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TE Connectivity Catalog 1654025 Revised 3-13 Wire and Cable, Harnessing and Protection Products te.com © 2013 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. 1654025 GIC 7.5K MS 03/2013 TE Connectivity, TE connectivity (logo) and TE (logo) are trademarks. Other logos, product and/or company names might be trademarks of their respective owners. Global Contacts Wire and Cable, Harnessing and Protection Products Markets Served Americas UnitedStates – Harrisburg, PA ProductInformationCenter: (Technical Support) Phone: +800-522-6752 +717-986-7575 Fax: Menlo Park, CA  94025-1164 USA Phone: +1-800-926-2425 +1-650-361-3860 +1-717-986-7575 Fax: Asia Phone: +86-400-820-6015 Europe Italy Phone: +39-011-401-2632 CzechRepublic Phone: +420-800-701-462 BalticRegions +46-8-5072-5000 Phone: Nordic Phone: ++46-8-5072-5000 Poland Phone: Benelux Phone: +31-73-6246-999 Spain/Portugal Phone: +34-93-2910366 Hungary Phone: +36-809-874-04 France Phone: Switzerland Phone: +41-52-633-66-26 Russia Phone: Austria Phone: C4ISR Commercial Aerospace Ground Defense Military Aerospace Military Marine Missile Defense Offshore / Civil Marine www.te.com/ADM Space +43-1-905-601-228 +33-1-34-20-86-86 Germany Phone: +49-6251-133-1999 UnitedKingdom Phone: +44-800-267-666 Need more information? Web Site Technical Support is staffed with specialists well versed in all TE Connectivity products. They can provide you with: n Technical Support n Catalogs n Technical Documents n Product Samples n TE Connectivity Authorized Distributor Locations +7495-790-790-2 Visit www.te.com/ADM for additional information on all our products and market segments for the Aerospace, Defense and Marine markets. © Copyright 2002, 2003, 2004, 2009, 2012 and 2013 by TE Connectivity. All Rights Reserved. 99, UNIBOOT, VERSAFIT, VERSAFLEX, and ZEROHAL are trademarks. ATUM, ALTERA, CHEMINAX, CRES-LOCK, DURASEAL, DYNALINK, ELECTROLOSS FILTERLINE, FASTON, FLEXLINE, FLEXLITE, HARNWARE, HEXASHIELD, MICROFIT, MINIRAY, MINISEAL, MTC, NF-100, PINPAK, POLYCRIMP, QUADLITE, RAYATEN, RAYBLOCK, RAYCHEM, RAYBRAID, RAYFLEX, RAYFOAM, RAYOLIN, RAYOLON, RAYRIM, RAYSPOOL, RAYTHANE, SEALITE, SEALAN, SHRINKHOOP, SOLDERGRIP, SOLDERPAK, SOLDERSHIELD, SOLDERSLEEVE, SOLDERTACTS, SPEC 44, SPEC 55, SPEC 80, SYSTEM 100, TE LOGO, THERMOGUN, THERMORAD, THERMOCOUPLE, TINEL, TINEL-LOCK, TE CONNECTIVITY, TYPE Other products, logos, and company names mentioned herein may be trademarks of their respective owners. Printed in the U.S.A. +48-800-702-309 Kevlar and Teflon are trademarks of E.l. du Pont de Nemours and Company. Mylar is a trademark of Dupont Teijin Films U.S. Kynar is a trademark of Atofina Chemicals, Inc. Skydrol is a trademark of Monsanto Company. Steinel is a trademark of Steinel GmBH. LuxCis is a trademark of Radiall, S.A. PROFIBUS is a trademark of Profibus International. Disclaimer All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their application. TE Connectivity makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. TE Connectivity only obligations are those in the Standard Terms and Conditions of Sale for these products and in no case will TE Connectivity be liable for any incidental, indirect or consequential damages arising from the sale, resale, use, or misuse of the product. TE Connectivity specifications are subject to change without notice. In addition, TE Connectivity reserves the right to make changes in materials or processing without notification to the Buyer which do not affect compliance with any applicable specification. Export of TE Connectivity products may require licensing. TE Connectivity www.te.com Wire and Cable, Harnessing and Protection Products Table of Contents TE Connectivity Embraces the Most Valued Brand Names Worldwide ………………………………ii About TE’s Wire and Cable, Harnessing and Heat-Shrinkable Products ……………………………iii How to Use this Catalog ……………………………………………………………………………iv Application Overview Seal It ………………………………………………………………………………………………1-1 Connect It …………………………………………………………………………………………1-2 Insulate It …………………………………………………………………………………………1-3 Protect It …………………………………………………………………………………………1-4 Wire It………………………………………………………………………………………………1-5 Hold It ……………………………………………………………………………………………1-6 Join It ………………………………………………………………………………………………1-7 Beautify It …………………………………………………………………………………………1-8 Reduce It …………………………………………………………………………………………1-9 Repair It …………………………………………………………………………………………1-10 Flex It ……………………………………………………………………………………………1-11 All of It ……………………………………………………………………………………………1-12 Electrical Interconnection System Design HarnWare™ V6 ……………………………………………………………………………2-2 to 2-7 Integrated Military Harness Systems …………………………………………………2-8 to 2-18 Product Sections Heat-Shrinkable Tubing ……………………………………………………………………………3 Molded Parts ………………………………………………………………………………………4 Adhesives ……………………………………………………………………………………………5 Adapters ……………………………………………………………………………………………6 Assemblies …………………………………………………………………………………………7 Electrical Interconnect Products …………………………………………………………………8 Wire and Cable ……………………………………………………………………………………9 Application Equipment……………………………………………………………………………10 Supporting Information Equivalents and Conversions …………………………………………………………11-2, 11-3 Temperature Conversion ………………………………………………………………11-3, 11-4 Glossary ………………………………………………………………………………11-5 to 11-13 Part Index ……………………………………………………………………………11-14 to 11-26 i Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Wire and Cable, Harnessing and Protection