Jobt lo b€ furBed 8¡¡d
shruEk l¡to posltlcn by üe appltcatlca of bot alt. Solder aleeves are
aveilable vtü or ylthout an eDvlroumeatal 8e¡1. (See Ftg. belos).
Lúl ( ,L5*-rE-aá
th- r - .*--¿E- .3-- É llt---r
tr.¡- tü
1t . ¿-:i- tü9.É
'<.?.- - ^-? rd,

2-I-5-E
Cllmp€d o¡ectrtcel JuDcttms oftsr ñ..y a.dva¡tagBa a.ad
8¡s prclsred
fo:. 6l-6lrtcal ccoDetor ,lEctlc,os. The uee of ü¡¡,_spuC
wlth MIL-SPEC tooltag g1v€s a hlgh dogree ot reUrUütty. c(Dt¡ct!
lt lt recomm6Ddod thst ¡ddldoa¡¡ pr¡catcoE , ¡¡d cottrol¡ beHor.v6!,
to help ellEl¡l¿to erroE and glvo aa ov€n g¡oater
cqloyd
leg¡ce of ro¡rr¡lUty.
(a) Uee oaly one rlze crlmp b¿rrel (t¡ltde and outr lde dteE€t¿rs)
colo¡r coded rylt¡ 6e elze wlre heü¡g t¡€ seme color¡r code.

O) Use rbgl€ ne8t colq¡r coded crLop tools to Ioetch the

colou¡_
coded vlre e¡d co¡tact.

(c) Preclude ell chence of the i¡Buiaüon from g€tlr.g l¡¡lde

the
crlmp ere¿. Then c¡ver crlmped Jr.uctfoua where requfred
wlth traDspareDt shrl¡k tubhg.

(d) Do not u6e prelDsulated spilces.

(e) Mal¡tal¡ a coBat¿nt lDspectlo,n alert for aDy abDor.aalttles tE the

g, compoDeDts, too tlD g, ¡¡¡t proceduree.
c.rtrapfn

Brazed Jr¡lctlops

Brazlng lE 8tñ1ler to solderlng except a much hlgier teEp¿rature 18

requl¡ed (althouBh les8 thatr weldlDg) aDd a Euch stloDgEr Jo¡lt ts
obtslDed (app¡oache8 strql gth of weldhg). ID one appllcatior¡, a wi¡e
coatod wlth brazlng alloy tB Jolnéd to coEopoDeDt terEl¡a ls by brazlag.
The compcncnt lead alloy need not be cloeely conEolled, as requlrul
wlth weld€d rolnts, aDd the resultáDt Ju¡ctlon EUets ar6 readüy
vte urüy to8p€cted.

Welded Junctlop8

Varlous types of srelds have bean e uccec s fr.rlly uaed for electrlcsl
Jr8ctlo!6. Rertste.Dce weldbg meltt tb6 base lEsterl¡.¡,s w'ltb Do fluer
requlrod.

Weldtng, followed by Jolnt pottiD8 or €acsp6ulatloü, offera mucb Promlse

t¡ slumtnlum ccnductor terrnlDattcn. The e tructurrl +ype weld
precluder all poaetble faüu¡es resulthg trom the .Iu mlllura cold Oow,
htgh Tc, and lorv yte¡d stross. The welded JrecttoD area wcr¡ld be
aubaequently encapeuleted to provtdo eeellag end Eebsnlcal prot4r16.

2-1-6 -9
f s¡ml¡g600 of Alurnl¡tum Co¡ducto¡s
The prbclpal probleas bvolved wlth ter'ñlñaHng aluolntum coaductora
artae from fou¡ propeñles of sürml¡lum olde forro¿tlcn, co¡d Oow,
co€tlclq¡t of therrDrl epa¡stc,o (Tc) a¡td Burceptfbluty to corrostc,n.
Alu ¡El¡lum has ¡ hlgt¡er temperatu¡e co€fflctent of thermel epa¡s[on tb.a¡
copper(24.7t0 1?.6), a Lower ¡ooórlus of ela6ttctty(1 oto 17) ald I rouch
lcrer yleld streagth (4 to 10), Tterefore, ¿ny Euccessful terE:l¡atton
sytt€rD for alurD.lDium cGfucto¡s rnust overcom€ these ob6tacles.

Numerous ahrml¡lum ccDductor crtmp ter mlDetlc'D EysteEE bave beer¡

developed a¡d e'€luated by AMP lncorporated (Reference 3l) aDd the
htrndy Corporatl,ou. A typlcsl terrnl¡rattoB for rouDd wlre l,s ghown i¡
Ftgure 2-23 a¡d for foll coDductor l¡ Flgure 2-24. I¡ each case
Ter¡¡lDel perforatlcaE plus very hlgh crlmplng preasures a¡d crlmp
cootÁct area reforrEatlons a6sute that oldes wUl be penet¡ated aDd
that many cold+reld ccntact areaa wtll be c¡eated. ltese c.otact
area8 re¿ct ladividually to the stresses a¡d excursicas resulttEg from
temp€rature cycllDg aDd curreDt loadlngs to maLDtab gas sealed
Juncttons, Tbe complete Ju¡ctlou area must be adegusteiy Beáled to
prevat sub€equ€frt corroeloo.

ELASÍCMER PERFORAIEO
BUSH IN G INSERT
IHERMAL
BOOY

fWO STAGE
CRIMP

2-1-6-10
 C-u!!ert Crrrvtas C¡p¡cttv .¡d D€r.tbI
O¡¡reot4arrr/ta Capectty - Tho s¡rc!¡t€rryhg ceprcs ol
cGductora l¡ e c¿ble tE prtlEsrlly r i¡ctla of thG t rnpGtrh¡la rt o
tb¡t c¡¡ b€ tolor¡tod b thc cebl.. Thb, tD ü¡¡¡, t d@.odat a táe
dae§ of poryor dtlstpadm froo ohElc 10860! b the ccaó¡ctor,
rblch reault hoE 6¡rr€ot ioveb rad c(D.dr¡ctor !Gú tsts¡ce.
TeEpor¡ture rtse b ¡1.!o d€p€Dd€at oa tle nd!¡ro tor ccduct..g
het away froE üe cable, a¡d oE the cr6e.€ec$oel abepe of the
cable. ltle abapo detsrEl¡les tle aEol8t ol curttc.e ar€a 6 ü€ cr¡t_
alde of the cable for hést dtsrlpttca.

The net eÍect of the rurüce dtffereace allcrg a greater ct¡¡reut-

cerryl¡g cap¿ctty for FCC. ThIs f8ct ts deEcn8trat¡d by.
(Refereace 32) l¡ coEp¿rattve dats of e z-rDch.,*lde cqble of-NAsá
25,
0.004- by 0.040-t¡cb couductorE (Z?.gsugB €gr¡lvBlcot), r,r{ a
2s-wLre bu¡dle of 26- or 2E -gar.rge ror¡¡d wl¡ea. See Ftgrrree 2-2S
8¡d 2-26 for comparatlv€ d8t&

200

t o
i5'../ o 150

ó
q)

tr
ic0 & roo
o o
t- F
5C 50

0r23456 0123{56
Currerrt (Amps) Cuñ6t (Amps)
I¡ ¡tr - FlC, 2-25 l! vrcuu& - FIC. 2-26
r) I,.b 20 OAUGE RhJC
STRANOEO CONOUCfOR
fEFLON INSULATEO
b) No 25 GAUGE R{C i{OTE ALI- CONOUCTORS
STRANOEO CONOUCTOR CARRI EOUAL CURRENTS
fEFLON INSULAÍEO
c) 4x 40mm CC:'IOUCTORS
ON?5mm g KAPÍON INSULAIION
FCC (27aWG EOUlV.l

2 -1-6-1r
The orrreat carryl¡g cspaclty msy b€ uprated for FCC for the s¡me
coaduc¿or cross -sectloo &! follows:

FCC Cabl6 UpratlDg Factor UpratlD g Factor

Confln¡¡8t!0|¡s Ip Af¡ Io Vect¡¡m

Stngle-layer 1,50 t. 55

Tlree -hyer 1,35 1. 60

Ten -Iayer 1.05 1.05

Addtttorial üern¡¡l advantagee ce.n be realls€d U a FCC rtroult1¡g beet

sl¡¡k ts conatdered.

De-ratLDg of R\YC wlreg are glven tn the table below.

The data t8 ákeD from ESTEC Speclacatlc,n QRA-10, MIL-W-5088,
USFC Seclgcatlc,n {0M 39582 (Referei¡ceE 18. 19 s¡d 33)'

The upratlng factors for PCC are wlth resp€ct to curreat ratLog of
RWC glvm lIl the follow.lng table.

RWC Current Rattngs

WRE Mex Deslgn Cur¡stt (amps)

AWC
BUD(ile (15 or more) Stngle wlre

QRA-r0 MIL-W- {oM 39582 QRA-10 MIL-W- 40M 39 582

I 5088 I 1 12 1
5O8E I

21 1.s I 2.s 2.5

3.0 3.0 5.0 5.0
20 4.0 ,, t 4.0 I 7.5 11. 0

l8 5.0 t 0.0 s.o lro.o 10. 0 16.0 a.)

I
16 6.0 13. 0 6.0 | 13.0 13.0 o
(lJ
tl
14 8.0 1?.0 8.0 1?.0 1?, 0 32.0 E
|
11. 0 23.0 11.0 I 23.0 23.0 {1.0

(U E:poeed space €riv l¡onmElt.

12) Eucloeod ccritlolled spece 6l vl¡otr meDt.

The currcnt cpecllled wtll gvlerate s temp€raü¡re rlre of approrir¡EtéIy

SOoC above JmbteDt temperatu¡e b a vacuum a:vl¡onmefit. Precautlons
should be t¡k€n,so thÁt the total teq¡P€rsture of the *'lre (ambl6t + rts€)
does not exceed the cc¡tlDuol¡s oper8tbg terüperature of the Yl're'

2-¡ -5-12
Volt¡ae Drop - The tottl tmpeda¡ce of wlreE &¡rd c¿blo8 ¡n.t g,cr¡Ird
r€tu¡! path! 6b¡lt !6 luch thst the potatt¡¡ dl.ff€r€nce b€trrGc¡ the
pol¡t of volt¡g€ r€8ulstt6 s¡d tho lo¡d does aot e¡ceed th€
lt¡qlts !bo*n
lD the t¿b¡e b€¡ory. fte eÉect of coDductor operuthlg to rrycrahEe
oB
coaductor rolbt¡.Dco shsll be tske ,¡to accornt fa delermlubg theee
lE.D€da¡c€r. NorttlD¡l ryltelü voltagDa ghall be urd for .etrtUsUag
the cu¡reot to be u6éd ln det€r''rñhg th6 voitage drcpr.

SYSTEM VOLTAGES AND ALI.oWASLE VOLTAGE DROPS

Power §rpply B¡s Load MaxlD1um Volt¿gB Drop

MIL-W-5088 40M 39 582

5V d. c. 100 Év
28V d. c. zv
56V d. c. 3V
115 V a.c. rms 4
200V a. c. rrng 7 :,
Referencea 18 and 19.

The voltage a¡d regulÉtton requlrement of each unlt LD the spacecraft

shor¡Id be ascertalned a¡rd lt8 p€rformance evaluated lrrh€D operatbg iD
the maximum voltage drop coadltlon. The load t.Btt regulatloo réqul¡e-
mqrts shall be m8¡datory.

The effect of d€cle¡Blng the allo\rable rolt¡gp drop ls to locresse the

wl¡e AWG and herice the wl¡e ¡ras8.

Power Cable SIz lns

Power c¿ble tlzlng can be baaed otr etther marlEuñ power lose or
maxtmum allowable rclt¡8p drop, the more commc'n requlremeat b€lDg
the volhge drop requtremant.

Nomographe 1 snd 2 can be u¡ed for m¡¡ua I c8lculeltcn 6lrd üe ESTEC

SHARP computer Programme for complex a¡sly8Is. For calculatloDÁ
ull¡tg SHARP r€f€r to the SHARP u!€r ma¡u8l-

2-l -5- I3
Slzl¡g for Melmum Voluse Droo - Nomograph I
The roqulred wlre geugs ls obtsl¡ed by drawbg s st¡rtght lbe hom the
load cr¡rrat, Scale A, th¡ougt üs alloeable voltsgE d.rop, Sc¿le B, ad
pror€cll¡¡g th¡ough to lbel€ T. From tbo l¡¿6r86ct!m o! Scslo T d¡aw a
Btrst8bt ll¡e thlough ihe route lea6h, Scele C, aad proJed oo !o gcele D.
8cel6 D glv6s tho requl¡ed re6l,Bt¡¡c€ p€r Eelre. §lslect the AWG uslng
the value l¡dtcated oE 8csl6 D a¡d Tabl6 ltr. Check tbe AV for the
aelected AWG by perfornt"g the reverse procedure. The appltcatloa of
th6 Doruoglaph ca.B be er¿adod to cov6r the curr€at rs¡ gB 0. S to 1Oo
arDperea and rcltage drcpa 0.005 to l0 volts. For acale eEeaal6 ree
t8ble.
Scale D Multlplic¿tton Factor

&ale A Scale B Scsle D

1 10-r 1o-l
I 1 1

10 1 1o-l
l0 10 I

Sl¿l¡s for Mlplmum Power Loee - Nomograph 2

The requl¡ed AWG ts obt¿hed by drawbg a stralgbt lbe hom üe

allowed power loas, Scale W, througb the load cu¡rent, Scal6 Z, esd
prorect on to Scale T. From the tntersectlc'a on Scale T, draw a llne
through the route length, Scale C, a¡ld prorect ca to Scale D.
The lDt€rsectlon on Scale D glvee üe deel¡ed wtre real8t¡¡ce, ln
ohms /metre. Ualag Table III, compare the ',alue obtal¡ed Scale D
ürd the resbEftce of the varlou8 wlre gauges. The wtre gauge
requlred lt thst whtch aproacheE the value glveE co Scale D.

Scale W Scsle Z Sc¡l€ D

1 I 1

1 10 1o'3
-1
10-1 1 1o

Nomogfs!ü! 1 aad 2 c¡¡ ba u¡ed h! c@Ju¡ctlcn slth each oth€r to

opttmlse AWG for roltege drop a¡d poser loea.

lVhqr ¡tzlag for AWG the foUovlDg shot¡ld b€ t¡k€a lnto .ccor¡Dt'

l. Allcry 0.005 ohm for oach Pl¡! coD¡e?-tloE. -

z. Allo; o. oO5 ohm for each crtmp/aolder ccocct lcD '
3. Il po*er th8rla8, t. e. more t!¡¡ 1 r'.n¡6ctor, the 8€lect€d AWG
mu¡t be capeble of carrying tbc full loed cu¡re3L
2-1-5-1{
tEslStAr.CE LOAO CuneExt
M Olll,ls A¡{28
o

.3

.7

.6

.9

,90---- - 1

90

0
7

r{6 iú¡aPH FOf o€fF:talxl¡o wlRE

}.¡OMOGRAPH 1

2-l-6-15
,lEsrsI ¡€€ FO'ryER LO SS
M OTMS w^??s
o tY

T*
NOUIE L.ENGTH l.o^o t t&
1
!oc) M ET IES AMP
30
c E

¿oo

,too
,10
o: o
6
70 7

0
to 5

é0 ta

,to
¡o 3
r5

20

1O

NO¡,IOGRAPH rc)R O€'ERMIÑING POW€R LOSS

a
IOMOGRAPH 2 I

2-1 -6 - l6
 Tab¡o III - l{lre Rosl¡t¡¡ce RWC F-'r FCC
AWG Reslrte¡lce ohr¡s/metre

Rr¡/c trcc .
24 082 081
066
22 052 051
20 032
2l
20
r8 020 .021
l6 016 . 013
r5 .092
1{ 010
13 .006
L2 006
11 lo*
L0 004 ,028
E 0023 . 018
b 0015
4 0008
, 000 5
0 0004
00 0003

' AWG ere the approxlmate equlvalqrts.

RtñtC r'ah¡es Per MIL-W-81044
FCC r¡alues Per MIL-C-55543
Wire MaE s Egtlmation

Power a¡d signal harness mass estfmatlon can be made by using the
S[{A.RP computer programme or thror¡gh the use of Nomograph 5.

From Nomograph 3 the hamesa masE 18 obt¡lned by drawhg E stralSht

llne from the wl¡e m¡ae/metre, Scale A, !h¡@gh No. of r'l¡es, Scgie B,
8nd Zrorecthg ül to Scele T. From the lntersecttori on Scale T draw
e stralght lln€.th¡or¡Eü the route l€ri8th, Scale C, and Prorect onto
Scsle D, read off the har¡eas maes.

A complete spacecraft har¡ess ¡r.a6a can be comprtocl l¡ üIs marner.

A¡r allowance for sheeth csn be added by cslculstbg the dlBmeter of tho
sfcath, ustng NomoSi¡aphs ,l and ó. r¡ld 8ub€tth¡ttng eheath mass pcr
untt l€r¡ r;th o¡ Scale A of Nomogreph 3 .

Sheath mas6es ere 8lvelr.below.

'":-'.:
 .

r5
I
ro

ROIJÍE LEXGÍH
M€TR€S

xo of, wl¡€3

..,
.1

ÍOIAL M o
A ROUfE LELoll{ f SS
MA SS
GMS
WI / MEfNE ME IRES
0Ms
: ... - -
*O¡rOOArfr< FOf, OEIEnT''l¡'l|'O W¡nE MASS '

Iirc MO GR APH 3
2-l -5 -18
lleneás $reeth masaes.

Bore Wt BrDr /metre

§ze
mm Ccnvolex Vlto¡ RÑF1OO Fle¡ CcDvolex, Vtta¡
Coadull 8¡d RNfloo
ruEu€d by
1' l- 9.ll 3.23 Raychem Ltd.
;:; l-
6.4 I -
1.3.83
18.47
4.31
7.7 4
30.26
Flex Condu tt
?.1 | rz.s 42.0 auplted by
e.5 l- 30. 12 10. 90 fuperfleÉt Ltd.
I I
11. zs.a 45.4
12.7 | 37.2 lu. u, ti.zt 55.7
9 II 49. I
15. 94.5
19.o oz. o 82. 31 2e. 69 132.5
22.2 I gg. r 174.0
zs.4 I rrs. o rs-r. +r ¡i. ro 197,5
31.8 [ ror. s
38. 1 I zaz. +s :?s'0

Matelrs¡:

Cca r¡olex - Irradlated crosslt¡ked lqfo¡¡ (hen8uoropropylale¡

VltG - Radlation cros s lt¡¡ked vtDylrd€ne ftuorlde/
RNFlOO - Radlatlon crossl.l¡ked Polyolefl¡
Flex Coldult -P.T.F.E.

E8tlmatlng harnes8 dliBmeter - Thls method of esttmatl¡8 har¡e8s s12e

t" tag"¿ a"t*t"t¡lng the uDlts reqr¡ tred Íor the uumber of wl¡es of
"p.t uaed, addbg thc aumber of untt8, ths¡ coDvertlng the
each dlameter
rotal u.llts to hsn¡eas dlameter' Referalce 19.

(al D€termtae Do[ilDal dtameter of l¡Eulsted wlre8 or the I'verage

dl¡meter of mu¡tlple shlelded or turbted ecnductorc'

O) Nomo8raph { converta wl¡e dlsmeter or average out3lde dlsrDeter

to u¡lt8 for 10 w1¡e6¡ coD¡/etElon to more or tess th¡n l0 lr
lhe8r.
(c) Noñogtaph 6 converts totsl u¡tlts to hsnrolt dlrmator.

2-l-5-r9
 )
EErple I

Dlam€tor l{o. §/treg UElt¡ for 10 Wlre¡ Unltá

0.0E0 t5 1.36 2, 01
0. 120 6 3. t0 2, 48
0. 150 20 4. 80 9.60

Totsl UDlts l¡ &¡cdle t4, L2

14. 12 u¡lts = 23.grlm (0.94 fnchee¿

Ex¡mple 2

AV Dlameter No. wlrer Unlts of 10 Wtrea Tot81 Ualt8

0, 116 43 2.8L LZ. L

B¡ndle diameter = 22.35om (0' 87 t¡cbes)'

This procedure should be followed wheD deternrlnt¡8 the requl¡ed

dlameter of heat shrl¡k hrbtng, convolute tublng, cl¡t-outs h strucb¡re
a¡d duct dtmaalons.

For rtruch¡rsl cut outs a¡d duct dlmer¡81c[i8 a¡ allorm¡ce for sbrEston
protectton muSt b€ rn¡de.

2-t -5 -20
UO HANOAOOK OF iLECTRONICS PACXAGING OESIGN ANO EN[ EERINC

l/ l6 m,n

¡
cables should be Positioned to nri,rinrli¿e the inductive and capacilive effects'
The improper placement of wires or cables may cause sefious opefating
difñculty due to thc spurious oscillations or other electrical int€rferences'
Care must bc laken to PrcYent dcterioration of wirc
imulation by proüding
0
sufficient clearance between the conductors and heat4,encrating components
such as fcsistors, tr¡nsi§tors, tran§formcrs, and v¡cuum tubes'
. All wire must bc protectcd aSainst abra§¡on. Wircs ¡nd cables should not be -l l--
routcd oYcr slurp crtgcs, screws' nuts' lugs, or terminals, and should not be L6r thoñ
l/8" lhick
Mor! th¡n
¡/8" lhicr
routcd or bcnt aiound rharp dctails th¡t may causc abrasion under normal Fior/ro l3'10. U¡0 ol orommot¡ or roundtd cdgÉt
opcratin8 conditions. Also, clearance for moving me¡hanical parts must be
provid€d.
Thc size, type, end numbcr of wires routed between the yarlou! comPoncnlt.
When is rcquircd to Pas§ wirin8 through holcs in üin mctal, thc-conductor§
it The loc[tlon of the wlre runs with resp€ct to the framcwo¡k for chmplng.
Thc isolation of crilica.l wiring to reducc the intercircuit intcrfcrcnce.
üould bc protcctcd by using Eronunets (Figurc l3-10)' Ccramic, nylon' Teflon'
RF The protection of personnel against radio frequency and high voltages.
or similar plastic Srommet§ ihould always be used to Protect wires carrying
are cmployed' When the metal is thicker li,hen conductor pairs are carrying altefnating current, they shou.ld bc
potentia.ls except-when coaxial cablcs
it.n in. and the electrical requirements perntit' the edBes ol the holes may be twisted whenever possible to minimize undesired magnetic flux. Wircs end
I
roundid to ¿ radius of one'hatf the metal thickness'
,.60
The designcr must always remcmber that harnesses ar¡d cables must always
be
eccomPlished, and accessibility to o
locatcd ¡uch that circuit ifacing can bc casily t.50
parts and components that may rcquire replacement i3 not limited lndiüdua'l
"";
ru 'ff:
140 "oo;
ir", of hames shoutd run parallel or at riSht angles to cach other whenever
posible. " 1.30
\
Figure3 l3.t and l3-12 .have been incl,ujled !r-e111o¡ptn!.c .1!e engineer or
t
desilrcr wiih a-mcans oftát"..rni,',g rñi it'ata"r"tistttt of a wi¡c.bundle when
dcsi;in8 -l-g¡!E^;i¡-imblf. Figure t3-12 shows the number of wircs of a Iiven _o I
5
r20

10
W.4t-..rj}
1..
| '^o
'r^V
A"ricñ iüii¡" U-i locludcd in a largcr circlc of known diamcler' The sttcn- ! tm
dsnt cslculstlon lr a! follows: ,!
: I..it-.*tg
!
oso

o.ao
/) IZ ..f
T.ffil
- ¡u¡¡bc¡ of lncludcd wüe¡ 070
¡V D I r7 T

d¡¡meter of bundlc D -'0.94+

d 060 ,, N"oeo7(; oe¿) r3/
R - -------- --. =: // : Má¡,múm
di¡mctcl ol wrIcs o o.50
whP,. N
^ur¡b..
ol wi,.3

- 0.94)2 + 3.7
o=a(o.rr' t/ O ' Hol. di¡m.l.r ,n rnch.1
d 'Outt,d. diá,n.l.r (O D ) ol
N = o.go:. @ld 0.40 wir. iñ inchet
D
0.30
R=0.94+
d 30 ¡o 50 60
M¡timúñ ñumb¿.r or w,.et lNl
F'orrr. l3-l l. Wi¡a bundl. diomclct.
Figur. l3-12. YYir. bundl.¡,

devices
Figure 13.13 presents some of the most common commercially availablc
for tcrminalinS wire s.
 '¡..!tr!*'i3.tlt¡r' t r¡ft .

8 CONDUCTOR DIAMETEP (m,n)

o NJ (, § u'r I \,
F
o o ooo o o
!
i:-,\, ir§(,
Orn

UNITS OF IO CONDUCTORS

¡9
I
.t
t(n
il
i¡

UNITS
(rlr¡
z - Ul Í\-' (r§tn (¡o
-.\) ooo
I
a
o -rou.oó f\J q
O'L)
BUNDLE DIAMEÍER (mml
A aummary of csble brrlee! o¡¡e ol !'arlot¡s D¡¡cD€eD sPscecrÉt [s
gtveo'ln üe follo*bg table'

Wotgbt of Vartous EuroDe¡! Sácecraft

% wt. of
Wt. of
S/C I¡se
s/c k& Bame38

9. 6 95.8 10. 6
HEOS- 1 106 10. 2
9.5 104. 1 10. 4
HEOS -2 115 1.0.9
7.6 80. 1 8. 1
ESRO.I 86.6 6.5
5.6 69.2 8.09
ESRO II 14.8
?.6 o. I 105. 4 7,2
ESRO IV 113
t.o 240,7 5. 94
255 14. 3
co§ B 10. E {1,t.0 12.08
46{ 50. 0
TD
60 3.3 b.c ¡G¡ l8
DIAL l¿.9 5.O
I L. I 3.8 5. .'
AZTIR 286. 4 Ll. ?
320 33.6 10.5
HELIOS 323.0 4.9
339.0r 16. 5¡ 4.86
o.rs (3914) 7.5 115. 6 8. 13
A¡RG Lzl 9.4
14.3 7.0 189. ? 1.v
SYMPHONIE 204 4. 82
3.7 4.6 76. 8
UK3 80,5 ?.03
5.4 1.7 89. 6
UK4 8.9 76.8 9.76
x4 ?.5
4.s 61. 5 4. 87
x3 3,0
12,9 19?. 3 14. 9
29.4

'Predlcled.
l¡clt¡dé
The E¡á8ea thcrüt l¡¡ the sbot'e table

(.) Cca¡etota - bcludlag lB8t€r¡lDg snd pl¡6

e' g' solder s leeve€
(b) Csble 8¡d rt¡e - bcludtog terñlnsdoDa '
(c) Cable hsmeas tuFport - poltl¡s' rhrl¡k boott cable cla rrP¡

(d) Cable cllpPtDg

2-r-5-22
A suúousty of csblG ¡¡¡d vt¡c grr¡ges ulod t¡ rnrlq¡¡ E¡ropá¡
rp.oocrrft b glvco lD üe bllo*trg rsble.

Uee S€ctlo 2.2, 12 6r trrdo.oü bert66o rtntle coro ¡hlclded cable

s¡d loultlcoro cable.

Wtre Gau*e¡ ued o R¡rope¡¡ Spaceclafr

Spacecratl Ctrct¡lt Wlre Slres Ram¡rk¡

IYp€ AWG

HEOS A.2 POWER 20,22. Mably a togle core

SICNAI, 24 Ed t?ls ted palrs
cEos POWER 20 ,22 ,24,26, Mably EIDgIe core
SiGNAL 24 ,26 Bad bxrls led pel¡E
RETIIRNS t2

ESRO tr POWER Twlst€d Plr€d

§IGNAL 30 muldcore cable

ESRO rV POWER 20 ,22 ,24 TVlated paLrs.

SIGNAL 30 l{ultlcore cable

x4 POWER z0 ,22,24 TvLst ed Pails

SIGNAL 30
COMIvfA¡fD 24 Inut,t-""
OTS/MAROTS POWER L8 ,2n ,22 ,24 Tvtsted patrs
HL CTJD z6 )
ANALOG 30 I Multtcore cable
DIGITAL 30 I

co8 B POWEB 20,22,24,26 T\rro wl¡e8 for

SIGNAL Redu¡dancy. 3 wile
U curront > l aEg.

2-r-6-25
 2. r.6 Flottt!g

fhe porfo raaace of encapsu.la ¡g Dlat€llal! arc aff€ct4d apprectably

by factorr auch a cleanllne¡¡, r¡m¡lona¡¡hlp, preparatio!, proper
loraulatto a¡d adequate cure .Ee ar¡d teEp€rabrre 6cf 20),
The affect of vacuua exposure ca¡¡ caule cootaJ]l tDattoE of tba netg-
bou¡hood and poaclblllty of coroaa effect due to rel€ase of gaaea
I
lt votds a¡dcrack¡ cñeD ueed !o the preaence of BtroDg elect¡ical
flekie, RadlettoD exposure ca¡ lead to a chcEical chaage la tbe
potting compound with changes to the electrlcal aDd EechaDtcal
I c traracterlsttc s of. tbe material 6ef 23).

The mecba¡ical aud electrical requlr^eEeBts *""¡"üirog,c?E- ,

pouDdsare ltEted i¡ the table 2.L.6.2. "r

Procurement and fabrication coets should also be conaidered, these

requlrements are ltsted t¡ the table 2.1,6.3.

The advaotagea eld dlradvantages of potthg are givcD tn table

2.1,6.1.

Tebl: 2. 1. 6 . 1
AdvaptaEe8 apd Dtredvantage8 of PotttpE

DtradYaDtagr!

Provlde. mecb¡¡rtcal rupport Ilcreareg harne8s !aea6.

to con¡ector plo,/wtre jolnt.
ModtflcatloBs not eastly
PottlDg wttb conductlve epoxy lEnléncnted et reer of
provldGs eD sfflcteDt ctrcuEi - coaDector .

fercnttel shleld for EMC.

llcraalGd f¡brlcettoD tll:la
Provlde! envtrfrntt¡eltal lGal r¡.d cott.
or¡ loD envtronmant¡l con-
n6cbr!. UDdGtcct€d vold! or tDpurltl rr
cla c¡uaG hlgh volt¡te brerk-
dow¡ t¡ vacuuul .

2-r-€-1
 1a

l'
l:
)

Trblc 2. 1.6.2
Cbaracterlatlct of Encaprulatl¡E Compq¡¡dg

Charact6rtrtlc
l. Electrlcsl - DoD coDductlve coE¡por¡nd8

0) Htgh dtelectrlc wtth8b.¡rdlng PreveDtlm of electrtcal breakdowa

voltage b€tween adraceat contácts
(tt) HlSh volum e rerfatlvity

2, Electltcal - coDductlve compounda

(t) Low volume realstivity - Provldee total clrcumfrentiál shÍeld-
lag - Iow conductlo¡ path to Sround

3 . MechaDtcal

(i) Good bond strengtb Good adheslon to Eetalllc and non-

Eetalltc [oaterlalt - for environ-
Eeotal sealtng aDd support of events.

(i t) S€mi-rigid IIaJd or sbarp edge8 ca¡Dot damage

the wlre lDsulatloB due to flexing of
tbe wlre

(ltl) Cood wlre bu¡dle penetration
Ite encapsulant must flow between
all tbe wl¡ea to provlde adequate
support and to ellñl¡ate voida which
can cauae electrlcal breakdown at
htgb attltude. lD the case of con-
ó :tlve epoxy provldes low resista¡ce
path to ground.

4, No deterloratlon under operattonal Mechanlcal, Electrlcal and chemlcal

condltlon! perforrn:uce must not degtade to a
Ievel '*here malfuncttons could occur

2-t-a-2
 llblc 2.1.8.3
Prrurelaent a¡d Fabrtcetlotr RequtreEGotr

Requtremont

SoraSe ltfe of I y6ar E i¡Leum Bedr¡cer wasits¡r üo to lútog.

BuIk F¡lcbaso E8y b€ Eedo.

Potlffe of 30 ro lDutes E¡l¡ll,lu! Allows adequate ttme for fabrlcattoD

More tbrD I a!.enrbly caa be potted
at a ttEe.
No daDger of Elx berdcúlrg before
pottlDg proce&¡re ta coEplete.
(r
Low Toxtctty Beó¡ce3 need for operato!

Boorq TeEp€ra§¡Ee cule wlth Allow¡ aegemblt€s to b. potted

Baxrü¡E curc tlD€ of 24 hrB . I¡ !l!¡.

I n. need placfng aaaemblY tn ove¡ -

I not a practlcel Proposttlou wltb
complex cable rEaembllee

PottlDg cbaracterlBttcs LEprove

ttm e

Stlople yl lxtDg a.ud appllcatton neaucea oP6rator lral¡l¡g ttEre'

I
Por8lbUtty of removal I fo" implemeatrn8 Eod{lcatPaJle
potttoS coErpotl¡dt requirer to be
(\- reuovable. otbervl¡e r¡odlflcatloD8
wtll re¡ult tr¡ lcrtpped aesemblle¡.

2- 1-6 -3
Clas¡rll¡es¡

Prlor to tho pottln3 oporatlon vorlfy that tlc aaaeubly trae paared
tho QA lDrFtloa for coapllaac€ to tb. de¡lg¡ rcqulreao¡tr. F¡lluro
to do so can lead to ext€nslve rerrork ryit! tb. oncuba¡t co.t s¡¡d
delay.

The aasembly should be ex¡::rbed for :-

(8) I-ooae or brok¿n atrands

(b) Forelgn Eaterlal, e.g. oll, dlrt, gr€a8e etc,

If conteralnants are preseDt they should be removed by wlplng wtü a

Itnt-free cloth, da¡qpon€d wlth a eultable cleanlng ageat, follo*'ed by
a wtpe w lth dry llnt-flle cloth. Tho cles¡¡log sgent should not have
a¡y detreEetrtal or chemlca.l sctlon nlth tb6 loet6rtsis of tle ¿see-hly.

The pottlng fsclllty f!u6t al¡o be free of conts.E lEabs. Spoc lsl
attentlón rhould be glven to work su¡{aces a¡rd pottlDg uté'Drtl8,
Adequate ventllatlon to accoEmodat8 the voluEe of coapormda,
solvents a¡d prlner€ belng used. wtth forced draJt ventlladon or
extractlon faclllty wh€re toxlc fumes are geDerated, 1g a baglc
r,equtreIrletlt.

Handll¡g Prec autlons

In general, the cherolcals lnvolved are eafe when prope rly h¡ndled
(Ref.1), Neverthele88 all proeess sp€ciflcatlong shoqld contelD
prec tae handllng requlr€Eent8 (tabie belo*) wlth spec l,el not€ to 8¡y
¡D,a¡uf acture rs ln gt ructlons.

Xa¡ ¿lt¡S_Eeq utre-en!x

Avold contact wlth ro8te riel Ur€ prot€ctlvé clothln8.

Prrvc¡rt ccntect wlth open
b re¡ls on sktn.

Avold lngeltlon and Us6 extractorü or forced

lnh¡laüon of vepour8 dr8ugüt v€ntl¡atlon
U¡e face oask.

C qltaml¡ation of eye! Obtaln medlcal.' ¡ttentlon

Itrmed lste ly . ,

2-1-6-{
 No a¡nok!¡g o r aakod fla.uea Ftro rt¡k
ln LEEedl&t€ fac tltty of
pottl¡g coEpor¡lds Elcspa ol toxlc ñ¡¡o¡¡
C on t¿¡-nlD Btl ca of

Medtcal faclllüea should b€ clo.o at hs¡d.

Pottlnq P"ocedur€s

Pottl¡g procedurc! for sll rypes of epo]ry reshs, polyursthsEes bestc

alloy follor the ¡a.ue cycle, na:uely :

C Ieanlng

Preper8tlcn of Elx
(
Appllcatlo! of prtEer

Af,plleat!m-of éDc apsula¡rt

Curlag

Post tDrpectton.

Refereuces 24, 25 8¡d 26 glve detalled potting proeedures which ar€

recoE¡¡nended as gtsndarda, a¡rd should be u;ed l¡ coujl¡lctton w lth
the roanuJecturtrs' data. Flglres 2-27 , 2-'9, 2-29 and 2-30
lltu8tr8t€ ccnveutr,oual PotÚ¡8 of ctrculsr a'I recta¡8llqr cofulectors '

Completed connectora Ehould exhtbtt tle fol rwLug characterlsüca:-

(8) Adhes l,on,wtth Eo op€nt¡188 at th€ cL xecto r.'to-compound or

wlre-to-coEpound l¡lt€rf ace.

(b) HoEoogeDelty, wlth no Burface boles, bubbles, void tbat

oxPooe a¡y srlre t€ rElnatlon.

(c) Cl,oanllne¡¡, wtth Do vt6lble fo!€18! I!'A16rt&¡ lnclu¡lona '

(d) L¡ck of t¿cklneas '

(e) Conftgurstlon to the dtoen¡ioos rsquir€d, wlü no comporad

on tl¡e ahcll, wlroa, b!6rt8, or ccntactá tn arees ottre r th¡¡
aPclflcd. '

2-1-6-5
St¡nd¡ rd Rs*o rk

1. Exccrr potüng coEpou¡rd to bc rcoov¡d by cuttfag nvry wlth

r rhrrp la¡tru¡lGnt wlüout üa¡ghg thc coaccror or wttt
l¡¡u¡¡tlon.

,nc lualon¡, bubbl¡¡ u¡d votd¡ - ¡¡clu¡loar !o b€ turovod wtü r

ah¡rp l¡ ¡t ru¡ai¡t üd bubbl.. or vold¡ to bo opcned up ln e
alraU¡ r r¡rnD6 r !o .llry appllc¡tton of arry Dottl¡3 coErpoqrd.

3, TarE,l,n¡ttm rr*ork - cut rwry lba coEpol^!¡d to axpo.G tha

t rEln.ttoa. rcqul rbrg ¡.cwork, maj<¡ tho chragcr ¡¡d roc lc¡t
rll tha rGsorl€d ta r¡tnotlon. prlor !o ¡r-tttlng.

2-l-6-6
 WIRE OR CABLE COMPOU NO
SHIELOS
(

CONOUCfIVE EPOXY
CTROUN0ING COMPOUNO

NON.CONOUCTIN O
POrilN6 COr.{POuN0

CONTACT - SEAL
PRIMER ALL AROUNO
IXSULAÍOR EOGES
a

-
-'\ -

i
I

MOL C ONIACI SEAL

:
., :

L
'{5 INCH MAx.