Products TE Embraces the Most Valued Brand Names Worldwide As a truly global player, TE Corporation has facilities located throughout the world serving customers in a wide range of applications. Tyco Electronics Corporation was established in September 1999 and since then, the company has rapidly grown and strengthened its competencies as an electrical and electronic component supplier, with product offerings in 25 passive and active product segments. The company has facilities located around the globe serving customers in the aerospace and defense, automotive, commercial electronics/ communications, industrial/energy, marine, medical, military, and rail industries. TE’s product portfolio continues to grow, encompassing connector systems and application tooling, active and passive fiber optic devices, complete power systems, wireless components (including IC's, radar sensors, and complete communications systems), GPS and integrated antenna systems, heatshrink products, circuit protection devices, magnetic components, wire and cable systems, touchscreens, PC boards and backplanes, smart cards, relays, sensors, electronic modules, wire harnessing and labeling products, battery packs, terminal blocks and switches. customer service personnel enables you to make your next generation of products successful. A significant result of this continued growth, and a real benefit to customers, is that our technology leadership becomes even stronger. The synergies of expertise in materials science, product design, and process engineering, coupled with knowledgeable application engineers, sales representatives, and ii Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Wire and Cable, Harnessing and Protection Products About TE Wire and Cable, Harnessing, and Heat-Shrinkable Products TE’s Raychem brand of products, pioneered the application of radiation crosslinking and the development of heat-shrinkable polymer tubing. TE’s Raychem brand of heat-shrinkable polymer products is recognized worldwide. It is backed by a history of proven performance, reliability, innovation and superior quality. TE manufactures the world’s largest range of heat-shrinkable tubing – tubing that provides cable protection offering exceptional insulation, mechanical protection, and strain relief. We are the recognized world leader in heat-shrinkable polymer technology. A broad-based product line of wire and cable is engineered to meet or exceed the most rigorous technical specifications. Performing from -100°C to +260°C [-148°F to +500°F], the product line encompasses fire-resistant cable, smallsize controlled electrical cables, multi-conductor cable, high-performance radiation crosslinked ETFE airframe wire, low fire hazard wire, high-performance automotive and commercial wire, and NASA-spec and other space-application types. Additionally, a variety of low-cost, easy-to-install components for wire harnesses and cable assemblies are available including splices, adapters, low-profile rectangular connectors, and contacts. These components are approved to widely recognized standards and specifications that include UL, SAE, MIL, Defense, DNV, Lloyds, and ABS. TE also provides customized harnessing design supported by a pioneering software package, HarnWare, which enables fast, optimum system design with materials and assembly labor estimates. For over fifty years, customers have recognized the global capabilities of Raychem products. Combining these advanced products with superior technical support and a global sales/service organization, customers with worldwide operations count on TE to supply the knowledge and products they need to solve specific problems and help them take advantage of opportunity, anywhere it arises. This philosophy has earned TE a reputation for leadership in materials science technologies. Developed from these technologies, Raychem brand products are sold into many industries including aerospace, automotive, electronics, construction, electrical power, utilities, manufacturing, pipeline, process, rail and mass transit, and telecommunications. iii Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Wire and Cable, Harnessing and Protection Products How To Use This Catalog This catalog has four main sections: n n n n Application Overview Electrical Interconnection System Design Products Supporting Information Application Overview (Section 1) presents general design ideas based on typical uses for Raychembrand wire and cable, heat-shrinkable tubing and protection products. Application photos depict examples of how customers use our products to enhance the performance and improve the reliability of their specific products in one or more of these generic applications; Seal It, Connect It , Wire It, Insulate It, Protect It, Hold It, Join It, Beautify It, Reduce It, Repair It, Flex It, All of It. Electrical Interconnection System Design (Section 2) describes wire harness components and harness protection issues and provides a step-by-step guide to selecting the right components for a particular wire harnessing system. Products (Sections 3-10) showcases our product groups. Each section provides: n An overview of the product group. n A table of contents that lets you see at a glance the product families in that product group. n n n A selection guide to help you determine which product family will satisfy the requirements of your application. An explanation of the part numbering system for that product group. Information pages on each product family. The product information pages provide some or all of the following information (depending on the product family): n n Product features/benefits. n Abbreviated installation guidelines. n Specifications and agency approvals. n Part number selection information. n Product data (dimensions, properties, and materials). n Ordering information. n Location availability. Supporting Information (Section 11) provides: n Equivalents and conversion tables. n Temperature conversion table. n Glossary. Typical applications for the product family. iv Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Seal It 1 Application Overview Advanced materials and product design have resulted in a complete line of products offering the most effective sealing available today: adhesive-lined tubing, molded parts, and a variety of solder and crimp connection devices. These easy-to-use products provide superior waterproofing, resistance to hydrocarbons and other chemicals, protection against corrosion and oxidation, and a barrier against dust and dirt. n Heat-shrinkable, adhesive-lined products—tubings with high shrink ratios, and molded parts—environmentally protect connector-to-cable transitions. n Waterblocked and anticapillary wire prevent water and most fluids from wicking between the conductor strands. Bundle sealing products block multiconductor cables. n Adhesive-lined, heatshrinkable tubing and end caps seal and protect electronic components and in-line wire splices from fluids, moisture, and corrosion while also providing strain relief. n Heat-shrinkable caps lined with an adhesive or encapsulant form a moisture-resistance barrier around stub splices and wire ends. n Heat-shrinkable, moisture blocking systems are designed to provide reliable sealing of wire bundles preventing fluid ingress. 1-1 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Connect It TE’s electrical interconnect products offer reliable, more cost-effective alternatives to traditional connection methods—such as hand soldering, or crimping and then insulating by taping or overmolding. With our electrical interconnect products, you start with a precisely engineered, fluxed solder preform inside a transparent, heat-shrinkable sleeve. When the product is heated, the solder preform melts, and the sleeve shrinks to create a connection that is fully insulated and strain-relieved. This ease of use expands your options even as it enhances the quality of your end product, as in these applications: n Easy and reliable termination of EMI shields to ground, ensuring effective EMI attenuation. Shield termination products are available for computer, data, and instrumentation cable, communications and video cable, and heavy industrial cable. n Splicing of one component to another, such as a diode connected to one end of a LED. n Coaxial terminations to PCBs and terminals. 1-2 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Insulate It 1 Application Overview Solving an insulation problem can be easier than you think, especially when you consider the family of Raychem brand products from TE that can provide superior alternatives to standard methods of insulation such as hand-taping or molding-in-place. n When heated during installation, our radiationcrosslinked tubings shrink to conform to a variety of shapes, providing dependable insulation. n General-purpose polyolefin tubing is widely used to insulate and strain-relieve wire terminations and connections. n Heat-shrinkable end caps insulate wire or cable terminations, providing protection from dust and dirt. End caps with adhesive or encapsulant linings also provide protection from moisture because the lining, when heated, melts and flows to fill surface irregularities of the substrate. n Delicate electrosurgical instruments can be insulated and protected from abrasion by using one of TE’s medicalgrade, heat-shrinkable tubings specially formulated to meet the requirements of USP Class VI for medical use. n Components on a PCB, such as capacitors and fuses, can be insulated with a UL VW-1-approved heat-shrinkable tubing to achieve a specific product rating. 1-3 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Protect It Designing a brilliant solution is good. Protecting a brilliantly designed solution is even better. A whole family of protection products, made from a wide variety of materials, can provide comprehensive protection: mechanical protection, strain relief, resistance to abrasion and crushing, EMI and noise reduction, fluid resistance, and thermal insulation. n Tinel-Lock ring braid terminations can be used for applications where shielding is critical. These shape-memory-metal products attach metal braid shields to backshells and provide 360° protection against EMI and EMP. n Heat-shrinkable tubings provide mechanical protection for hoses and pipes, and also reduce problems caused by wire chafing or cable abrasion. n Easy-to-install heat-shrinkable tubing and molded parts provide excellent strain relief and electrical insulation for connectorto-cable transitions. n A heat-shrinkable molded part can relieve the strain on a multiconductor cable to a D-subminiature connector. n Heat-shrinkable feedthroughs relieve the strain on cables entering junction boxes. n Highly-flexible, heatshrinkable fabric tubing provides outstanding abrasion protection for components such as rubber hoses, plastic pipes, and harness wiring bundles, recovering easily even over awkward substrates such as bent hoses. n Heat-shrinkable MicroFit tubing is used to provide insulation and strain relief for fine-gauge wire (24 to 42 AWG) and fiber optic cables in such end products as medical devices, computers, communications equipment, and commercial electronic products. 