11:"j-':
 i
coNouclrvE E POXY POIIING COMPOUNO
6ROUN0rN6 COMPOUND

.COUPLIHO FOR @NIRACI

INSULAÍ ION
POIIING SHELL
ANO RING cor+{EcIoR Bool

FIG.2-29

t.:
r-

I
t CONIACf SEAL

CONNECfOR
BOOY
 I

2. r.7 llcdundancy

Redundancy is one of the met¡ods by which the harnese reliability can

hc increased. Effec6ve redundancy is not only dependert on a pln/wlre
philosophy ¡ cable support, clamping, muü¡¡g and insEllation muat also be
t¿ken into accúunt-

Ttrere arc three poseible modes of failure, namely:

open circ'uit

ihort ci¡arit
a high resisancc

Thc following table lists t¡e m()st common faults, their failure mode
nnd possible causes, listed in order of probabiü§.

Tlrc failure rates of mechanical loints are shown in the next table.
Not¡: that a failure rate h¿s not l)een assigned to a wire.
The methods of implcmenting rcrlundancy in the harncss ate shown in
t¡bular form. The reiiability fiLures are based on tlre operational
iifc of t}e OTS spacecralt (pro(luct of operational life and fai.ure rates
ot io ints ).

Al1 thc methods involve splicing in one form or another. The subiect
ol splicing is dcalt with in S3ction 2. l. 8 and should be referred to
whcn contcmplating thc use of splicing to effect redundancy.

2-l-7-l
ti
f-

COI¡¡,ON FAI'LT8

Frult Mod. Ca¡ua

$prlng Ddrllug 1¡ roc¡Gt o/c l. Q¡l fellu¡e ta Cctccdag apüag

coat8st HlSb ,t¡ilatDg t[lld€ aockst col'r.ct
Resl.t¡.!c€

Broke¡ wl!€ et wtre to o/c 1. LEd€qr¡st¿ lrpport at tbe wlr€ b

coEtsct ,olDt s/cr coDtsct ,ot¡t
2. T[ut wlfe.
t
3. _ F¡fpl¡g d¡rtog EsüDg aül de''t.Hñg

L Pla b€ú ürrlng ue¡¡8 o/c 1. QA f¡llu¡e tir-dátectag'bcalptn* .'

i. 3/C2 prlor to EÁü.!g

2. hotBcüve cepr Dt fitted to
l rrDsted colEcüra
Pia purhed bd< Et o/c 1. Pln tnorre cüy h.crtéd
comecto¡ - rcnoally
asloclrt¿d T,lt¡ reBov- 2. ColEsto! taorcctly allg¡cd
able pta co!¡eetora 3. Plu !€taluer mlrafag

F recü¡red cable/wlre s/c 1. tl¡tre/ceble EEm€d 8t htDge pol.nt

l¡ lhe loom o/ca 2. IUlre/c¿ble Elpp€d bry moylng pa¡ts
3. I¡§. 1ñg d¡rtDg lDstallsüoo,/tewi cdag
4. Abra¡lon üe tD lladequat€ atpport
rad clamplag - rlbreüou durlng
ln..dr

¡¡otoa:

1. Op6a ctrd¡lt wlll occr¡r firgt. 8/C to ahell d coaD6cbr or to

erthr¡r brokou wlrc cra develcp
O/C ¿¡d 8,/C ca¡ occr¡r ¡lmultr¡ou¡ly. S/C m¡y b€ to ahell c(
coDDcctor or to rDt¡.r pln

3, Ge¡rerrlly ¡ S/C to sE"t¡ct¡rt beúord oaplctc fErcü¡re to produco

t¡ O/C

2-r-7-l -
t
Failuro R¡tes
f(
lhe failure rate¡ of mecürenical lolnts are ¡howu belo*:
I
Component/operaEon Fallure rat¿
t ConrEctor pin I x 10-9
SoIderiDg I x 10-9
t Cri mping 1 x 10-9

t It ls worth noting thst e failu¡e ratehes not been assigned to a wire.

The probability of a c¡lre frech¡r!¡g Ur the loom ts htgh but Ír de-
creased by lavoking a wire redundancy. Redunda¡t wires are.
t
t\i normally twist€d together, congequently any mecilánlsm which
fracü.lre8 one wlre wlll lavariably frach¡re both.

ct_ Redundancy Metiods

f,
The various methods of lmplementing redundancy and their respeclivc
; reliability are shown below.
t 7
é.
¿\
rI Method Redundancy Eqrivalent Cct Relisbility

1. NorE )- 0.999946
Wire 0.999946
3. Pin 0.9999999956

4. Pin and wire 0.9999999956

The reli¿bitity figures arc baged on the operational life of the oTS
spacecraft aad should mt be Eken ss valld for all rpacectaft. The
rellabtlity figures ahown are intended as a guide; similar figures
shd¡ld b€ obtalned at the stert of each apacecrajt desl8n.

Met¡ods 2, 3 and 4 are achleved by epllcing a wire lnto the parent

wtre bry mean¡ of a eolder or crlmP ,olnt (see Secüon 2. 1' 8' Splicing)'

The advantage8 ard diEadvsntage8 of the cendldate methoda are given

in tlre following table.

2-r-? -3
Mctiod Adt rot¡8or Dlrsdvrü8r!
1 I¡s wlrc ur¡l¡ Efl3lG potat frllurc rt @arcb!
I¿w @o¡¡ctor m¡¡¡ corDplota !or. of llorl

I hour cooDéctor Eart Doubla wlrc m¡¡¡.

I¡orcr¡cd poaalbiu§ ol E/C b
¡Er¡cü¡rG t¡ wtra rcro to
frect¡ro.
§trgle potat fatlure st @uBector

3' [nc!ea.e rell¡llllty from O/C IDcreasod coDDáctor Eaúa.

fallure of cotn€ctor Pt¡/wlre lncrea¡c poeetbtlftY of 8,/C ó¡e
to beat pla rt @uEcto!.
lncre¡¡ed Polatbt[tY ol E/C b
coD¡ector back eball.
Sllgltt lacrcree lE Ett..
I¡crc¡¡ed relf¡bttlty from O/C Iloubled wlre m¡a¡.
fallure of cooD.ctor Pln/wtre Double oa¡ecbr t!¡!t.
tnsreascd Poaalbtll§ of S/C d¡e
I to bé¡t p1¡ 8t @D.Éstor.
I fo*""""¿ PosttbtlttY of s/C to
| .o-gco"
I
back ahell.

I tacreaeed poaatbtlt§ of S,/C to

I ¡tsr¡cü¡re lf wlre were to
lfrecure.

3' Prcfelred method

Reó¡nd¡nev Sclecüon Cr1t8r1¡

tndltcrtmtn¡t€ uae of ¡ rcdrndsncy phtlolop§ crn le¿d to ru tn¡fÍlclsnt

and lnelfectlvc corltSur.tlon. The necd for rcórndaocy, hss to b€
applted tn det¡tl l, m¡xlmum rellsblllB for mlalmum m8t¡ p€nalty
ls-to b€ cchlcved. It t. Ipt porrlbla or ¡dvl¡eble b specdfy ' red¡n-
dancy method whlch lr¡a s unlver¡ll rmllclüon' All thtt cen b'
st¡tei sre thc Sround nrlcr *hercby r rcó¡ndlacy method c¡o bo
¡elcct€d.

A fundÁment¡l requlremenf la thrt ürr meln¡ ol provtdtng redunüncy

la ecceptsble for u¡e ln the erwlrorurG[t. For uemple. rpllclng 16
not pcrr¡ttt d In creu,/ compattnaata (RGf oirDcG 19)' Thl' aocr'l-
t¡te! thr u¡e d redr¡nd¡¡t ctrq¡ltr.
2-l-7 -1
A furücr rcqulrouraut ta tlrt rpuclag ¡hcr¡ld bc krpt to a E¡tDl.BuE
(Rc(crc¡ce 17); til¡ t¡aptler tbrt reóradaucy sbq¡ld b€ krpt to r
mlnimum. Thlr t¡ o¡¡l¡taut wltb tho 8/C l¡iluro mode probrbtll§
rod tbc med to coutrln tle hrr¡orr n¡r¡ ¡¡Í{rl¡ rcccptrblc ümltr.

The bsrtc reqqlromeat 1. thrt Do .l¡gIG p¡rt früurc ¡hould rca¡lt la

the totel or p¡rüsl los¡ of ¡ mlralon. B¿low t¡ ll¡tcd the atcgorler
whlch roq\llre reó.rndancy, whllet th6 cxt trblo ld€Düfle. tio!€
rtgnelr whtch, lf l,ort, ,.r ¡ c.u!e total or prrtrl lo¡r of ml¡¡loo
c¿pabillty,

Redudaacy Bequl reEaDt!

Clfcult RcdundaDcy Pln ¡¡dlor Wlre Rcdundeacy

Crcw rrpport uültÉer Re¡üctcd ElrsloD
Totsl lo.r of mlsrlon Lo¡¡ ol ¿11 érperlm€nt!
I¡¡¡ of o¡a qottrtr.Et
(Psrgal lo.r of ór «pertrneut¡

Crltical Stgrralr/RedunCaucy lrfcthod

8igDel Reüradaacy Ivfelhod

Powe¡ 3or4'
Telcmetry Comr¡¡¡¡rd¡ 3

Tlmlng PUI!er 3

Atü!¡de Control 3

Pyro/tcó¡lc Dsvlcc! 3 8r ErlDlEu¡l dr(r¡lt

tf vltrl

t M.thod { to b. u.Gd tl powcr .h¡rtD3 lt reqt¡lrcd.

¡-l-?-6
 2. l.E Spllctn8

MIL-W-83373 and MIFC rpcclllcation {0M39582 hl c codllct!.Bg vlelr,r

ou thc aubJcct od 3p¡lctDg. The I\GFC epectflcaüon, $ñt dr l! prlmgrtly
l¡tendcd for apece vehlclc¡, perrnlt! tle u¡e of rpllcl¡g provtded the
number ta ket to . m¡DlEu¡t ¡ad ta ¡rot u¡ed ta crew comg.rEr¡entr ¡
MIL-W-635?3 oo tüo ot!¡r t.'r¡ prohlbtte tbe u¡e o( !pltca..

Spuclug hgg beca uaed on r¡meror¡s Europes¡ satélltte! wtthout any

appareut fellu¡e¡ attlbut¡ble to spllctDgi ESBO I, ESRO tr, a¡rd UK
rpacecratt X4 cortalnly üd not culfer by the rrae of epltcfog. The
fatlure rat€ of 1 x 10-9, uled ext€Dllvely by Aeüablltty Eugbeer! lr
equ¡¡ to th¡t of e ¡older or crlmp ,otul

The u¡e o( pllctag lg recommeDded wtth the followtng coDrEalnta:

,l 1. It¿re rh¡ü be rct more thea 2 rpücea l¡ a¡y oue leagth of

wlrr
2. Spllca¡ ¡b¡ll be etaggered to aeofd br¡nchl¡g

3. Spltc{ng lhsll Dot be u¡ed for repalra, wltirout deaigl authorlty

4. Jol¡lDg two plece. of wlre togetier

5, Lcsted where undue etrete wlll be ptreceJ on the wlreg

6. frfry be u¡ed ln all areaa except crew comperEoeDt

7. Subrect to vlsual lnspecüon of all splices (SécüoD 4.¡l)

8. ElecHc¡l tért ó¡rtng m!,m¡tscü¡re of the h¡roeag (¡ee Secüon

4,4',t

Lóc¡ioD o( Eoltcc¡

Thc locrtloa of rpllcea on ¡ crblc/r¡¡t¡e l. d4!dÉÁt upoa the EMC

rcq¡lrGlnrnt! c the ¡lo¡1. CoDllderaüon h¡! to b6 glven to thc
locrÉoa d lhe rpltce wh¡n ¡hlelded c.bt. tt u¡cd for EMC of EMI
gcrtrüvc/aurcspüblG rl3¡ele (ace Eccllqa 2.2.3). For mlxltñurñ
ahlcldag cfflctcacy lh€ 8tnourt of uo¡hlclded c.b¡c nurt Le kcpt b a
1 m¡DlEuul.
I
¡ l,8F C úpcculclüoo .10M39582 .t¡tc. "S_Uc!. .h8ll Dt bc loc¡tcd
it wlthln 3 luche¡ of e coD¡Gct¡r'. Thl¡ (úmeu¡tou l¡ t¡kcu 8. bclng
ma¡urcd f¡ou the c¡d of tüc coDo.ctor pla. Corplcd vtlü tilr
{ rGq¡lroa.ot rpoclftoÉoa .lO M:19582 tclulrc. tt¿i ¡hlcld¡ bc trrrnln-
t rted mt mor. ti¡¡ ,l t!cü!. fron tü¡ nrr of lic-€4¡cbr Pt[. !
T
é
lpuctlg l! rúq¡tr.d ou rhlcldcd crbtor, rltüor¡t trücbf¡¡. lüla r oo-
prourlrc ol tác ! .!d { fDcb dluo¡lo¡ illl b¡ l.qt¡lr¡d.
[(
¡-l-e-l
t(

$
 lo0l¡m (4 lncheú) of ua¡htelded wtro t¡ mn¡tderGd exccsrlv., E EoFo
rc¿ll¡üc roqulr.mc¡t bctry SOmm (2 t¡ch¿r), tha 4ltce belag rcomno-
d¡tld bctwcca tbo lhtald t rmlasüoo ¡rl thc rc¡r cl lb6 co@ctor ptn
(Rdcrc¡oo l6), Flgure 2-31.

Oa u¡¡hlclded wfre thc loc¡6o¡ cl thc gücc to tbs IGFC requ¡rracst

1r ecceptebla, the pcae§ bcl¡g thc fu¡üc¡ ¡way tb¡ rpll cc i¡ l¡o¡¡
thG @D¡racto¡ ti€ gret r la the E¡aa ol 6e red¡¡d¡¡t ¡,lrc.

lte ml¡Imum d¡tancc ln whlch a tpltcc .-,, bc ro¡de la el¡o drpeadeot

on thE t,?é ol orEestor la whl ch thé sftr€. a!€ to be teñlLt€d.
Em'l¡onmeatrl @DDrctor8, wtth .Grllñg g¡oEt¡uet!, Eo¡¡et b¡ve t¡e
apllce outelde tte grommet to ret¡t! ltt aeallng ql¡aUty (Flgure 2-33),
I¡ thl¡ c¡se the apllce ¡hould be terElDst€d a¡ch thst the e¡vt¡oa¡¡eat¿l
Besl lr rct dorEoyed.

Spliccr, on non-etrvlrolDr.ntal conrcbrs, ca¡ b€ poaf üoD6d l¡ ¡bowo

ln Ftgure 2-32.

E r¡vl ronment¡l ¡¡d mn-cm'tronmentrl coD¡éctor! cr! uü¡l¡c clsg¡plng

dewl ce3 ¡nd ttrult be t¡t¿a lnto accd¡lt wbln poetüonlag apllc!!,

SEeln rell€f clrmpa porc a¡¡other problero. Nolther spltccd rolnts

nor ¡l¡leld t€rmh8üon3 may be poalüoned uade¡ tbc clemp aupport
Flgure 2-34.

Stággerlng of spltcree lr alro requlred tn ordar to dsEttr¡te the tr¡lk

of the Bpllces evenly along the loom, perüctrluly when uslag con-
volut€ o" he¡t shrlnk !,¡blng.
I
Method¡ of flollctn¡

l1- Thert¡n&rd method¡ of ¡pltclng are lllustrat¿d tn Flgure¡ 2-35 to

2-38. Tl¡o¡c met}od¡ ere gemrally rcceptad for úPac€ ve!¡lclc l¡d
¡etelltte ¡ppllc!üon! (Bcference 1 6).
t
Thel! .ppltcrdon end coúts'¡lot¡ a¡e dst8flod ta tl¡e follogrñs. Thé
cholce of mGtlrcd uled lr d€pendont uPon:
t
(8) QenttnS t€mPcrat¡re - eoldcr ,olnta fnult not be urcd when
the cpcrattng t€rnPersh¡rs is ebovo the mclÉng t€mPeraü¡rc
I
¡.
of the .old€r

tt O) Th€ av¡tlable cprce for ¡PUda8 - phyrtcel\y melhod 1 1¡ thc

lrR1llG.t and method { th6 btgSert.

(c) ItÁ¡¡s ol the apUce -met}od 1 te the Ughtr¡t, metiod¡ 2 and

3 ere compe rrble ¡nd meüod 't th€ he¡vleot. The ¡n¡¡¡ of
ü method { cao be decr¡¡ed by ultog ualB¡ulrt4d la-llno crlrnpr
i.
f{
l&
a¡d tlGc\rtn8 ¡rt r c.rltrpirnS. Thc ¡n¡¡r o( ¡rathod 2 l¡ lncrcr¡ed
wh.n alvt Fo o¡n cotr l rrlla¡ tr r€$¡trGd
2-l-c-2
-

$
 50mm i{OMI}ü

tt
lr
ST{IELO fER MINAIION

,t

WIRE SPLICES ACCOMMOOAIEO

CONNECIOR IN IHIS REGION
FIG.2-s1

BACK SHELL
WIRE SPLICE

rtc. 2-32

wl RE SPLI CES ACCO|,i.(OOAIEO

IN fHIS REGION HEAT SHRIN XA 8L E
T-1 CLAMPI NG
GROMMEI
BOOT

i seulces PRoHTBTTED
I oven IHIS LENCTH

\YIRE SPLICES
ACCOl,ll¡l0OAf EO
IN THIS REG¡ON

FIC.2-33 FIG. 2-!{

2-r -6-t
Mcthod FlSurc CoE!EalDtr Appll ca6oo

1 2 -35 I fb6 brcd couá¡ctorú g¡u.t Crlnp rad rold6r ptD

bc tqdrt¿d bgeüer aoa-erlronmeatrl
tl Tho dl¡!r6t6! d the twt¡-
o@ctor! oEly
tcd coEó¡ctor! m¡¡lt rct
b€ E¡ct€r the¡ the dr-
m6t€t of tbe pla AWG
Itt ñ¡tob6r of wlre¡ llmlted
to3
2-36 Hat .brlEk tublng muet All eppllcsüoar - wherc
be clar to aüo¡, lDsp€r protocllon floB lBtre.!
üoa o( tlu Jolat ol raolru¡re ta ¡eq¡tred
s !€U .ea¡lDg b¿¡t ¡hrlak
ü¡bc mu¡t bo u¡od

3 2-37 lllrnbor ol s't!.a eFtlrtDg All appüceüo'¡

rn¡il I-Yl¡t tbe roldar
¡Iar¡c l¡ coDlE'¡laod by
¡lze d ¡older lleeve snd
dl¡¡netor of wtre. 8ee
tudvtó¡s¡ "." nul¡cür¡e¡l
recornmeodaüoo¡
I 2-3E Nu!¡bar of *lrra All smllcatlm. rvb.ro
GEt€rl¡rg rod lervlog protGctlou frol¡ lagrcre
the ¡oldcr ¡lccvc lr ol Eolai¡rc tr raqutred.
coa.tr¡lDGd by th. A ..U .cúll¡g h.rt .hrtD¡(
¡lzc ol roldcr rlccvc i¡bG Euat bc u¡cd.
¡Dd df rEctGr ol §.lrG.

CONNEC1OR PIN HEAI SIIRINK IUBING

I

-#=: HANO SOLOEREO

JOI NI
FIG. 2-35 FlG. 2-38
SOLDER INSULAIEO
SLEE VE INLI NE CRIMP

FIG.

:,-.t-_a--t
 2.r.9

Thc wcd<c¡t pobt, t¡ a¡y b¡¡¡e¡¡, l¡ al tbo soldGr/crtDp Jolct of

8 06¡eoto!, aaG akctcb balow.

SOLOER OR CRIMPJOINI
WIRE

POINI
c0r{NEcfoR

C6tt¡u8l flclt¡g of tb. wtre due to vlbratloa or cmltluel h¡ndt§g

eodr¡ce¡ Eetsl fstitua l¡ th. wtr. whlcb eveoi¡ally flacü¡rcr, glvtng
a¡ op€n cllcult ¡¡d a potttble rbort clrcutt,

Botb of tb¡¡c a¡llr¡¡ctton¡ ¡¡urt be guarded Bgal¡lt tf ly.tem rclt-

Ebtllty la to bG Eslataln.d. Tbere arr threc coDv8attoDa¡ metlode
ol provtdtag a¡pport, arncly:-

Mctbod f . Sleevhg each Jol¡ct wlü a hest rbrl¡¡Áble h¡bl¡rg -

Ftg 2-39.

Matbod 2. Encap&latlDg the b¡ck of the conDector u¡tth e lther

conductlve or BoocoDductlve epoxy - Flg. 2-{0.

¡lcthod 3. U.G olrtr¡ln r.l'.df clsmp. - hetslllr or heet rhrlnk-

rblc mouldlogr - FB, 241 snd 2-12.
\-(

,-r-0-1
 CONNECIOR
CONNEC fOR

HEAT SHRINK SL E EVE

FIG, 2-39 FIG. 2{O

WIRES
CON NECI OR

HEAI SHRINK
MOL OIN G
CONNEC IOR MEIAL CLAMP

FIc.z-,tl F¡G. 2-{2

2-r-$2

L-
 Tho edvaatagoe aad dtradv¡¡tagcr ol tbc vertci¡! Ert¡dr a!e.ElvGa
bclow.

Ea.y to tnsta¡l LIE tt€d to uaa oo c@¡¡6ctor. s,tar!

,1641¡¡g c¡¡ b€ l¡aGrtad betwea pla
Ecooomlc lpl¡ e¡d pl!
Modtflcatlotr! ere ea.y to B ls¡( of d'Elagp to lDru¡8$oa wb€o
alfec t r€!!ovl¡g !l.evLug,

F
.*--- --- ' Low Il1a6a. Iloaa Dot provldo sD aDylronatñta¡
real
I¡exp€aslve
l(
t
Provtder a.¡r €ovlro¡Dcotal Hlgb Ee.!.
¡eal.
t Modtflc st 1oa¡ to c@¡GcüEr c!¡Dd
Safeguard! agalait S/C fault reedl¡y bc llpl.Ecatcd.

Provlde! bette! ruptnft ih.ñ L6g curc ttDa.

I Eethod r e¡d 3.
I

Exp@.lv..
3. l.ow cort H§h narr
MGtaUlc Eaey !o taetall Rtrk of S/C ll wtre frechrrc¡.

Modlf lcatlmr rG¿dlly affect€¿ EnvlroEEr€ots¡ seal ooly exlrt. o!

envlrm¡¡eotal coo¡ec tor !.
( 4, Irw colt Sonr€ rlrk of damrgo to wlre l¡.ul¡tt6
Hoat uñcn rGErovtDg,
Shrt¡k E8¡y to tDrts¡l
mq¡ldlng Htgb¡r as¡¡ .ho" E€tbod l.
Modlllcatlo¡ arc roedüy
efcctcd. Do.r Dot provldo rD alvlroDE.lt¡l

I¡rts varlcty of oi¡tlct eD¡lc.

av¡fl¡blo ,

Thc m¡¡¡
o( mctbod 2 t. dGpod@t oo thc uumbcr ol rrlra! t.ñtlatGd to tha
conD.ctor.!d tha coDDaotor atr.. Tho n¡¡¡ of Ectbod 3 t. d.pGdrtt oa thG
con¡actor rtza rnd matlrlrl of thc rcltrl chmp, Aa.uml¡g trg ld¡ttc¡l
conncctora potir¡t h¡a I m¡ra:lñ.! maa¡ a¡vlDE.

,(
2- 1-e - !
 I

,(
I
2,2

¿.3.1 SUJüErú
t
Thl¡ ¡ccüoa E{vat r t!!. rr¡ d..c rtFttoa o! thc ¡uo¡¡t¡g of EMC, tbc
f¡¡torr t¡volvcd od r guldr to tb¿ 'rr.o rt¿¡ o{ c".tEf tr¡D.lGr. It
I ptlr@tr ¡ &t¡llcd aurvay ol t¡a f rcton rrlcv¡út to c rbllDg hrro¡lseg
r¡d bow tic hrr¡cr¡ &rlp cra t¡lltEacG t¡.ra frcto ra froEo ¡ prrcttod
l¡.t¡Ihtloa .tr¡dpolDt.
t
I¡trpdwtlon

F
-t. Tba-t¿r¡or El,cctro-. ac'6t1c CoroFtlblllty l¡ tsl€o to Eoa¡r üo condltlon
wbca no cloctrtc¡] D.ñ¡¡¡.ta ¡ te degradad outr td€ ihc tpcc tfted ltrnttr -
Docaara¡y for co¡rrct Fr rlorE¡Dcc by clcctro-.F ctlc l¡ta r{a reoce
r(
l\- froo roy groarr6va sou¡ao.
Tb. c¡octroEt¡ctlc ovlro¡o¡lt .xp.rl@c6d bf r tFc6a ¡¡¡1 1"
ga. rrt d § tia ryrccc rrlt .o t¡¡t tt b poarlblc to ¡¡¡§¡c tt¡ envlrq¡-
E.Et froE bo*¡ drt¡ wltlout tlc tatroductlco of E¡Jor r¡.¡¡roptloaa.
A hlgb grcpo.Éloa of tho d¡t¡ for tnc urlyrl.r rt E¡ fron rh+ crblc
h¿¡|!G.! ¡¡d c¡¡ b. vrrlGd by tbe dcrtg of rh. b¡¡a.¡¡.

Tb. LEplGt[atülo¡ of coüt¡'ol ol l¡tlr{GEocc t!, ¡aht.va colopatlbtllty

tr pcrforacd lD two .rr.!; llrrtv ln tlc qulpcoaot ¡¡d..condly l0
tb. c.bltñg.

Tbc ¡occh¡¡Icd dcotgl cea c¡¡urc t!¡t rrt- 6qulpE a! b fuliy ac rroaed
to rohlBl!€ r!cGpt16 or p¡oPa8¡U6 ol fl-ldr by tb. l¡trrarl clrcult!.
TbG ctrcult¡ co b¿ do¡tgFcd .o rhrt tb.y r€ BpaJ oDly to t¡. apctfled
l¡tr¡t .lt¡rl. rad grac rrio oly opocUlcd outF¡t ¡tgDab. lt ct¡ .rlco
t¡¡t tha colt ol pr.ovl¡ll"g flltr¡t to Go.ur6 tbl3 lorcgobg l! Eot Jurtulcd
t
ú algr¡r thrt wor¡ld lnt¡ rlcrc r¡! aot 3to6 r¡tcd l¡ tbc ryst E.
Tb¡ rcorgc lor E¡Doauvr.ü lD rh. b¡Eaaa dcr§a lr GxtaorlvG r¡d th¿ rc
l! no rDlv.rülly rcc ogtlrcd b..t rpgrc.ch to t¡. br.t problco of
,ntnlñlalDg br¡¡c¡¡ ¡o¡¡e wbll¡t áaaurl¡g EMC,

Íta ll 'r.lt¡ ¡rc wtttrl¡ t¡a G¡IrrDlG rro3r oll

¡ r) ¡ll wlr¡¡ t¡a¡c ¡ccocd follc'wta¡ t¡€ rborLat po¡¡lblc routc¡
r¡d h¡dl¡d tofltho r wb¡n coovr¡lcat tor tnlll¡¡rus Dr..
t
I

I
b) rlg¡rl. dlvfd.d lato ¡[]ry dlü¡rot crt¡fort.¡, aach crt ap¡y
ror¡trd b&panddr!§ cmvcntlo¡¡lly ¡c r¡c¡cd tlth r¡ ovcrrll
i or¡ictlc ac r.o a¡d tlt rc trao ta ral¡rtlona tot¡l¡y
c I rc uEf! r.atlrl V rc rrGocd by oooductlYt .prv .

{
1-¡-t
§
:'
 Tha ilexlblüs axl¡t¡ to üa ¡olectl,oa of tbe:-
o l{u¡r§6¡ ol cstrgorL. l
I
a Whlch eatatorlo. .ra ac ncarrd
I
? Whbh cat gorlc¡ ¡h¡rc co¡E-Eoo
acr.Ga
a WhLh catagorlee ¡h¿¡e coE.Eoa
mutar
Tbc phyrlcal repqrstlo¡ of r.outr!

Tb€ pr@(lElty of th€ router

to t¡6 grould plaie
Tha ac ree¡ tcrEl¡¡ tton t€cb¡tq¡¡..
Dcll¡ltlon¡
(e) EléctroEss6tfc CoEpa buttv (EMC)

Tbo succe¡efu¡ oparatlon of oa€

or Eror€ lt6E! of cqrdf.eat
tn the ,8Es electroaagnetic
cnvtrooEeat.
(b) Electro¡¡a¡a¡Gttc lat¿ rfe relc€ (EMI)

olectro¡nsgnettc rsnal o¡ dt¡turba¡ce,

Ior _iy.""f
aen ¡aade, t¡at car¡ have a D¡tur8l
dÁgradtas
of s¡l e¡ectrice¡ cqulpEent. "fi";t;L;per¿óon
(c)

(1)

trter{erence slpela t}et sre proaeDt

freqrrcncy, or over a
tt oaly o¿e
(e. s. . a *0,"**"Jli,lii.HT":1íXf'ff:
(ll) Bro¡db8nd Lnt€rfersnco

lnt€rfcr6¡rce etgneJe rh¡t arÉ p¡!!6nt

over a wlde range
of f ¡quonclea. Th¿rc ar¡
of bro¡dbr¡d lntorfcra¡c6, naooly,
rl¡ttc
"har"ca rr¡doru o" arr""
"irr'uol.ee
(hevtng no rcgular trcq,,"o*
(havlng phecc r€Sullrity
of "r;Lffiffise
-urÁü;.;il:, r-¡lir"::
aotac
r-
aurooobr rc rdu;", "*o"""rl
roa_chlnery, etc. )). totarfc;*" -.*ff ; "",,1" 1",".,
.r¡;"¡;-;;;;"
r¡dirtcd, or cqrductcd. or both.

2-2-2
ñ,
 (d) Rrdlstád ht l6ruEc.
Elcctro'rr ¡gncttc l¡tarf.rbg clrtE¡ ¡rdlrtad lroa ¡ay Gqulpp,6t,
ctD¡ra or l¡t.rcorñoctbg wirt¡¡g.

(r) Ccadu4t d Int rfGrrocc

Elact¡'oEsgDGtlc lDt6 116 rt¡¡g €a€ m/ coadrrct¿d ou c¡btro¡ or

wlrlng. c.g. aherlng comBon rGürr¡ ll¡...
(f)

í
A oea¡ure of the l¡t€rfe r€nce a§lel vo¡tlgE Equlrrd @
sl8ñal or pcnrer leada to ceu!é qutDE€ot pe rforanace
dogradatlotr or EaalftEctlm.
i( G) Conductsd Surc6Drtbtltw

A o,e¡¡ure of tbe lDtarf€rÉn"6 ¡tg¡al voltaga nqulrrd on

f
t[aal or po*,er leedc to caur€ €qutF.Dt p€rforE¡Dr6
degradatloo or B¡lfl8ctloE.

I 2.2,4 Couollng Mechr¡laro

(8) CoErooo lEEde¡c€ cq¡Dllag - Whsa ¡ coEductor lr abared by

I eeverd clrcults, tbe floc, of currÉDt fro¡¡ ooe circult through
thle coo¡¡on tropedance prodtrcoa s voltagE drop th¡t E'ay
¡ffect t¡e operatlon of otier c lrcult¡ eharlng tie ea.m,e condl¡ctor,
I If tle coo-aon l-Epodece ts e slg¡sl ¡eü¡tr for ¡everal
gLall¡r che¡nele, tn!6rchá¡n6i c roeatalk w lll occur.
I Tbe co¡trol of thlr Eode of coupllng rtqulr€r I detstl€d
loow ledge of th6 l¡t6lltl r€tuñ (0V. neutral) circutrry of all
cqslpent!, The ta¡e¡tloa of . wlrG b.twcGo two avalt¡ble
cqr¡Gctor ptna doet ¡ot snauro tl¡et the wtre carrlca tbe
cur¡lEt, the EsJor prcpoñloo wlll follow s¡y alt rDÉtlva path!
dcpendcnt cD the ratlm ol the t¡opcda¡ccc.

o) Electric cor.¡oll¡g - WhaD two cooóEtorr E¡.e ln clo¡e proxl.lly

to Gsch oth€r, s.E!,ll but &ll¡ltr c.p.cltor ls foraed. Tb¡
coodrJctorr stt c¡pa¡rlto r al.ctrod6a, r¡d üe c¡blc to¡¿l¡üoo
end ray otle r noncoodr¡üva lnatrrhla lona th. crpacltor
dlGl,cctrlc. Aay vrrylag volt¡8r 6 caG of t¡. ccDdr¡cto ra l.
t cepacltlvc§ couplcd lrto t¡. LEgcü¡c.. coo.B6ct6d to tbÉ otb.r
codlEtor,
(

pl 2-2-3

q
 Tb6 foUo*'l¡g llgurÉ t! a plot o( c r:o¡¡t¡lh v' frcqurocT wbarc
d= wtrÉ ¡Pac bg
D= dls.E t6r ol wtrc'
c t= lcogth of corllt¡oo rcutl¡g '

H
--
| , FAR ApARt' C^, lO-tOO
"Ara "r"r'\ O'
.*.. ¡s sFrowx

?*1 NEAR t''r''o'.too"

ürol
-revl\- cLos' {o t t-t s''zoae

I
I

I
ilm
3ffi
w
(-) -
-b
l.L
ll-
t!
o
(Q^/\

d>>h; h=0
=L
L
-¿

g o
3
rffi-inz ffi"' '3oJ?3*Pi.LT.*'s' loMHz 3o DoMHz3ooMHz

I
rlSrtflcs¡t lor blg!
El¡ctrtc flcld coupllng lc üc mor'6
i
t-p"¿-". ctrcultr ' 6Gl" 2)'
Electrlc f ,,61d R6dt.Etton Tcctnloué6

S€p.rsta tb¿ ctrcultt e¡ much

e¡ Fúrtbl..
0
ltr'acc by kG€Ph8 tbc wlre
i 1l) Rsdrrcc thc corPltng crprc
1 rt abort rr Porrlbl'c '
i by rbl6ldtÁ8 Gttb'r
ru) R¡drrcc t!¡ couPll¡8 c¡P¡ctt'¡cG
tt
É
ooc or bth wirc¡ '
I
¿ Shlcldirg boÜt nl¡a' Stvcr oexlmu'rn dccouPll¡¡'
t
i
L 2-2-1
t.

t
 (c) Mrgotic coupll¡g - Tbc prcacacc of e lmgltudnal cooducto r
prodrcer e ¡E¡ll h¡t dalblt lndr¡ctoce. Whan two cGdr¡¿tors
¡ro h clorc proxtalty to .ach othar, a tru¡foro¿ r 1,6 produced
bccruec ol tta E,utlrsl hd¡Etec6 but GrLrt! b.twc.n coDdl¡cto rú .
Any vlryl¡g curFrat flov ln oac c6du.tor ¡ '""f aÉcally
coupled Lnto rh. otb.r coodr¡ctor ee ¡a l¡ducad volt¡A! bacs,l¡¡!
of tll. trsD.forErr ectloo. llegn€ttc coupllag l¡ t!¡ ¡oor¡
rt8]1lflcot for la, lopcdaac¿ clrcult¡.

M¡peH¡ Ftreld R¿dr¡ctlon Teckriose

t) Rt¡ ttrc cablea ar clore to tb.8Totod pla¡e ar poaalble,

i It) Tvlrt togrth€ r tbe elgaal ead slg¡al retu¡! wlt!. Tb€
tllrt t!ad! to Eeke tls local EMI coatrtbwlou¡ c¡acel
out ¡tace tra há¡ced voltsgo tD esch t¡c r€rD,€at8l twlst
!( s!6e !r sppftrEoatáIy 6quat 8Dd o!'po.lta to ltr DGlghbour.

ru) 9.6 3 negnetlcally rhl,eld wlre to wblch the rrl¡dve

l p.rn slrllty ol the shl€ld po>>l,
Flor,l ¡ llsgr¡€tl,c fi6ld pol¡t oI vl¿n rhr chlcld could
t floet, br¡t elcctrl,c fleld coupltlg rtqulrea tie shleld to be
gto¡¡r¡dcd, s6e e¡Gctrlc fleld coupllng.

I lv) RoudDg elth€r a wl¡e pelr or haraerr ln a cyllndrlcal

sbaaü.

I Tb6 d€gree of ¡Dagr¡otlc Ebleld,¡g HdB = 20 logaoG"/2r) dB

Wbero
gr = r,al8üvG púrE6sblllty of magaeüc aheatb
[ '--
( t = tl¡lch¡¡. of sb.¡ü
r = out r radlu ol ¡beet!
v) Wrephg the wlre pelr or hlrIors wlth a hlgh Fr¡lesblltty
t t¡0., wlth 50% ovcrl¡p púr tu¡!.
I

¡-2-5
I
I
REGION WHERE
3K. ELECIRIC. FIELO COUPLING
IS GREAIÉSI
|t. --
-,= IK'
L
o
z 300
o
?.x.xx
100
o)
UJ
U
d
o o

o 3 V ICI IM
z
I
Q
REGION WH ERE
= MAGNEI IC.FIELO
Z
1.- !) 0 COUPLING IS 6REATESI

ol
t 0.r 0'3 I 3 t0 30 100 300 lK 3K loK
CIRCUIT NO.2 SOURCE/LOAO IN OHMS
I

z-2-8
 trbL l .b?. th. LF ñr.nrtlc rhlGldt¡g cüccdvaG., ol
t¡p.. b dB.

T rpc B¡dlut ol rtr¡ A¡¡¡c¡r

0.10 0. 25 0.5 1.0 2.0

T6cblt 30 2l 18 10 {

Nrtlo 0. 00.1' 32 21 16 L2 6

Co-o¡tlc 0. 00.1 r {5 ót 31 19

Co-o.dc 0. 010' u
I EyF¡r¡oE 0.004
52

¡t6 38
38 32

28
26

20

Hyaa mon corngrtcd {9 43 tl 31

8 mtl.

nrfrrtncer {0 , 4l a¡d .12.

CoEEstt! lt¡octtc s¡d L ¡,-'49.§9.18!ES
Above ebout 10 MHz, eléstrtc flcld cor¡pll¡g ,illl dwayI
predomlaaa, Belcnr 10 MHz 8 gln6rJl¡aüou ca¡ be olrieadlng,
tbere wül be both uragaetlc aDd Gléctrlc coupllag wtt! ¡ bla,
t ?ard Gl€ctrlc coup¡bg. At b¿Iow 100 kXz elt'¡er electrb or
lrirgiaüc coupltng will prtdomlarte doperal"g oD wtrl.ng gaoroetry
md ctrcult l¡pcdance¡, e grucrr.lierüou l! show¡ h f §ure belw .

2- Z-1
 B.ld .¡out 100 lg.!, tt c¡¡ bo ¡rarnltacd [¡'66 rh¡ fl¡urc:-
l) Ivhcn t¡. ctlcult lEFd¡¡c. prodrctr, ZiZn < 300 ohnC,
tto prbctplc oouDll¡t ocb¡al¡u l¡ E¡&6fu ft ¡d.

tf) IVhca tlc cttcutt lBp.d¡acG product¡, ZlZn > tO t 6hrr¡t,

. tb prtaciplc coupll¡g Eeh¡DtrD¡ t! elcclrfc ft ¡d.

tX) Wb.D th¿ cl¡cult l¡otE¡.ñcc productr, gog,p <Z.Z^ < lO¡dU,
tüe coupltag E¡y b€ olt¡cr 838!rttc or cl,ectrfc lbid
dcpeadbg upon relatlve wtrr¡g groErtry.

Not6 t¡st ttrc ¡bove r.lsüoD. smly oaty for pnll,el-wt!ú patrr
¡¡ ¡bc'a ,n thé b.Grt lkétch to tb¡ ftguF. U .lrhor or botb
palrr. hed ulcd twlrtGd-wlrc groEat¡y, tlc mrgnetl,c-coupltng
uodc would havc bcco 4ürtraüelty rodr¡ced a¡d tbe grrph
l!¡¡¡ l¡ t¡r lrguÉ wo,.ld ltg¡Ulse¡tly Eo\r. to tle locr l,eft
Gbé E/T-fl,rld cñr.aover ttra mtght rpproxlEst€ 1fr, Eor€
or trlaa¡r oo ttc oth¡r h¡¡d, tf .tthcr or bth parallel-wlre
Dúlrr bsd r¡¡cd ¡blelü, thc cLctrb-ftald coupllag Eod. eould
b¡vc bcc¡r aubctotlrlly rldr¡ccd, s¡d tl€ tr8ph ltD.r ls th€
flgure would atgatltcutly Eov€ to tüe upper rtsht (tb H/E-fleld
croaaov€r thco u§ht apprcrd.E¡te s clreult lapedeace prodtrct
of lulz, Eo rr or I.!!). G tb¡ other l¡¡Dd, lf e ttber or both
pÚrllel-wtre paln h8d rucd ¡bleld¡, tb¡ electrlc-fbld
coupllag mode *ould h¡ve bec¡ ¡r¡b¡equatly reducéd, ¡rid the
greph llnea ln the flgur. would rtgnlftcaatly Eovc to t¡€ umer
rrSht (t¡. H/E-f,[Dld cñ,.!over thra lolght ¡pproxlro,at ¡
ctr€ult tEp.d.¡cc prorlrrct of 1!9I2, E¡o ¡c or 1.!r). For twtst€d-
¡hlcldsd Flr wlr.!, tlr¿ ¡blft ta H/E cro¡a-ov€r E¡ay Eove lrr
oltb.r dlr.ctlo! dcp¡ndl¡S upa üc rel¡üve d€coupllag
cffccüvc¡s¡1.

Tb coupltng rcórcdou EcbslqtJ.. wlll u;. .nd , whlch conpllag

Ercb¡¡lllr prcdombatc a.

e. r.-Couplba R¡tlo ol l¡t ñonoac'{ou wlr(a¡

Aay coupllag ctreult ccrtlta ol r rourco, qna or Eo¡a

taenaDrkrbn patha, ürd e lord. Spurlou coupllag prtlr
caalrt of co¡¡.o,co coad¡rctor tD¡p.d¡Dcar , Eutu¡l c6dlator
c¡p.cllr¡rcca, Eüud coDductor taductrlcc.. rrdtrtad clGctr{c
fialü, ¡¡d rrdl¡tcd E.¡rGtlc flcld¡. Spurlou¡ r§arlr lroa
ti¡ ¡ou¡ccr ol htatlcrclcc rro corplcd ürou¡ü thcrc
dr.tlbr¡tad tñ¡.El.r!ú rtür lnto tlc rurcrpttblo chculta.
Tbr rnplltudo ol lat¿rfcruncc cor¡pl.d bto tir rur;pttblc
clrcult l. d.t rab.d by thc emplltudc ol tb rourc€ of
bta¡{aE¡ca ¡¡d tba r¡tlo ol lot¡ rlc rocc dtvt¡tm b.tro.!
tbo tt¡¡¡al¡¡lon prth od tb rucrptlblc clrcult t rtlta¡tlnt
t lEp.dtcct.
¡

2-2-6
tt
 Faul rcd Dcco¡ollu¡ R¿tlo Bct¡,ca bt¡rfcrcncc oou¡c¿
ed 8u.c.ptfbl,r Clrcult
Tto ¡.mgu¡¡dc of t¡. llt rLrbg ¡leD¡¡¡ b6lDg trü.Eltt d
by dJrccat c@óatorr t! r fi¡cllú of tb. t rElastt8S b¡rd-
wrro dcllgn. snd Ery vrry batscca tb extttEa lt!'''lt! of t
ferl rotlüampra¡ or rolllfvolt¡ lDd r frw ¡.Ep.re3 or
hudrcd¡ of volt¡, brt wlll geucrrlly bo Étw.ca a fcw hr¡¡dr€ds
of Eutl.'ñFnlr or Etlllvolt r¡d ¡ fa r¡EFr!. or volt .
Htgbar 8.Eplttt¡la oftaa rcqulrc rpec lal hrt!és! a¡¡e¡rbllec
tiat ¡rould ooranlly be routed roparrt€Iy, wbll,e lorvc r
amplltuder wor¡ld Dot repr€36t r rtgDfflceDt b¡z¡¡d to oth¿ r
ctrcult! r¡d wou¡d oftao bé clr¡¡lfled ea rueccpdble ctrcult8.
Tbé e.Epltn¡de od redtstod lDt6 rfa reac€ is a fl¡¡¡ctlo¡ of th€
cpeclflc rylt¿n¡ snvlr(aaaat, but geucrally hes aa qulvalent
ccaü¡ct¿d lot8r{oraoco 8¡Epuñ¡dc lowGr rhen t!! otb6r
codt¡ct¡d lat¿rfcr€lcG rmplltndc for¡d l¡ tle ¡eme ryrt¿rE,
exc€pt wbGra blgh-pwer trElBlttrrr ere bvolved. Tbc
8Epltfi¡d€ whl,ch aay rppoar re Dotro h tbe eurccptlbie
clrcult yrlt¡out r§ltf baatty ¡rfGcth8 lyrtaE F rfo mqr¡rce
d€t€rEl¡€! tbe r¡qufr¡d decanpllag rltto b.twa€D t¡6
htcrf6r€ncc ¡ourcc ¡¡d tbr rueccptlble clrcult.

For dct¡lled theory of E lcctrtc ¡¡d Ma^gDcdc fl,eld coupllng

refcreoce¡ ({0) , (41) ¡¡d ({2) ¿ro r€colo.BGad.d.

( 2-2-9
 2,2,3 H¡rnc¡¡l¡g for EMC
Ib. p!éGdf¡g r@ttJoa c.t¡blt.hGd" r Dr¡¡r. r¡d ctu¡c¡ of elrtro-
Ea¡D.ttc tatelor¡rcc (EMI) rld d!¡ou¡¡cd th¡ mca¡¡ by rhfoh EMI
c¡¡ ba rcá¡c cd to r! úcrpt¡blc l¡vcl. Tblr ¡ocfoa dc.h wtth üc
actbodr uacd, l¡ thc dcrlp of ¡ orblc b¡n¡c¡r, b acbtevc Ell clcr¡ll-
Daaa.
':9,
St¡a¡l Cl¡¡¡liicetlo Frs. 2. 2. 5. 1
Stg¡r¡ Grouplr¡g r.t2,2.2.6.2
§hlcld M¡tartrh/Groundlag - p.r.. 2.2.5.3
Ctrcrlt Groudtng p.re. 2.2.5. {
HalDca! Rouüag p¿lr. 2.2.5.5
Ftlt rf¡g p{!.. 2.2.1.6

Tt. toltlsl bane¡¡ dcrlg! tr p€rlora€d t¡ coDJu¡ctloo sfti tb. EMC

teem u',.sg th. de.rP guldell¡e glv€D lE FEte.. 2.2.5.2 to 2.2.5.5.
Adoptlo! of theee gufdolr¡eú ln th€ l¡lttrl !¡¡tgn wlll colurt ElntrDu.tü
modlflcattoaa rcrult ¡g from detaücd EMC elalyttr.

2.2.5, I Stroel Cla!.1ftcst16

MIL-W-5088E, I!ÍIL-STD-46I4(Nottce 4), TOR-1001(23ü7F4 Ecf . 50)

a¡d Rcfereacc 2 beve dtffertng crltérle aud E€tüod! of r§ul cl¡¡¡tfl-
catfoD, th6re bctuE Eo lEtv€r.ally ecccptod cb.rlflc8tl@.
l
Thc rtg¡rl cl..!ütc¡tl6! glva lD Tsbl€ 2.2.1 t¡ offcrcd s. ¡ bstlr
J
¡. for rlgnel clar.Ulcatfoa, bavtug becn occclrfully ulcd on th! EgRo tr.
'r:"- ESO W, UK-X{ ap.cGc¡sft a¡d l. eurrt!¡tly 1! u¡. of tha OTS tPac.-
crrft.

t
d

+.
I
ü 2-2-tO
!
ll
ft
 ?.j Trblc 2.2. 1 8§uI Chrrlf,cetlo
R tlc Ed,/ Wtrc Fñ t cld
Ch¡ ¡ 8tr.l T)pc Vott F r6qulrúl or F¡ll [mc
T:rp.. Grq¡üdEB

Powar
I D.C PrtEary ALL 0 Ttv
Da SLcGdsry ALL 0 TW
Pow¡r 8)ochroat¡atto¡ ALL < L[lH¿ TW
!
I
i Po*g.r
¡
If AC ?rlj¡ery ALL < 1¡lfl¿ TWB SPG
t AC Sccoa&ry ALL < n[H, TW§ SPG

I2 P./rotachplc a
I ALL ALL TWB MPG
3 Co¡trcl Sl¡aalt
Flrbg LtDc. ALL ALL TWE MPG

i 4 Dlslt8l strD¡f¡ 5-25 < lMllz TCI

s-2s > l/¡ré TlV
1-5 > ll¡ rGc TW
>25 < L!V[]lz TW
>25 >1¡sac TW

5 DlEtt¿l SlFsl! <t < llwHz TWS SPG

S¿rl¡l <5 < lgsec TItrS SPG
Parallcl
Clock
Spcbro

6 Dl8lt¡l stgD¡1. <5 >J l{Hz Cotu(t8l MPG

Anrloguc CoDd ttloDcd ALL ALL TWS MPC

8 Aaalo¡uc UicoDdttfoGd ALL ALL TW

ALL TWS SPG

9 Irw Lavc¡ Comme¡d ALL

ALL ALL TW8 ¡aP€i

10 tttgh l.ovcl Coomod

Thrr¡atar Acü¡¡tl@ AL! ALL TWs MPG

l1

TW Twtrtrd wlrcz r¡¡¡hlcldcd

TWs = I\xt.tGd rlrc¡ ¡hlcldcd
SPG = &lald ¡tq¡Ddd ¡t ¡iÉ¡l rtrrrc¡ colY
MPO = fhlcld 3rouadrd tt both Gd.
2-2-l r
 2.r.6 ,2 8t@d Gror¡rJlps

O¡ouptD3 pl¡y¡ ¡¡r hport üt psEt b aürhlll .8 EU cot¡rp.tlblo ryÉeo.

'Il¡rc r.rc 1 ¡".xb¡r o( C ¿r¡tt¡ n¡La rtróh rra to b. apllod !o ¡ror¡p'lD8
ol ¡l¡¡¡l¡ .
Rüla'l. 9¡¡6 ¡tgndr ty?.. Bu.t Et b. ¡i¡or¡púd tofcthlr l¡ t¡. ss¡uc
Eulticora orblc (tor etg¡¡l claretllc¡ttoo aDd tlD., .G. Table
2'2'll'
Rulc 2. Por.ar, algD¡l r¡¡d pyrot&hlc clrcr¡lt Eu¡¡t Dot bc ¡r,oupcd
tog.tbar to co-'r'.oo looa. ltc rprcerelt oeb¡¡lcal co-
ftturrtfm c¡! b. tr¡cb tb¡t tbt. fdcal c¡¡rct bc ¡cblcvcd.
I¡ tir¡e clturD.tüc.a tbc kn¡lb of cor¡:¡o lootng rbuld
b. k pt to ¡ EEIEuE.
Bul. 3. tñh.!6tly rt¡y ¡ll¡¡l¡ .h¡ld Dot b. g-oaDd r¡d,/or looocd
t wtth qut.t rlgulr.
Ru¡r ,t. StÍDrl t.Ed .18!¡l!ri¡l|!. .üor¡ld b. tlor¡p.d togrtb.! r¡d n¡¡
I: a. t?ltt d p.l!a, ñ¡d. or qu¡dr, twf¡rúht to b. cooirollGd.
, Tb¡ u¡mbcr ol t?t.t ¡br¡ld bc .. .bo*! lD Tabb 2. S . 2.
f
¡
Tabl6 2.2.2 Nur¡rbGr of TwtltrlMetrc (RavcbcB Lad.)
I
AWG N,r'nb€r of Wlr6r
1 1
2 3
?

20 30 (2§) 28 2{ (20}
t 36 (30) 2a erl
t 22 33
21 {2 (36) 30 33 (25)
1
2e 50 t3 {0
2E 5E 62 {5
30 83 5t t0

fbc lt8uro flv@ tD p.r@t¡cal. la tho Duub.r ol Mrtt p.r 30cE

Ecl. §1).

1t Ea.. nvto¡ rtlch c¡¡ bc rtelt¡¡d by tbG 3tor¡Pbt of .l¡D¡Ia bto

multlcorG crblc lr rhor¡ l¡ TrbI. 2. 2. 3 '
 ltbl¡ 2.t.!
NuDb.r ol Melr urta3 rb¡lr rl¡r¡ u¡1¡f róulücorc
I AWG 8l ¡ñr l. oor¡ rhr¡ld¡d o¡b1¡ ¡\r¡ldd o¡bb
:
I 2 c,26 6. CC
30 I 9.90 7.O
t
a 12.62 8.{9
I
¡
t.0a t. t2
I
2C S ut.{t 10.7
a 17. t6 18. {
2 11. r 11.0
?A 3 L7,1 ra. a
I t 23,2 rt. {6

2 ú.6 r{. t
u I 23.28 r0.0
{ t 1.00 25.6
ti
I
t
I Mr¡¡c¡ .rG fsr Rry§blE rlrt to !,CL-W-8 r0+{ - fh! bntd rhl.ld -
6@V.
:
¡ Xer. l¡ tr¡DrDra/EGt¡..
i
I
l
!
2.?,J.3 St.ld M¡tlrt8l/Groundlns
l Tb. oholcG ol ¡htcld mrlcrl¡l rDd lllttb phyr ea l¡oport¡.Et pa rt to
provtdtlt cffcctlvG E/H llclA dcoorpllry. Sblcldlag Ecthod¡ rDd
tb.tr chanct sl.tto. sr. 31v6 t¡ T¡bl. 2.2.{.
I
ft¡ orlt¡rt ,or th. r.¡.ctl@ ol ¡hldd torrn rrcr
l. -&l.ldb¡ .[ctlv.¡... ¡l EF rtd t¡'.
l

| 2. thl¡ld o¡t rtrl lrot.b - rur.r pl¡t.d ospp.r t¡ yrcl¡rr¡d,

ht r É¡d.rrbtuty.
!. ll¡¡¡.
.r .. For ¡a.rrl rprcoorrlt ri!¡rf oablb¡ aUr.r pl¡t d cof,D.r Ort r{ra
. brrld l. rrcEto-d.d. úuelsl¡¡d rbl¡ld tr only rrrtlrblc ca crbh
o(Drtn¡ot d rtL r Xyhr .r¡tar tor¡¡rtl6.

ltlrld ¡xr¡dto¡ r.S¡lrc-t ¡r. llyG h T¡bl. i.t. f.

Il-
2-t'l t
c .:
 -
(
'i '!11

Table 2. 2. ,l S¡leldhr Method8

,i
TyP¿ % Coveragu Ploxtblllty thleldlng E[fectlvoess Srleld RclaúI vc
I
f,laterlal w6ldrt
Hl& Freq Low Freq

RaEd bnld 86-9? Good Good o¡od Sllver-pl¡ted Hrvlo¡t I

Coppor
Tlmd Cqpor 2129/a
Scrved rlro 99 hcolleot P@r Good 8üver-platai Harry I
Coppor
Tlnned Coper .17.cij1la
a9
I flarvr fl¡t rlre 95 100 Pmr Excollert Excells¡t §lver -platod uÉr r
¡
Ooppor
Tlnned Copor ll.29/m
2
Fl¡t vlra l¡rB 95-98 Good cood eod Sllver -platod ught
Coppor
Tln¡od Coppo¡

Dtcellot -lght rt
I
Alumf¡f¡d 95 - 100 Cood Excoll€nt Alumhlzed ¡
¡hlald 95 - IOO Mylar r0. fu/m

t. Gore rt¡e - 6oOV - 2{ AWG

Tollon ltr8ul¡tld¡
2. f,rychom wlro - 8mV XIL-W-8104{ - 2'l AWG
--.F-4-

thl,oidl¡r Effectlv€o.lr

Provldlag lho !06¡auros of rlgDel grargtng, b¡r¡c¡¡ Douibg ¡sd

rhteldt¡g (SéctfDD 2,2.6.L,2,2,5.5 sad Trblo Z. 2. l) ¡re bcor?orat¿d
lnto the bar¡e¡¡ deslgr , ¡¡¡1g9oa¡ preosul!@! for EMI coElrol .hould
not b€ grBorally rsqul¡ed. If , ho*cvcr, duo to üe ccDrEsht! of ü€
, tpacecraft mecha¡Ic¡l ooflg!¡stlot¡, dl otrcult¡ E¡at ¡h¡re a coaoon loom
' addltlc¡¡al prec¡utloD for E !ÁI cmtrol r6¡y be requlred.
The ha¡¡eea l,r aubJeetad to I det¿U€d EMC aaasaLa l¡ ordGr to
eat¿bll¡h:-

(Á) Deed for eddttloDsl EMI co¡tol

\-i (b) source,/aourcee of EMI

(c) nutrbe! of susceptlble clrcults 8flsat€d.

The¡e are two r¡ta¡dard roothod8 of ,aEoductag addltloal Elfl coDtrol.

1) use of dq¡ble ehlelded wtre

2\ §rappt¡r g the offeDdlDg/ offeudod elgnal/etglala wlth a EMI

dhleld (S€ctloü 2.2 Tabie 1).

The Eolutlon Bdopted must provlde for EarllouE ehleldhg effoctlveDess

wlthh the llrnlts¿lons of
mase , mech¿¡lcal flexlblllty aDd cost.

where the numbe r of oüendlng/offended signala t¡ the loou l! Em¡lI

l¡¡ relation to the totd number of aignels b th€ loom the ure of dc¡ble
shlelded cable may prove adequate. A€BID a delálled EMC eDAlysl,s ts
porformed to eltrblbh EM compsllbtllty.

Who¡e thé oumber of oüended,/ofle¡dlng ttgneb tr largs tho u¡e of aa

EMI ¡hleld may prove ad€quate. A mlllrnum ahleld effectlveoes¡
(¡lt€nuatlon) of 50dB wlll l¡ moet sppllcstlo!8 provo 8d€gust€.
A d€tslled EMC snc¡y6l,a ruurt b€ msde to v6rlry tbat tho lÁ€e8ures
tskEl glve EM coflpaltblltty. The rhteldbg odacttv€Bcú. (sttsot¡sttcn)
of ¡¡ EMI shleld L c¡lculEtod a¡ follor¡r-

Sttcldlng eflectlvqrea¡ I = R+ A+ B
*here R = Roflectlon lorr I¡ dB (sloctrtc, rnsgrottc aDd plauo)
A = Ablorptlon lo¡¡ l¡r dB. Il the abaorptlon loga lr <15d8
th6 'ñ.tertcl la urltkely to glv€ ad€qu¡te EMI control.
If >15d8 the lorm B c¡o be ueglectod.
lb = Corrcctlon i¡ctor ln dB - for gtncml h¡t!e.! tork tht¡
tGrm l¡ ueuelly rmell ¡¡d cr¡ be neglectcd. For
crlcuhtlca rcG R6l6r(nc€ p. 118.

2-2-r6
 ?
Pl¡ñc Wav€ Reflectloa Lo¡ae¡. Pla¡e i¿yc ! cflsct l,co loseec ere §
depandeat oEly on the typc of rhtGld ms¡erla¡ !el6ct6d, a¡d on frequeocy.
A ltlal,ght odge, conD6ctlD g a poht oa tbe G/u (rD&crlsl) acole to 8
polai oD the hequ€acy .c¿l€, wlll elso t¡terr€ct tbe dB (att€a u¿t toD )
scaló to prodde the plaao rew reflectloo lo.s (!tg. 2,2. 1),

Electric Fleld Refloctlon l¡cge¡. Electrlc fleld reflectton losses are

dependeut only on üe BFchg becweeo the sot¡rce of l¡terfermce and
the thield, the rype of shtold materlal, and frequancy. A stralght
edgB, connectlnE a polDt on the LDches (separatlon dtsta¡ce) scale to a
potnt on the G,/u (materi8l) Ecale, wUl also !¡t€r8ect a potl]t on rhe
i rocallbrated vertlcal Ecele (¡tg. 2. 2.2). A Btraight edge, cooDecthg
! thls pol¡t on the uncallbrat€d vertlcal Bcale to a pol¡t oD üe frequarcy
scale, wlll al8o l¡tcrlect the dB (artsluatlon) acale to provlde the
I electrlc lleld reflecttoD loss.
1

,I
Magnetlc Field Refectlon Logses. MagDctlc Oeld reflectio¡ loeses
are dependent only on the spscl¡¡g between lhe ecr¡rce of t¡terfere¡ce
a sad the ehleld, the tyi'e of ahleld materlal, ard f¡equacy. Srteld
thtcloesr [s not crttical, but e low reluct ¡ce clrcumfere,Dttal path
through the shleld l¡ requtred. A stralght €dge, connec¿l¡g I polnt on
lhe lncheB (separatioD dlstance) scale to a pofDt on the G/u (matertal)
i scale (Ftg. 2.2. 3), wlU alBo lnter8ect a poht on the tJ¡rcaltbrated
vertical sc¿le. A stralShl edge, connectlag thts polnt on the uncallbrated
a
.,
vertical scale to a polnt on the foequency scale, wlll also totersec¿ the
dB (sttenuattcrn), p rol'ldlag üe magDetlc fleld reflectlco loEses.
..
Ab8orptton l¡gsee. Absorptlon losaes are dep€ndeDt oDly on the type
of ehield m3tertal, frequency, sDd ghteld thlcloese. A str¿tght edgE'
con¡ectlng a polDt oD the G/u (matertal) scale to a polnt on the thick¡ess
8csle, wlll elso l¡ter8ect a poln! on the u¡cÁIlbreted vertlcal scale
(Ftg. 2.2.,1). A Etralght edgB, conDectlng thts pol¡t on the uncaltbrated
I
T
veftlcal scale to a polnt on the frequency scele, wtll also bltersect lhe
I dB (stt6uatlon) scale, provldl¡g the ebáorptlon loee th ralgh the thleld
i msrerlal.

!) Ntuarlly, sbsorptlcr¡ loaeee need to be consldered only where

mÁgnettc flold att€lDuetlon ts requk€d. Electric field and plane wave
¡eflcctlon lo¡aes are usu¿lly adequate, eve¡ when absorPtlcn 1o8se8 are
ne gllglble.

I
2-2-18
 TILY¡I
t. cor¡r
(sFf)
a¡uxtxr¡a H to( )

l' -flx
-t ! o-t
f
I IE O
U
F
I l.OflE L

o
-t
i to-2.

a ¿
=
¡ a a
¡t to-!-
o ¡a colo ro[EO SfEEt
ao coa{tEicraL tRoH
a r¡
z z I
70
e
o (J
o
a
lt :
ac I: -
r o-¡
9
,o 6 a.r. tt rto¡
ú
u
ao T llarxL¡3t 3fÍfl
c ro -,
to a
co,l§rc
to
TUr{?AL
E ?fIXALOY a.7l
rd'

P¡IXE WAVE REf LECTDN tOlSEt Frc. 2-r-t

 t0'r

Siv¿r
coppcr
t0 Go ld
AJuminu m
M ogncri u m
Zitrc
lo Bross
Cod mrum
ú Nickc I

Plo tinu m
fr Tin
tt L?od
210 M oncl

ao
t0r

lo¡
o/t+
lor t¡ i. lóri*l
Nichromc
rao r (c¡¡! C ollc d R
Commcrcioi lFon
120
rM
10

t0x
o to: Stoinl€ss Stcd
4'l. Sr Iron
ó 5O Ni-lron
Pu rilicd I ron
¡5 4'l. Si lrm
(goin oñ.nt.d )
tcr 20 45 Pcrmolloy
78 Pc rm olloy
0 Hy pGrnick
to to!
t(H¡l
Mu Mctol
C on.t ¡c
t0c

t0'
E l¡crric F ic{d H¡llrtion Lo-r R.
_ ' ttc. z-z-z
 ttE

100

F
t, Silvcr
Coppcr
ro ¡ 6old
Aluminum
t¡ Mogn.s¡um
Zinc
Bros3
¿¡o §
1G'M tú cod mium
D to'l N ic kcl
.\ Plotinu m
{ Tin
ort) Lcod
-t I 10r \ Moñcl
!
:
,
r (c¡n)
:
tI
Nichrom?
r {rrdl Gold Rolle.d stc¿l
1o'l Comm€rciol lron
tsr

to¡ Stoiñl.ss StG.l

1or
4'1. Si I ron
5O Ni-lron
Purif i¿d lron
1X = 4.r. Si lron
(grdin oricntcd )
>\t 4 5 Pcrmolloy
7I Pcrmolloy
\ ryp""nicx
10

10

0.1

FI6. 2-2-3
qeñ.ctlon LG
P,:
 ! rou
I - Sup.rmoltq/
t
I'
rd 78 Farmo¡lcy
10r ,
hJrrrt rad lron
Coirtlc
1-79 Pa?¡nolloy
MJ'Mctol
50 N¡ I ron
IT
t-É - Hyp.rnick

rC 45 Prrmolly

'too x
i
-i o¡ l)
4 ./. Si I l.on
,z riá-niriJtc¿l
\ Flot Roll.d F¿ si
roJ
A {ór.i-
ba.l
i \- Cold Rollcd Ste cl
\
Comnre rciol lron

N ¡ckel
¡ 1 4.1. Si tron

I
j
r0K -l t0
:

; I (lrE) t
-{ r (mrn)
! 1 .- Stoinlcas Stcct
I

!t -l x 'J
1 I 0.1
Silvcr
I Coppcr
a
t .rl Gord
Chnomium
Aluñranu m
7
-ro Mognas ¡ u ñ
Zi
B
^c
rqss
¡ Codmium
A ot iniu m
fin
-10
:
,;. 0¡l
:

Abrorption Los¡r A.
Flc.2-2{
f:

1.
¡-
 EEmplB I

Efdf er8n' ¡ - 100 kIIz.

EMI Slold E¡t€rlrl - 4 rall Co{ctlc
Dlrt¡¡co b€troao EMI atorl rDd .urcoptlblo a§ntl - L2.7 útn

PLr¡e g/¡ve - 65 dB. (llg,, 2.2.ll,

Elecrrtc leld - 157d8. (F18. 2.2.2).
Magnotlc AeU - 5dB. (Ftg. 2.2.3).
)
Ab6orpttcn - 200d8. (lrt. 2.2.{).
Tbe plaae Eav€ aDd clectrlc ftéld sttcrut¡¡tloB t¡ accept¡blc, >6OdB.
Tb€ E¡gDetic f,eld 8üeDu¡tt6 t lc,r, but wha ccaaldered wlth tbe
I Ebaorpttco loca 1r ecceptablc.

2.2. 5. 4 Cl¡qutt Gro¡¡dhg

TttE ts aaothor ssp€ct of EMC wblch requtre! Doettculou! cere, 8¡d

le¡ds 6 to the gEoerel tlestEent of Deür¡¡ Il¡6, the r€qul¡68€ot8 of
wbich ere s8 folloer:-

1. To preserve seParailou of tbe elgnal ctrcults tro6 the pc,s,er

arpllee 8o thst the conelderable 1o1! drop s¡hlch ts poeslble tn
powEr clrcu.tt ts not sdded to the atpal a8 aa €rror. Fallu¡e to
acbleve thts obrecttve caa addltlcaally s€sult l! l¡rtsbtltty
occurrt¡g LD blSh g8l¡ 818D81 cl¡cutt¡.
, to us€ hdlvldual OV retum ll¡ec to tho poser source to paevsrt
co lIrEloD tlEp€ds¡rce coupll¡8 produchg l¡lerf6reDce.

4
To ¡r¡old tbe tormsttoD of coDlüuous loops 61th€r h ths r.trhg or
s co!Ábl,DstloD of vlrtag Bnd structu¡e wh,,ch ca! 81t/€ llBe to
clcct¡oE¡pcttcelly bduced nol.e h üc aignal ll¡ea a¡d cqrtrlbuts
to th€ reltdu¡l tD88D€!tc IñoEcDt of lbe rpacocr¿tt.

ODdoat

l. lieelly rü spac€crstt \¡olt¡gp! *q¡ld bc rcferrcd to r g¡or¡ld

pl rao of rrtlorm pot€ott¡i hevlag zcro lmpcdr¡cc tom ray oae
porDt lo ray othcr pobt. All ¡6¡trrl clreult coo¡octlaa ory
tba be m¡de dt¡Gcuy to tht! pl¡Do by thc rhortclt poralblc roüc'
Clrrly the c¡t¡bll¡hmot of r plene r tth zero lrop€d¡¡c' betrca
¡uy tfo potitr t! lot rtt t¡8blo tut p cttcrl rPProd¡nrttd! io
thL lo tbod e¡c reforrcd to ¡t Bultl?obt c¡rthb8.!y.t!t"'
i

(
2-2-t7
t:
 t
{
2. A.d rltom¿tlt/€ lrr the elaglc Dobt o¡rthbg eyttca rüorc the
Dcutrrb 8!6 t¡tlrcoE¡soted by e ooropl,ar ol rl¡bg yhl^b l! llrd
t! lo th6 rt!'r¡c§¡!o s! oae polDt @ly. b thb ryrlcm, rElé.r lrol-
I rtt6 of .lgñrl DGr¡llrllr of l¡ry r¡bay¡taE toE.lED¡l Da¡trrb of
I luy otber ay.toE ¡¡¡d p(f¡rGr zrro roltr tr potrfblc, e¡¡th lop¡
¡Dd comñoD tmp.dricé! arc brmcd. It tr l¡hGrotly út
precttcsl sltü RF ry.toE! rhtch cuploy co{d¡l lba, ¡l¡o
cor¡pUcatl6! arG latroducd vhore al¡nalr 116 rel€rEc€d to th.
zero ¡/oltr sÉe ol üo power augply.

Neulral Svstem

A¡ neüher arraDgemeü¿ caa be re¿ll,¡ed compld¿iy b pr¡cttcg, ths

ususl syEtem l,s s comproElse b€txre€o the prevlous tvo 8y8teE!
e:cept th6 RF ryrtoE¡, whlch are of ueerrlly Eu¡tlpht co@oct€d.
To lhts €od the followlag provls 16r ¡re u¡¡de: -

1. The reference z€ro voltagp ls thst of the sp8c6cr8t str¡ctr¡¡c,

all compoeat partr of whlch a¡e fully €lactllcaUy boodcd.
, All power D€r¡trsl Ib€s rle Lsolsted hor[ u¡lt c¡.ss.
3. A loople$ zero lolt bu.88 l3 establl,sbd for the p'oper sys¿e¡o
a¡rd üt¡ lE coDect¿d to the rt¡1¡ctt¡re 8t 8 polDt adr8ccat to üe
power aupply rmlt.

4. ful aigal uei¡t¡alr ere anaagod !o avotd the coal¡¡o! ure of

powor zero rcIt ltncr.
to th !e way the csuse of aDy lDt€rfereDce or larteblllty raay b€ eastly
dtagnoaed dur!¡g Etegratlca a¡d tf ¡ec€slsry the Doutre¡r rearaogod
to eltml¡8te the problem.

H8ír elr Ror¡tr¡f

Hame!! ror¡ttng tr ¡.D effsctlve meüod of rcórcbg cro¡¡ ccuPll¡g
whtch roay be cau¡ed by E ¡¡d H ftGldt.

The slgnal groupa formd W r.¡sl¡8 tho ruler gtwn ln S€citcE 2.2. 5.2
can n oi# be fiormed lnto loonu. Tbe comporltlcn of th. larbu¡ l@ rot
ls Cven l¡ Trbl€ 2. 2. {.
i
é

F
E
ll
It
h
F.
t*
2-2-16
E
 Trblc 2. 2. { Coram¡ l¿lca of I¡om¡

Loa T3¡po Sg¡rl Cl¡¡¡

P:rcr L, 2

; Pyrotocblc 3

-1

I
StgDrl {. 5, 8,
7, 8, 9,
t 10

-f L

Thn¡lt€a8 11
E
t
t The looma, wh€n l¡ltsusd l¡ the epscáraft, should b€.p.c.d tb€
5
ñr¡.t rE¡rtr dl¡t¡¡c€ ¡per!, 50mm bGlDt ccolldord tbe abloum.
I
¡ The amorEt of loom aegreEtttcn l,E e f l¡lctlm of th€ Pby.l,c8l
¡
t
::
dlmeEstoB8 urC peckb g d6.tty of the spacecrai. Wh.re , b€cau.6
of the lack of apace or lotDe o¿her pbyslcal coortr8bt, tbe loo¡o¡ ¡re
I ru, to8ether uldtttoaal rhteldbt n:ay bc requlred. EMC r'talysl.
wtli htghught aay probiem ltEnslt, th€ culprlt clrcutt any tbeo bc
*,tred l¡ dor¡blsd rhlelded $l¡e on the l@m Srorpr s! ldEtlll€d tD
Tabl€ 2. 2. { ladfvttually wrapped wlth 8 ¡ou tspé (§}ee 8É,rl,e 2.2. +
T8b¡e 1).

To rtrlD.lmlse radLated EMI eüectá the loomr e bould be nD ¿s clooc to

üa .pacecraft grouod pleae ¡¡ posglble. C8P.ct!¡oc€ couPltEg of tbc
etgn¡i! to tho SrotBd pl¡¡6 r¡rllt b€ "nlñlE¡l provlded tho !l¡1¡c6¡r6 lt
uroporly boodad 30 8! to form a Lolform grotod pleao.

2.2. 5. g Ftlter¡

!
Ftltrr, ar€ u¡€d wh.o: -
i
t (8) üe tcchr¡lqu¡ de¡cribcd l¡ thG prcc€dlDg prr¡ Strpb l¡c
ln.ufllctol to prGvüt EML
(b) rha DoLy rtgnrlr rrc acoerrted rtlhb 6lect¡otc u¡l!¡.
Normrlly ruch .t8Drlr rcr¡ld bo Oltcrcd wllhb thr clctrcotc¡
uDl¡.. ttoE ¡ crbl6 h¡E..rbg vt*pobt ÁltcrbS tlt¡l¡ thc
electr6lct ralt l. prcforrGd to h.¡llb8 Á¡tGrt b thG h¡r'Eér'
A poht to ¡ots l¡ th¡t l! !, oiro ohapcr to brt¡ll tlltGrt h thG
IY
I

h¡¡¡¡a rrlhar th¡a tn th. clrctrob. lElL

¡- 2- 19
 Thc tylr6 rn¿l ü:«$eooy reagoo of [ltora tr glva ta Tablo ?. 2. É.

T¡ble 2.2. 5 Füter Typc /Frau¡ocv R¡¡gB

Typ. Frqueacy

L l50kl{z !o 10o DfIl,

PT lsoklü to 18!lz
Pecd Througb 1MHZ tO l GH.z
Paper él€ctrolyttc DC to 20k¡Iz
Carralc , Elca8l¡a! 20k¡{z lo loMIIz
{.
Actlw : ñz to lLfIIz
Ab.or?ttv6 le¡¡ of kIü to 1oMllz
!:

'1. The re¡der l,¡ dlrgctad !o B¡fereaco¡ 2 a¡d 3 for calculatlG aldc br
fllter E€let!6.
Tbo D€t comúD 6Da ol Elt€rr u!€d tu cabl€ h¡¡leaea ¡¡e:-
(3) Ferrlte boad¡
(b) L
"yp6
(c) Pr Tpe

ferrlto b€¡ds are ñtted ove¡ ú¡e elgnal ll¡e, L a¡d Pi typea belng
fltted fD üe EtE¡al lbe, etther as lDdtvldual f,lters spltced l¡tá the
slgaal ll¡e or boused h f,ltor con¡roctom (8e€ S€ctloa 3.3).

For fllt rbB !o bc corüp¡Gtely €ff6ctlve the follortag tDstÁll8tlcD

prccsutlor Eu¡ t tle trk(¡:
(s) eo.¡¡r6 th¡tj t¡c lltcr c¡¡e t! o¡cctrbslly boadd to thc rP.cecrst
grood plrac

O) GoÍ¡r. tb¡t tbo lltcr lrd! rrG rdcqurt¡ly rhlGld€d ud

elcctrlutly bedad to thG .p.cccasfl SrorDd PI ¡D.

(c) t¡rtttll the ÁltGrr r¡ cloe¡ l¡ P.!tbl6 to üG .cr¡tcG of EMI''rhco

thG E!fi ts ceó¡ctcd to thc r6oGlrrl¡8 clrGrl¡ vtr thc tl¡¡¡l
wtra

(d) f¡.E¡l th6 ALcr, ¡¡ olo.a to ü6 Í¡.o.Ptlblc ctrcult rrüan tlc

EMI !¡ eu¡d by ndhtlo or EAI ftcld cot¡¡thf.