1-4 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Wire It 1 Application Overview TE is a leader in the development of high-performance wire and cable products for demanding applications, including aerospace, industrial equipment, instrumentation, marine, and automotive applications. Precision extrusion capability, materials expertise, and design knowledge provide wire products that are lightweight; smaller than comparable-performance constructions; highly flexible, yet mechanically tough; flame-retardant and resistant to a variety of industrial fluids. All TE products offer outstanding shop-handling characteristics for efficient stripping, wire termination, and bundling. Cable design software is available to create custom multicore cables with unique components, tough but lightweight jacket materials, and optimized shielding. TE can also design complete wiring harnesses for industrial or military applications. n The FlexLite family of hookup wire provides economical alternatives to fluoropolymers, silicones, and crosslinked polyethylene insulations for applications such as motors, appliances, and lighting, and for applications where thinner walls are needed because of space constraints. n Raychem brand of hightemperature, dual-wall or single-wall aerospace wire saves space and weight on both military and commercial aircraft and space vehicles. n Low-fire-hazard primary wires and cable are made from halogen-free, lowsmoke materials with a low toxicity index. They offer increased safety, with reduced size and weight, over traditional materials in mass transit and similar applications. 1-5 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Hold It To help you arrive at the best way to securely hold and position a component, take a look at the TE family of products and consider the many ways that you can use them: to keep components in place, bundle and route wires, create a formed shape for potting, or package components securely before final assembly. n Thin-wall tubings allow bundling of wires to create very flexible, lightweight harnesses that can withstand harsh environments. n Tubing can hold a covering (braid or convoluted tubing) onto a substrate. n Two components (such as a resistor and fuse) can be held together as a package by enclosing them with heat-shrinkable tubing. n Heat-shrinkable fabric tubing will grip substrates, such as harnesses, tightly to provide secure wire bundles without additional fixing. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 n Fiber and/or copper wire components can be bundled for a custom multicore cable. n Cable legs can be held together with a Ytransition molded part. n Multicore and filmbonded cables hold wires together and can also provide EMI protection. 1-6 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. For additional support numbers please visit www.te.com Application Overview Join It 1 Application Overview When you have a mechanical connection to make, consider the uniform circumferential recovery force of heat-shrinkable tubing and metals in your designs. n Join two dissimilar materials, such as a rubber flapper to the end of a nylon tube, or the handle of a medical instrument to the instrument’s moving parts. n Clear, adhesive-lined tubing connects water tubes in appliances to provide a rugged and aesthetically appealing joint which is also inspectable. n Assemble a bellows by covering a spring with heat-shrinkable tubing. n n Use Tinel ring adapters to provide the even circumferential force necessary to attach a metal braid shield to a backshell. Heat-shrinkable tubing is used to join polyester cords to heddles in Jacquard weaving loom harnesses. 1-7 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Beautify It Enhancing the appearance of your brilliantly designed solutions couldn’t be easier, when you use TE products. n Heat-shrinkable tubing— instead of tape—can create a smooth covering with no loose ends. n Hot-stamp foils (gold or silver) can attractively showcase a company logo. n Heat-shrinkable tubing can cover the mechanical attachment of one part to another. n Tubing can attractively cover a metal railing, such as the type used for crowd control. n Tubing can be colormatched to the original color of fiber, wire insulation, or other components to enhance the appearance of the final product. n Handles of a variety of tools can be covered with colorful, heat-shrinkable tubing to enhance the appearance of the final product. 1-8 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Reduce It 1 Application Overview With the trend toward miniaturization and higher-density interconnections, products developed for commercial electronics applications must downsize as well. n SolderSleeve devices feature a one-step controlled solder process for splicing and terminating wires down to 36 AWG—a method that is more reliable and less craft-sensitive than hand-soldering. n TE can reliably produce primary wire insulations as thin as 4 mils. Our design software optimizes component placement and shielding to produce small, lightweight custom multicore cables. These cables can offer size and weight reductions that can range from 10 to 40 percent vs. comparable-performance constructions of primary wire or cable. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 1-9 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. For additional support numbers please visit www.te.com Application Overview Repair It Whether for repair or retrofitting, TE offers a whole family of Raychem brand products that can provide flexible, cost-effective solutions. For example, most failures in electrical wiring harnesses occur within the first six inches of the connector. Raychem brand products make repairs in this area more reliable, long-lived, and cost-effective. n High-shrink-ratio tubing can be slipped over the connector without depinning to reinsulate or strain relieve the connector-tocable transition. n SolderShield repair splice kits provide the components necessary to splice shielded single-wire or multicore cables. n n Splash-resistant SCL semirigid heat-shrinkable tubing, with its meltable inner wall, can be stripped off the substrate without leaving a sticky residue, thus providing access to connections requiring reentry. n Flexible, adhesive-lined tubing can be used to repair damaged wire insulation, providing a moisture seal that is resistant to bending of the wire substrate. Adapters and Uniboot molded parts can be combined to allow reentry to the back of the connector area for pin repair. 1-10 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Application Overview Flex It 1 Application Overview In applications where flexibility or flex life are important, TE products meet the need — many performing even at low temperatures. n n NT tubing, which is widely used for insulation, strain relief, and abrasion protection on cable harnesses and wire bundles, remains flexible at low temperatures (as low as -70°C [-94°F]) without cracking. n For applications where a flexible 90° bend right after the connector is desired, Uniboot molded parts can provide the perfect fit. n DynaLink wire and cable is designed specifically for applications where flex life is critical: in the robotics industry; in lifts, typing machines, and sewer inspection equipment; and on ships where wire must be capable of unwinding from a large cable reel and then retracting smoothly without strain. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 Hi-Flex heat-shrinkable tubing was developed specifically for sealed cable-jacketing applications where cable flexibility is an important concern. It is also ideal for situations where the cable is subject to motion, such as in industrial machinery, transportation equipment, robotics, and welding. 1-11 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. For additional support numbers please visit www.te.com Application Overview All of It At TE, we like the word “multitasking.” So it should come as no surprise that our products are designed to help you integrate several tasks—seal, connect, insulate, protect, wire, hold, join, beautify, reduce, repair, and flex. In the pages of this catalog, you will find literally hundreds of products designed to provide thousands of solutions—across a wide variety of industries. Although you will find the catalog features an extensive array of products, keep in mind that, at TE Connectivity, we’re always coming up with new ideas and new products— so that we can help you put together the precise solution you need. Also, when you choose any Raychem brand product, you’re automatically backed by a nationwide network of sales engineers who can provide application and engineering assistance as well as onsite training. 1-12 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Table of Contents This section attempts to provide assistance with most of the considerations applicable to the design of cable and harness assemblies. Caution must be used to ensure that the design is appropriate for a particular application. HarnWare™ V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 to 2-7 Integrated Military Harness Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 to 2-18 2 Electrical Interconnection System Design TE Connectivity provides this information as a design aid and assumes no responsibility for and makes no representation regarding the suitability of a design for a specific application. Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with TE for most current data. 2-1 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 Computer Aided Electrical Wiring Harness Design Software Introduction A new version of TE Connectivity’s (TE’s) popular harness design software has been re-engineered using the latest Microsoft programming tools to offer improvements in performance and enhance the user interface. Additional improvements include new product ranges added to the database, which now includes over 100,000 TE products and several thousand military standard connectors. The HarnWare™ design wizard also has a more modern appearance and includes hyperlinks to relevant product information. The HarnWare™ computeraided design package enables users to produce high-quality wiring harness assembly drawings, parts lists/bill of materials, labor estimates, RoHS compliance codes for each component, cable cross-section designs, connector planform drawings, wiring schematics and schedules. Data can also be exported in a variety of formats to allow transfer of information into other computer systems. TE's extensive product ranges and systems approach to