Rclcrcnc¡ 2 ¡Dd 61 ¡rc rcooEroádcd ior e fu¡l.r tr¡tLc G t¡a

thorT rod rpüortlo of trlt.rú.

2-2-20
:
t'
I 2.2, I EMC A¡a¡wl¡
Uott Error !6roap3cÉ coropa¡toa h¿ve EMC earlyrLe progr.mmes ol
r- tL¡yhg coEplsrlly rvülrblc. Aa cxlnple ol r provea comprehe¡8lve
l prog?allEs tl! SEMCAP whlch we¡ dcvotopad l¡ ü6 USA by TRW Sylternr
É
t, ¡¡d t¡ u¡ed by üe MEII{ coa¡ortlr¡m"
¡
fr EMC aDd hara€cs do! 18¡ l. ¡a lD!6r{ctlv8 ¡ctlvlty. Ttc EMC end
[, ba¡¡eag dealglere egr6€ oo a commoa phlloaophy lor e tgnal g:rouPtag
E (S€ctloD 2.2.5.21, abteldbg (Escttou 2,2.131, groudbrg (Séctlon
E 2-2. 3,4t "pd routtrg (Scttñ 2. 2. 5, 5. ). fte b¡¡¡eae declgner ta
t.
Dos lD a fro6Utco !o l¡tcr?ret üe electrl€8I tot€rfaces (Scctlm I.3)
l¡to e hal¡ora d€ltgn.
E
C lrcul! dlagra rus ald mechsalcal layout are produced, detalllag wtre
E typ€6 , shl€l.llng sad grcr¡DdtDg codlguretta aBd routbS. TbtE dstá
l,e peaaec to the EMC €¡glDoer for det¿lled EMC aaalysls ior c§nflrm-
E
stloa th.t the dcrtgD lr clectrooagnc[caliy co mpstlble o: tdeuttficatlon
É
E of aly aress ol EM l¡coEpatlblUty.
§
h. Correctlve actloD, xhañ D€cearas¡, [E tskea by tbe harneal deaigner
á¡d the procear repoared uÉO EM coropstlbtUty ts 8r8l¡€d.

2.2.7 Boodtnr

BoDdl¡rg tr e¡ htegral part of cable hal¡eaa deól8D iDsomuch t'Ml

efflclslt boDdlag of ape.cecrat atn¡cture sDd uDl¡¡ to stntch¡re ¡s the
bs6t úor electlve EMI cootrol.
Eff^ctlve boodfDg lr also lmportsDt LD ltgüblDg protectloo, protectton
oI peraonnel from ehock hezard¡ end eploalma resultl¡8 from lgnttion
of eDloElvc nf xtule by ap.rk dbchsrSB.

|: Tt¡G \.rlc , rcqulrGmcat! , prrcttc€r ¡Dd tortlng are dl¡o¡e¡ed l¡

theory
li tb6 lolloyhg roctloor, wtth empb¡¡t¡ cn thc Pr.ctlce¡ u¡ed, ficr
dGt¡l¡cd th@rdlcsl sFro¡ch. Referace¡ 2 a.¡¡d 3 s.¡rd the
J:

Btbüo¡¡sPblca lcfcroc. thereh ¡lrcr¡ ld be u¡ed.

f. Bmdl¡s for EMC
I
IF A¡y tro pobt¡ cn r mct¡tl b .tn¡cturc, wb€thGr Glatrlcrlly
?,
c6.DetGd or ¡ot. ti¡y dcvclop r potatl¡l dlfcrcace At torI¡€
{. k.quccy, d.nn by
t
V = ASD 12 tt t/\l

t.
i
l,
+
2-2-2r
,.

b
hi
b'
É
,'

!
Í
;
r
n! xh.!c V = pot@u^i rllücrcooc
A¿ rraputldG of bduo¡d to¡t¡F E tic ¡rq!d ph¡¡
tÉ rnlcr..¡th ooÉap(odb3 to ÉquaoY
tI dt.lr8oa bctrraGo thG txú gobrr
I or
x
: z. Rarqr* [trazn ttx)l
rharc z . lnpd¡acc b¡tscco tTo Pobtr to I ¡roud pblo
I
Rf = O. 2e x LO-N/ uf / o ohn¡ /¡qur¡c

where p = peoorbtllly of m8t€r¡l rclrrtlvt to cot'r

q = coDdt¡ctlvlty of ro¡t.rl¡¡ rcl¡tltt to o-D.r
A grotBd pbae olcrr tlttlG equtpottatt¡l SrdDdlDB vrb', to Gqulp6'l¡!
tt¡it L grotndd, ¡t fr.quoa!¡ ¡rcta rh'ñ tbtt corrarpcadbg
mr¡¡t
to I/8¡ ¡t lower frcqucocte! the tEPdr¡ca bc oa tro Pobtr l!
propoltlE¡l to lba RF trapedance ba§rr6 ü¡c ¡rmo tro potEt!'
The RF trap.d¡¡c. oly brs atptf,cacc t ¡ potcotl¡l dt&rúc€ rf¡t!
b€twea¡ tl¡e t?o potntr ¡¡d a com¡¡o cl¡q¡l'rttDg cr¡lnEt c¡¡ Oc
b€t?6ca thcn. Ralccsca 2.

Bondlng c¡¡ bc echlevtd ellber by I Eotrl{o-mctrl ,ols! (Dl¡ét B"d)

or byrñ.'"r of a boadtog le¡d (bd l¡.c! Bood)' Bad boodt¡¡g bctsc€!
equtpmcot rud grcrrad rcfcrence pluc wlll bG ¡ cs¡¡! 6 of ElfI ¡'t
tt
furrat na¡o¿¡ ol rupro.r16 (trltcr¡, crblc ¡bl'¡ld r¡d EltI ahtold)
frorn bGbS mrrPlctclY .ü6ctlv€.

Thc lllGr!ütlt curratr shlch norm¡¡ly Oo* ho¡o ¡ lEtt to Srood

e
plrac rro tho¡i rblch retult trom dccq¡plbg udcrtrd rglkor '
ir¡p¡., ctc. bo¡a tb. btlnrl llD.r. Rclcmtng to tbo o¡urc below'
FIL IER

Zo'

2-r-22
 rl[rc RL = ¡od lEgdr¡ro.
ti = tDtartarúoG cr¡rrat
zo = B([d lEpd¡,Ec.
R = dc r¡l¡t¡¡cc b.odb3 .tsr9
L = bdr¡eo. of d!¡3 .trrp
ct = Pr.r¡¡lUc cap.cll¡¡oa
Thc btGnttoa E io pr€lrtat üe LDtarrcr(aof er¡rr€trt, \. hor:r Ootlng
ln the lo¡d, R¡ by provldlaB a lo? Uapcd¡DcG p¡th to !b. grq¡Dd pLese.
At lor frequeacle! abova lhe paar b¡¡d thc l¡lcrÍ.r€ac€ 6¡r¡Got, t{,
rtll no? tbmr¡gi Cl .!d Zo to gror¡ld.
U üe bond trapcds¡¡c.. 26, becomee lrgcr then !b. tGrct¡¡¡cG of tb€
cep.cltor tzc = L /twcl b ..rle! rlh thc load topedrocc (RD, th6
lnterfcr'.ace cl¡¡rcnt, \, wul flow thrq¡É¡ thG clFcttor rsd l¡rlo üe
lord tmp€dt¡cc. Stmll,rrly, tf thc boDd tnDdrace bccoao¡ comp.r-
.ble to thc lad tmp€d¡nco, lh6n k rtll b€coEr.tg¡ttrc8¡t.

Thc comblrlrd tmpdEc. of lhe lullt bodl¡g (6lrbcr by dlrcct or

lndlrect m€'ñ.) e¡d thc ¡t¡¡crur¡l ttDpadrDce b€t?G€u the ullt boDd e8d
co mfr¡on grosrd lelG"r¡cc polnt of ¡ .urc€ptlvc uDl! tr'crlttc¡l s8 a¡y
t pot.otl¡l dlñcrcoce bct¡ccn the uDlt rld thc coEllo grornd refercace
?tl¡ b. cd¡p¡.d t¡ tie u¡tt.
l.
:, The efiect of the c.ombt¡ed tmp€de¡ce o sD eEltttng tDlt l! Dot !o
crltlcrl. Th. cl¡cr¡lt Srornd tmpedeacc t6 r¡tu¡¡ly mr.rch Sreeter üea
the combl¡ld bnd ¡¡td ttnlcn¡ral lmpds¡cc, rÉ.ultlng l¡ the ua lt b'iag
I at the same pot€r¡¡l¡I a! tho coñmqr gtor¡ad rclcrence. Thf¡ stll
f: ¡Jrflu€ocG thc rcfert¡c. Potcatl¡l of th. e¡nltlbg u¡lt 8¡d ao mey change
-- r(
E E¡¡ogue rDd dEl¡¡¡ ttprL lcvcl rcferrd lo tülr potcntl¡1.
t
Clc.rty thc bqrd tmPd¡ncc .¡d thc atrucü¡rrl lmPed¡¡rcc h¡vo a
rl¡nlflcrnt rote l.u thc crGrt!6 of ¡ clcctromr9cttcslly competlble
F
elcctr¡csl ccrrfl¡Ir¡¡tbo. ! I¡ therclorc Graa¡tl.l that clo!' ¡tteotlon
E
b fB fn ltmltl¡rg both lmP¿d¡¡rccl w lhl¡ rccGPa¡blc llmit!.
E,idln r ln. l,¡EhlDllE Protccr!6

IJSitnlD I curr.at¡ llclng througtr the r¿sL.t¡lce p.th bct?rGo the

rtroko t.rmlD¡t¡qr pol¡¡t sr¡d thc a¡rth rclctrncc Po!ót ?lll produc6
votl¡¡! droF ih¡r mry bo dro¡eroru to pcrroncl ¡ad Gqulpñcnl'
slDc. lhc cutr.n!. cr¡ b qul¡. l¡ra! ({0'OOOA b .a ¡v.r'3e vrlue) the
rc.bt¡ac. ofth. dtacharat p¡tb rBu.t bc ¡¡ ¡m¡¡l u Po¡¡ ll¡lc'
(RcfcrGncc { ¡¡ld 3).

2-2-B
 .)

, Dcfl¡ttlcn
t ,/trboDd lr a cotocotloa th¡t L cü€ctlvr l¡
(¡) rcduolag DC potcott¡l bcrwo€a tbo bodcd pa¡t! !o s ¡ogltglblo
levcl uñca 0rll dectgl curr€ot¿ are flcbg,

o) rcducbg tbe lmpde¡co 8t BF !o E ltmlt con&¡clv€ to EMC.

Dl¡rot Bood!
Dlrcct boDds are echlcvrd by:-

1. Botth. )
2, nrwa[g lr'E¡'oero¡Dcot
3. Weldlag
{. BrrzlDg
5. §woatbE
8. Svrglag

Mctbod¡ 3 ¿o 6 toclurtvG ptlduce good boadr. Seml-permaaeot ,otDts ,

mrthods I a¡d 2, caE provlde elfectlv€ bondlag. Howover. relatlve
motl€n of the Jolaed me'rrb€r8 caa redtrce tbe bondtag eüecttveness b!¡
l¡rttoduclD g I varylEg lnpedance.

Tbc QA ¡u¡vclllr¡ce bvoksd oo lpacocrsft eDsu¡o th¡r bolts eDd rtv€tr

arG corroctly ¡¡¡cmbled.

l¡¡crt¡ ooulded lato hocycomb floors ca¡ b€ . pololt¡,al heza¡d lf not

¡¡¡cmbled colrrctly. ThG lD.crt! them¡clga¡ rre eecued by
rdhcalvc. vhlcb erc i(ccttve l¡rulatorr. Th€ ll8ure¡ bclo¡¿ ¡how thc
oorrcct r.Dd l¡@r¡Got ñcthod ol blcltbg l¡.6rtr.
lDaart Tht. l¡cc Eult b. b.l lD8 e r. troü¡dGE
facc abo¿ e ¿co of floor
ni"! !^*ntrns
--r

CORRECT INCOARECT

:8elf tegpn g ¡crsr., ¡t¡¡ s¡d aprtDt rrúhrrr, zlDc pl.tGd or ¡¡odl¡cd
ñut rDd bolt rfc not 3ü.rrlly rcccÉrd ra rDG.nr of provldlng dl¡6ct
bod¡.

2-2-2t
 F
I
¿
IEF
§ I¡dt¡ect Bood¡
i-,

r§ Provtilo of a low-tropdr¡¡oc p¡t¡ ¡t BF t ¡cblavcd by ml¡¡lEfr b8

t both thc ¡elf-l¡duot¡acc ¡ad r€! ldual oapa. ttraco of r bad, tbu.
rD¡rlEl.lag the pE¡erttlo rcrcD¡¡tt hGqualcy (Refcreace 2) (aae Flgures
¿
t
b.lc'*). Thc rclttgr hrtld up st re.oo¡acG could rs¡ult l¡ arc dl¡-
r char3or s¡d ltroqg clcctrl,o fl.ld l¡torfslac€ s! lbl¡ tcqucacy
: (SoLronoe 3).
t
I
)
:
BONOING
li
LEAO

I
l il-l -
ca

BONOING SfRAP PARAMEfERS

l E ouJ
za)
62a
ANfI RESONANCE

l iál
3
()o-
zz
E I¡J

a
E, < |
E
IN CRE AS ING R-F
'--I ehsn8e' s€lf- l¡dt¡ctaree
The Pe¡ssltlc caF.cl,t¿Dc€ Cg rs dllt'cult to
I andDcreskt'¡cearethecontrollebl-vsrtable.Therffectof!8ryl¡tg
the mechs¡lcrt dl¡¡e¡rg lofra ol the bcridt¡8 lead are I hown ln lhe
E followbg table.
á
Rofersnca {
L

E
t I¡c!otre \c \r L c
I
F
L€n glh hcreete bcrG¡!G I¡c r 6¡! a
B
E wtdth D6cral!a Docrca!6

E Thlcloc¡¡ DGcrGt!G D€crGatc

F
E Arer Docrctr€ Lrc ree¡ e
E.
E gp.c lE g tro m Doc r c:¡ e

F:
F 2¿2-á
E
 A n¡Ic ol thumb for schl6vtD g ElDlEum bodhg trsd bd¡¡cta¡ce l, rhar
tho leDgth-lo-*ldth rallo Ir k6pr ¡¡ low a¡ poo¡lblc (R¿for€acc 2).
Thl.r ratto lr grnerrlly EcGpt€d rr ótl (Rrfcr.acc. 2 rDd A).

Bondlag loed DC res b!8¡:ce 1,. a fiJoctloa of ¿h6 coaductivtty of lhe

bondlng le¿d n¡¡terl,al, ¡eogth a¡d cro.B sectlonal area. The effect of
i€ngth aDd croar 8ecllo[al &¡ea are glveo lo üe above tabte.

A¡ aelf l¡duct¡¡ce l.s th6 more hu)ortsJ0t of the two electri,csl para -
meters , the 5:l wtdth-to-l€ngth ratl,o r¡ cr/¡ e ldercd mrDd8¿ory.
: Thereforo thlcloess end (oDduc¡lvl¿y are the ooly v¿rlablo¡ tbát c8jr be
?
conslderod ln bcndl¡g le¡d DC reslst¡¡ce.
!1
The thlcloess b determl¡€d by the dogle€ of flexlbtJ. l¡y regulrGd of the
: bond lng etrap. A geoeral satemen! oa thlcloterr, oth€r !trr! cboore
.;. rhe thlcke Et that wtll fulftl the applt4atton, ce!¡ot b€ m¡de.

The table below ¡hos¡ lhe spectflc rosLBir¡ce of materl¿l uled for
bondlag leadr.

M¡terl,¡l Sp€ctflc ReEl¡ t8[ce

Fn-cñ
Phoaphor Bronze 9.{
Berylllum Copper 1r..2

Aluml¡lum t -1t <

Tlrned Coppor 2.83

Bor¡dl¡g leed¡ ¡re ¡vatl¡bl¿ l¡ ror.nd, fl¡¡ brald, or fl¡l solld.

Round bondlng lead¡ ¡rc undottlsb¡e b€c¡utc of lhclr hlgh eelf
bduct¡Dcc. F¡at loltd boDdlnB lcads ¡rc prelerred t'o br¡tdGd bodb8
le¡d! .t HF bcc¡u¡e b8.ld! tcod to h¡vc'¡ hlSher tolf loduct¡¡coi
they sre algo le¡c prono to mcch¡¡lc¡l dBm¡8ia.

Bopd ln f Re!Irt¡¡ce LIrüt.

The general bondlng rorbt¡¡rce llrnlt¡ rrG defl¡d l¡ M¡L-B-608?B
(AI¡C) ¡rid are ¡ummarl¡ed ld thr t¡bl€ bGlú.

tá
t§
I

t 2-2-26
e
É
tl
5
R€.l,.tapce LlElr! br DC Bodbf
E-.
.é

F ApPll,c¡tloo !lr¡. DC
it R€a L¡t¡¡rcG
rtn¡cE¡¡e<hror
to

t Erglortvt ücl arce¡ FtSu¡. 2. 2. 5

I $ock hez¡¡d 0. 1

Llght.¡ng kotocllm T. B. S.

R. F. poteDttrl¡ 0. 0025

The most strlDgEnt requlromerit ls thst for RF pot6t-¡ls. p¡ovHed

al¡ metal{o-metrl ,otnt¡ are bonded to the RF roqutrem€at of 2. s
mllllohme prolectlon from UghtnlDg, shock a¡d explos ive hazerda ¿re
aseured, Thls olro aaEuraes that ed6quate protectto sgrlDrt g fru¡t
currenta , wühLD equlpmats , ls lncorpor8ted lDto tho derlgD.
At 2. 5 mllllohms thc fault currenr ehould be llmlted to 35 orlpere€.
E€L MIL-B-m8?B).
Bondl¡r Electlvoesg i¡d Corroaloo

Effeetlve electllcal boade b€twea ettbor tcro rEtrést€d B lJnllar or

dl¡atmlia¡ ¡aetsls rney be lmpaired by deterloratlca lbrough eltber
gal rb or electrolyttc corrosloo , Reforaceg 2 8!d 3.
Ü¡lva¡tc corloslou develops from tbe formatloD of 8 voltelc ceil
brts€6 the fsclng eu¡faceg wlth mol,sü¡re &ctJ.Bg 8s au electrolyte,
Gelv¡nlc corroÉlon can ooly tske plece botweeE lwo dl,BslEll8r metsb,
where ooe 8ct6 as the a¡ode and the oth€r as the cathod€. The degtee
of corrogton L¡ depeodent cn the pos ttloo of the metatr b the elect¡o-
chcmlcrl serleo. The further spart th€ metsls ar6 lD tbe serles, the
grGatrr l! the corrosion.

The ctectro<h€m¡csl !erle. lE !ho*n la the fol¡owb8 t¡bte,

lleclrolyttc corroElon alco requlree two metÁ18, wh lch need Dot b€

dL.lmllsr, l¡ cont¿ct through in €lJctrolyte. Decornpo€ ttloD tt
sttrlh¡ted to the pleronce of locel electrtcal cu¡renta. ruually er a
rc¡ult of uahg tho ¡tn¡cturo e! the powtr retufrr.

S¡lvrnlc rnd electrolytlc corrorl@ ceo be mlnlmlaed by:-

1. UEIDB ccrit&cthg metaLc whlch rrr clore tog€thGr l¡ the electro-

chomlca I ssrlor.

2-2-21
 2. &rüag thc d¡w ol tho ú¡clDS ¡t¡¡f¡cs¡ to 6al cr¡t thc rut8ülro.
Ce¡a ¡bqrld b€ t¡ka l¡ üs cbolce of tuoh r ¡ee!45t. Tbia
re¡b¡t¡ t.od to crGcp r¡¡dsr ths lol¡t ¡.ad drtroy üo b{od.

Ayold usbS üo !t!r¡ctu!€ ,, *" ,o*o"

"*.
Elétro<h€lalcel lL¡lé - R€úBréoc. 2

EM¡ (Volts) á¡odlc cDd

rDost e¡r Uy
Xrgnca lu.o alloye +' 2.37 corrodd.
áeryllhrm + 1.86'
AIEEI¡firyft + ,,. 86
Ch¡oBlu-E + 0. 74
N[ck6l + 0. 25
Tl¡ + 0. 1{
Brss 6 + 0.13
Ccpper alloye - 0. 3,1

Moael -0 34

SlIYer -0.E0 Caüodtc eod

l€'rt e¡! lly
Gold - 1.50
cortrod6d.

t.
§.
E
F
r
flL 2-2-28

t
 HAZARO LEVEL. BOIIOINO
RESISIANCE CAPABLE OF
tclnlt¡¡o E XPLoSIV€ VAPOUR§

raax 80t{o RESI>íANCE

Ffi FAULI CURRENÍ
mof Ecf loN

ts 3 ( 5C7t9lm 3 l s 67t¡o@
E

NcE FoR Ftc' 2-2-6

E
( SHII-3'ffiH;ffi S,J"H',.3.o*'?{'B'§.,?'¡T

h
 Dl.¡¡ tmll¡¡ -'let¡Lc

Groupe M6 t¡Ur¡¡gf.¡ I Cüegory htnF (Voltt)

1 Gold, eolld aad pllted I

+ 0. 13
I

,t Rl¡odtum pleted on Sllvor pletod Copper + 0. 05

3 Sllver, eolld or plated, hlgb ltlv€r &lloy! 0

Nlckel, soltd or plated, mcael, Nl, G¡ - 0. lt

alloys
5 Copper, broaaea, Cu, Nl slloyE, A¡rsterltlc -0 m
corroa16-res iata¡t 8t66lg
6 lE% Cb¡oElum type rer l,Et¡¡t St€a18 0.35
--:
,,1 12% Ch¡oElum type restEts¡t SteeL8 - 0. ,ls
8 Th plste -0.50
9 Lead aolld or plBled -0.55
l0 Alunl¡lum, wrought alloye or dr¡¡elllolutn - 0.60
type
Iu
L

Alu¡ablum, cast slloyr of the stuccn typ€ -0.60

The potenlta I dlffereoce shal¡ Dot exceed 0. 25 volts.

BondLUE Pr¿ctlceg

The followlng table tl,st8 eccept¡ble aad uaaccepLable prs4tlced LD

seléctlon 8¡rd l¡st¡¡latlon of bondlng leeds,

Acc6ptsblc Pr¡ctlce UD¡cceptabl€ Prscttcc

BoñdlBs l€¡d mstorl¡l CoDDoctlo8 boodbg le!d! lD

Tl.od Copp.r ¡erto¡
Pho.pbor BroDro
B€ryl¡lum CofPGr Hetlcelly ranad boudtng loed.a
Aluml¡¡lum
Socured wttb ¡elf t¡PPhg lcrñt '
Ke€p ¡! lhort sr potalblc ztnc or anodl¡ cd ¡ü!. bolt! rDd
wsrh6ra, sprlDg or lt¡r valh€rt,
Ule the mlntmum numb€r Uee of wHeIy dtffcrl¡s dl¡ rl¡olh¡
bodlng lcede rÉGtal,
S€cr¡re w[!h lockd fq¡toer¡ R6rtrlct flexbg of ooveble Pertr
E
ID¡t¡ll b a¡ iccc¡¡lble po.lttoo

I
B 2-2-??

t
a-
,

:
I

t
I
I
..
Seellag lor provtaülca of corro. fJm Ia o§ requlrcd wber6 thc Joh !¡
; lubrect !o deap or w€i coadlttm! br aay ieogth of ttlaG.

ft81J¡€s 2.2.6 lüd 2,2.7 tú?s ¡D.tbodr ol brtrubE badfag tad.a,

I ¡ddltla¿l metlod¡ a¡c ab¡r¡ b RrúcracG. 2 s¡d 3 ¡od h
MIL-B- 5087.
-q|."r.r

..

lltttttll lltil
tIi C ORREC I IN COR REC T

BONOING OF COMPONENTS rIG.2-2-6

i
ii

INCORRECI
HAVE RELAIIVE MOVEMENT

2-2-30
2.3 PTTotschtc.

1L o,l/errlrllnt ccarld.rttlGs ln thc dcltp of thc p¡otabtc

h¡r¡c¡a are tbo.c ol pcrrcancl ¡¡d sp&cccreft.slety. (h¡r:ae
lef cfy requtr.oeot¡ of tpth the Eart ¡i á-ud W¿rtcra TeBt RangÉ.,
rdereocer {8 s¡d {9, lac v6"y ¡llrü¡r; th¿¡¿ ¡pcctftcr oo¡ are
gaorally rccop.tüad a¡ tbo autborettvo &ru¡ocota.

Hazards to PTlot¿chlc Deelc€g

Pytotech " t.' dcvlceg requl¡e protactlm frou tbe follov.,Eg rorlrce!;

(a) eiectrortstl,c dlr€bargÉ

o) eloctrG¡gDctlc llold!
(c) l¡duced voltsge!

Elocfroetatlc Dllcb.arEe

Preeat day pyrotechntc devleeá are déripGd. su.h rh.r they wul
Eot b€ lnlttet¿d by 8 capscttor cbsrged to absut 3 küoi'olts,
(refer€Dce 2{), The po.stbility of bÁvl.ug chls larEér cb¡r8e bui.ld
up acc tdeotali; ls rather reEot¿¡ Dev€rthÉlesr adequete precauttor s
EuJt b€ tákeo to enaure th.at th€ buud u, ¿ a¡not occur.

Tte reader ls dt¡ected to refer€oce 7 for a more det¡tled dtscusslcn

of ¿lecrroat¿tlc dtgcharge pFotechDlc igDltlon. Electrostatlc
hrlid up r esult¡ from t¡edéquet€ e¡1d i¡etfective rrrücture boadlng
ree lecticn 2.2. 5.

Eletrorúerpcttc Fleldr
All pyrotech.alc devlces Eurt b€ dcttS!€d to aurvlve electro-
!D
EoagDcttc eovl¡com€ot! i expotur s to !Ec!c envlr6-r¡e¡ts must Bot
prGa€ot r b¡:¡rd to ettb.r pcrrcnael or apececraft Dor degrrde the
porlormeacc or thc rcltabiltty of üe pyrotccbatc sy3t6m .

Tha ftald ih.t thc tDltlstor acturJly r6cetye. depodr oa tbe lhlGldLDg
ol tl¡c ryút¿E ttr.U. It dcpad¡ cD lbc ettrEurtta E t¡. harlGt6
¡.od th, ¡,ttau¡ttú duG to tha phyrtcd locltton vlthla tb¿ cpecccrrft
ItrGlf.

It rbuld b€ raru¡ccd th¡t tlc rttsau¡t loo dur to locttlcn wtthto the
rplcerrft t. E.3ltg1bt6 atrd th.t ¡ll th6 rrtaur¡16 rrutt cosro frout
.hlcldEg ol thc pyrotcchntc c'tcutt¡. Rdcrocc¡ ? rnd {2.

2-S-I
t

.;
hó¡cod Volter€.

Ralcr c l¡ m sd. b ,e ,6 2.2 lot tb ¡réb¡.Etr. df tDá¡cGd

volt¡gla t¡ ceblc¡.

úa hl gb volt¿gé or currGBt tr bá.rccd l! rba pyrotoc ba f,c

firl¡g'r¡cflcl.Etly
lb6 l¡ltt lat loo ca.n ecur. pl/roa.cbslc flrlag lt-ct h +¡cG-
craft ¡ou¡t bc tro¡tcd ae h-tghly rurspflblo llns..

I¡ order to reduce tb. hrzerdr to pyrotehfJc dcvlccr to a.o rcccpt-

¡ble level üc followtaS requtrea€r¡tr ¡b¡r¡ld bc de.l¡rrGd lDto rht
pyrot ch,a ic harnea!.

L Electrtcal e¡d m€cbartcal t¡ola o¡ of th€ p).rotehDfc flrtog

ll¡eg f ro¡c all oüer power aad al¡D¡l c trcult! - toietly
ilolaied routl¡rg.

2. Pyrotecbnic monltor,/actuettoa ltle Eurt Dot b€ n¡¡ Dert !o,

{ñtefilr¡l¡ed wlth or share tba a¡ee Ioulücore ceble or
coD¡ector a! the f lrtDg lLncú.

J. Twiltt¡g aad ehleldtag of the flrl¡g lbc!

Tot¿l ctreuofreDttel shleldlDg qf +he g¿§t¿/soññector Jotnt
(reJ rect,,ou 2. ¡,.6)

5. Provide a¡ efflcl€llt grouad plane (.6. setl6 2.2.5)

6. Grouod tbe lbell of the plTotecbtc devfcc .
Rur ¡ie pyrotechnlc circult¡ b üertnrlly llrsultt€d c¡ble wbeo
hat¡Uéd h eng{ae compsrtm@tr.
Mo.t cable! uacd tn rpacecrelt b¡ve adequlta thcnnal prop-
cñtcr for thlr rcqutrcmeBt.
8. Gror¡¡d !h¿ flrtEg ctrcult ceblc rbiald to tho ¡p.cÉrsft
grou¡d pla¡c ,

The Srou¡rdLog Fpt¡rta must bc c¡tabltah¡d t¿ rcduc. f¡dr¡ctlvÉ

ttray clectrlcal eacrgy corpllag p¿tha Bld to roótce th.
Esrtmu-E .lectlvG s8terl¡a apGrt¡rG lorEcd by rbá ftrllg
lced¡.

9. Pú rcdEd'My tr epplled to t¡l f lrt¡g clrsult .

10. hltrll dlrcbrrg! rG.l¡tor h floül¡t lbcr, c. g. , ll¡ct
bctwcen rxo mloFúrttch¡.

2-3-2
J]
F
E
E
p
F
¡.
8¡htv Et vlo¡
, §.fÉy drvb.r r¡. r.qul¡rd br:-
5
t 6) Pratétbü ol th. .yü@ vo¡t{p lD tt d-r ol t¡. bt :bc
T
5 d thc P]rrdchlc dcvlÉs .bÉfry to frcr¡Dd ¡lt r ttltrt¡¡'

É
Thl¡ l¡ ¡chtavcd by f¡lGrtt¡8 r furt¡tor b tbG ho{ ll¡c, ¡e
t, Ítgure 2.3 . f , c/hlcb acts ea e fule tD tb. Gv.at of tb. brtdge -
wlrG rbrtLDg to grü¡d.

FIRING RELAY
coNlAcIS FuslsroR
BRIO 6EWIRE
FIRI
\OLIS
ov

SPACECRAFI GROUNO

FIG. 2-3-r

The pbyctcal toc8tt@ of th¿ fu.lútor t. d€P€adeDt upca the

prdrchfc !ytt@ tnt€Srstto plaa. It P]Tot¿chtcs' lJ1-
útslled tD the sPacecrajt' are to be 8rh¡rtcd durtng lDt€grattoD
tbe fuli3tor requlrer to bc ecce¡¡lbie.

Tte arm coD.D€ctor i.s cn td€al locatio for üe

furlrtorr. Tte futlstor ca¡ ¿llher b€ replecod or e DeY arln
plug ured. It tr Dorloal to adoPt tbc tlrow away approrcb '

(b) !¡rot ctfo¡ of pcrroacl a¡d ¡Pscerrfi frolo loadvsrt¡lt

a4ü¡lttdr of the p¡otecbalc düvbc.

To do üt¡, s bsrrlor tDu¡t b. phccd bctvcea thG pyrotebo !c

dcvlco ¡¡d tb. rGrD¡l¡dGr of thc flrbt ctrculta ' Thc mo¡t
coGEG m stbd t¡ to ProvtdG e ¡sfc a¡d arro dcvtcc l¡ thc
pyrdcchn b ftrlas lbc.. ulurlly tn tlc form of r IAFE/ABM
c(DEEtor, Ft8. 2.3.2.
FI RII{ G L INE S 5AF E/ARM CONNECIOR
r-
I I FIRO f EC HN IC

L--J
Ftc 2-s-¡
- - t-r-t
 Tha ¡¡Ic cG.Détor prea@s ¡! opc c t¡suü !o t!. ftrfry
t
lb.. troor tb. lt¡t!¡ cllcl¡tt ¡!d tbort ctrü¡tt' t¡. ftrls3
IEG. to th. pFot-hb tb¡r r¡drrht lt larcp.rreblc.
E
i
t Tt¡ r¡a ccDaetor coplctcr táa llrb3 ctrcultr batru th¡
dEt¡atcr r¡ld tL pyratehtc d.vlcG. Tb¿ ¡¡le
ftt'rñf
cúletor mu¡t bc fttad ¡t a¡l tb¡ca orccat for t at rDd
p"cp.rrttú for l¡'*h.
I
it Prgcrúlot¡:

$/bcre a raqutrcmeot qlrtr lor Eore th¡.a oe ¡efe/an¡

colGctor, üc r¡fc/ara cooDetor ¡holl !s ol dtffcrlng sbcll
arza, pett rD sld orlcatátloq. The reqr¡trrcat forcludcs
tbo pocrlbllity ol b¡dvGrt¡¡t annlag ol tbe wroDg Itrtng
ctrstlta.
(c) hotetl@ of pcrraael órrbg haadl h3, tr!¡.por!8t¡oo ard
ID.t¡ll¡tlcD of tbr pyrotrchDl,c d¿vlcc.

$oclftc roqulrGE€ot! sra dcllD6¡t6d l¡ Relcreace¡ 46 eDd {7,

tbe re¿der abor¡Id fsr¡tllsrtlG hl¡o!6u crtth tbe re<¡rl.rÉtDeDtr .

Il¡ere ere I wlde varlcty ol plrotochtc dcfllccr whlch are

u..d iD .o Ee.Dy dtüer.at Bppll,catlmsi lt t! tEpor!fble to
lay dorro h¿rd a¡d frlt n¡lé. for thalr b¡¡dl l¡9, Thc
follor/.ag ere howGv.r eppll,catlc to ell alü¡¡tLDr:

lúod.E prrrot cbd o dGvlÉa ylti tbG 1 sEp - 1 }ttt D ftrr

¡Pcclflcrüo¡ rrc rt urrly ¡r aGrrll". to at¡ry cl¡rrlat¡
¡. tbaa p¡ld¡c.d b ü/, 0. 3 rnp ryccfflceÉos ol r fa,ycerr
r3o, NGvGrt¡ala¡, lt la l¡¡¡dvl.rbls to h¡dlc pJrrot!..¡rñr c
darvlcaa uldar oGr-trlD stGtrla co¡dfioru, ru cü Ú:

(¡) DurlEI ator:!. - rb¡a r¡l¡ tDaul¡trd ¡t¡'r¡cü¡rc c{¡

plck tp br¡c @Do.GrÉoor of rttüc clcctrl o{§.

2-3-4
f
 oi b ol,or prGt.E tty !o t!..EGB ltt r., r.d¡r -¡¡lf-t
¡!d hlÉ voltr¡: ltarr rt¡r¡ l¡órd cr¡rtü¡ cE
ddort tba ptroaébb d.vb..
Prot-tlo l¡ rohl¡v¡d b, 6r¡rt!¡ tl¡t I rbl Ir ftltcd ¡t ¡ll
lh.. ó¡tbt b¡Ddtb3 ¡sd trE Frt¡tb.
A¡ pFoteblc d.vlc6. cta bc lltttrt d by th¡ plck <¡p ol rtre y
curr.Bt¡, tb6 d.r lca., coDl¡l¡ar. tld hrDdltD{ pgrm¡ol
¡bould br ü tbG .rs. pot otl¡¡ rA.n rülovl¡f tb. 3h¡¡t ,

tb. .rrG.t coadltlo bcb3 rta ¡ll tb¿.. .rr g¡qEd.d !o ¿

cooao groud ptoc.
I¡¡t¡ll¡tlcn of Prrrot¿ctnb Dcvtcc

Tba follostn3 precórc l¡ r¿coona¡dcd for lnGrllb3 thc prro -

tebtc daYl,c. l¡to t¡G ftrbS Ih...
t. Msbt¡lD r RF rllacc u¡tfl a¡ch ttEG r. thc d¡vtse b¡¡ bcco
l¡.t¡llGd b th. tlll¡g lbc¡ ¡¡d rll por*norl b¡vc bcca clcarcd
lroa tbc tEE.dtst vbt¡üy.
l,
It. E !Átmulo uunbcr of pcrrccl ¡h¡ll bc u.cd to tb.8r'rallg
úaqr¡(6cc, co¡¡Eaorurata *ttb a¡fa,ty rad rolrebü§.

3. Obt¿b documcotsry evld@G tb¡t tl. alctrtc¡l cootttrutty.

b.ulrtlñ rcalateDcc s¡d prool volt¡¡! t .tr o tbc b¡¡¡e¡r
brvc beca conplctcd ¡nd ¡rc rtthlD tbG dc.lgD r.qr¡tretocstt.

{. Wlth tbr r¡f6 ca¡Gctor rsBovcd chék lo a¡urc th¡t ¡o

su¡rta! t. Oowl¡g t¡ tbc ftrtag lt¡c¡, ao¡ ¡¡y voltas. .pPcsr-
la3 rc¡ora tb. flrtDS lt!c..

5. ED¡¡rG tb¡t tbe pyrotachr.lc bouat¡¡, cútrLDor ud '¡rrmcl

rrc arc[ndcd. Gly etlcr thl¡ b¡¡ b..a dco. mry thc pyro -
tehlc dGvtcG rb¡¡t b. rcaov¡d ¡¡d tho dcvtcc l¡tt¡lld ts
ttr b¡.tDf .

6. Thrur¡b thr rno c(Dstor cbrck for .Lctrtcd cGtlsutty of

tb. pyTú¡h[lc brld3o rtro. A l,or out r¡t rfi.lanrt!¡
t!.EurD.nt Euat b. s..d tor thl. t rt.

Tbr enolag c@Gtor ct¡ x,? b. lltt d.

¡-t-6
 2,1 It¡¡!... h¡f¡UülG
Thr o6¡¡16¡ r.qulrcaGt¡ f,or
h¡r¡c¡¡ E¡t¡¡l¡tl,co lrc ,u.t a.
bpor!¡a! r¡ tb¡ cr¡otrrorl obrrri.rr.É;;;iü;;"...