harness design provide complete harness solutions to meet the requirements of most markets, especially demanding applications in the defence, rail, aerospace, naval and motor sport industries. HarnWare™ software to guide the designer through a series of design operations. The harness system can be specified and a range of fully compatible components can be selected. Features n n More detailed and accurate design with the use of preferred parts, helping provide best delivery and price. n Designs and quotations produced up to 20 times faster. n Promotes a systems approach for choosing components, materials, adhesives, etc to help confirm parts are compatible with the intended service conditions and with mating parts. n More cost effective designs, minimised transcription errors and a more disciplined approach to harness design. Compare Design. n Updated COP Listing. n Materials and Equipment Listing. n Extended User Parts Library editable by users. n Improved export of Parts Listing. n Create Shape Function. n Fiber Optic Module including PRO BEAM Connectors. n Database File Path Selection for Drawing Translator, User Parts Library and Weights. n Users can supplement the databases of preferred parts by adding other component data into the HarnWare™ User Parts Library. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 The HarnWare™ software utilises a drag and drop drawing interface that enables the designer to rapidly draw and designate the overall parameters of the harness. This drawing combines with the Benefits 2-2 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 (Continued) Computer Aided Electrical Wiring Harness Design Software 2 n Micro Heat Shrink Moulded Parts. n Spin-Lock Adaptors. n STXR Adaptors. n ADK Rectangular Backshells. n Soldertact Contact Devices. n RF Connectors including TNC, BNC and N Type n GPR Rectangular Connectors. n AMPLIMITE Rectangular Connectors. n VG95218 Pt 28 Multicore Cables. n RG Coaxial Cables. n D-SCE Range of Identification Sleeves. n RT-780 Heat Shrink Tubing. HarnWare™ V6 System Specifications Since the introduction of the HarnWare™ software V1 in December 1995 many key changes and new features have been introduced. Version 6 of the software contains design modules for heat shrink sealed systems, conduit systems, 1553 data bus and fiber optical assemblies. The new V6 version gives a smarter, faster, better solution for harness design and component selection. Microsoft Visio: For HarnWare™ software V6 Visio 2007 or 2010 software can be used. Only the 32 bit versions of Visio are supported for use with HarnWare™. Electrical Interconnection System Design New Products Included in Version 6 Microsoft Windows: HarnWare™ software is compatible with the 32 bit versions of Windows XP Service Pack 3, Windows Vista Service Pack 1 and Windows 7. It is also compatible with the 64 bit version of Windows 7. 2-3 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 (Continued) Computer Aided Electrical Wiring Harness Design Software Materials Selection for given Applications Wire Selection Advice Wire Routes Links to Data Sheets and an Extensive Help Section Cable Lays Component Selection User Parts Library Design Checker 2-4 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 (Continued) Computer Aided Electrical Wiring Harness Design Software 2 Codes of Practice HarnWare™ can list the Codes of Practice (COPs) TE uses to support its harnessing products including information on laying wires, shrinking tubing/moulded parts and terminating connectors. Export Wiring Data to ATE HarnWare™ forms allow data such as connectivity, connector references and contact references to be exported to a text file or to the Windows Clipboard. This data can then be used in other systems, for example, automatic test equipment or other electrical design software. Export Marker Data to TE Wintotal Software System A Marker Sleeve page can be generated in Microsoft Visio software and or cable marker text and formatting details can be generated in an '.xmt' or COMMS file that is suitable for import into the TE WinTotal labelling software. Electrical Interconnection System Design Export Parts List Export Parts List menu options allow parts lists contained in the current Visio document or a selected set of documents to be exported to the Windows clipboard or a text file. This data can then be used in a spread sheet, database. Labor Estimates HarnWare™ will total up the assembly times for all of the products in a harness, selected by using the database, and output a grand total. The labor estimate sheet, that forms part of the HarnWare™ document package, works like a spread sheet, and the times and labor rates within it can be adjusted to suit local conditions. Tooling and Equipment The HarnWare™ Materials and Equipment option analyses the drawing and wire list. Materials and equipment that are relevant to the parts contained in the harness design are listed based on TE Codes of Practice. RoHS Listing The HarnWare™ Restriction on Hazardous Substances (RoHS) Codes option analyses the parts referenced in the drawing and wire list. A list of RoHS compliance codes for each part can be added to a page in the Visio document Weight Estimates The HarnWare™ Weight option provides a means of estimating the weight of a harness. Where component weight data is not available, users can add the relevant data to the database. Composite Weights and Parts Lists This option generates a composite parts or weights list for a number of drawings. Design Comparison This option is initiated from the HarnWare™ Tools menu and is used to analyse the changes between two Visio design documents, typically two different revisions of a harness design or two similar designs. 2-5 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 (Continued) Computer Aided Electrical Wiring Harness Design Software The HarnVis™ 3D harness design visualisation system offers automatic generation of to-scale 3D models of wiring harnesses and components. These 3D models provide “virtual prototypes” of harnesses allowing the user to see the harness with lengths, diameters and parts shown to-scale. By simply clicking on a part, the user can access such data as part numbers, materials, finishes, adhesives, etc. These “virtual prototypes” reduce the potential for errors, harness lay-up boards (also known as nail, form and peg boards) can be modelled and pegs can be automatically positioned along the harness legs. When a long harness leg makes it necessary, legs can be bent to fit a lay-up board. 3D models of harnesses and of many TE parts can be exported from the HarnVis™ system in the form of IGES files for use in other CAD systems. 2-6 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design HarnWare™ V6 (Continued) Computer Aided Electrical Wiring Harness Design Software HarnWare™ V6 User Friendly Forms 2 Electrical Interconnection System Design The forms for selecting the wide range of TE components are clear and easy to use with many links to data sheets and design help topics. 2-7 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems Assembled military harness. TE’s integrated harness systems have been developed for a wide range of defense and industrial applications. Each system consists of compatible components, including cable jackets, heat-shrinkable components, and adhesives. Performance of these parts is assured because all components are tested separately and as part of an assembled system (see photo top left). A typical designed harness consists of seven component parts (pictured at right): Additional components for harnessing systems include the following: n A wide range of special devices, such as SolderSleeve devices for primary wire interconnection. n A selection of electrical shielding (screening) options, including braids and termination assemblies. n Multiconductor (multicore) cables. n Specialty adhesives and sealants for complete environmental sealing.** 1. Primary wire and cable 2. Heat-shrinkable tubing 3. Backshell adapter 4. Molded part 5. Adhesive 6. Cable jacket 7. Marker sleeve* Military harness system components. Table 1 on the next page serves as both a summary of Raychem brand products for specific harnessing systems and a selection table for harnessing system components. An explanation of how to select components for a harness system follows. *TE Identification products information available at www.te.com **TE Sealant product information available at www.te.com 2-8 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Table 1. Harnessing Systems and Their Components Components Wire System 10 System 20 System 25 System 30 System 100 System 200 System 300 44 44 44 55 99, 100A, 100G 55 55 ZHTM RW-200 RT555 Tubing Versafit NT-FR DR25 VPB Adapter material and plating finish chosen for compatibility with the connectors. Molded part -3, -4, -71 -25 -50 -100 -12 -55/-125 -35 — -25S — -100S — — S1017, S1030 S1124, S1048 S1048, S1125 S-1125, S-1255-04 S1030, S1125, S1125, S1255 S1255-04 /42, /180 — /164,/86 — /86, /225 S1184 — — /180 S1184 — — — — Cable jacket Thermorad NT-FR FDR-25 Thermorad Zerohal VPB RW-200 RT555 Marker sleeve* TMS-SCE TMS-SCE TMS-SCE TMS-SCE HX-SCE HT-SCE HT-SCE Preinstalled Rayaten molded part Adhesive Precoated adhesive Conductive adhesive 2 Electrical Interconnection System Design -51 *TE Identification products information available at www.te.com. Selection Process Selecting the components for a harnessing system is a four-step process: Step 1: Select the material system appropriate for the operating conditions and environment to which the harness will be exposed. Step 2: Select the adhesive system appropriate for the material system you select in Step 1. Step 3: Determine the level of EMI shielding required. Step 1. Select the Material System. Detailed in Table 2 on the next page are the major material systems for use in a wide range of operating conditions and environments. Choose a material system that: n Has the physical characteristics your harness requires. n Will accommodate the operating temperature and the fluids and abuse to which the harness will be exposed. Step 4: Select the components. Each step is described on the pages that follow. A selection table accompanies each step. You can also use HarnWare software to design your harness. 