Hg:f::j_}3t p lrlrrerl rcart froo¡ r.a¡doq¡r¡

lüordcd d" ¡._..;hrrq fü;fffr
r l5::a*"s
b.t¡-tl¡ttd, .
¡
F H¿¡ac¡¡ t}?a. I, U. E¡, V r.d VI h¡vc t¡¡llt-h pror&rtoE, hrt
.boq¡d Dot bc t¡Jra ea b.LEl tht¡
E edGqu¡t . E¡ch tlrtall¡tlm Eurt
m-r¡rrcd b ¡¡Grt¡b b€
u ¡¿jnro¡l *",-d;;.""r;.
I Hr¡¡Gu t}?e. fV ¡.Dd VII do iot
h¡ut-b proEctton, cou!€gu€at_
ly, rll ptrattel b¡ za¡.rj¡ ¡bo¡ld _b¡vc
bc ¡votdad or edeqr¡¿f¡ prot6ctfoa
glvco to tb€ vl¡c h¡r¡cl¡.

2,4,r Pro,tact l,ot¡ R cqul rGE aatr

Tte locattoa¡ of ttc mo¡t probable arear eñ.re

s.brE¡rco do_,8tÉ
a¡d eut{b¡or¡É c¡a occur arc wh¡re
a brt¡al¡:_
re) paaeoc throtr3h ¡ hole or cut crü

O) pa.¡.r ¡rqod a corEcr, brscklt, .qulf clnt.

lc) ta g4orad to qcaaalvc cotsct by pcrrcnacl o! ogr¡lpE€ot
(d) p.raGa [csr or ot or Dt¡t¡, boltr or rlv.tr.
o!'¡ arcar ñsy .8rat rad e dcrrSncr .bd¡Jd ¡,oc¡t s¡d tdcat(y
poarott¡l ba z3rd.r ¡t ¡¡.¡r¡y.t¡Í.
b lhe dcrlgn.
H¡EGraar t!¡t rrc tttscbcd to aarGubllo. vbcrs ral¡ttve
ecura or ró.ra tt t¡ t¡ clo¡e prqtEty to EovLDg p.rtr, EovqmGat
furtb.r pot ofl¡l hr¿.rd., Not oJy l. th6r. t¡o ir* a¡t
b.lo3 trrpp.d betwca tb. EoyEg of tbc h¡trc¡¡
*r,. -i
dÉcrtorrttoc crurod by oc U¡r¡i¡¡ .¡bbl"S
u""¡'.I"ro, ou,
trld,E¡ rod bodlog c..B ecur. "S.ü;;
*otLr or ty

To otaLa l,¡o tüo r t¡k of ,r-Etrg! partr.Dcat prot.cttoo

5d oth.r d.ñ¡a! nu¡t bo tlrt¡llGd. Cñ.rc t¡e Ur_".¡ fro ¡brr¡lo
lr_rvCrr' hra3r lhcr thc prdcrrrd roc¡¡¡ l¡ ¡.¡ to
o r"¡uri
wlt_h r tyt t, Co.ldarrttoD ¡bq¡td t,c ¡1votctoh¡nc¡¡
coatroll¿d
o( Fcc {n¡t Cdr¡ctor c¡blG) t¡ thl. t"rtre;,-;.'iJ.*,* tb. uro
.¡.lcr to cGtrol ¡¡d tba torqu. lr loÍ scfcrcncc 39¡. ,.

!-{-1
 --::-t-----:--

J
&¡DErt a¡d Cleropt¡g

\trhaa lnrtall lng h¡r¡a¡¡a¡ tt t. LEport¡I¡t th.t rufltc lc6t útárfcÉ

l¡ patd to tba dcrtgn a¡d sclcctloD of trctotqucr ol b¿m.e¡¡ st¡ppoñ.
Ito crl!€r18 to bc coa¡td¡rcd arc:-
(8) Provcútloo of abrartoa

o) Prcveatloa ol Elgls¡loD fithl¡ üe aupport clffnp.

(c) Mal¡tahtnS claera.Dccr when lqttbg thrc ¡úh tr¡lkheads or

ltnrctur8.1 member¡

(d) koveEtlon of mecb¡¡lcal gtrato th.t ccr¡ld breal wirtDg or

c(IoDccttoBs

(c) PreveGttroD of e:<ceaelve movem€ot u-rlder vibratloa

Peralt free moveuat of ¡hock vfbratloo

I
mou¡ts

el Prov€otlon o! tnt€rfereDo€ b€r\re€a b¡¡¡oa¡e¡ o"'l otber

equlpE6t, EovhE pafis a.od hlnge llnea.
E
He¡!e66€t are D1o6t frequently dá'ñ1gEd durl¡g tbe tlstallattou
pbaee aad are caused by er(cesslve tiáái¡S, ktakiag &Dd geDeral
F maltreabeat. To pre6erve tbe lDtr: gltiy of t¡e harDeÉ8, teEop-
E orary Eupport a¡d cl-empe ehri¡ld b€ u¡ed, these cE¡ be ldentlcal
to th€ fl tSlt hardwa¡e or plata spot ttes. @{g-q g S!o4 !e
used care E:u6t be ta*€a to saruro thrt cold Oon of *'1re lD8ulattoDg
E
ói pro-tecttve a!,eathlng cs¡Dot occur.
Tbere are v¿rtour paftorar of cabie cLampr, a aelecti@ of the mort

I coarao.rly urGd are liiurtreted ln Ftgr . 2.,1. 1 to 2.4. 5.

Tto cbotc. of clarDp tr lsrgcly dl,ct¿t€d by tho typ€ eod phyrtcal

alrc of tb6 han:e¡¡. h ordér to ¡r.tr! lD tho tclcctlcn of t¡6
.Eproprt t cla-urp tbr foüowto3 crltsrl¡ ¡bor¡ Id be u¡ad:
(8) cla.úp rt26 ¡hall bc rde?uat€ to bold tb6 h¡¡¡e¡¡ LD potttfoD
v,¡lthd.¡t pl¡chtñ5, dsforElDg or ds.EeIl¡t tbe h¡rner¡.

E o) tb. clo*p ¡b¡ll b¡va sufflc lcot grtp t6 prGvcat crceFS! ol

tb. hrrEer..
(c) tb. ol¡'ñp tr coopellblc r{tb rhÁ phyrlc el dl¡D.ñ.tou. ol tb.
h¡¡¡o ¡ ¡ .

tdr !o claj¡p .€lcctloa l. .bo$¡ l¡ T¡hlc 2.{.1.

A 8rr

2-{-2
I
 FOfiWARO EOC€ tr WEOGE(PLASIIC
CLAMP)OR FORlflARO EOGE OF MEIAL
Ct AMP PULLEO IN SLIGHILY ÍO\{ARO
CENIER OF CLAME

WEO GE

CLAMP CLOSED
WIIH NO GAE

CLAMP I5 NOI CLOSED PROPERLY

CONVOLUIE IUBING IS PINCHEO
EETWEEN THE CLAMP OPENING.

EENO A'I THIS POINI IS

NOf ACCEPTASL(YETAL
CLAMP ONLY )

CLAMP OEFORMAIION IS
CAUSE FOR REJECIION
(M€TAL CLAMP ONLYI

FlG.2-{-l
 TASIJ 2.,f .1 CI,AMP SELECTION GUIDE

I-ooDx Dorc rtpatroo L¡oE LooE Cleap Typc Flg. 2{-

1)¡po DI rrn atar
b Ela. I , J {
Eucl,o¡ed l¡ i
E fluoroc erboo I 25-50 x
Coavolut€ TubiEg I 50 - 100 x
T > 100 x
Eucl¡o¡ed l¡ tr <25 x
Fluoroca¡bon tr 25- 50
C@volut€ Tlrblag q¡¡t n 50 - 100 x
Ffbroglasa brald tr > 100 x
m x
EBctroled ,¡ TFE u¡ 25-50 x
CoDvoiute TubtDg m 50 - 100 x
m > 100 x
rv <25 x x
@eu Bundle rv 25-50 x
11/ 50 - 100 x
w > 100 Y

EDclosed I¡ <25 x x
TF'E Shrt¡k v 25 - 50 x
Tt¡bl¡g v 50 - 100 x
> 100 x
VI < 25 x
FlexfbI¡ Ar:nr,¿rsd YI 25-50 x
VI 50 - 100 x
VI > 100

vII AI
FIst Cooductor vn wrdrh
Crble vtr aBd
1¡II HBlgbt

2-1-3
The l,oc atlñtr of clo-rp dovlcc¡ rbouJ.d arpport agrl¡¡at vtbraüoa,
chaftDg *ld general dsmage er w6tl a¡ mBl¡tshlog ü¿ b¿rnc¡¡
conftgurattoD,

Clamp rpectng .bould b6 be¡ad m üe tollowtng:-

1. Dlrta¡co betwe€¡¡ llrst cls-Ep a¡rd back ol c(E.Betor to b€ Dot

greater th.É¡ 375 mm .

2. Dlstá-uce betweea l¡termedtet¿ claxapc to b€ Dot gre¿ter tba¡

375 Em.

3 . Wbere harness passes througb or over grollmet8 a clamp

ehould be Located a8 close ea poeafble to the g"onm6t.

To ai¡tai.:x the hancels conJtguratloo the clampe aloug a hanreea

m
run should be staggered and at least oDe clamp placed at oacb b<nd
radtus .

Wher¡ breal<outg f¡oo tbe main b¿me6s are made at a cupport cla.Ep,
they glEuld l¡e srade l¡ e directtoD away from clamp ecrew a¡d the
edges of the cla.op itseU. Where tbl¡ c a.D.Bot be achleved care
must be taken to eEaure that phyelcal darnage c a.D¡ot occur, ¿ddt- . -
ttonal protectloD bebg l¡stalled if necessary.

The bend radtus aloog the Iength of a ha¡tees or at a breakout

ehould b€ carefully coatrolled. Too sbarp a bend ca¡ cauge tbe
wire LnruiatloD to crack or bsulatlon fallure due to cold ftrow'

Recomme¡ded bad redil:-

(a) optl$u¡n bend radtus shell approach 10 tl¡ner t¡e out tde
dls¡o Bter of the hárDels

O) Ha¡¡eas ccrDts!¡lD8 10 AWG wtre or ¡ma.ller eball have a

ml¡EnuÉ bend radlus of th¡6e !ln1€8 the dlsm etor of tbe
h¿rne¡c .

(c) H&rnea! coatatDl¡g f0 AWC a¡d lsrger a5all h¡ve s ro llLEruE

b<Ddredlur of rtr tl¡nes thc dls.Ester of tb€ hernera.

Tablet 2.4.2 , 2.4.3, 2.{.{ Stve tb¿ E,¡ !¡¡um b€¡d rsdtur for
dtffergat tlper of cmvolute tublDg.

21-1
 E
(ü

L@? CLA¡'P
EX¡l't.E OF I.-o' CL¡¡f A}I) SADOLE
TT?E CL¡¡iP.

FIG. 2-{-2 rIG. 2{-3

I {F
oq.,ar cft? cl¡r'?

Fto. 2{{
\

. IElrt lñ FCC lx¡t^Ll-afloll

s¡r?ñlif Hoo«

E.
 lratlLl Eúa c.rgn
Cúa CariA.lt ¡¡rlE l..¡lii
i
I r. C.n¿{li
t T'lrc ¡¡ddlc mountinf pl¡t¿ TG92 i! u!.d whcrcvlr '¡ble run¡ elon3 conduit or tubinS,
crou€a ¡t riSht ¡ngle¡ t! th. c.nduiL C¡n rl¡o bc -'
,¡ ¡ rt¡ndaff in ¡urfrc¿ mountin¡l.
["

1
I Double bolt hole t)'Pe
rotate - ctcured 8t
will ñot
both endñ'

Right Anglc
llountinS
TYpcr Providc
rrthod for
.upportinf
bundlc.
through bull'
hcrd¡, hola in
c¡bincu ¡nd
rrll¡.

FlG.2-{-ó
 TAB LE 2 , {. 2 Ml¡l¡u¡! Bead Eadh¡¡ for Cotopre..€d
Pol ytetralluoretbylcoe (T?E ) Cmvoiute T\rblug

Tubl!g I¡!td6 Dle.Eotor O:tltdo Dt",ñct.f W¡ll Thlcko¿¡ r B6d R sdb.¡,

Slze Noml¡¿l M l¡i¡oum MaXfmti",r M l¡Lou-' Ml¡Loum
06 3/16 0. 181 0. 320 0. 020 5/ L6
09 o /.ra 0,2?3 0.{l{ 0.020 1/r8
3/8 0.364 0. 508 0. 025 s/E
I6 0. 485 0.633 0. o25 L5/ 16
b/ó 0. 60E 0. 758 0.025 t- r.i 16
24 3/4 0. 730 0.914 0.030 r-L/8
1.0 0. 97s L ,226 0. 030 1-i /,
40 L-L/4 1.2¡0 !. 539 0.030 L-7 /8

TABLE 2,{.3 Mlnlgtum Bmd Radlus for Ncro-Coopresccd

PolltetrafluorethyleDe (TFE )C oEvolut¿ T\¡bl¡s

T\¡b i¡rB Lnslde Dlamet€r Or¡trtde Dtametér weu Thtcl¡er r Bé'ad Radtus
St ze Nom tnal Ml¡l¡¡um Ma¡l.mum Ml¡taum Mt¡lEuE

o3 3/16 0.181 0. 320 0. 020 L/2

09 I /32 0.273 0.414 0.020 3i4
t2 3/8 0.364 c. 508 0. 025 1.0
l6 0,485 0.833 0. 025
s/8 0,608 0. 758 0. 025 r-3/4
24 é/,t 0.?30 0.91{ 0. 030 r-1 /8
32 1.0 0. 975 r.229 0, 030 2-L/2
{0 L-!/4 1.2r0 r.539 0.030 3.0

TABLE 2.4.{ Ml¡lmum B€nd Badius for Fluorocarbon

ELa¿tomer, Cro¡¡lt¡ked CoBvolute T\¡blDg

Tublng lns lde Dtarneter G¡talde Dla.Eeter Wall Thlcloea¡ Bend Radlua
Sl ze Nom t¡aI Mlnlmu¡o Maxt¡num MtnlrnuE Mloumum
A A B c C

06 3/18 0.42 0. 030 0,{0

09 9/32 0.30 0.t2 0. 030 0.90
1/e 0.36 0,60 0. 030 1.95
l4 7/16 0. {0 0.65 0. 030 2.60
l6 r/2 0.50 0.77 0. 030 3. 25
20 5/E 0.63 0.9t 0. 0s0 {. 15

24 3/4 0, ?5 t, r0 0.030 {.96

28 7 /8 0. E7 1.25 0. 030 5. 86
36 | 3/32 1. l0 1.50 0. 030 6.50

2.4-5
 )

2. {.3 ProtétlvG Grolodct¡

Thr ccnvat!o!81 E ctbod cl prcaétrñt hr¡ncr¡c¡ rvhlch r¡o rq¡Ld ovcr

3hstT cds!., or Eiy cGt¡ot r8y Protnul'ú r' by cov'rtaI t¡c pro-
trustoD ot eharp edgt r'lth Tcflca or rtrollsr lDilárttl ' Crtarptller '
úol.ld or apltt cable tTomm d! aro ured rñlro tbc brtactr€l p't'
tbrf,¡gh atñ¡ch¡ral ¡rcEbcr¡ wtth tb. ddlltm o{ I r¡pPort cla'ap to
- -
prgveDt the porrlbtlüY of cbafbS.

Ftgurca 2. 4 .9 Llluútrat8 typic&l h'tsl'lgtlo¡¡ rñcre g'oEE€t

.6 ütd 2 . ¡l
protcctlú e/6¡¡d b. PPltcd.

C AfERPILLA R GROMM E f S

E GROMMEÍ

FIC. 2-4-6 FIG.2-4-?

cafERPILL4 GROMMETS

SPLIf CABLE GROM MEI

FIG,2-{-E FtG. 2-{-9

¡-{-6
2.1, 4 Har¡e6ú Rcr¡érf

H¡rueeg rorllag rbculd be deatgncd t rvold abrali.oD, cuttlng, charp

edger thra El¡llnlrt¡g thc porllb[tty of dr-r agp rhrr rhe né€d for
prot€c tlvo DAt¿rl.elr,

Tbe rouüag of b"aroess l¡ cloge prorLu l¡y to llamrable Ouid llDet

tE a Practl,ce b b€ ayoided, Where a hg¡¡e¡a h.r to b€ ¡¡.tt¿d
cloae to llammable ltoes a nr l¡trnulo of 55 mm phyaical BeparatloD
¡buld be ecb!€vod. It ls peEoisstble to rout€ bameaaes along
¡on-flammable llufd ll¡ee provlded a E l¡txBu.E of 13 Em phyEical
lp¿clng ls Eoaluta,¡ed.

A poi¡t to walcb uáeo routl¡g along fluld a¡d gaseous llne8 ts the
proxlIntty to coupungs; addlttonal prot€ctlon tDay be requtred at
tbe8e positlons.

becha¡ical aspects of h¿r¡eee prot€ctloa the electrlcal

ID addttlon to
requlreE@ta froB EMC (E lecf,roEagDetic CoEpatlbtltty) have to
be ccnsldered. A baelc requlremeot of E¡.¡C ts rhrt prower aad
slgnal harueeees are physlcally separated by a tn i¡iJruro of S0 mm.
RaDgE EaJety regulatloD8 requlre t¡at pyrotechltc ftltDg ll¡es be
separate from all other power ar¡d stgDal barlless.

Frequ€otly a desig¡.er le faced wttb the sttuatlon '¡rb€re tbere are

t.'roor tDore ideatical con¡ectorE 6 a¡ electrcnic rE.it. The risk,,. ,

l¡ thls sttuation, of tmproper conÁectton is bigb. To mlnt¡ni8e

the rtek of mlsmating, wlre hameaoes sboüd be so routed artd eup-
ported üat tmproper conDections c aDlot be made. If routing
c a¡-uot, i¡ it8eu, ml¡t-IIli6e the risk of i.:n proper con¡ection8,
apecial marklngs or ldeDttflcatlon sbould be provtded to htgiltght
prop€r con¡€ctloDa.

Ftgr.res 2. {. l0 s¡d 2.4. 11 tllustr3te typlcsl rou!t¡g concepts.

2-1-7
 fRUC TUR€

SIRUCTURE f
t

2INCH (MIN)
FLA,'lMABLE LINES
1/? |NCH (MtN) FLAMMABLE FLUI
NON -FI. AMMABLE
C ARRYING LINE
LINES
LAMP

FU'ID CARRYING
LINE

CLAMPS TO PRO VID€

CC CLAMPS TO PROVIDE ADEOUAfE SEPARATION
AOEOUATE SEPARAfION
2 INCH ( MIN )
É C' I.IARNESS ASSÉ MBLY FLAMMABLE I,.IN€S
1' 2 tNcll ( MIN )
CC CLAMP FOR NON FL AMMABLE LINES
PRIMARY SUPPOR T
ARNESS ASSEMBLY
FOR PRIMAIIY S UPPOR f

SEPARAIION OF FCC HARNESSES FROM SEPARAIION OF WIRE HARNESS FROM

FLUID LINES. t- I(;. 2-4- )0
FLUID LINES. F lG. 2-4- I I
2.4.5 HarpGrE Fabrlc atlon

Hqrnorre, roay b€ fabrlcüed urlag ¡gvcral dtffcretrt t6cb.utqu6t.

1. Dtrect @to spa4ecraft rtn¡cq¡re

, S€orrate cel¡le ra¡emblla¡

3 Fabrlcat€d oDto 8 troulatsd rtncütreú or Jlgt

Fabrfcatlon dtrectly onto the rpacecraft wlll greatly reduce the

ha¡dl f¡B of the completed aaaembly and \',111 eltmfnate the ueed for
tra¡8portatlon Jlgú.

The disadva¡tager of th.l6 m ethod of coartnlctloD are:-

A hig! rlrk of damage to the rpacecraft aurlace8 a¡ld stnlc-

rural memb€r8, due to poor accelr for operatora, a¡d I lack
of apace to depo6tt thc toolr and equlpmcnt requtrcd to me¡ufac -
re the harne¡ ¡.

The har¡eea wtll be very dtfftcult to clear¡, and the .pacecraft

atructural rleanltne8s could be degraded, by cable rheath,
screen wire. solder and pottlDg compoundr,

The ttme reqr¡trd to bt¡tld the complete rpacecralt 'dll be

ccnsiderably lrlcrea8ed ü¡e to the requfremslt of a eompletad
Btructure b€fore har¡eBt f8brtcatl,on rnay beg:l¡, thua prevmt-
l¡g any further operstlon! to the rtruct'rre or assoctated
equlpment untll lhe hamerr fab¡tcstlon a¡ld telt ls complete.

Thts teclu¡tque l! not ', ecommqrded, due to th€ ht8h rtrk of

!tructural damage and ext€nded fabrlcrtton time.

Har¡erlet may be fabrtcated urtng lopsrste cable areemblte¡ whtch

msy bc conEtnrcted on th€ work b€nch a.Dd 6r')¡6queñtly Lo6telled
l¡to the lpacecrajt rtnrcture. U thc ¡t¡r¿cErre 16 locatod on tbc
same últ€ es üe cable asccmbllc¡ betns ma¡ufrc!¡rad. th€m pro-
grer.tve 1¡!tallatlon lr po..lb¡a.

Suble$¡ant modiftcsttrrn of reprtr tr ;t.Epltfted ó¡c to ttÉ fecülty

of ceble arrembly rub,rtlü¡l!ú, Thlr mGtH of fab¡lcattcrt y/or¡ld
be de¡trahlc qr very larl! Ln¡cq¡rG¡ nrtcre rthul¡t€d rtructure.
or Jigr rvould be extrcocly coatly r¡d lpocc c6.uELD8.

The tech¡J1u6 har ccrtah lnbGratt dltedvEts¡la,

2-{- 8
 Tte ry8tem and subryüteEl eléctrlcel LDterleceg murt bG
de6igDed to accommodate u¡tque Llt€rf sae6 betweea equtprl€Dt¡,
thereby l¡crealtog co¡t and uasc of coüDectorr a¡d cablc.

The length of cab¡e a¡¡embllea Eourt b. c¡tabll¡b€d by trlal

l¡rtallatloD and tber6after muút Eal¡tat¡ the sa¡oG po!tt!@
wtthl¡ th€ harac¡¡ or hrtld. or any aubrcquent b¡tld, to arurc
that the l€ngth ertábltrhed lr correct.

Strnulated strucü¡re8 a.nd ,Ítring Jlg! may be u6ed to Bood e{fect to

fabrfcate hanresse¡, thereby cmlinlag the riak of 3tn¡ctural ¡!¡ña8€
to tbe pertod of inBtsllatton only,

The harness fsbricatlon wlll be a concurr€a! taak e/tth t¡r 6tn¡cbtre

bulld, eo reductnB pro8ramme tigle.

Sfmulated ltn¡c¡,¡rer a.od Jt8s ca¡ be go cmatruct€d to prorld€

gufftclent acce¡a and trnproved vtstbtllty for operatorr, tbua r€ducin8
manuJacturlng tlme a¡d e.frsurlng $¡ellty lr mebtalned' Al¡o a¡
t¡cresaed number of op€rators may be uttltred, to furüer redr¡ce
Programme tlme.

The har¡eas clea¡Ilneea Btc.¡dard wtll be attal¡ed more readtly tf

not obatn¡ctd by tbe spacecraft rtn¡cture.

The teat requlremqrts and transportattori of the hartecc oay be

fuutlled whtlBt Bttll attached to J18.

Conrlderatlon muet be 81ven l¡ the de8l8D ttagp of tbe harDe.r' wtleo

ustng slrnulated 8lncalres or .il8E, !o the removal and ¡ub¡equeat
l¡ltauattcn ontú t¡e spacccralt Etructure. The harnee¡ muat not
form a clo¡ed loop or loops around any htegral rtructural member'
Any hoie, that ha6 e tt nb of the hame66 parred th¡ough, murt b€
of a ¡ufftctent size lo accommodsta th€ con¡ector lhst '*1ll b.
attac h.d lo th€ llrnb.

Stmulsted rtructuret and Jlcs ¡hould be construct€d to repreaaDt

t¡e h¡r¡elr lnterf acer to equtPmef¡t! to8ether wlth atruch¡re P¡o-
ftle¡ a¡d a¡¡y ttructural member¡ uófch wtll plec. re.trlcttotrr uPon
the ror¡tl¡g of the harne!!.

They may be made Írom u,ood, metal or mctel fsaed \"Úd ' Wbere
tbe bameat tt to b€ tertGd oD the .lrnula!€d rtn¡c§rre or Jtg, e
metal face rhotrld alwayr he Pr6.ented to tb€ hame.., 8¡d 'lI ruch
f ace¡ ¡bor¡ld bG el6ct.-lc&lly bondcd. A commol búdtng Potot
¡bould bo provtded for sttachm€nt to tPri oqulF¡€tlt ' ThGro rbould
bc no rharp odger, protrudtng .crcw hcsd¡ or cut 5d8¿l to Ea8 or
dem agc tbc cablo¡ a¡ the hernc¡¡ t¡ fabrlcstcd.

2{-9
 ECTDT t
colFoxl¡?t tat¡GtDx

corDrrt

3. 1 erlGÉo ñlcl¡
t.¡ WtÉ Btr
3.¡. I Wft. b.¡l¡d6,
3,7.2 wlrc ¡¡d Crblc Pr¡¡aalo Da¡¡
3.2.t Wt!. !¡d C¡bb X¡¡ui¡ür¡¡¡r (D¡roDa)
3.r.a Cop¡ü rd AbEtEt¡E Wtr. Ddr
3.3 C6aat E Data
3.3. I n¡d¡¡f¡trr C@G€tolr
3.3.2 C@.Ér E f-a!.n Clltcl¡
3.3.3 Co.ctor E¡¡troürr¡r (D¡¡c?.r¡)
3.a ml¡¡ Cory¡d¡

E¡nn ¡rt

Tbl¡ ¡oodc rcrlr. lüc srttrt¡ for tü¡ r¡l¡d¡¡ ol @rQoGl

prr¡ ol r c.bL b.¡!r.. Tbo rtcotrt'¡I, Eáobd§d .Dd
cbcElc.l p¡opsrt a ol tb! rlatq¡¡ brü¡¡lE rrc prurnted.
Al¡o bcltrdd ¡t. Danñto d¡tr rad Du8o!.8 a4,9llcr.
3. COI'{PONENT SELECTION

3. I Se lecttÍi C rtterla
The requtrement! ol a¡ eloctrlcal tDrul¡ttco for u¡e l¡ EFc€ are h
m¡Dy wey! l¡llqua, ¡sd .ubrta¡tl¡uy more demandl¡g thsn thoEe lor
u.€ e the 8¡or¡d. The t¡brlcrttm r¡d gtcr¡ld -testlDg of e spscecraft
lyEtem demand pbyelcal e.Dd olectrlcal excelleace l¡ thr bsuletton
m¡terl,al. F\¡¡t¡ermoro, wha the m,¡tGrtalr ¡re to bo u¡ed l¡ cr¡ter
space, tho destgn er¡glneer mu6t cqr8ldor thél¡ w€tght, re8lrtance to
radhttcr¡, and performr .e b s! ultr¡+lgb r¡ecurm, R€f. 23, 5?.

Or¡tglsE g characterl,Btlcr
k¡
R¡dl,rt[ca res [6t¡¡ce
Welght
Re6lltance to cold flc¡s
Reslrta¡ce to ci,¡t {hr:ougb
Re!Eta¡ce to abraslon
Adhelto to pott !r g compcrunds
ReclltáDce to wi.kl¡g durl¡rB solderl¡g
Ternparrh¡re chsracterlrtlcB

or¡tBr€ ln s Chsr.ctrrtstlcs

To r{¡B u¡e a aucceaaful mlsslon, the spsce vehlele deat¡ler must

recoEnEe a¡d acccr.§t for the decreaSe l¡ externsl s.tmospherlc pressure
at hlgil eltltudes. Tte preasure decree8e8 from about 10! mm Hg at the
Earth's surface to 10-6 mm Hg at 200 kllometres (125 mtl€s) and leae
tlran l0-12 mm Hg beyond 65o0 ktlometrer (¡IOOO mtles) eltttude.

SrbluDstlcn (the escape of molecule8 from eollde) ts enhanced by the

lrck of atmo6pher€. The lripact velocttl6s of moleculer eecaptng tom
the rurf¡ce of I ¡naterlal generate prelrure crn the surface e¡clo¡ure,
At a glven temperature thla p¡es6ure l.¡ called the lapou r pressure.
Whoü th€ moleculoe rebou¡d from each other l¡ the e'ricloaure and
boSb to colltde wlth the parent materlsl, üey are Eald to be ccndenslng.
Equlllbrium ts resched when the rete of mol€cules escaptn8 equals the
mt€ ol !ho6e cofldeDsl¡8. Thl,B canDot occur i¡ spece, ?h€rc subltm-
etlon proceedr r¡rrover¡od. lt a rate dop.ndqrr qt t€mPar¡ture ¡ad
m¡torl8l.
PlaEtlctaers uE6d In certaln pl¡stlc msterlslc have relatlvely htgh
v¡pour pre8surea, wht¿h, I¡r htSh vacuum (le!r than to{ Torr) c¡n
cau¡e tr¡lk losse¡ and cba¡¡8eE h materlel charactert8tlcr by prefer-
eatl¡¡ ráporbrtlcn ól volsttlo cqrstltu€Dt!.

3-r -1
In era luatlng the cr€tght losa and outgasslng performance of aD tn8ulatlon,
It16 lmlbñant to conslderr the i¡ttlal and subsequat Bteady-state
wetSt¡! los6, the total wetghE loss, and the extat of coDdglseble
materl¿l8 evolved as a functlon of temperature.

Non-volatlle co¡de¡sable wlth these lnsul8tton8 wtll presum¿bly not

presñt any evaporstic,n problems a! temperatures b€low 20OoF.
But tf the lnsulation, when heated or LrradLated, releasee volatlle
aubst¿nces that can coadease on coldor eurfaces, optlcal syatema máv
be lmpatred by cloudlng or corrtrdlng. (Ref. o5 ald 56).

B.edtatlo,n Beststlnce

Organtc materlals are Busceptlble to dañrags from nuclear redlatlc,o.

The ¡eeult tg a chemlcal change; the moleculo8 thst glve the materlel
tt8 ld€nrlty are altered and new polymer chalns ere formed, The
cor'¡centratlon of these degradatlo'r compounde t¡creases wüh l¡creatl¡g
radtatlc,n, resultl¡g tn changes l¡l mecha¡¡tcel a¡d phystcal prop€rttes'
I¡ most c:¡aes these ch¿ngeE are not beoefl,clal, resultl¡8 l¡ detertoratton.
Dlfferent levels of lontalng lrradlattoü are €,uc.ountered ln dlffereat
reglons of space. The four mal¡ sourceo of redlatton !¡ space ele the
l¡ner radlattc'n b€lt, the outer radlatlon belt, aolar emlsston, 8Dd
co8nüc rays. Table 3. 1 shows the tcnt8att.ra dose8 produced by the
protons and electrons at the pesk of the lDner radlatlo¡ belt, by üe
electrofis at the peek of the outer radl.atton belt, by protons a¡d
electrons of the steady Bole! emisslon, and by cosmlc-ray protcn6.

Tabie 3. L
lonlsatton Dosagee ln SPace Prorluccd by Atomlc Parttcles

lontsetton (megaradB /year)

§¿¡face and th rougtl

I mglc m2
Inner radlatt€r¡ belt to6 to-l - 1
Or¡tor radlat¡on bolt tos - ro7 ro-2 - I
Solsr emls8ton to-l - ro lo-4 - lo-3
Coo mlc ray8 lo -6 - lo-5 ro-6 - to-5

Adhe¡ tcn to Pottt¡[ Compor¡¡dg

Potentlal sou¡ces of trouble ln,spac€craft are: fattgue of soldered

Jo{nts, breakage of wt¡e at lolder iohts tn corDector aeaemblle¡,
8Dd
peietiatton tnto the back of t¡e cc,n¡rector by molstu- e ' dtrt , dust ' and
other forelgn matter. M6chaltcal elampe glve eome protectloD ¡t üe
cost of bulk$ess but offer noihlnB tD terris of electrlcsl performance'

3-l-2
 --^.--<..=.<É

For theae reaaors, üe end¡ of the wl¡6 h the cattactB at the brck of
the conDeclor are gvnera.ty potttd. The pottta g mat€rl,ils aeal out
forelFr m-a.ner, tmmobl,llse the eolder rotDt, aDd hold the w1ru,
provlded rh¡.r th6re ta a good búd b€twoo th€ pottlng metertsl a¡d the
wtre l¡6 ulatlon.

Resl,sta¡ce to Wlcld¡ls Drrt{¡c Solderhq

Flow of eolder under the wlre l¡l8ulatloo ehould be k?t to a ml¡lmum.

Exceeslve wlcldng (more thaa one{lghth tDch) adds u.selesE wetght
8¡rd promotes stuf Jol¡ts. Most tmport ¡rt, [t causes t]re copper
eondrrtor to b¡esk under bendtng or vlbrattoD. It alro Eakes ii
dtfftcult to fabrlcate a cable herness l¡ llmtted spece. StDce the
har¡ees ls laced up to the cqlnectton for mechanlcal support, tha
wtre8 muat b€ able to take Btresses at some potlt otier than the solder
conDectlon, whlch te the weakest pol¡t of the hÁEeEs (lI the aolder
wlcka loo far under the l¡Eulatt.n, all Btresses are tra¡¡-mldted to tt,e
§ :d( r :onnectton).
. 1al, r far':tor determlnhg the amount of wtcldag ls the outer coatl¡g
o^ ¡..i cut lon4uctor ltself. The conductors mo8t oft€D used h
l..ok{lp wtr 8l¡ver-pla:ed ,- ' tl¡¡Eod copper. Solder wets better
. r silver '-: \e tl¡i thus 'tcld¡g acttc,a lB greater on ellver-
'.rlated than o¡r i iD.led copper.

Wel.¡ht

Wetght t8 e prtme factor when conslderlng a¡ bsulattoD materl.el for

uae l¡ a spacecraft. The llghtesr cable/wlre whtch will meet all the
requtred electrtcal a¡d mechanlcal perrlormaace should be ueed In
order to meet the gpacecraft mass maiglDs.

Resl,Btance to Cold Flow, Cut-Throu(h, and Abrastcr¡

?he coid Oow, cut-through, and abraElo¡ characterEttcs of an lns'-'latlon

materl¡l are tmpoñant n¡eaaures of tte rorlGb(üty nnd the amor¡¡ of
fabrlcation d'rterloratl,on that wlres a.r,d cables udng lt can wf':rstani:.
Wlres to be used l¡ Batelllte ha¡¡eeeee should have Eood c-:d r..rw,
cut-tbrcl8h, ürd sbraElc,n re!lstance to "rrard agalnst danl.i"e csLsed
by leclng. clampl¡8, and vtbratlori.

TemDerahJ.:'e Rcqu lre me¡ta

'I'he rpace.reft temp€lature ca¡ be ot:¡bred fro rn. tt -. therEial anElyats

and the cor¡ect w'lre téIectod. ir'osi oI !h! :ommonly uasd h¡ulrtlone
can sur!.l?e cycll¡¡g betwe€ri -55oC aDd +1sooc.

3-l -3
More det¿tled aneatton should b€ psld to the wl¡e l¡¡ulaticD lI the
operatl¡g t€ r¡p e ratu¡e ts htgh, aa one of the etfects of hlgi temp€rarure,
darbg l¡radl¿tle of orgE¡ l,c matertals, ts to llclease üo amoqlt of
damage thar ts produced by a glvan radlattcn doae,

Corona

Corona betweo electrodeg and lneulated wlres @curs whenever the

voltage gra'jleat lD the al¡ apacee belwecn t¡em erce€da a crt¡tcal
vslue (Referace 42). Corona ma¡lfests ttself as a lumlaoua glow or
ag a srnall current b€twe€n energfued olectrodes. S¡ch corcEa
phenomena result trom locallsed crltlcal gradleDts. Ultlmrtely a spark
or arc carryr¡g larger curreDt formé lf üe crltlcal gradteat progresses
acroas the whole spacr¡9. Electrr:al CLschargE8, hcludtag corona,
ln gaaes foUow Paschen's I¿w, whlch st3tes that breakdowa \oltá g€ j,s
I functlon of gae preasure tlmes effectlve eicctrode spÉclnE. Bas ed cn
Paache¡'s l.at,, corona oD.set voltage data for lneutated wLrea has
generally beca preaented elther es a ñ¡nctlon of ga.s preeaure multlplled
by effectlvc aqJductor Bpaclng, or as a hlncttoD of s tmply gas pressure
(RefereDce {3}.

The tonLsed gas crested by corona degrades the electflcal and physical
properttes of the l¡sulatton on wlres (Refer€nce 44). Thls degradatton
ts undesirable becar¡se l¡r tirre lt destroys the layer of eoltd t¡sulatlun
adjacent to the gas. Furthermore, corona wthl¡ electronlc wElng
generates spurlous hlgh frequency currents that hterfere wtth
commr.nlcatlon a¡d may trigger sensUlve clrcults. Corona also
wastea and dlssoclates some materl,als, creatbg uoráoue gases and
od<.,urs. Corona-free design 18 achieved by ltmttl¡g electrlcal slresses
l¡l the gas¿8 betwem l¡sulatlons and berweqr t¡sulatton and ccnductor.

I¡ order to preye¡t lonlsatlon, also referred to eg corqla, or partlal

dl,acharges betweer the or¡tstde of an unshfelded wlre coverl¡g and
grourded structural elen¡sltg over whlch the wtre passes, or between
tt¡e l¡sulatio¡ a¡d a bratded shield, the s,tre crverbrg ahould have
adequete "equt\Élent l,nsulatton thfclqless' for the cmdl,tlqrs of
operatlon. 'Wlre coverlDg" mea¡a a¡y comb¡¡ation of enruded or
tapql l¡sul,Bttcn8 aDd lDsu.lstlDg ,rcket8.

Ioa[satlon c¿usea cheñücal snd mecl¡entcBl d€tertoratim of the covert¡r8s,

ls E source of radto frequency l¡terference, ad produceE by -products
whlch can corrode adjac€nt metÁl-llc compoEenta. For AC op€ratlDg
volt¡gEr not erceedlng 240 volts RMS, aay Cv6 th tcl¡les I of fl¡w-free
l¡Bulatioo ls sdoquate to sumgr't thts \olt8ge at a¡y presaure or
temp€rature; thlclc¡eBs !e dlct¿ted by mechaatcal requl¡emarts.

3-1-4
 I I I

8K

6K
5K
G (x
I 4)

ffi
E 3X
ú
F
J
o
,_
l¡,
(,
F
J
o
F
E
'W
fi"c
F
tn

z
o
É r00,000 FI 2000c
o
o

n, I o .2b i0
r.J..Il.....lMlLS,
¿0
I EOUIVALENT IHICKNESS(tIOFWRE COVERING t = l(¡ K2 l(¡
I
For hlgher AC voitages the ñequl!.alerit lnsu]3tloD thtcloess' can be
fcr.¡rd lr¡ Ftgure 3-1. S€lect the approprlate orrve for the s tmults¡ecü.8
¡nl¡lmum pres8ure and m¿Émum temperah¡fe of the arDbteDt al.r to
whtch the ¡rlre wtll be e:eoeed and resd t¡e 'equtEleDt lñÁr'l¡tloB
thlcloees " correspcadtng to tho op€rathg n\fS voltege. h tpa.ce
appllcatioDg due to partlal or coIlplete €aclosure for preaaurlaatle
and due to local b€&ttng, the arabt€nt pressuros a¡¡d temperahtr€s b
the equtpmm! may Eot correspor¡d to tho€e at the aa¡ue slftbrde cr¡t8ld€
of the craft. Equlpment operat,¡g preaaurea and temp€rarures gbculd
be used tn the determtnadon. The ^equkaleat tD.suladoD thLckJ¡ess"
ls related to the wl¡e coverbg a¡ld t8 shcnra ,.n Ftgu¡e 3-2 where tl,
t2, etc., ale the Buccessive thtcloesses and k1, k2, eta., are the
re8pecttve relative dlelectrtc con st¿nta of ü¿se same wl¡e covertlgE.
The r¡alue determlned ts lDdep€ndat of power frequacy up to at least
several kllohertz. The vaiues of Flgurc 3-1 are based oo üe
l¡ceptlon voltage (corcaa st¿rtlng voltagE).

For calculation of corcaa l¡ception vollage see References {0,,11 aDd .12.

Once lonisation has st l¡ted lt does not extl¡gutsh untll the appli€d
voltage [s lowered to the corona extlnctton volt¿ge, whlch may be as
much as 20% lower (Reference 18). A factor of safety sheld be
allowed so that a tra¡8leDt voltage wtll Dot l¡itlatú loDlsetloD whl.c h
wtll not dtsappear at the op€rati¡g voltace.

The mlnimum CIV of a tcrtsted pair ls al§'ays greater thaD that of a

spaced palr havl¡g the same wlre stze aDd lnsulation thlcloess.
'Ihe dtfferñce in ml¡lmum CfV betwee¡ a twLsted pair and a spa.ced
pair delJ¿nds on the dielectrtc constart of the lnsulad.on, thlclaness of
l¡sulatton , wtre slze, and voltage stress (Refermce 43).

Corona dlscharge l,s a pañlcular probLem cn spacecraft htgh voltage

systems. The htgh,/olta8e breakdowns have been attrlbuted mal¡ Iy to
lnadequactes ln l¡sulatl,oD (lncludlng conformal coatlngs 8¡d pottl¡g),
tmproper ventl¡rg, degrssbrg and workma¡shlp probleme (Refererce {5).

Srieldlng and Enclosureg

I¡sulatton and Shtelrtlag: The cholce of l¡sulation for any wfres c&rryl¡8
hlSh r.oltaS" has a¡l tmportsnt lDou€nce on the PrevEltlou of bre¿kdown
problems. In general, the voltsge ratlng for the ln8ulatlcn fa epace-
crafi. ehould b€ sub4ta¡ttaLly ht8ler than that requlr€d for gtornd-baaed
oper8ttcn of the same equlpm€ot. It ta customary .o tcqulre a ratbE
rwtce as hlgh for grouad operatlon, and not unusr¡al to requ.tre rating8
ftve ttme8 hifher. h addlttm to a htgh brealodorm ratl¡g, the lnsulatio¡
=ust ftt enugly .tlto the coDductors to be free of r.¡otd8 both wlthln the
tnaulatlcn and betweeri the l¡suistlon a¡d the cmduct-Jr. Thl¡ t¡
necesssry to prevent trsppl¡g of 8a.8 b€tweqt l¡8u]adoa a¡d cooductor.

3 -1-5
 Gas pockets ID [rsu]Átlon or h pottl¡g co rupol¡nds or coDformal cost-
lnga are psrtlcul¡rly h¿zardous becau.se the bd.¡Ddary b€twe€a I 8olld
dlelectrtc and e g'ae of lower dfelectrtc clonEta¡t gives 1186 to an
lDcreaao b olectrfcel atreaa o¡ the gas. Thic oft€n ls enougb to
cau¡e breakdown ln tbe gaa, whlch l¡ tut! rorult¡ l¡ heaü!¡g aad
decompoE ttloo of edjecent i¡sulatloD.

Grou¡ded shtelde ehould be used over the fnsulatioD of hl8h ','oltsge

cabllng whmever poaelble to co¡.tah stroDg electrlc flelde l¡ the reglcn
tmmedlately adjacent to the LDsulad.o and !o reduce the llkellbood of
iolt¿ge breekdow¡ tn the volume outstde the lllsulat€d w1¡e8.

It h¿s been shown that the 1'oitage developed acro8a the ga8 h a
capacltor wlth a layer of ga8 and a leyer of solld dielectltc betweeo the
plates ls glven by

I tr + 1
(
,2

where V ts rhe aplled, tÍ is the thlcloesB of eblld dlelectrtc. t2 [s the

thlclgless ofthe ga8 layer, and ( ts the dlelectrtc cct3Et¿Et of the solld.
The dlelectrtc constánt of the gas lE assumed to be Eear u¡lty. The
quantlty that determlnee gas breakdown ts the electrtc fleld lDtenstty.
IJ we determlne the electric field ln the 8as l¡ a rold a¡d dlvtde !t by
the field that would exl8t wlthout any eolld hsulator, we fl¡d that the
electrtc field 1¡ the ge8 ,n a void may be hs!¡y tlmes thet whl,ch the gas
would eperteace wtthout the presence of the soltd tnsulator.

Another phenomenon that must be guarded agalxst l¡ the case of

lnaulated wlres ts a progresslve type of fauure lorown as 'treehg".
In tht8 condttton, a lesion tn the lnsuletlon ls produced by exceeetve
electrlc fleld or by lmpact of charged partlcie8 f¡om a¡ electrtcal
dlscharge hr the gas near the l¡sulatlon. UDder contlnued electrlc
atress, the leslon progresses as a aerlea of bra¡ched chs¡nelg thro.lSh
the tnsulatlng layer. The strntlartty of lhe apP€erá¡ce of tbe branch
channele to the bra¡ches of a tree g1ve8 rtse to the name. Somc
tnsulatl¡8 materr.als (such as polyethylene, polypropylae' etc. ) a¡e
eEpeclally susceptlble to this type of ¿allure. The only method of
avotdlag treelng [al]ure 1,8 to keeP the applled flelds well belo¡r thoee
whlch cause the fatlure by ellmtnatrng sharp coraers and pol¡t8.
In aome lnstanceE, the stplled fleld wttl be 1e88 thsn tbe cor€oa lnltl'atton
level for the conductor wtthout l¡sulattcrc.

The arc regtstance t8'the ttme (Eeconds) that e Eiatertal csa €ndure a¡l
arc acroaa tts su¡face before electrlcal breskdo*n. Thls tB not relstéd
to the at'lllty of the mátertai to endu¡e electrlcsl stresB wllhout treel¡8'

3-1-6
i

I
ODe fuñher ccnslderatloD wltb regerd to l¡¡ul^aüoD lE t¡at lome
EsterlaLs a¡e Eore lll«ely tha¡ other8 to fort|l ¡ c@ó¡cttDg pa¡h sier
I glw ur arc{'t/€! ba¡ occu¡red. Thls tr c8ll€d "tr.cklDg'. If ¡r¡ch
I p¿th of reduced reslst¡aco tB formed, th€n cubaequ4Dt breákd*!!
occur moro readfly ad le¡d to furlher hsu¡rtim bre¡kdcn¡. Tlre
mrtertel le¿st llk€ly to forE Buch ccDductl¡g patla eho.rld b¿ us€d.
L,DlrlnE A-ceats

SLDce m.o6t gasdlrchalge phaomena characterlsttcs of electrlcal

b¡eakdocri problemc ln epacecraft are trtggpred,by the presace of oae
or e few chsrg€d pt¡ttclee r¡ear the htgtr voltag€ leada, aay lt€pr thst
reducz the number of charged parttcles are llkely to be helpful.
Solar elestromagDetlc radl,etton f¡ Epace wlll produce pos t¡lve and
D€gatlve charg€d partlcles by photolmtsetl@ of EB moleculea as well
¡t electronE by photoemlErlon from Boltd Eurfec€s- Thl,s rq¡rce
charged parttcler.ce¡ b€ ¡DllDt mlred by aUocrrDg srollght io reach cnly
those parts of the hlgh voltsge rystem whlcb roqulre lt for successfuI
op€ratlorii e. g. , the detectors lD aD exp€rtt,lat to meeaure sola¡
radfation,'o¡ the easeoflal elements of a sra+eekl¡g gul¡qn ce devlco.
E¡er8etlc charged pa!tl.cle8, llke coErDlc rays gr aotar sbd partlcles,
or eveE eEergetlc trapped pafrlc¡elr, may p€aetrate to the vlctDtty of
htgh voltagE systerDs 8¡d, elther thrcr¡Bh thetr own presence or by
secondary partlcles, trlgger electrlcal hreakdow¡ eveots. The lower
energr charged paatlc¡es of sola¡ pla8Eas, trapped radlatloB belt8,
and tbe icnosphere are also haza¡dous becauEe, bebg much more
numeroüs than the hlgher enerE/ partlcler , they ce.u atplflcaDuy lo*.er
the breakdown volBge by accumul,aü.ug ln the vlctulty of htgh voltege
leeds. The lntroduction of lon trep8 for partl,cles up to a certaln
eDer5/, aDd the shteldl¡B of htSh lDltage elemats by 8urroundl¡g them
wlth solld rD¿terlal are measure8 vhlch have proved res8oably
effectfve agBl¡st electrtcel br€akdotm caused by che¡ged partlcles.
HIBher e,¡er§/ perttc¡es w'tll etl¡l p€Detrate, but rLDce they are r¿httveiy
fery thelr adverge e§ects are oft6a tolerable. GamEra rays s¡d hard
X-rays wtll produce lml,EEtioD that ceD be a haz¿¡d to htgh voltsBe
syrtems, tÁ¡t the6e ray8 ale ao p€aetr¿tbg lt ts not ueuaUy fe.asfble to
shteld 8gBb8t theF. The beot plr¡¡ ls to loc8te hlgh t/oltege equlpmat
¡s f8r from such rrd¡stlc,a aou¡ces ae poaatble.
One other way to erold toDlsatloD effect8 lB to svold the preEeúce of
E¡6es or rrBpours thBt resdlly proó.rce [oaa; for ex¡mple, rvater rapcür
t! qulte readuy toalsable. water sbrorb€d 6 ps¡t8 of the €qulprÁcat
or tr¡p€d ¡¡r pottbg compounda. oey be relerced elwly b tho 6Pac€
€nvlfoBmeat to c8ure trc¡ble orlrr s loDS p€rlod of tlme.
Recommeoded proceduled ar6 to d€-EaB all comPoaeot¡ a8 rr¡¡cb e¡
posatble prlor to l¡r¡ch s¡d to mlDlElae exporur€ ol the qulpmoDt to
humld atmoaphere b€tweo th€ tlmo of de-grlltDg 8Dd tb€ ttme of htoch.
ir€El8n fe¡turea whlch ficlllt¡to thlr ld¡d of headlhg ehould b€ hcorpor-
¡t¿d.

3 -1-?
 3.2 Wlr€ Datr

lte follovhg rectl@ cootsbt results of errah¡stlca ol Ll8tellal¡ br

u8. lD a rp¡c€ appllcrtlca. . Theee a.re preeeotd h t¿bular form aa
detstl€d b€I,ow.

Tsble No. ?TtI€

Det¿tled Charectertatlc8 of varlous

In.Ulatloat
3.3 RadlatlcD Efiecta @ Orgatc Eleclrtcal
I¡¡suletto
3.4 A Comp.rls@ of the Wetght Loas of TefloD
TFE, $ecütcatloD ¿14 rD/r Novalthene ¡¡1
Htgh Vacurm -* -

Comporetlve Abraelo Reáktslce

3.6' ' Comperatlve Cotd Hoib Resl,stá¿ce

.t. 3.7... .." Comperatlve Cut-Throu gh Res tata.uc e'

3.8 Recoumeuded l¡sulattm §ervtce

Temperatu¡e
3.9 . Er¡aluetlor¡ of Matertal

F: 3. 10 Budle &leld ¡vfatertal SelectloD

+
4:
§
n
§

3-2-L
 'rr. t-. ."f |t¿.l ,

| \lllt l..l lr.r¡rlr'l ( h¡'.« t.rr.rr\. .,r \.rrr,u1 h<!l¡ll,rr rll, r. ri,

:J r l't - lll,
¡l r lt¡ X,9¡.. ,l ¡.\ t' n,i. ,
t, lr¡o¡rli l hl ¡ t

!.ti ::,li l.:-ro 1.1t5 t,l

1!Eú.D¡ !¡,,.¡rIr.,
anú., I ",,.
t-, I UO{I
D-d.Ullrr rllh ¡ü..1!.. crúr I ,t-o"
l-¿.b¡lli, to lr¡ll .r¡o. l.-,"
clr.k.l ,t.¡.¡r<. IE.lLnr r:Írll-r
l
tilkir r..¡.rr.. trr¡ól I E¡..11ñr ¡a¡ r

t, w.t.r .b-.Flú l'll o.otlraii o. ¡o o. atd .o.ot ,¡ót o. t a .0.1o r/t. rr I ¡.t/2 ¡t. o. ol 0.i/2ait o.o! /rai.
I la "
,o16 I",.'ot' ta la
t§ .to ta t0 '¡ ¡ ¡oll to ¡ ¡ ¡ol! lo toli !o t0 tol'
I
¡§ o¡L{ - c6
\'5 !.5 1..' l-0 2.i-!., l. r I l.a
.t l!:L::"-i, l:'
I
?. r 2.

¡.tol Itr.¡or
I
¡ to_' ¡ t o'l ¡ lo-'
l¡..lFt!ó lrlo. I¡ toi 2 ¿ a
-t to'l ,4,,O'I ¡l ¡ lo_l ! ¡ ro'l l6 ¡ lo'l
to -10 lll
,.ñk. f.ñFt l¡E I
'40 .60 "ao .ao -40 I -ro -nl .40 -45 -¡o -45
Dqhú f(r ¡t0 ,'4 ?50 ¡00 .oo I to5 ¡f¡ Ito ,00

Fr t ¡roq
.l
toao 21 ooo I .*, ¡¡ ooo tieo ¡0 000 | ! tooa
Il--rlO.r25C 0. ¡oa¡ ¡,lra o.2oa¡ Lrlt r.6i, I o- ¡r 0. at¡t Qilt2, l.'?t o.llra
¡¡oat¡¡|. o{.!..lklt,
ta @o t.o lro mo L,o *o ,ao 000 .l?o ooo i0 oao
*'r.l . ,o' t.tl0 !. rr¡ 0, 0001 ¡..a2! I ¡2. x I t.2, 'lr.?lt !l.ali r. ai¡
¡ r.oc to I r-rt5oc ro r- ¡ooc r¡ trloc ro
tlocr I ro ¡"cr to'cl ,0 ct lo(l ,o c,
t0'\:
tl
too
I
lo
lo
,,
p
1.,
lq
2l
to
.)
ól
.tlo
tt
t,
2t too
¡no :,
.,t
,
aoo ¡ioo ¡1, taoo ,o00 I t00 aoo qo ll!lu, Iti
li I 5 I 7 t!.2 I r¡l I rtl
I
. Tñtn A. f l. tt¡Frl ü N..d.. ..d Co.. bc d. trFr<!. ar I 3br. clo(i
't. f rütn¡.i. ¡l¡r.or, aahl{ ,¿l ¡a-r,rtrr¡l Co' .- U.l¡¡ D¡¡Ei ..¡}od..
., l.l-l b t.r.l.a
 Il¡¡,!! ..t r. rrq tr-h
F/a-¡ E¡ i.{ ro ,''-r t -¡-.
?rl¡ ¡-§
l¡al..hr llt .¡ c O;.t ll-rabl b.¡¡.¡¡- (IrC lar
(¡t (a t?l (D (¡ (lt) l¡¡¡

t
3 I
-: i ii
I l1¡ ¡¡ i
t r¡> l¡i i't ¡li tII ¡u
¡»-tÉ o. oal¡ ,o_l roS lo
I
fFrr ra.o-¡tL ñ¡!¡a ]r. r--
¡.a
l¡+.
: .-....:-
o.@tt ¡rl0 t0 lolc

h¡r-t.t. En¡td ¡.:- ¡ta-ít o. oo! to_l to5 ¡ol

t.5
.E o, ooot ?rtO-? !d¡¡. ,ol-rol ¡ol

I ... -lor d ,¿.lrrd. 1.5 ,¡o-{¡¡ 0.001 ro_ó r¡! lrto! ¡r.,07

l. o d"" o.@l! aatt ,o' a.¡ot

atl-aÉ aE-.-
¡.0- r9-s 0. @¡5 Ttro - lo rot
E (d¡.rcl l.l .E-aó ¡l¡¡
tr.GC (¡¡tl ?: ,.ñ
t.€ - ?o@ o.0oo¡t 3.orro ¡¡ot 'tct
..j,'.'
t.: ¡,O-¡lq: o.@t a- arto - ,o' tot h¡h¡6.r¡r.r-.
¡. a
-t: a-tu. r¡-a¡l
r¡¿

o, i3- i:É3to 0.00: hlo' l0 ¡o?

r!881 ¡. ¡

¡.0- ¡oo-5!o 0.002 ! a¡ro - n.íDl. ro6 Jr¡oi

1.5

0.9 a50-a5a o. oo¡ ¡.1o_6 n.Íb¡. ro6 lo

1

toi l0
t-¡u..EGaü ¡11..
¡

-to lo ,lol
l. L- «xr-loo o, o{¡l ?¡¡o{ to
t -tolo
t. ¡

0.t-
o'.
a!o-roc
:'t'
o.oo:
. I ¡.¡,¡o{ -¡¡lol -t0' TG.¡1. .¡ñar¡ .d
bl-L.LñD Élr¡'
d-r-¡. (¡l.r i..r
I

ln."r,. l-.,tf¡a ñr_ l,'!t¡.

t.a !!o-ae o. oo¡r I r'ro-' ¡r¡ol ,.¡o'
19l-f .l.t- o, oo¡ i ro'' toi ¡r¡ o lloaa¡ldr t¡8r..-.,
,.2 ,.
¡. o! ,,, T\
o.*. ,.. l. ..,0t _ I o.n" ¡r¡ o' r.!'

¡, r ¡0,¡.o.' o. oor I ro'l t0 l. !r :,,

l.la
; ,"¿,]¿. '

¡a{to.r o.Jo¡l . ¡ ? ¡ro 0.rrb¡. tot

lo?
'l
.ra6llt lr..¡.-

f.0- ttrD t. ¡t aO-tl o. tol¡ t. uto'l ll.¡§¡. ¡¡lo' t tol

,.0- {tltt ¡. ¡¡ tqr-{¡(| o, oo¡ ro'5 to5 ¡.¡ot

 TABLE 3.4

A Coroplrlro of t¡. Wé lght I¡¡¡ of Tcnoa TEE,

SFclftc¡do ,l4t od Novttbsa. la r Hlgh V.cur¡E.

Welght ol TtEc l¡
lÁ¡t rtd wlrc raaple Tcntara§¡rr vLuu¡c. TrctgE trorr
Gr!¡l.) (toura) &a rcout)

TcOca TFE 100 0.(x

Teflo TEE 300 108 0.29
Novrthac 200 166 0.06.
Novrtb¡ae 219 . 16E 0.11
Novrthc¡s t. - -.200 - 100 0.dI
Sp.clflc.tlcn ,t{t 27i 200 0.ül'

Not lvslbblc -: - _.-..;l

Tr¡dearme for Raycbem wlrE to MIL-W-810,1,1.

,--a",
!
F-
I

TAB¡¡ !.ó
Coprrflvr á¡rúlo B..lrt8cc

s? Abrr¡ ba i -' i j '-: b¡h¡¡ ol t¡o

nrdhgr onEf-EññE
1 a0. a 86.7 26. t 21,6 12,3
2 43.0 39.5 2L.7 24,3 15,3
3 36.7 {ó. 0 27.6 24,5 15.2
1 83. t ,. 38.8 30. t 24.1 I
12.3
5 86. I 33.6 33. { 2a.t 12.2
6 38,7 30.6 80.5 21.t 1ft. 5
7 48.0 33 .7 27.4 27,0 16. 2
t 37. ! 45.9 E0.5 21,1 12. 3

h rlth¡¡¡tfc
rr8c 39.4,-.:-. 39. 3 2E. t 24,1 14,2
r¡¡bo
3S.3; 34,7 26,4 21,5 12,3

ROVAfHENE
R AYOTI N. N
ÍELON ?FE
SPECIFICATION ¿¿
IEFLON FEP

INCHES OF TAPE

t-2-0
 TAB!¡ s.6

CoEFrrüv. Cold Plc R¡¡bt¡cr

\.6Á ¿ | . . Tl.Et to F¡llurc (bourr: al¡utor: ¡cod¡)

lpuaü)
NgvlilrnG n¡yolla-N¡ TeOo TFE SFc. {{. T.116 ¡EP
13.13 00:00:01
12.50 00:00:03
11. 88 00:00:03
11.25 00:00:0E 00:00:(X
10.62 00:01:2.1 00:00:24 00:00:02
10. 00 00:04:33 00:00r.10 00:00r03
9. 36 00t22117 00:0?:05 00:00:03
8.75 Oltl2t2i 00:30:i2 0o:00¡17 00:00:02
8.t2 ü1232:.08 00:49:00 00:01:53 00:00:22
7. 50 l9:55:00 0,1:38:1E 00r09:52 00:0E:30
6.88 >24:00:00 19:23:33 01:13;29 00¡50¡00
8.25 >2{:00:00 15:31¡ 10 08:00:00 00:00:02
5,42 >2,1:00:00 >24:00:00 00r00:03
5. 00 00:00:{{
4.37 01r1{r 0?
l-
I

3,7 5 >2{:00r00
t

s-2-6
 . TABLE I.7

Con¡rrüw Cut-Tbrcgh n .!rt^Ec.

l¡rulrtlca Cut-throu3ü lorcc Ootedr)

0116rl¡¡
f.rt 1 Tc.t 2 T6.t 3 Tc.t { Avc rr¡l
Novrt¡.nc ta. 3 L2.2 12. 96 12.3 13. dl
SpGc tflc stlon 44' tl.! L2,E rL,2 13. 3 t2.2
n¡yolln-N' 12.1. L2.1 11 .7 12.1
Tcfloa TFE s.2 9.8 9.2 9.1 ,0.3
T.no fEP ?.o 6.5 8.? 6.5 E.?

I
FORCE IN POUNDS

Cut-throu8h R6tlrtst¡co (avorag6 d four rcadtnge¡

 ¡
T¡blo 3.8 R¡comm¡aded b¡ul¡tlm 8orrrlcc TcEp.r¡E¡ro

U¡tr!tsl fü8! TcEpGrrü¡lc tr'

.
Abovc
Krptoo
2oooc :

{0ooc -g)oc
Polylmldc FuEr-Polyfun¡do Adb..lrrú goooc -2oooc
TFE teflcn , H6¡t ¡\¡¡cd 2sooc -20ooc

15ooc to 2oooc
Polylmldc FUtrr-FEP, Hct i\¡.Gd 2oooc -2oooc
FEP-Telo, H6¡t I\¡!ed 2oooc -2oooc
TFE-Gl¡r! -FEP-Bo¡d¡d TeOo¡, 2000c - ?ooc
. Host Fuld
125oc to 16ooc
FEP-C T6f1qr , ¡l.rt R¡red 1500c - 55oc
Poiylmld,r Fum-Phaolic E¡tyrrl
Mhe¡tw Bo¡ded . :. 1500C -toooc
fEP-C-E¡ory Adh.llvt Bo¡¡dcd . .:, 136(,C - 550C
Polytmlde Ftlm-Epory Adberlvo
Boad€d 135(,C - Sgoc
Polyc8lbcnst8, He¡t l\¡¡ed rzooc - 550C
Morcchlo¡o-trl-Ouoro Ethylene,
He.t l\¡!od 125(,C - ?ooc
10ooc
Polye;ter Fllm-Polyorter Adhe¡lve
BoEded loooc -toooc
Polylmlde Fum-Polyeeter Adhc¡tve
B6ded 10ooc -loooc

Thl¡ m¡torlrl 1¡ dtftlcult to Pr@ctr ¡nd .ha¡ld oly b€ c6sld€led for lt!
hlgh trrnp€!¡tr¡r€ c¡psblutlor.
,
.ir' Tamporrlu¡€ rllo h th€ coductor due to l-R lo¡ro¡ mu¡t be sddod to
rr¡btent tompcr¡h¡Fe ol crble to det€rml¡c total lnlulatlon t€mp€aoh¡re'

3-2-€
 i i: ' T¡bl. r: t .:'
Dñtü¡tt.. ol L¡aarl¡l

R.l¡tIY. Cqrt C]¡rral Ura IU,l-l!dara

tt¡t r¡l,/Xr¡.d Dc.crtpa¡..

Poha.i.r f{a
x¡r-¡¡l¡¡to. doala ttaP ¡¡u¡lt, Ú..d dtly AÉ€Fo. - ,¡¡Li ot3 r[,c-rt?t
Wrqr
bn¡l.tl(n oraa ¡üLü¡.
" .LLH. o AGI ..bl-.

Potr lmldc
Iultt<:aP. l-r a-bb¡.. ¡¡.u¡W r¡"d 'llt Hré A,túFc. rtr-;-rrt¡¡
T¡F lYr¡9 Alrctai
. dl.Ft b co.t oltFl o. Ff,P.
To¡tc v.r¡l.¡, tood G¡¡t..t..ltt¡c. - ,rlrlttlly Útd lllú
Coa¡l¡a
,or !¡¡¡!at rlta brl¡l¡Údr lhcra crFttoL ¡Dd
radl.lt¡ r..¡.§¡cra ¡r. d.iltod.

Elr!:I!.ale!!! bcryor¡n Al¡oñt rtL-r-raa

Eúñ¡¡ lo fL.tttDpl¡¡rlc co¡rFr¡d tg.ly u¡.d '¡ xl¡' A.r€Fc. (AGD III-r-lat?l
b.u¡¡l¡or. Ooúlrarcl|l
Ooñr¡crcl¡l - Fd
T¡f. Xr.9 UF.r ta.ngc¡orra lt!¡ll Fcra¡ta L' ol l¡'rñÚ' ¡¡a¡l¡tbt .DUcn d
¡catb¡.dhs¡tvt. l{d t9ñmol, u!.d for p'lmrt corúb¡ rlfa br¡n-al.
(¡ rl.. haul¡Úd|.
I
i9 FohciiT¡.rr.
I LrúCoca Ill-C-lt
ra cL¡r¡ct.rLtlc.. n.§¡F d 'Lllo'ba'
G¡r¡üttm Lot
f,ú¡ú lca Good
Ahcr¡ft ¡ll-t-ta
¡oa..ó l¡.. Allt'orB¡lt¡ raqtlr'd b¡ 'loctric¡l Coltl!.ro5¡
lt. to ,.!v.¡t dctt d.tla ria .¡9oaad ¡o llt'¡t or
La¡L
lDa @¡!!lGrct¡¡ rDlloba
T¡e. Il¡p Ilrdl.d tGtrP.r¡ü¡ta r¿¡i¡. prÉ.h¡dct lh' u" ol rü.!. t E...lr¡taallÉa.
ó.re-a¿tLb¡ ¡Átattc- f{oa tú.1, utcd bt rtt'
b.ultdo-

X.l- ¡
l(Poh.i¡o.rr¡¡r-
! ñúrúr¡rl.!.¡
_---*--.i_
(> ba tr¡¡¡rar..L tl¡a b.al ut.d L r¡c¡'i oñt Lodütta
I c.bla, b¡l ta aült ¡tl ctacb.
'
f¡ób ot¡¡¡l¡
I
I

lT¡F ryr¡p -d rlld ll-l.c.l¡h¡a, Oclbb ¡t ¡.,r Ll4'r'tür-'

¡^rtraa.. úttt to odtcr ú¡tcal'tlt'

Ar¡oFol talt-t-l a¡rt

i.ar¡kca 'a¡rt.rbt" to tn¡t honroaGn@u' ¡!d Hl¡tr
/Ilrcr¡ll Xl¡-9-tl? ta
D¡rtt ll, ¡í.t aü¡. Ea6ll, conüt¡Gd ttlh ñUt"' Co¡rrlt¡crcbl a0Itttlt
llldt Al¡crañ r.pLcrd b¡ ¡, u,Í-laa?t
n.qult.¡ '.bl..b¡' lo ttr¡L. bon¡oíci"d¡'' to¡ttttl!
ctau¡Lí ln ¡rúll
¡f.plL¡tlqra.
 T.bl. lr0 (o6tbu.d) -
Er. ¡,¡¡rioo ol x¡¡.rt t

)tt.r¡l^l.t5od Da.c¡lra¡6 Rcl¡tlr,. Cort ' c1¡rñü L,r. . ¡(n-Qclio.t¡a

I ,.,r.ii .. , ! ,.
LC!9!-gI¡L .

Co¡¡h¡ dlipcrrla, co.t ot ¡ rt D?.d l¡lul¡tlú. Fü..d at AatoaDacc'

hth t.ípcrttu¡. to cotl¡uolE lllñ.
a
- ,ti
.,,r . .

,.
El¡B
lac¡t.. ¡io( l¡aa¡dod rga u.a ú prllÚ¡r, - *;,1. ¿.. Ac¡óDac..
' ''.: -Arrcr.o ,
¡
i .. lim9oñtuta ' . ,l:
bar!¡llar. Cornñcrcb¡
t.
t.flon IFEPI
,'|
I

E¡¡¡.üalan x.¡t¡bla.od lora¡ la¡¡p.rrlura c¡p¡bllltr, odt.rrtr. . Lad.ñL . ¡!c.c.Fo¡ rtt-c-l?, .

'.* ' . at;rlt.¡ lo TFD. cq ba Gnr¡¡d.d t¡ a r[&!aa ali¡ll¡t . , Ilr-i-rat¡t

i to oat.. ü.roopl{th ñ¡t.tl¡l¡. Dod Éf t.qütrr ,+lb ta¡r,r-¡lt.
i1I . :*ebtcrla¡. , .i.ft : :: .. i,,,.i'|i r0rar95r! 1,
.i , . ¡i'.'
T.r. ft¡g i rl;t.Grl¡bl.. tood o¡¡t¡ct..lttlr.. E t..¡hll, b.\': ¡at¡,-w-t ti
oi pb ho¡aa ¡!¡d h.rl to vlrtu.llt all lúorn cicmlcrb ao¡arr3lt.
EdrolraL.. ,;
. Úfr.t- co.1h¡ D.ov8c! lor 9.rñabtlllr. . l' ¡aodatra. ':.3"lñ.F.a ¡a t¡-f-al ta ¡
: .. c¡ccllc!¡i hcrt ir¡hblut. hlah dlclcctrlc. W.tat b¡a.d. '
.
. ', i
:*
. ta¡y ba ¡..d ¡t lo?Gr ¡rmp.¡.tt¡ta 1ü.! TfE ....,¡
Lrld . Ia, ba ha¡Hc.l ova. rlt. bi¡ñdla¡ to Provtdo hlA ... ¡tatqFoa
lcmpañtr¡rc ,¡cl.l. lU hr urc .a ¡ p¡tñrt, , Al¡cni
,l
i. .
:. bau¡lü- brÍ¡¡¡.. ot Frt¡lly,
'I 4*. .: ii;;6ür.t¡i .i ¡.- , ,
,,
c..t,r
't r' ';i. Ii
hlrrúl-
lrr dLl.ctrlc cú¡t¡¡l Gü¡p¡cd rtth hl3h alr@lh E¿ ,aod.trr. i
Enñ¡l¡
abr¡a¡6 rcrlit.¡c! ¡llotr u¡o ¡. üh r¡U baul¡tlot
,r.aaE l,r .pcclr¡c tr.Ytr, ¡l¡É. rúra grodtEl
. p.a ¡.! ral3ht ¡.d poa.Dlt cott .¡vlntt. Eoor lq :
tar4.i¡¡¡r. n.¡lb!¡ltY. I
TrF f .., Fr¡ ., , , m-.rt¡ .or- b lotE ot tn¡¡¡ l5d c¡ol¡. !{oa utad
a. D¡to¡¡, haulttloat. U.Gd a. b..o c¡oli b l¡mb¡tal. i
Fol¡vb¡lldor.,
nrptB. fKrr¡¡ |llr)
¡tt¡¡.!.. ¡t¡¡d 6.¡.rt¡l rlü toad ta.ll. ¡lratü. llor.ñr, L.d.¡¡t f-úFoa Il¡-t-D¡a
¡-d. to b-om. Hnl. Ed .úGn poor lmFct IIl-I{lO,al
r..l¡t-ca iia Gd¡llad ovÉr t¡rF atr¡¡d6d cúá¡otort. I

F¡, trrp Bkh .tr-lh ¡¡d ]d¡h¡... !.mD.r.¡úr. .trbull, I

I
-aO 1o.¡m"f. 1.nall..t16¡ü o¡, b. ioc¡G¡tad b,
crt.¡|,ale t chlqu.t.
I
I t.
I ..
I .l':
 .", ttl

T¡blú !.9 (c<.tbü.d)

(^
Ev¡lu.tl6 oa I|c(h.d A

¡a¡thod/lltt..t¡l t).rc.¡alo n6hrlv. @i¡t Co.rÉ|t U.. Ill-Q.cukrrb

lr.ñ lr.tc
Folt.ra.r fro ort.r Flyc.l.. lltE¡ (l to i Xll.) rll,t polyG.tor Coñmcrcl¡l cqulp. ¡r u,-c-tagat
ot r¡rall¡ñc ¡d¡¡calvc. Itollld .upport GqulpEÉl
¡rd 0l3ht l,lü rn¡dtnüB
tcn¡D. ol I l)oc,

A/F¡? TE ou.; FlttrYrldr OIE¡. (l lo t Xll.) ltlt FEP IGdro'h, - c.oú|d arfrpon ¡trd ¡aIL-c-!¡Eat
tú.r [lr¡r (l ro I Ltl¡). nlthr.qutprnat rlth -
rn¡¡lmum tohp. ol 2ooec.

fÉ ¡¡E ol fEP (t LLt¡). CoÚlpr¡t r¡ .¡d Al¡ht r [/c-ar¡&t

ftP ao a
a$¡l9n¡a¡¡t, raqulrbS
aFcI¡l clcir¡c¡l
t ch¡r.ct.rlrltc. ¡¡dlo!
crrogcnlc opcr¡th3
lrtnErllura¡ rlth
mrrl mr¡¡n tcmp. ol l?úoG

('¡ Aü P.rlrrt!. lto q¡a.n Lrc]t oÚ ,obnñU. tü Fly'dld. ¡&clñ' lllai Fl¡Ot .qulprñar br
,I Ery hltt¡ o9c.¡rh¡
'¡: I
tañFt¡au¡la (rtola ¡
2oooc) ¡!d otr.'la
vlbrtl lat.

aód
Oú.rü bU tfü f.lr¡l¡td. Gült¡3 o. aI.¡ Hl¡l l¡D[.d ¡lr¡ Lq|.
to
Alt Pólt¡Db (2oo"c') htó
o6¿Ero.¡ cr.ü¿4 l¡aa gotrll[td. coiad C¡|at .lda. 'tt¡¡af-
ntht qulpE.ol.

Polrra¡d. - ll/FEP tlü ,otrtEld. cúlb¡ 6r .ldé¡

C6dtEto. fbll Xcdlró C¡ol¡ld .qulpErcor ¡¡d xt¡,H0!a!
GúdlEto.r.ldr.4 l¡- tllDEP lrratñ.t.d otlror ¡ld¡. llEbi .qulpbdlt rül -
ñ¡¡t¡lur¡ t r¡p. ol 2o"c

rFd.d
rEP Horút6ao.¡, clñ¡a¡(E tlü coodrElora Lbrulrtih l..dtoú for ¡fd¡d aqúl9múl
b D. proccr¡. r¡or. rcldr¡ 1,. lot
Dtr¡atd
ctlllcal ¡¡rl rp.ct¡l
aL.trtca¡ cL¡r¡c¡.rrrtba
¡¡a rqúl¡.d.
 (

r-,¡!A)!. rjÍ:R .-,ü ,-

Table 3. l0
Bundle Shleld Itlstorlel Selecuon Ch¿rt

Corroalon neslatance
Coudn¡o¡s Qeraüng
Shlold M¡brt¡l Tomp (A¡r) Ms¡ fC)
Effecdvero¡
Alr Abnosphere Ltquld Atnoaphole

B¡rr A¡mlcd @por 105 Poor Poor Excelle¡¡t

Tlaaed @per 150 C,ood Felr Good

4
Ellvcr-plrtad Cqcr 200 Good cood . Excallent
'I '.
1....
i,
I Mctcl-pbtad Oqct 350 Excellent Ve¡y Good Good ¡t ando frcqrcnc¡r.
¡9 Poor at rado frol¡rency.

Nl del-clad C<pper 500 Excellent Very Good Good at audo freqreacy.

Poor ¡t ndo freq¡ronc¡r.

ttrl¡lc¡¡ Stecl 550 Excellent Excellent Poor

L
(
3.2.2 Wlr./Ceble PeraE tllo Dat¡

T¡blc¡ 3. 11lo 3. lt lbt th€ ol.ctrlcal e¡d roeb¡¡l,cal psrsE¡d€r!

'r¡¡cd b tbe ¡electt¡d ol wl¡c ud c¡ble.

Thc core to !c8ra or coro to cora o¡p.clt¡ac€ L not apeclf,ed ln any

wl¡c/c¡blo speclltc¡dm. The capacltaaco Agu¡6s sP€ctfled h the
t8blo balw ero ac¡¡r¡¡ed v'Eluo. of Rryoheo 1116 to Sec lftcatto
MIL'W-tlo¡f4, ,lü ¡creco.

T[ble 3. 11

Capsc tt¡Dce plcofBradB /metre

E6
'.9:
oo
zo
22 t L77 310

24 2 150 270

21 3 140 240
26 ¡. 217

26 , t 14 205

26 3 116 202

26 4 r06 190

30 .1 207

, 92 167

3 84 r{6
E2 144

t 314

-¡.

':
3-2-13
t
t

Tsbb 3. 12

ncrlrtrrcé of 8Ea¡ded r¡d Eolld, Sllva r¡d Tt¡ Pt¡tsd tr¡trc

',

AWG
lhr. Sllvcr Plrtc Ti¡ Plrta
l{o AWG SD/a ohu,/m oh¡q/u

t2 19 25 28. S .00593 00596

l4 19 n 18. 0 .00934 00940
16 19 tt. 2 .01{8 0151
l8 1 7.y .02L2 0213
18 7 ,t 8. 25 .0202 020¿
18 19 30 8.94 .01t0 0192
20 1 4.62 .039, 0341
20 28 5. 17 .0331 0334
20 l9 32 5.72 .0298 0302
22 I 2.ü .05t, 0541
22 7 30 3. 28.. .0506 0514
22 l9 34 3. 56, .0{t5 0{95
24 I 1. 82 .085? 0t62
124 32 2. 09 .0t00 0E13
124 19 lee
t_ 2.24 .vt14 078{
I zs
lru
I ze
1
7
l9
l*
lss
1.15
1. 30
L.4
.13?
.130
.122
139
133
126
lrt
I
1
t-
I

l¡e
0.72
0. 82
.225 226
2t4
Ilso
ze
,, r.9 l¿o
l_ 0. 8?
. 20E
,207 216

lgo
l¡o
I
7
19
l"
142
0..15
0. 53
0.56
.v7
. 32E
.322
351
3l?
u2

3-2-1{
 TlblG 3. 13
Wlre ad C¿blc b MIIaW- E10,1{

60gv 1000v 260{'V

Wfre AWG
Dla . l,i¡!! ' Dla M.!a I)1¡ lúr¡¡
.:'.: mm gD/ú EUn gm/a E!t grr.,/a

30 0. 66 1. 06
28 0.7 4 1. 36 o]ar 1. ?9 :
26 0. 84 1. 9{ 0.99 2. 53 :
24 0. 99 2.98 t.t2 3. &¡ L. 42 1.47
90 1.16 4.47 1.30 5. 36 1. ?3 6.{
o
L 1. y,
20 6.71 1.50 7.75 1.96 9. 1
, 18 1.63 10.45 1,80 11. 1.5 2.2L 12.8
o 16 1. 80 12. 95 2. 01 14.00 2.44 1&2
o 14 2.lE . 20.4 2.39 2L.2 2.89 24.0
I
2._7 . 33.5_.- 3. L2 35. 8 3. 8o 38.9
10 ...-.-.. 3.48 49.5 {.06 5,4.0
8 5.06 93.2 ' 5.53 n.0
b . 6.S 146.0
4 - ,: 8.23 235.0
10. 1 352.0
0 - 12.0 585.0
00 : 136. 1 ?33. 0

30 1.19 3. 13
E 28 l,n 3. 5? r,42 1.62
o 26 4.47 1. 60 6. 26
1'! u L.52 5.8 1. 85 8.8
,, 1. ?0 7.7t 2. 03 LL.2
6 20 1. 91 10. 6 2,29
(¡)
18 2,2t 15.0 2. 59 19.2
16 2.35 17.9 2.79 22.5
o
sé 14 2.7e 26. 6 3. 16 31.4
t)
L2 3. 32 37,8 3.91 62.1

o 30 1.91 5. 65
a ZE 2. 06 6,7 zi,t ri. r
6
G' 26 2.28 8.32' 2.7 A t2,6
Io 24 2,66 11.0 . 3,01 18. {
. .É)
22 2.92 14. I 3,3? 20. a
r. a 20 3. 32 20,4 ., . 3.77 26. 6
o 18 3, 83 28.7 {.3E 36. E
.¡ 16 ,t. 19 u.2 {.90 a6.0
o l{ 5.0 50. I 6.71 66. a
¡ t2
.

,2
F 6, 11 77 7. 10 10?. ó

3-2-ró
rF
L
t'
;

I
T¡blc 3. 13 (Co¡üu¡od)

o
30 2.01 7.0
E 2E 2. 18 8.5 zl.u L2,8
8
E
26 2.39 10.7 2.52 ta.2
q) ?l 2.72 1,1.6 3. 19 22.0
3.09 20.0 3.57 28.0
E
c 20 3.56 2E.o .1.01 3?.0
¡r 18 ,O.0
4.0E 4.77 52.0
8
16 4. tl {9.0 5.23 63.3
E
I 14 5. 35 ?2.0 6. 1 t9.0
É t2 ?. 31 111.0 7.85 153.5
o
30 2. ?r1. 8.49
I 28 2.U 10.28
t
{)
26
24
2. 89
3.ü?
13.40,
18.46
3.32 25. 60
a ,1.01
20 35.70
18 4.70 52.40
8 l6 5. 15 63.30
'r 14 6. 10 9.1. 12
B
t\ r2 7.il 145. 5

3-2-18
:*[
3. 13 (Corün¡réd)

TaEDcrrü¡¡. tri'ñt : 136oC (2?59r) Mrr(. m(t¡cfDr

:. tapcrrü¡rc
VoltrSr r¡ttDg ; 600 voltr (n¡¡)
J¡*¡t tc¡¡llc .t¡G¡dn : a000 prl (El¡)
Jrd¡¡t ebog¡tloa : 20O% (Drh)
J¡ck¡t flew¡ ¡ 15O0 volt¡/60 cp. (rar) 100% ts8t
J¡ck6t wet delasHc .EGD8ü : 1000 volt¡/l Ed! 60 (p. (rEt )
Jrdct t¡tul¡üo! roltlt¡¡€ .- : 10 toGgphnrt Pe¡ 1000 ft (Eh)
: 150 i 3oC. Ad¡aceat l¡yer¡ ah¡I! rpt
eück togelhcr
Ma:rluura welgbt : !5ml¡¡l +5%
Dlelcctrtc rtr€!8ü : 2500 volta/l rntD 60 cP. (m!)
Flsmll¡blUty i 30 lcc (B¡x); 3/,1 lacb!3 (uax); no
fl¡nr{ng of É¡¡uc p¡pcr
Sbteld ccerrge i 90* (Bt¡)
Llfe cycle : 200 t 3oC
Accelerated aglag 2 225!fc
IBñelr¡oD taat8 : Dteaétar l¡crea¡ m¡x. , !p crackl¡8
e 5%
o¡ beados, m delectrlc breakdown
Propella¡t rG'llrte¡co : lib dlelectrtc b¡e¿kdosu
I.owtonp€Ét¡¡e (Cold bend) : -65 = 2oc: ¡ ü¡r! (13d)
R¡dl¡tlo¡ rsalatuc€ : 500 megrreda

Colour : §/hlt¿ Jackrt Prderred

Oroar wrlÉt ¡oda lD vscr¡u!¡ : 135 = 29c, x 19-r *76¡12 lmax)
a
¡lter 250 lDr¡rú st trErp.rai¡re
Rrtc of wetgbt lo¡¡ l¡ v¡q¡¡n : 135 = 29C
Ttmc 8t tóBp. Rstá of wclght loae (mex)
(hout. ) (¡m1cmt¡}t¡)
2.9 1x10{
26. 1x 10-8
.!,.,
260. - t x 10-?
Coadcn¡¡bl¡ 136 = fC. t¡r.t¡ltü!6 t0% (nt¡)

! -2-r ?
 TrbL 3. 1{
I
600\, - 8l¡tsle Cor. UpshtoldGd Wlrc - llr!! spd O/cr¡U DtrE.tlr

Speclfl crüoa

MI¡.-W-El0¿1,4 {0M39613 Mtf.-w-81381

AWG
800v 600v 6{x)v

Dt8 Mar3 Dtr M¡¡¡ Dle M¡r a

Dtu E¡X ma)( ml¡
30 .68 1.06 .91 1. ?5
28 .- '.74 1.36 .99 2.2
26 .E4 1. E{ 1. 09 3.0 . ?6 !:?r
z4 . ..99 2.98 L.22 ¡1. l- ^ --:.E9 -iE-2-.6&
1.18 1.17 1. fI Hf c:t'il f . 02.r:'r ' '1-r .{. 02
r::20 ^ 'l )'1. 3? .6. 71 1. 5?' ' 8.23 r.21 -'&2A
18' -1.63 l0.,ts 1- 88 12.3 r.17 . 9.6¿
16 r. 80 12.95 I z. zt
Il" 16.35- I r. es ,¿+'tuoo
14 2. rE 20.4 I z.ts 21.3 I r. ge
-rs.60
:
t2 2':7 33.5 II e.rz I ss.a I z. rs 28. Eo
10 3. Br I sa.o
8 I s. rs I roo. o
6
4
II e.s'
8.0
I r52.0
I 233.0
2
0
00

-
:
3-2-r E
3. 2.3 Wlro ¡¡d Cablo Ma¡uf¡c¡urcru lEuloD€a¡|

Mr¡ufrcs¡ror lypo ID!ul¡tloo Co¡ductor FtEIr h Vcodore

Codc

Raychem RlflC Polyrlkcn¿ CU Tla, rllver {41

,ld.. Po§eryloae HS. CU.
ALY füd¡¿l

FCC Polya.ryleae AL 8U

Fotiergfll BWC Krptou CU Tlu

üd H¡nroy Hg.cu.
ALY Ellver

BICC Ltd BWC P,TFE. cu._ Tlq rflver

AL-

Tdlou G01
.'
Tdloa/FEP
lwc CRAeflon CU Tt¡
K¡ptoD HS. CU.
ALY §llve¡ J0l
Gore Ltd llylrr Nlck l E02

Irn/PTFE BOlA
I&ptoVPTFE BOlB
I(¡pton BO2A
T€floD./FE P BO28

FEP cu Ttl 1E50

Po\í¡¡rü HE.CU.
PTFE ALY Etlvc¡ 1Ct5
PTFE I.f.c*.1 1900
PIFE/G1¡¡¡
Flbrr. 2000

V arlcr¡r AL Al¡¡fle*

.,. ,l

t-2-19
f

3,2,4 Cofcr ¡d Al.*blum WlrE ht¡

Thc follorlag t¡bl6! SlvG D¡ r¡Ectlt/c d¡t¡ for ¡tr¡nrlnhrwr ¡¡l
cofar vlrG.

DILCID( 16254 (Coprr) FILCTI EX 1?258 (Ah'-'rn+"r"¡

AWG Me¡a Ovcrell DC AWO Il¡¡e C¡¡cnll DC
Dla.Eet€r Rea. Dla¡[.tar R¿a.

I 98 J..' 0(r21 AL6 u 6.0 0039

6 164 8.8 0015 AIJ 76 - .?.8 ot23

{ 232 8.5 0009 AlA :.00 n¡ 0(ne
351 10 .3 0000 AU 150 11.1 0010

0 te2 12.7 000¡t AL0 2L4 13.1 0006

00 703 14 .0 0003 AIJ()0 272 15.0 0005

The d¡ts ln the above t¡ble la ¡Dpltcsble to FILOT EX wtre

wfth P\¡C,/Poly¡¡¡i.' " l¡¡¡ulatlm - 800V rethS,

MIL-W-E1044 Ooppes MIL-W-81044 A]'!ñrñluE

AWC M8á a Overall DC AWC }taaa Over¡lI DC

Di¡¡oeter Res. frlsE6t6r Re..

22 1.11 t .16 0{95 22 2.08 1.17 .0905

u0 a,?l L,37 030 20 2.98 1.3? .0578
18 10.,15 1.63 0192 18 ,1.02 1.63 .036
18 12.05 1.r0 0151 16 6.10 1.80 .0320

M¡¡a l¡¡ gr¡.urE€r/Eatre

Ovcrdl dl..B.tar t: EE
Dc Rr.:, lr oh.E!/Ertte .

Thr d.!l ln the.bovc t¡ble¡ l¡ rtDlb.ble to Rsychctü Ld. rtro

wlth fldhtloÉ crat llnk d polyr¡kcae tn.u¡úloa I600\¡ tln8.

s-2-20
3.S C@aetor Dsta fSGc a¡.o 8-tt6 2. t.,lt
3.3. 1 Rcct¡¡n¡l¡r CoDaetolr
Bcld¡¡t Ep€c tfl¡o¡tloot
_ _:¡¡.,.;
,'GErC"8-31r-P+
. GSPC g-3rl-P-lo ''
MIL-€-24308

E 1 z (, No of
Sp€c fftcattoE Code '-r E ¡qt ¡ c6tect c) Qualtftcattoo
-gi É¡o &u
CE 1l< B
ljF
6q
É L¡ !lc oGr
iuclt Statu¡
EE dú
E
,(!
1\ ú =2
>aÉ
E!
<¡ alzo ,i§
MrL-C-2{308 NM 20000 20 9, 16,
N}TA 2000 7.t thro 25,37 No
NMB 200 30 aqd
NMC 20 60

GSFC B 200 20 I, 15,

3-31r-P-10 c 20 7.5 3?6 tb!o 26,37 No 11-P-10
D , 30 r¡d
50

GSFC B 200 t2,28

s-311-P-4 c .20 5.0 250 a¡d 42,?O Ye6 11-P-4
D 24 a¡d
100

1. Cu¡rcot ratlEgr 81v€o arG frr l wlrc l¡ frec alr ffcf . qBA-10)

2. - .Voltatc rülDB ¡F,pltcrblG

. ',: i
to e¡tth¡dc ol 21.336 ¡@ O0, OOO ft. )
i

Roct¡an¡lar Flltá¡ Co¡cctor¡

Relcvs¡t rpcc tflc.ttoB - MIL-C-2{308.

3-3-1
 ,I

Typlcal Fllter Perlormance

a¡
i;'
o'o
o
-r-\
6¡)

lro
;.0
..dtii
+ xror{ ¡l€ouar.cY
lro 3tl¡oaio atforJfxcY
>20
ilr

J ro 0x¡ r0 orar
FAEOTTENCY lN MH¡
'0o '

FCC Connectort

Relevant Spectftcatton - MIL-C-55544

The selectlon of FCC connectort must be made tn conjunctlon wlth

the selectton of the FC cable, Ma¡ufacturers of FCC ueually
ms¡ufacture a connector specfftcally destBr€d for their Partlcular
FCC conttn¡ctlon.

1.1 0 Connector Selectlon C rlterla

The crlterta for the .electton of a conneclor can be apeclftcd h

three maln cateSorte!, namelY:-

Chemtc¡l

Mecha¡rtcal

. Elétrlcsl
Matertalt capable ol emmttt¡ng erc"rlvG ndtour or toxtc Srtt'
when expreá to low Proature or hlSh tÓñp€rstute mu¡t not bo
u¡ed.
g,¡chmatcrl¡l¡ lncludo ztrc, c¡drnt¡E, zl¡c or csdrtrluE elloyr or
platlng. Tht. rGqu trGm erit la GlsGtrtlal¡y thrt d crow telGty 'nd
comfoÉ.

3-3-2
 M¡tcrlah cóoáe rncchanlcat aud electrlcal char¡4tcrls c! ere
dcgradcd by radteflo ¡h¡ll uot be u¡cd. ¡ee fe¡te
i.i.
Materl,eh uátch o¡tg¡.r l¡ a hard vecuuur ahell ¡ot bc ured.
Tolera¡ce levela are dcpaadent on af¡etor ,"q,ri"áát, .
:'
Mcehantcat Crttertr

thermql ahock a¡d clrcUng

Motlh¡re rertat8Dcc '

Durabtltty

Vlbrstton

Phyr lcal rhock

Mra.
Eletrtc.l Crltrrtr
'
.: Bc¡tó¡rl Etglatt.E
. P.rr.sblltty
I

. DtclÉtllc wlthrtsDdtlg vott¡3r t.

_l
I¡r¡l¡tle R.atftrsa.t-,
i§_
C6t¡ct B c¡l¡!¡rc¡.' pbllock.t I

Volt¡tr r¡tlD3 .
I
I

I
c'l¡rrü BrttES !
I

r-t-t
 _---------,*_f

I --:'--.1jj

I
l,
I
I
I
I
:
I
!

C6t¿ct dcaltty
,

Crunp Rcrtrtraca pt!/wtra."' : ,l

:
.]., ,.oj..:tt :;-' :
i
Tablea 3.15 to 3.lt tnclullve 3{va paramGtrlc dsta of tb. mo.t
commoály u¡ed coo¡¡ector¡ wbü¡t Table 3.19. ll.tr 3omr of the
vendors a¡d thelr pr.oduct ran$r.

Íre ¡hell ¡tze rdcrrcd to In TülG 3. l? rclrta to thc phyatcal

slze of tlte connGctor- Ttre ¡¡¡rllcr üre number ihe ¡m¡ller the
phyatcel ctze of thc @nD6eto!. . .s

,!

¡:,r.,,i.'.\1.;:.

i
3-3-a
 .--__..*-F{.¿__. .iñ-r

TÁbl6 3. l5

DWV Wlre Tart aoot¿ct Crtmp

Sp€cUfcatton
ac rm!
CrLup
Slze I Ra!latsDcé Roal¡ts¡ce Tco¡lla
EV !oV kg
zoocl sooc
28 1.5 16 26 3.6 r. 36
{0M 38277 200 28 2.0 20 30 1,0 2.26
24 3.0 l5 {.5 3.82
,, 6.0 20 30 5.0 6.«
24 3.0 25 {.5 ...5.4
40M 39569 250 5.0 13. 6 2g ,t .5 1.25
20 7,5 r5 .0 28 {.5 10. 88
18 15. 0 z0 36 7,0 16,37
r6 20,0 2l 36 7.0 22,67
I4 26,0 2L 33 6,0 27.21
t2 35. 0 38 8.0 {6.35
G§FC-§-311- 250 at 26 2.0 IO
P-{ 23 . {lsn 2.0
GSFC-S-31. r- 30
!." P- 10
:!f IL-C-24308 600 28 r,.5 60 Not l. 36
-+ at 28 Spelflcd
¡.
24 3.0 {5 3,82
,E|
2 1 .3¡sn 5.0 60 6.U
20 7.6 D§ 9,07
i":
t.' 5.0 40 40 6.14
l{ MIL a -38999 350 35 9.W
16 13.0 25 25 22.'57
L2 23.0 23 {9. 89
MtL-C -8373 3 200 28-22 73
-
20-21 55 c{
l8-20 {9 8{
12 and 12 7l
1,1

MIL-C-E 15r r 200 r.5 60

6.0 {6
20 7.3 t6
l8 13.0 60
L2 23.0 50
5.0 30 3. 82
MIL-C-83?23q 200 20 7,i 36 9.üt
l6 r3.0 2l. tr. 22.G7
t2 23.0 2E {0.9
I {6.0 20. ,1.7
I 60,0 10, lE6. 0
I 80. 0 10. Itl.a
too. 0 16 2te .1
0 1t0.0 l0 t17.0
DWV - i.rrtc. rütDg X ¡t 33.528 b (100. OOOIt) - nñri¡l.(l
ü
-TABLE 3.16
Contact Engr$¡g rnd S.psrrtlo Foncc - ga,

Spec lflcstlon Ccrit¡ct Dfax I\,1¿r( UID

Slzo Engagtng tlcpe.ndon fhperstloa
i tou t82?7 3,t0 2n
,,
t
(.
20 206 206 ,22
i¿.
40M 39569 10 398 398 50
t:
t L2 590 590 88

csFGs-311- P-4 26 336 140 14

csFc -s-311- P-10 30-20

MIL-C-24308

3,11 341
MIL-C-3E999 20 5L2 5L2 21. 3
16 852 852 56.7
t2 852 852 83.2

,.,
r\1tL-c- 83733 20
16
!'

L:
23 .- 193 1{.0
MIL-C-81S11 20 340 19. E

16 8t0 *,7
t2 680 85.0

20 509 9.8
MIL-C-83?23 18 8{8 , s.8
t2 E{t i. '¡&1.7. ,.

t {ó20 I ..32S.
0 i
1 462. O
I
1 6?S0 I

0 9000 -l :f.
9(x.0_
I

t-l-c
 atlllf ald Dollattn CouDltDR Mehanlaa
I
Coupllng Torqr¡e cm k¡ I.oad kg ¡hell
gpoc tltc at fo! M cch.n lrar Dat€ d6!r elo mate denate !lz€
E¡¡f ñl¡
8.8 1. t 8
40M38271 Balroüet tx.2 l.t l0
.6
17 2.2 t2
22.0 4,1 14
28.1 4.1 18
6.8 1.1 ü
,t0M39569 Be]roDat 11,01 1.1 t0
15. { 2.2 L2
r8. ? ,t. { l{
23. 3 1.1 l6
{.0 2.72 2
GSFC-8-3 ¡1-P-4 Ccñtre 0.6 c.86 3
Jack 13. 16 0.62 1
I
l¡ 22,6 13.87 I
3,1 . o 22 -67 7
Flengr. malc A
GSFC-S-31l-P-r a¡d fcmale B
MIL-C-2,130t Iock ¡crcr¿¡ c
D
E
9.8 t. I I
MIL-C-38999 Bal"oBet t3.2 1.1 It
17.8 3.! 13
22.0 3.3 t5
29,1 3.3 l?
30.8 6.5 t9
36. 2 6.ó 2l
30.6 5.5 at
4{. 0 23
Flea3c. malc 31.7ú 31.7t A
MIL-C-83733 a¡d fcoalc 1t.27 lL.27 B
lo¿l¡ ra¡e¡n
8.8 1.1 t
' 18.2 1.1 10
iar--.-trttt Ba}!act 22.0 {.{ 1{
26.1 a.{ 16
s0.8 a.a l8
88. t 6.6 20
35.2 1.1
7-7 ,1
t.t 1.1 E

.lflL-C-E3723 B¡Fa6t rE.3 l. t u

rgd r5. { 2.2 l{
&rrr t., a.a t0
tt¡-d la.{ a.a L
!0.t a.a ¡t
tE.l a.a
(
Table 3. l8

I¡!ert Pltr Pla P1¡

Speciflcaüon Reténüoa Estc¡üon .
h!crüon ExEaetlon
kElcm¡ kg kg max kg msx

10M38227 5. 25 4.5 6.8 4.5

40M495699 20 - 20 AWG 8.8 4.5

2á - l8 AWG
30 - 12 AWC

GEFC 3-311-P-{ 2. 8l s.8

GSFC S-311-P-10 4.22. 4.0t 1.36 l. 81

MIL-C-%308

MIL-C-38999 ?. 03 4.6 - 22 AWG

6.8 - 20 AWG
11.3 - 16 AWG
11.3 - 12 AWC}
MIL-C- 83? 33 3. l6 4.6 - 22 AWG 6.8 ,1.53
9. I - 20 AWG
11.3.- 18 AWG
13.8-12AWG

MIL- C- 81 111 !.t't 4,4 - 22 AWG 5.,1,1 - 2E AWG 6.8

rPectfled 8.8 - 20 AWG 5.{4 - 22 AWG
11.3 - 16 AWG 9,0? - 20 AwG
11.3 - 12 AWG 11.34 - 16 AWG
i13.6 - 12 AÍrc

l,fll-C-83723 7.7

t-t-t
3.3.3 Connec-torMr¡rúecü¡rÉrr(Eur@ea!)

Table 3-19 Lllt of .om€ VeB&rú a¡d tholr e-ap¡Gc,br RspgG

I
SpeclflcÁ6on !
E

tlflL-c-5015

MIL-C-81511

c€Fc
s-3rr-P-4

xrl,-c-5554{
 SECt!O¡¡ 4

EAA¡ÍE8E XAMTTACfl'AE

corrEltTS

I
.4. ¡{rr.ua cla i3
. 1.2 Br¡ú. ll¡w rrt, ptcH4 rd l¡ll¡¡
\- a. t Er¡na¡ Idosllltorüo¡
a.{ R¡prit LLibd.
1.6 Wtr.6EtDpt!¡
{.6 Tr.üB
r.6.1 T..teodlü@/h¡o¡¡Uo¡
l.A.z t¡t 8¡S¡¡oe
a. 6. 8 Vle¡rl E¡¡¡l¡¡üo¡
1.6.1 Elcct¡tcrl Cod.d§
1.6. 6 ¡Drr¡¡aüoü nr.btr¡c.
{.6.6 Ixclcatlo Wltlrtradrg Voltrgr @WV)

lE!ry
i¡ !cdüo! rrtcqr yr oa r¡Dcct cl cbl¡ h¡a¡¡ iad."o*.. !ü¡ü¡d
r¡lctblc re.t¡ Er& rro prcrrctd rld ProcérGr lor thc u¡h¡¡rcr¡ rtrigpt¡g
rlrr rüt crblc r¡a dro¡¡¡od. C¡bb hüu. t tü!3 ta lEbdad rd pt¡d¡d
i ¡.-¡d¡ld fort¡L

d.¡f¡ad ¡.¡*r¡crrrin3 pñro¡¡ for Dl&r{.!tr cl4d{i, bad r¡rl* d

.
B lt rids! l¡ ür¡ct¡d b ti¡ ¡podft¡ttou rd ptoor... U.t d lD Eoctb!
.4.
t:

3.4 Potüpg Compo'tnd! (aee elco S€ctron 2. 1.8)

Table 3.4. I g1v6r ¡ ltlt of potürg @ñipou¡ds uced ln the encapauleüon

(back potá¡rg) of clecftlcel @nDectors. The general out8strtDg limlts
8re:

% Wetght LoÚ (wL) ¡ 1. 0 (Rc(. 58)

% Votaüle Condencable rnÁterta¡r (vCM) = < 0. I Eef ' 56)

T¡ble 3, 4. 1

?otüng Compound %wL % vcM

Eccobo¡ú Solder lPo:q No. 58C BE BA

BA BQ
Eccobo¡rd Soldcr EPoxY l'¡o. 57C

Epon 828/Ver¡¡mld 140 0.2 o.0z

Sollthaoe, C 113,/300 0. {9 0

0,36 0.05
Sc)tchcest EPo:<Y 2E1

0. 82 0. 13
scotchcas t 22 AlB NffI-?l-16923E

Styca.t 2850 FT EPoxY 0.3{ 0.4

0.54 0.01
Stycalt 1090

(r) (¡)
Soltthan r C 113./Boüthane C-113-300/
0. ?6 0, 19
Crp-C -Sll IYGI- 5¡Dtbuvl Tln
óth.rret" t -L2&ytc I¡¡ mlD.! ceñt 7'1
(r) (r)
llolltñ¡n: C-U3,rtoltó¡D. C-113-300/ r. 02 0.28
Dtbut/l Tta Dllr¡r¡to T- 1 SÁtcrr¡¡/Stlfls*G I 35

tloltth¡E C-l 1 3¿.!oltth¡'6 C-11 3-3oo/TltrDlutn DloxldG (r) (r)

R-960¿blbütYl Tta Dltr¡ret8 T-12

BQ - tb,t! Eretortrl lr qu¡Uftod h¡t tcqutr" Brt¿h S¡l-lttcruoa Prlor

to ¡ccePt¡¡oa

(.) - w"L¡¡d VCM llgurÚ rr por IIABA Tl{D ?632 (Rd' 36)'
Recommcdcd for u¡¿'ro
oa IME (8d' 25)

fn gconl ¡11 olxc¡ ¡hcr¡ld bc tubr.ct to tt'üag lot wL Úd VCM' pn¡atb'd

t¡ávfürf tDgtGdr.,atr of r nlr nry oE tirú! osa b'6 6¡ttld'bcth'wttll¡
umtt¡ tut vb1¡ corrcct§ coat ourd.d ¡!d Proct"rd ant tüc
pri{flb.d UE¡lt .
*1
 ñc ¡cqr¡lred 1*-¿l of clea¡lt¡ca¡ t¡ a fu¡cüoo of EhlloD reqt¡lremcot¡.
Qle¡¡ll¡6¡¡ levcl¡ ¡re apecllted.t ayltaEi lcvel; lir h¡r¡e¡¡ lgvel
.Euat bG coElpsÉbl! wlth the ovcrell ryrtcrr Flq¡lrcE2Bt. I¿vcl¡ ol
clcr¡ll¡e¡r mutt b6 rpecüled oE rl¡ rPpllciblc dravlagr aDd tPcdftcr-
üolr.
1.1.1 Cl¿r¡ln¡ A¡¿nt¡

I¡oprcpyl rlcohol, othyl tlohol ¡¡d irrkloac W rrc tüc t¡rce mort
cour¡Do! cleaut¡g egcdr uaed lor cleadn3 crble he¡no¡¡'

D€t¡tled evalu¡üon mult b€ msd. to enn¡ro tlr¡t the clernlr:g egent

doc¡ ¡rt chemtcelly lcact u¡lt¡ the h¡rn¡¡¡ m¡t¿rlal¡. Chcmlcal lnter-
rcüo! c8¡ modtfy thc mecbsnic8l ¿¡ri elcctrlcel properÉec of the
tnrtrrlsl!,
{,r.E r/¡cr¡um Cle¡nlng

tt6 terno!'¡l ol lrrge p¡tüclc! t. by urtng a powerfirl vlcr¡um cle¡ncr.

ttrc ¡¡zzle of the veq¡ura cle¡¡¡er mu¿t bc clther of to(t rvbn brf3tlc'
hg¡cd, or loft ptr!üc to DrGv€trt tlic ¡¡zzle from drrnrglng tl¡e cal¡lc
h¡t¡¡¡¡.
For h¡rn¿¡¡es ln crlüc¿I cpttc¿l lli¡rÉotrs lt ls nece.aery to ve6,¡um
uDde! ulE¡-ylolet lllumln¡üo¡ ptcklt¡8 up ltrdlvtdual parücle!.

4-¡- 3
i
I
Trbla 4.1 - Cbr¡ütc¡üoa ol P¡oó¡et ClOr¡Uq4!. !.tclt
r
r Tól. 4. rb
T¡blc l. h l¡bn Vol¡ülr B..ló¡.
t:

t
C¡6rÁJlEa!! 8¡¡8c S¡¡{r¡¡ q¡¡üty ol
L¡sal S¡¡!üty
l-svaI ¡d Plulü P¡rÉ cr¡¡¡t¡ ¡wB
I 10 6 Lo¡¡ t!¡¡ 3 A t¡¡ thrn !. ! ¡t
t
t
6 2l 1.0 ro8
{
16 L..¡ th¡! { B to
25 I 2.0 úÍ,

b 180 2.0 Et
50 1á 2A c to
z5 7 3.0 ES
50 1

15 2e0 3.0 lrg

25 to
100 á0 t1 D
{. 0 !r8
100 I
15 {100 {. 0 Erg
25 1100 to
E
200
5(, lto 5.0 Eg
100 18

2l ?000 5.0 E18

5() 1000 to,
300 F
100 90 7.0 E8
250 Lee¡ tl'¡¡n 3

50 11000 7,0 ES
100 950 b
500 o
230 23 10. 0 Elg
s00 1

100 6500 10. 0 mE

250 170 to
?30 H
500 7
1á. 0 Elg
730 1

250 1000 15. 0 ürt

$0 {5 J to
1000 1
25. 0 mg
,;# I
Dertv¡üoa of Cla¡lloc¡¡ Lqve!¡. Ifu. clc¡¡lTct' lÜ"'l' eod rlgc
vttll¡ crcb
larcl of T¡ble 1¡ *"r" by plotu¡s ttc q¡wcr tD Fl3r8. a. l. ¡lt¡¡rÚ
l. f-pf"i pofnt f . E¡mbct""tr!GT"d
of at¡¡ prrüct¡ ¡bcrc 8l"o vc?r¡r p'tücl' tl'!'
'lzt
{-l -{
 Á.
(

r^ lil
l!
J
It-
É
<r
IL dl
t!
o
&
lll r ol
fD'
-
l
z

8ro
J

-Í,ol
tr¡

,\
n! ói'o ,\
s lol5-2o2s3s l5 lml25l50 200 300 s00 tmo 12501500 2000

P IO.
SCALE'LOG PARI IC L E SIZE -MICRONS

I
 l
¡ 1,2 H¡rn¿¡¡ Handllug. P¡c¡dn[ spd Earüpl

Elcctrlc¡l h¡rno¡¡ ¡g¡cmblle¡ r6q¡trú vsrylB8 dcgrace cl protrcüoa 1t

dl tlmc¡. The pcrlomence ed./or rr¡t¡btltt ol r hr¡¡e¡r ¡¡¡cmbly
. c..' bc dlracüy elfect¿d by the lack of ¡dequ¡te prcleglry or plotocüon
d¡¡lEg lB-plocera haadllag, rtorrg:, 8d rhlpnoa¿ H¡ru¡¡ r.lrrnbly
pmtoqüoD ¡h¡ll be €Doldrréd r^e tie ryplt caüo! ol plotacüva E.¡ru!e.
to prcvcut damage fnom phyal cal md clttraüc Gwt¡o!¡rteDt! ürln8 I ntre,/
lnter faclll§ h¿odliag, f!-p¡occra, tsellpor¡tlon, and rtor¡ge operaÉoDr.

Haraa!! Aaremblv H8ldllps Prot€cüon

l: llc¡nere h¡¡dUag absll be dooo carefully c¡d h€ld to s tülElux¡m tó reó¡c€

the poealblllty of cou¡cctor dsmsge e¡d work-h¡¡rleDhg, o! lats5re of
the wlflug. All conneetor¡ ¡hall be protect¿d wltt a¡lt¡ble rmr8-fifing
pla!üc o! met¡lllc dr¡at crp!, except whea lt 1r neceertT to rvork dtre cdy
{ upoa them. or whe¡ ¡¡¡t¿d. Ha¡nc¡¡c¡ nllh erpoad met¡lllc srnour
bratdug ah¡ll be prot€ctod witl I sulteble out€r crrverllg to preclude
rlorr.ge to thc ¡hleld st¡8!d!.

I¡Er- lat¿! PleEt Protec.llop

whele,t/er haroeaces ele reqr¡hed to be tra¡lported. they aball be

packaged for ¡hlpment so thst tlle han¡e!! doec mt becorae üm8ged.
Co¡¡Ec'tols eh¿ll be tndlvid¡a[y rr¡rsPpd \rlth ¡ytro! bsgl ¡¡d o¡shiou
materlal to plevent demage to themselvea or o6er P¡Lt of the h¡¡¡eea.

Protecdve Contai¡e¡s

Ite beraesc shall b€ p¡sced lntD s sujtably slzed G¡lhloaed contliae¡.

the contalner construcüoD 6¡d mat€rlal eh¡'ll be of tud¡ tnt€8¡ity to
provlde poltüve prot€ctlon f¡om phyatcd e¡d cllm¡üc euviroDJnent!
ü¡rtD8 atorsge a¡d t¡8DtpoltaÉon.

Prot¿cüo¡ of Metglllc Armq¡r B¡ald

Mct¡lüc wqven brald har¡ee¡ aaaembly ghaU b€ hsndled carefully and

prqerly protectEd to preclude any denrage or d€formlv Euch 18 6rls,
deata, ot lbrerlone, to tl¡e armou! b!.ld sE¡Dda. Thls protéeüve
cot erlag ¡h¡ll be tn¡telled at cornpleiloo of armorr brsldtnS end remÉln
on üe h¡rne¡g uuül convolute !¡btng la applicd.

1-2-L
 {. 3 Harne¡¡ ldentütcaüon

Temporary and p€rm¡nent tdeuüftcrüo¡ ol hrrnc¡¡ e¡¡cmbllc¡ a¡d

connectors ar6 n€cesrery lor h¡rnc¡s lDlr.tlsüon. Tcmporary ldoaü-
flcaüon 18 us€d furln3 b¡rne¡¡ mamrfacüue, tñcy rhould Dt ¡tf€ct t¡c
aaeembly End ¡hould mt spperr o¡ thc co¡¡pletad h¡r¡¡¡¡, Whcn u¡cd,
temporsry tdenürlcatlon ¡hould be eeorrcly ¡E8ch6d to tbc h¡r¡s¡¡ r¡¡it}
a card or m?tsl t8B ln ¡uch ¡ mln¡:rr th¡t vtll not d8m¡t€ the eorernbly,
Appucaüon of ¡dhe¡lve trg! l! not perml.tlblc ó¡c to thG rtrou¡ po[i-
biltty of h¡rne¡¡ contrmlnaüon.

Thc t¡pe of permenent ld.nütlcatton mÁ,rk!! src U¡ultlrt d tn Flg¡¡s!.

4.2 lo 4.5. The m¡telal comporlüon le dqeadeat on the ¡ppllcrüon
of the har¡eee, tüerefore lt lr essenl8l thst the @rrect tlD€ la cholcn.

The §ro most co¡¡rmon tlgee of marke¡ ¡r!:

Stamped metalllc t¡gr

Stamped lnrul¡tlng sle€ve!

Icientlflcatlon dlregt on to any aasembly wlth ¡u tndellble l¡k or vlbro

etching i8 Ecc€ptable ptovtded adequste prscrutions gre t¡Ien to enture
that the marldng cer¡not be era¡ed or beome lllegfble,

A combi¡ration of alpha/numerlc characEr¡ lruke up the u¡¡ique ldenü-

ficadon. The appltcaÉon of the marker ¡bot¡ld not damage üe harrles!
and should withstand the same t¿mpera¡¡le ¡nd oü¡er condltlon¡ to whlch
üe h¿rnese ts subJected. Pgrüculer att€nüon chould be prtd to the
flammability characteri8tics of t¡e marker mstertal when t¡e harne!!
tg to he used ln en oxy8en rich etrnorphere, crew cornp8rürent rr ne¡!
flammable flutd ltnes.

1\¡o markere are ueed, one to ldenüfy tha matlng conneclrr dealsÉuoo'
the ¡econd !o ldendfy the aaaembiy. The connector deelglaüon ehould
be locat¿d aa nesr to the resr of tl¡c coonector aa po;elblc but to mrve
them I tomrn f¡om t¡e coErector 8nd orienat¿'d auch tl¡¡t lt c.n b€ ...lly
read once tnstslled. Hsmert a¡eembly m¡tkcr! ceo bc plrced rr.y-
where b€tween 200 and {00mI't from the coD8sctor aod rhanld a¡pclr
¡t le¡at hvlce on an a¡aembly, one et elt¡rl end. Wh€re thc h¡laer¡
haa mul§ple bre.ak-oute, ¡ h¿rne¡a ldenüftcsüon ¡hould rPPcrr ¡t e¡cñ
end. On very long eeaembllea lntermedlsto markcr! ere r.comm€ndd.

l.

I l- 3-l
.l
 COHN EC IOR
IIARNESS REFERENCE
l--f ,100?"É,, r!¡¡. 0EsrcNAlloN

I SLEEVE
\- p¡¡y NUr'iaER
COHNECTOR
REFERENCE
I l.,----f {00Euo tD¡¡. --HARNESS
oEstGxArlo¡r

\plnl NUMBER

FIG. {.2

CONNECfOR

CONNECIOR REFERENCE
OESIONAIION SLEEVE

206 w3 P2
I E0co ''"-. 120?w tJ l¿)

BANO MARKER

FIG.
'.3
¡

CONNECTOR
)roo-. rrr.

CONNECÍOR
I BANO MARKE
I
,.--
.il ARNESS R€FEF:'':E.
I\ OESIGNAIION
:,

FIO. {.{

CON N ECIOR

CO N N ECIOR

{NEClOR REFE
CONNEClOR REFE
516NA]lO¡r
0E516NA]lO¡r
UE>It,IYA ¡¡UN BAr
BA
CONNECTOR REFERENCE
OESI6NAIION SLEEVE

F¡G. {.!
I {.{ Beoelr Mctltod¡

Darnrgc to stre,/c¡ble/con^lGctotl. shllrt Dt bcl¡g ra acry d¡y

occt¡rrllc€, doc¡ oca¡r wlth rdlt€l3nt trfubllry to 9r.a€!t tha dGafpar
wlth prublomr.

Darnrgc rurt¡lnod ó¡rtru m¡Ed¡cü¡rc lr rclatsvcly cerl§ ovcrorc,

lrhll.t dsm¡gG to rn ¡Etslled h¡ru¡¡ t¡ oot ¡o c¡¡lly ovcrcooc ó¡¡ lu
tb n¡ln to ¡ccGa.lbt¡lty ¡nd üme.
n@atr mothodg h8vc ¡ t€nd.lcy ol bcentag rt¡d¡¡d PrrcÉc.' wlüch
lr not la the be¡t lnt€rert! o! c¡ble h¡r¡a¡l lDt Sltty. A d6t¡¡lt .ytEEr
for r6porüng, logglug and t¡¿ i.sulng of rcPrlr ¡chcma l¡ nccar¡ry.
the followlng ryPro8clt l¡ r¿ommeud¿d:

( 1. Do mt laruc to f¡bdcsüon d.P¡rtmelt r.ny rta[d¡¡d r.pstr

¡chcme¡, I! you do yor¡ run thc rlrk of rcPatrt bcl¡t8 c.lrlad
out wtthout QA or Deat8n ApPlo\rrl.

2. A demage rePort ¡rt be r¡tlGd by QA ¡¡td r€P8tr rchc¡n€!

hsued proS¡etelvcly wlth t¡e rDPñ,Plste da.lgr¡ suthorlty
!¡nclion.

3, Each rcqr¡e¡t for ¡ ¡epel¡ adremc ¡tra¡la le con¡ldered l¡dl-

vtdt¡¡Uy on lt¡ mérlt! but I at¡oag bi¡! tovsrdt r'Jecdo!
¡hould be malntslned ln thc flr¡t.l¡ c8rct to dtcoutagc
f tmlllarttY.

Ttrere Bre de{lnlt¿ crit€rts for lnsüsBtlon of &mege rerlr' Flrrt

end foremo.t la taltsbtllty, followed by ümc Ü¡d coat'

Rollabllttv

Englncertng model: kovlded the en6neclng model harneel/ceble

ae¡1mbüeJare rDt tntended fo! cot, verlloo to etthes qr¡llulcsÉoa'
fll glrt or fllght tPlre model r€pstr! caa bG rcclPtsd'

Qusllftcaüon snd Ftlght modeh: Danegc ¡.Drlr c¡n be

rccepted oa
r¡l En-easenüel rlgnall. D¡m¡8e to Eracnü¡¡ rl8:'81' mult !e!u¡t
lo rcplecement of tha demegcd ctomponctrt.

Tlmc

E thcr¿ l¡ ¡r¡fflclont ttmc ln üc plog¡aErmc thc ri4f ecttv! @mpo!.Et

rhould bc ¡ePtlrrd.

{-{-l
 .l
t
Cort

1lo o¡t d tap.lr rbcr¡ld bo congrr¡i ylti th! o.t d rcpl¡Ern É.

Th. ño.t coatloo ltultr claor¡Ítlrcd ótrfry frbrrlcrüo¡ ¡d t¡¡b,llrioo

Wlrc rnd Crblc

lück¡d *trc torul¡Éoo

scr¡¡lcd wtrc lna¡l¡üon
Blokln cond¡cto!/ablcld .Eea&
Cut tn¡lk¡ ou cond¡¡cto¡ rtrr¡dr

Co¡¡uctorr

Chlppcd coañ.cto! lnr.rt¡ TLorc ua r rlr¡d¡rd or r.cog-

Cr¡ckcd @onector lDlart
Corloalon ol cotr¡€clor lbcll
Drnrgcd ¡u¡l¡ce fl¡Jrh
Brokrn pfar on colD.cto!
Ea[t plD, on cona€ebr
ProtecÉvc She¿ihl¡¡
drcd rcA.lr ¡chcna¡. All drmegud
co¡Detorr ¡hould bc rcpbccd.
fha¡c r¡¿ bl. ¡vdl¡blo for lEslSit¡rr!-
l!8 b.Et pf!., t¡rt! u.! l. Dt
raco!¡gr.dd.

Dmaged h.rt lhrlnk t¡bln8

Drraeged drlvolut! E¡blDg

PotünÍ

Vofdr tn potttn8
C¡¡dced pottl¡g
t5a .dhcllo¡ to crblc or corrcsto¡r ) pottad Úrcmbly c¡¡ oa¡y b€
T¡clV potüDt ) tfifDed r¡¡d thc ¡¡¡cnbly
rspott¡d

Wtr. rad Crbl. R.Blrr

l. Ncked Srlr¿ I¡¡uhüon

Mdrd 6c corc conó¡¿'ton h¡ve rct bocn demgcd r rrPal!

c¡¡ bc c¡ffcctod by nüDS I bclt ¡brt¡lc ü¡btDt wrr thc d¡o¡apd
¡¡ar fhe .!.ry1D8 to Plotü¡d. r ñlüñuE of 15mm from tlr¡
denqcd lrr¡. ¡a. Ftgure bclor.

l-'1-2
 t
Nlcx HEAI SHRINK IUBING

IRE

U rxtat ltvr q¡ork ls lqulred rt tt¡G @ntlctor r Ep.tr c.n b€

úlacl4d by overtng tho damrgcd .rc. wlth r! rFroved, room
tcmpcra!¡ro cr¡rc a¡ch ¡¡ Anldtc.
la
,ó. Scr¡rfcd \ tra lna¡l¡Eoa

A r@alr crn be el¿ct¿d by cwcrilg tha dsmrgcd ar.r wlth sn

I rpprovcd, room t€t¡pcnü¡rr cuts.
II t
If the demagc ls erde!¡lve wtt$ dcg ¡bre¡ lon tn¡lklz hc¡t
I ¡hrirü !¡blDg ¡hould bc u¡sd ¡¡ l¡d crtad ln nlckcd q,lre ¡rr¡ul¡-
I
üoa lcp¡lr,

3. @
Eepslr¡ of tlrlr nsü,rra rre leltrlstld to Development, and
Eaglneertrg rDn-f ltght model¡.

lte lepair i. effected by cr¡táng the wlrc ¡nd rerolning by use

of an in llne aplice, e. g. solde! ele*es. (rttnp lnllne
¡leeve¡ wlth inaula$ng ¡leeve. H¡¡¡d rolderlng rnd coverlng
the JolDt wlth sn inlt¡lsüng alewe l! Bccept¡bla.
If t!-. broken atrandr ar€ at t¡e connector t€rtnlnalot¡. ct¡t out
the dsmsged B.lre l! clo¡e !o thc drnrge 8t Polrlbl€ e¡rd reterm'
lÉt€, cnturtDg th¡t üe ¡emrde r¡lte la not rubractad to rrv undue
at¡ea!.
4. Broksn ghleld SElndlrr

E the extont d the dsmrge l. ruch thrt the algnrl c.n bc d€8ir¡ded
by EMI thcn rD r@s¡rú ere permltted.

Mlnor damage can bé 8cc€!pt¿d, thG l¡rruLatlon b€lnt tepatred ¡!

detsUed lD 1 ¡nd 2, lrbre ertá lv€ ümege cln ba rrp.l¡cd ¡!
¡hosn bclow.
I
#..

(
{-a-3
 INSULA]ING SLEEVE

L]
't0 L-l
LOER SLEEVE

Reprira on rd¡ld wlre sheaür rEsndtlg l! rDt recommeBd.d.

The preeturc on lrs8rt polutl¡g !trand!, nücn applytng tbc
heat lbrlr* tüuI¡tt¡g slegve, ce[ fo¡ce t,t¿ broken útt?¡d
end¡ l¡to lhe wtre ln.ul8üon, tceulüng tD a potettü¡I, Ú rDt
8(É¡81, core to ¡bleld fsult.

J. O¡t M¡rk! on Copá¡ctor gE¡ldr

The¡e a¡e iavrriably ceuecd by tl¡c u¡a of ¡rad¡¡lcal a@per!

in the prep¿ratioa of the wire Drlor to t€rñlD8üou.

Thit tllp€ of f¡ult rhould be vlgrycd aa ¡ brok¿n rEer¡d end

repa.lr elfectert ln t}le game m¡Ercr.

6. Dam¡¡ed Heat llhlnkable T\rbt¡rr

Ilre¡e ere trrc ¡t¡nd¡rd repalr mcthode:

(¡) Fttüng sn ¡ddltson¡l plcco of lhrlnh i¡búEg orer thc
demaged gre. vlt¡¡ ¡n ovcrhp ¡t Gadr ard of rrt le.t
tlren 1S¡nm, aplytng ln aprovcd ¡alq¡t bctreea tñe
freyed aurfacer.

Ttl¡ mcüod lcqr¡lrct tt¡t the un¡hn¡¡k ¡¡blng c¡n bG

¡lld ovcr thc coñ¡rcto¡ rnd rlrc t!ñnltrrüon¡.
(b) wrapplug a lcngth of ¡h¡l¡ü ürbl4 ovcr thc drtarsGd
.rcr, u.lDB 301. ovcrhp. Th. rtut r¡rd llnl¡h of ñc
rrrp rhrll crtrad ¡ mln rnum of SOmn l¡orn tñc endr
of tho d¡¡n¡8pd rlaln¡:' Mcllrcd

t. G¡t oll thc rqutr:d lcqúr d urrhnnh i¡btn8

2, Sllt r¡oDg lt¡ lcn¡ü to fonn r lauü of trpc

3. Cort om flcc r1ür ra ggrwcd rdrc¡lvc <a

4
1-1-1
 4. co¡t th. d¡mrgcd r¡c. vttb the !¡BG ¡óc¡lvc
o. Wrap the Ep. srouDd ttc darargld.rc. ¡¡d hcút
lorm lnto poatÉoD. Spot üe. mey be rc<¡rtred
to hold thc ¡p€ tE Do.tÉoD

6. Re¡¡ove rry tenporery üe¡ e¡d bcc tic rapelr

Dem¡ge Corvolut! T\bln¡

To po.ldon a oeu, leagü of alc*tog ovcr th¿ üueged arca

requlle! t¡at the ed termlaaüoa! bc dl¡m¡¡ücd. Coüvob¡t¿
u¡blnt r€p8lr! erc bect tmpleme¡lcd L? urlr¡t tic mctbod
de¡grtb¿d ln pi¡ag¡rph 6(b).

E. Voldr tn Potüp¡

Volü 8¡e repelred by tnlecüug potüE8 (of the r¡E. tlDe) l¡to
üre vold, ult¡g a syringe. A vcEt bole muct bc prortdcd bfore
lnteclloa. InJccüon of the potttag ñult coEül!¡é u!Él thc vold
.rld verit hole ¡rc ftued. WtÉrdrtw the 4rriagc iDrcctiDg potülg
unüI rlc .yrtnte h¡¡ been fully ¡ctr¡cted.

o CradG tE Pottlp¡

Cut the pottlng until there is ao evldeoct oi iie crack aDd

rdtu wtth the ga¡¡rc tlpe of potüEg coEDoud. Durtag all
potüng reFs¡E cle¡¡llneas etsul'rd! aod potüng requireEeota
muet be rn¡i¡:t¡tned.

a-4-6
 4.5 Wlra SElppln(

Tt6 rnort wldely used procesEes for the rtrtppiag of wtle lasul¡.t'lon r,,^;
c¡ble ¡heaü lDsulatlon are mechAd c¿l 8Dd t¡ertnri.

Geoeral Process Acc€Dt8lce Crltlrta

'The 6Elpplng operatlon eh¿Il be performed tu cuch a m¡¡¡er tlat the
conductor Btrauds are not eevered o¡ r,l cked. Mlnor lougiürdnal
sclatcher aod clro¡¡nferentl¿l nlcks on t¡.e mnductor shall be acceptable
provlding Buch scratcbe8 and alcks do lot pe¡etraÉ through the p¡ating,
Reference (1).

Thls reqr¡tlement i8 b€st met by uslng toollng sDd fabricaüo¡ t¿chnlques

which csnEt damage the corductor et¡8¡de, ghield etra¡ds or lDsulaüoE.

Mechanlcal strlppers ere deElg¡ed for rou¡rd wl¡e and rouud ceble,
whlch 8re p¡e8et to wl¡e/cable diabet€rs.

The tltn wall, lagulaüo¡s uaed ta MIL-I#-81381, MIL-W-810,I4 End

40)f 39526 result in mulücole cable betag a¡}'üh8 tut dro¡la¡, even
though t}te iudvtá¡ei wlr¿6 ale clrsr¡Ie¡ eB rhoq'B below,

The combiDeÉon of thln wall gheelh lnsuleüoD, 0.05 to 0. I mll thi cic,
the trregrlar form of the cable aad the l¡sbfUty of mechanical strippels
to follow the contou! qf the cable !e!ult8 ln I hlgh probabtllty of the
shield af.rand8 belag aevered or ¡ücked,

hermel strlppt¡g of cahle Bhesth tnsulrttoa p¡es€nt! g dlfferont problem.

The tempera!¡re of tbe tlermal sEippe" üp 18 Euch hlgher tüan the
melüug point of t]:e cahle lhe¡tl¡ tlruhüoD sad wlr6 tEulatlon. CoD-
seql¡ently when üe heat le applled the c¡ble ihe¿th tD6ul8Éon lt melt€d,
hest ls sppUed to the ¡hield EEs¡ds r¡d by he.t ErErfer onto t¡e ertre
T.
lrúulsüoa, eaulln8 lt to ¡nelt. fbla la mo¡e lcverG on flrt wl:e ¡hteid
ceble¡, aec flgrre below.

t;

(
+o-l
MOLIEN WIRE INSULAI IHERMAL STRIPPER
SHIELD INSULAIION

WIRE SHIEL3

The reeult ia a poeeible co¡e to shleld f¡llu¡e wlüch r'.ññot b€ vl¡r¡slly

ecen durlng fabricaüon bec¿use 6f t§6 6s'-ll¡g s[¿t{.

hef erred wtre,/c¿ble sñpping meüod¡.

1. Wlre gEippina

Thermal st¡lpping of c,i!e lDluleüou lg tüe preferred uctbod.

The rlsk of phyelcal &mage to the coaó¡ct¡r stra¡ds ls mucb
less t¡8¡ ¡ould t¡e t}re cÉse lf med¡a¡ical 8üpperE grere ueed.

Mecha¡ücal strlpp€rs caa be used where üeru¡l Btrlppert are

¡rot available o! are implacüc¡l to use.

z. @.lsr
The ltripplB8 of mulücore cable by eit¡¡er m€cha.ulcal or therrael
strlppers ia rbt re@mmended beceuae of the hig! rtak of
üYnrge.

the followtng procedure t¡ rocommeuded.

cuf
1. wtth I !ha¡? hlf e,
cl¡t t¡e lhs¡t r
lnrulrüoa, lD tr/o
dt¡meetcally cppo-
rlte plccec lor a
dlrtance of 25mrn.
.,
Peel brck thc ¡hc¡th
ln.uLÉoa to thc
dtmc¡r¡lon ¡how¡
x r- <il¡tr¡cc bctweca
thrslr¡ t rmtD¡-
üoa potrit aDd Gnd
of wlrc.
l-ó-.2
I

rl 3. Cr¡t off pe€led Ehesti

lDáuIrüoD usltrg ltde
ffi
cuttarr.
t
4. O¡t off flr¡t
50ram
of the ocpo¡ed ¡hleld
I s¡d wtre, :---'JE-t

Refereace (1) coDtsiDs comprehensive aod ra6rfactory meürods

aud '
I
L"frniq,r"t ior the outol ad ueage of medu'Bi cal snd therm¡l ttrlPpets'

I
(

{-5-3
 I {.6 Tcldng

lte oblcct ol toaüag fr to p¡ove the

¡re¡¡.r¡ nr cal r"d elcct¡tc¡l
ol the spacecraft harueratag. rlts8rt ty

Three levelg of tesü¡g erÉ re(plred,

neuely:
l. VerlllcaÉoo cd procela codomtty durlng
Earr¡fscü¡re
2. po6t fabrlcsttoD
tertt tg to e.t¡bltsh tñ6 codortnlty
h¿rn¿e¡ to the dertgl reCr¡frei.;; of the
l
3. po¡t iu¡ro.Ileüon t¿rüDg
b e¡gu¡e rhrt t¡e hs,neaa ha!
degraded by baraeaa ta¡tallsUoi Dot be€D
wl¡¡uo¡¡
i ( 4. 6. 1 ?est Condiüo¡g/p¡ecauüo¡!
I

d
1. All telt eqt¡lpBent uu¡t be effectively grouaded
o gpsc€crzfvwirilg
Jtg Eust be e{fecüvely SEouaded
3. tbst ail test eql¡tpmeÉs h¿ve q¡rreDt
I_eÍy
cgtea
vs¡id8ñou cerüfi_

4. FUgüt staDdald coDnectors rDuat

faciag with üe spacecraft fltglt *-- leads
be used on teet *-* tnter_
c.o&ecto;;.
5. UDde! D qlro¡mst¿¡cea may tert probes
or riDgie pins
lue¡ted into t¡e spacecraft hat,:ress
."' be
coraecto;-.'-
6. UDde¡ m ej,rq¡mate¡ce may tte E.i¡e
probed with a t€lt lead prcL
or cable insulaüon be
or clips
Con'.-etor murt Dever be demated whllgt
a test la tn progress
t.6.2 Tect Seor¡enee

The tert rElueD.oe for pott frbrlc.,üoE sDd l¡lEt¡rüoE t! rhora

b€¡owi
Vl¡utl pr!¡g¡8ph ,1. 6. 3
conüE¡lty - Pü¡grlph {. 8. {
Io¡ul¡Éoo rellltl¡cr
- prrrgrrph {.6. S
1:l_"-*" vttüataadtag voltege _ prrrglrph {. 6. 6
(Dl¡^/)
vlrtt'r - p¡¡r.rTh a.8.3
NOÍE: DWV tnult ody b. pcrloñcd oace, pr¡¡t:rph
raG a. C, !

{-&1
 ,
{.6.3 Vt¡u¡I Exr-ml¡¡üon
to ld'aüfy f¡r¡Itr t!¡t r- ñtrit b'
The obtect of YIr¡¡l eramlD¡üon lt
vcrttlcd bY clcclrlcll tartr '
provtd€d ar gr¡ld'ellDea for vl ¡¡l q¡slll-
Tbe followtng check Ust 1!
6on.

Polt F abrlc8üoÁ

- Irorcocrc of Hodúog

- txc6tive uDsup?orted ioopr

- Co¡rest b€od rsdl

¡o 8qy branch or rfaSl.e vlte ln sry br|^lch
- Lack of
.ten¡io¡
- Cor¡otloo

- Dedoraed or btokea cout¡ectott

- Frrcü¡¡ed Poü88

- ftt¡pü¡led oieeving or ¡heat¡lng

- Xllrü¡rbcd ahleldiag

- Brok'! 8tr8Dd8 et JolÁt8 to PiD!

¿ad flett¿¡lag
Evide¡ce of loruleüon
nldrs' h¡rag ' abtrriou
l- -
- Cle¡¡ltueas

- DaD¡god PtDs

Po¡t 1n¡6ll¡üon
rdded
po't frbrtcrüoE vl¡u¡l tbe foucn'ins ahcr¡ld bc
ta rddlÉo! to tie
to the ched( llst:

- AdG$¡¡t€ e¡Pport ¡¡d cI¡mpi¡g

Corrrst otrlP/üc lttt¡d ¡¡d

Ét ddorErGd
-
¡ H¡rurt rp'dDg scclg'¡bl'
: -
Frn ctc
- E¡rElÉ tor fltl r¡d fcr¡I¡ - Ec'v18
¿.:

- Cl¡¡Ilr¡' rtrDd¡ti E¡IdrtD'd

it¡
I 1.uz
(
{.6.{ Elecfrtc¡l Cond¡ultv

Tert th.at thc polnt to polrü etect¡lcrt con¡ccüotr! are ln ¡ccord¡¡cc

c/1th the dealgn requtram.Bts &Dd thst t¡e corr€et AWG h8! bcco u¡ed.

l,§FC epeclflcaüon 40M99S82 Rcfcreucc (19) reqllres t¡¡t the rcllr_

t¿nce from point to polDt does rDt cxceed 2.0 ohlns *.lt¡ a EarlElum
te8t voltage of 50V dc.

For t}le tert tD be mceDllgful the reslat¡¡ce e4ecled for e¡ch coErc-
tion Ehould be apecüied. If the me¿¡ured value ls out8tde t¡é rpecúled
value lt c¡n be concluded thet etther the iDcorrect AWG hs¡ beeu ured
or a dryftad ,oint extlt¡.

Poe,,er wlrlDg should be teat¿d for voltsge d¡op ¡e weil aa couüE¡ttv by

either inrecüDg the ayatem voltage at the BeDdiDg eud and DessurlDg the
voltage d¡op at the receiviug end or by mes.Eurhg the llae locp resls-
tá¡ ce.

An AVO modei 8 or 9 lDatmment i8 ideal for rÁealuriDg coDüE¡¡lty.

The uae of buzzer t]?e iDdicator is rct recoDlmeoded ee tley ale melely
Bet to operete below a 8et velue with oo i¡dicaüoE of t¡e ln¡e rellst8¡ce
readlng.

4.6.5 Inaulation ReBistapce

Insuiation reEi8Ence tesE sen'e tvo pur?oEeB, oamely:

(a) Prove t¡at there 8,re ¡D lmproper coEectfoEr

(b) Prove that tbe proceaoea for wire ltrlpping, &lderr¡g/

crintplng sEd lnstall¿Uon e¡e of t!¡e legulred stsDd¡ld
(
ltc general @adlüoE! for en lnculaüou re¡lat¡nce t¿at tre:

1. All ¡vtrea rct electrlcelly couoested tD t¡e wlre under te¡t rad
lpr¡e plDs ¡re ¡horted to S¡o!¡Dd

A tert voltsge of SOoV dc (Rdereace f 9) ¡plted for 10 ¡ccod¡ wlti ¡ ;.

¡!.r!ured lDrulafloD rellrt¡ncr of mt le¡¡ th¡D f00 mGgob8l! la rdegu¡t
for tr!üng the h¡ru¡¡.
Tl¡e 60 ¡ccoad¡ cpcclrled lD RefercDc€ lg t! coalldered too long. E
thcr. lr ¡ frult oD üc h¡¡¡ea¡ it wtll ¡hos, IrrDcd¡tely.
The t !t voltegc lr ¡ppltd b.lxcca th. pta uDdar trlt end grorad.

¡
{-8-3
 {

{.0.6 Dlrlecñc Wlth.taEdfps VoltsEc (DWV)

Thla l! ooc¡rloar§ rdcncd to rr ptlcl voltaF taaL

DWV vtll pror'¿ thrt th" s,l¡c l¡¡ulrtfo¡ rld €lDrctor üclcc|trfc¡ b¡vc
Et béB degraded órrlng febrf caÉoD, h¡¡dltng ¡d ¡¡brcqr¡cat t¡¡trll¡-
ÉoD l¡ t¡G rpsc€crút.

DWV terüEg ia geucrally recognleed 8! bcllg potcrr!8lly accuurulaüvely

de.Er¡sdve to iD¡ul8Éoa, therdore, the tclt lr performed ouce o¡ly, ellhcr
o¡ polt f¡brlcáEon o! polt tDltrlbüoD.

Poat febrtcattoD t€!ü!8 1! recorDmeDdcd o¡ crble ¡c¡cmbue¡ t¡co¡polz-

Eng an overall protocüve !hcal!.

For a @Eposlte a¡d coroplex he¡ne¡e qrttbor¡t s protaeÉve shesü r¡d s

b¡rae¡¡ f¿brlcated oa c ¡iaul¡ted B§'ucü¡re lt 1! recoohe¡dcd Ést DWV
teat be peforrred oE poBt l¡¡tallaüo¡.

lte geaerd coodlÉo¡s for tbe te¡t ¡¡e:

1. All wiles rct eleclrtclly coElactad to the wl¡¡ uldrr telt rd

rPare PiDs ara shorted to g¡u¡ld

2. All coDrEstor ¡hcll¡ are coúGctéd b f¡ouDd

Teat

The sirc u¡der test sh¡ll bc subrect to 1000V rE! (50 or 60 e.) or
15OOV dc fo! ole EtEut€ m¡Éauu, lc¡¡age cl¡!!¿!t lb¡ll Dot c¡cr.d
0. 5 nlüarrperea. ltc telt volt¡8E bciag conotctad b.trce! tb. PID
u.Dder t¿rt aad grouad.

a-c-{
 ÉLEc-rÉ rc.A L- §.r-] ¡> t= L'L_C-rÉC)FJ l(-

\A/ t At F-.i G
Tahle WII'E SF)}'ARATION ST]]II i\IA RY

S¡] PARATION
F ROIÍ
w aus of i sf'EctAI. rvtRF;
c11', sCo t,¡l t)ESCrrf t{toN flx^lfP{,ES oTrtER c^]s I Tnt:,rt tgx't.
Elec. It,* er ,lf';" ..,tar8,,." S' DC ,. AC motors, t, r , lrcr (r5?v rr) i)Jo shrel,ling
lvirins elec. loads Higher EMI heaters, general lcfcept as apDroved
sources Spike & Iighting, relat/s
t¡ansient originators and other solenoid
such as relay coils mob.s. devices, synchr.r
or transformers (pawer. feeders excitation
e\cluded, see Cat V) __
\
I1 ¡llecLronics 28vac & DC to electronic Solid state radic, J ,IL.her( lqr r h,,' Shield ma¡ be
Power and loads, less offensive than interphone, auto-pilot. requi¡ed. Ma)_ use
Instrumen- CAT I'noi as high current computer, antiskid, T*'isted Pair
t¿tion lóads, not spike producing slats, spoilers, fil-
tered 28VDC, LVDT
excitaiion

lv Sensitive a. Circui'Ls su-sceptible to a- Analog audio a incl',es (lC. -* )

Circuits & low level EMI but not synchro signals &
Ir¡*. Invel as ert¡eme or critical bridge circuiLs
Sources Microphone & demo'
dulator circrLit"s,
LVDT signals

b. Loser ievel pulse source b. Analog video and b. Cont¿inment

digit¿l circuits shielding multi
ple point gnd.
3,...=s(:c -*)
S¿fety of Exlended separate require- Transmission )ines, lrom cach other Multi, gnd. coax,
Flighl ments for coax aDd foa waveglide & coax wire in CAT and Shielded and Tvisted
lsolation wiring of ext¡eme offensive (r¿dio & radar). fire oth¿r CAT's. Gen as reqd. May gr:oup
$ri¡ing and defensive character - warning, EED's feeders I2\ from recorder oi
/-
associaled with safety of primary generalor oiher 92,/tee.iFr transforrner-coax
flight and mission success feeders runs. L{3¿.Ah,4) but don'l mix.
Transceiver coax
not to be grouped.
s.-... "r (-7G-*)
vt Sub'system Spccial lalitude permitted a. Wiring between f¡orr all C-{T s As applicable to
lYiring to mix categories of one and equip. of same including other CAT II & IV
orllv one suLsystem in dense subsystem. trlay CAT VL Do nol
wiring areas for a max. of cont¿in CAT l, combine CAT \¡t
three feet frcm connector IJ, M V. subsystems.
if possible (Requaes Wire
Instl. group coordination) b. Gene¡'ator conlrol
and regulation

bÉlFl!-Jt-Tr¿¡F¡ 3'
EL ECTROHAGNET IG COI'1PAf IBILITY EI'1C

The c0ndrtton nhich prevai_[s trhen electrrcal and electron¡c

equlpment ls collectlvely perf ormlng lt3 lndlvldual f unctl0ns ln a
common electromagnetic envlronment Yrlthout causing 0r suffeling
unscceptable degfadatlon due to electromagnetlc lnteflerence f rom
other equ ipment/systems ln the 6 ame env ir0nment.

ELECTROMAGNET IC INTER - Et4 I

Th e p n e n ome n o n result¡n'9 Yrh'en electromagnetic energy caus.es

unacceptable or undeslrable Iregp.onses ln the lntended 0peratlon of ':'
equipment, subsystemg or 3yS y3tem3 or otherYrlse degrade3, I ImIt.S..;Oli+i l

tnter rupts tne I r ef f ec t t-v e--p€-r-l-o+ma nce,

 J
t t
ELECTRIC MRNESS CLAMP IJOL'I SELT'LOCKING I,JASIIEI{ A \,IASItIIH IJ t.ot:x uaisrrtr< ñ [/j
(BASIC PN) NUT (BAS]C c lj^s r (i ll,N) i
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ST[[L ITESISTANT STIDL RISI STANT AI,UIJIN¡ZEI) ( ulr2 ) ( ) (AN96oC) T l.

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l,iI LtI ELECTRIC
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 TDtsEso

TABLE I - R¿co¡ocnd¿d types of c¡blc3 for plrtt cular epprlcatloa¡ (coacludcd)

Clrculr R¿coocsded typc of cablc

LlgbtlDg loads la¡e thao 5 A §lagla ylrcs, r¡g crc¿aad

I¡ducEive loads less then 5 A Shgle rlres, acreeued 1a some lostaDce6
IDductlve load¡ ¡ore theD 5 A T§16ted, screeoed
Dtglt¡l clrcult5 '¡\rl3tcd, tcrecDed, f¡dlridu¡I ¡crceD8 ,.D
' 3b!e lns taEccs
Pulse circufrs of al.l types Tvl6ted, Bcreeued, i¡d1v1dual acreens f-u
aoDe lDE trEces

Q,o"tog.r" cl.tcults TsLsted, acreeaed

Slochr frr16 ted , r.u.s creened

S ervos lYi6red
Lorlevel 61gaa1§ of all types Trrl6 ted, acreeoed, lntllvldual screeo¡ i¡
aoDe lDs taDees

r'Ilght aefety clreults fylsted, ecreeaed, i¡dlvt'dr¡al ¡creea¡ l¡

r""' ,tae.. lss.-!fg.i.l. .. :,:. :.. j,,.,,,. i -,i ..'; : . "..-: 1, :. ::,
.
-

i.-" r., ,l i _¡'''':'"'r.r

" "'
flre uarBi.ug gy6teD TsI-Etad, acreeoed, i¡d1v1du¿1 acEeeas 1D
aoDe l¡sla¡ceg
Fuel qusutlty c¡bles Ce¡d,el
srrt.a l¡dicrto¡ cables Cer:l,aI
Jt"eUa
I, ercom¡¡lcetloaE nieropbooe T¡rlD-trrlBted, ove¡al1 or l¡dlvldual
c}fcults a cree¡-6

Yldeo ¡od 1o¡¡ r.f. trequency llues Co-r¡1al

A¡teED,a fcade¡E Tri^-rrlal. or co-a,rlaL

lo.{@
ScreeBE ebor¡ld be cm¡eeted 10 lccordáaée úfth ib€ dutp¡¡ii deelpers
rcco@Bdatloss. r¡ general s1pal acreeas Ln the freque¡cy raage up to 50 rn-
¡hould üe grouaded oE oDe cod oly, aomall, at tb3 3lgnal 3ourcc cad, eod above
2 IlBr rt both c¡ds. lor the reralalog frcqueucy rauge (50 XEz to 2 XBz)
evlsloD for grouaillag o! both c..de .¡¡y bave to be ¡aile.
 ISO/DISB¿¡

I0.2 Cabl! chaslf lcaElou

'o c.aure satl.factory crpera¿r.oD of all 1as!a11ed equfpaeat lo the allcrrf t,
degregatlo! .¡d sutflcleDt oeparatloa of ¡r18aa a¡d c¿bice ublcb ray c@duct
er¡It laterfcrence fron olber r¡l¡es and cables rhlch oay be auaceptible to or
Í.aterfércacr ls Dece.aerJ¡. Baslcarry l'terfereocc e,litlog rlrr.,e aad ae.altlve
rlres ahould' be kept apert !8 far as poaslble.
For mrc l¡forgatlon aec ,ñri.! A.
10.3 Recosoended t of cables for catfoa
fable I glvet a lt st of recoended typee of cables to bc used for partlcuLar
appllcatloor aad oa pa.ttlcul¡r type of- cfrculta.
TABLE I - RecoEoended type6 of cables for partfcular appll catlon8

!Crrcut r Recorended type of c8b1e

Pr1¡ary poirer to equlpDent, Trrts fed, r.macreened, 3 or 4 co¡es

3-phaee

Pr{ñt'r, r.c. poreE to equlpEeat, Tr¡1o-Ey16ted, rnscreened

slugle-ph. es

rlrary d. c. p@er to équl.paeEt TIflD-ErrlB ted, r¡¡e creened

. I-\r.rs+4, lqgsEe?eedr .3 o¡ .á. s9r.s.

Secoadary a.c. porrer to équlpEeat, ndEtea, t§1D., uoecreeDed

slagle-phaee
Sccoadary d.c. ¡»orer to cqu!,ptreut hrl3tcd, trlu, tnaereeocd
Ontetrl'butloE ¡rrrlng f¡d¡-tsls tcd or alogle rmse¡eeoed
Outgolog porrer leade froo equlpoeat Tyl3tcd, scrcea ¡ay be necessary 1o
1a.s !rac€a
BestlEg or reslstllre loads ¡or¿ TlrlsBed, r.oscreeoed
thaE 5 A
EcltlDg oE res ,.str.ve Io¡de L¡s Slaglc rlrca, r¡a¡crcc¡cd
thrD 5 A

1t
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NOTES;
OETAIL X rx o .osol !!j rnnu rno
r, rxTEñPREr or^l,yrrc r^, urL-sfo-loo. sc^LE 2/r L r O,2!6 x .026 0P
2. roix¡¡aN§H¡F siALL 8E tN
wrTH urL-STD-¡54. FEQT 9.^CCOROANCE (2 PL^CES)
¡. u¡f€nr^¡-: 5oo. 0x602, rNJEcfto¡
¡ot-orN6 ¡k ^cEI^t
€xTtusr0a¡ r¡ fERr^1, p€i
asTr¡ 0-2r J¡. 6Ra0E l_
R€IrcVE 8L]iR5 ANO 8ÑEAK SI]ARP
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5. uñLESS orHERrt§E SP€Ctr EO. i^OrL
artLETS S¡lAlL 8E .0_! r¡^r.^LL
6. ^NO 0R TAG tElS rfEr¡ t^rr r¡r!-5To-tJo.
8^C
unx
(^s
zooss-ooa-r
rC^8LE).
r:- * nÉv !
^PFL (.x r +0)

6 .orsl 33Í

SEE SEP^RATE P^RT5 L ISf

SEC T ION A-A
5C¡Lt r/l

DEfAIL Y
scALE 2/!

*"--.-. 0 .,-..
 lo
I

NOTÉS: lNLEss orNER!*rst spEcr t rEo

r. ll¿TtRPlEl oi^rtrs tar !rL-sTo-100.
2. roft(r¡¡rsH¡P SHAIL ac rAr r¡¡t-5lD-45a nto'I 9.
¡. sor.Dan t^r rrl-5i0-20¡o usr€ rrtr 7.
.¡. ILL SotoaÍ co{r|.c¡to¡¡s sHr¡.[ 8t r^x c¡t-s¡o-a5a.
(
iEo'I 5.Ar¡D aE^o PEi PPS100-Ola-00t.
5. irvfrrrc €Y¿LEtfLric rtR PFsroo-oa9-oor.
§. fr^nt ^5 9rorr
^xo PtR rrstoo-oál-oot,
,. rrR¡( Pai nr[-slo-tao,0^@tD 0n I^cGEo rlH P^RI
NU¡Aai lx¡) Ravisrox LEvtL,
^PPr@ñr^ra

saEr{oral&a
SEE NOTI
2 PL^CIS i Pt^cts

CH.CK PR/NT
SEE SEPARIATE PARTS L IST

TTRM INAL BOARD

ASSEMBLY

)
 (

Nof ES: uNLess ofHEñsrsE sPEctrttD

t. rxT$PnET oR^r¡ 6 l¡t ¡¡ .-STD-100.
2, roixuxs{rP s,raLL sE r^r !rl-sto-ar. Rlq ¡ 9.
!. soLoen l^r| l¡rL-STD-2000 usl|{c l¡fra ,.
,r. solo[i colr¡rtclroris sri LL 8E l rll-5l¡F11,
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6. fMit As ^¡0
$iq PEi PP§roH5l-001.
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SEE I¡OIE
sEEnol€l&1
2 PIACES J PLACES

CH'CK P,F /NT

SIT SIPAR]AII PARlS L]S1

l ERM iNAL BOARD

ASSEMBLY

TAI/( uirr'1 lÉr!-l 51i.,¡i Y \. r¡,{- -", l\\-1\'tS6