2-9 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Table 2. Material System Selection Operating temperature Physical characteristics Flammability System 10 -20°C to +60°C [-4°F to +140°F] • • • • • • • Fluid resistance Typical applications Operating temperature System 20 -55°C to +121°C [-67°F to +250°F] Environmentally sealable Lightweight Small diameter Flexible Flame-retardant Self-extinguishing Resists common industrial and military cleaning solvents and degreasers. • • • • • • • • Used in high-performance industrial applications, and in military communication and test equipment. Environmentally sealed Tough Flexible Low profile Flame-retardant Self-extinguishing Resists most commonly used military fuels, oils, and greases • Specially suited to military vehicles and engine compartments, low profile shapes save space and weight. System 25 -75°C to +150°C* [-103°F to +302°F] • • • • • • • Environmentally sealed Rugged Abrasion-resistant Very flexible Flame-resistant Self-extinguishing Resists most common military fuels, oils, and greases. up to 70°C [158°F]. • Specially suited to military vehicles, aerospace and marine applications, and communication and test equipment. System 30 System 100 System 200 -55°C to +150°C [-67°F to +302°F] -30°C to +105°C [-22°F to +221°F] -55°C to +200°C [-67°F to +392°F] Environmentally sealed Tough Flexible Low profile Physical characteristics • • • • Flammability • Flame-retardant • Self-extinguishing Fluid resistance • Resists most of commonly used military fuels, oils, and greases. Typical applications • Specifically suited to military vehicles and engine compartments for higher temperature applications, low profile shapes save space and weight. • Environmentally sealed • Flexible • Low toxicity index (as defined by NES-13) • Low smoke emission (as defined by NES-711) • Low corrosive gas evolution • Resistant to a range of military fuels, oils, and greases. • Specially suitable for confined habitat areas in military and civil applications. • Extensively used in surface and submarine vessels and underground railways • • Environmentally sealed Very flexible • Highly flame-retardant • Resists long-term immersion in military fuels, oils, and greases at elevated temperatures. Used where there is prolonged exposure to high temperatures. Used where a harness may be permanently immersed in difficult fuels, such as in fuel tanks. • • System 300 Operating temperature -55°C to +200°C [-67°F to +392°F] Physical characteristics • Environmentally sealed • Highly abrasion resistant • Low profile Flammability Fluid resistance Typical applications • Highly flame-retardant • Performs in aggressive fluids at extremely high temperatures • Permanent immersion in aggressive fluids *Per VG 95343. 2-10 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Harnessing Systems and Their Components — NBC Survivable Systems* System 770 44 RT-770 -770 S-1264 RT-375 Components Wire Tubing Molded part Adhesive Marker sleeve cover System 790 55 RT-790 -790/-791 S-1255-04 RT-375 NBC-SCE NBC-SCE 2 Electrical Interconnection System Design Marker sleeve** TMS-SCE **TE Identification products information available at www.te.com. System 780 55 RT-780 -780 S-1255-04 RT-375 Material System Selection Operating temperature Physical characteristics Flammability Fluid resistance Typical applications Adhesive Selection System 770 -55°C to +125°C [-67°F to +257°F] • • • • • • Environmentally sealed NBC resistant Flexible Flame-retardant Self-extinguishing Resistant to NBC uptake and decontamination • Base-line system for NBC resistant applications System 780 -65°C to +175°C [-85°F to +347°F] System 790 -65°C to 200°C [-85°F to +392°F] • • • • • • Environmentally sealed NBC resistant Flexible Flame-retardant Self-extinguishing Resistant to NBC uptake and decontamination • High temperature system for NBC resistant applications • • • • • • Environmentally sealed NBC resistant Flexible Flame-retardant Self-extinguishing Resistant to NBC uptake and decontamination • Extreme high temperature system for NBC resistant applications Material System System 770 Adhesive Type Two-part Epoxy Component Adhesive S-1264 Precoated Adhesive Designation — Service Temperature 150°C System 780 Thermoset tape S-1255-04 — 200°C System 790 Thermoset tape S-1255-04 — 200°C 2-11 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Step 2. Select the Adhesive System. Two types of adhesives are used to bond heat-shrinkable boots and transitions to tubing or wire jacketing: n Thermosets, which include epoxies and other two-part systems. n Thermoplastics, which include pre-coated meltable adhesives applied to parts during manufacture and those applied as meltable tapes during assembly. Table 3 below outlines the differences between thermosets and thermoplastics. Table 4 shows which adhesive type is appropriate for each harness material system. Table 3. Comparison of Adhesive Types Method of adhesion Application Cure time Strength Disassembly Repair/reassembly Table 4. Adhesive Selection Thermoset Cures through chemical reaction. Two-part types require mixing and application at assembly. Varies with cure temperature. Oven cure usually desirable. Retains most strength at elevated temperatures. Items can be forcibly peeled apart when heated sufficiently. Requires new adhesive or hot rollback to reenter behind connector without affecting adhesive bonds. Material System Adhesive Type System 10 Thermoplastic System 20 System 25 System 30 System 100 System 200 System 300 Thermoplastic Component Adhesive S-1030 Thermoplastic Melts, flows, and solidifies. Precoated types require no preparation at assembly. Not required. Adhesive functional when cooled to room temperature. Loses strength as melt temperature is approached. Items can be separated when heated to temperature of the adhesive. Can be reheated to form new bond if sufficient adhesive remains. Precoated Adhesive Designation /180 Service Temperature 80°C S-1017 /42 60°C S-1124 /164 105°C S-1048 /86 120°C S-1048 /86 120°C Two-part thermoset S-1125 /225 150°C Thermoset Tape S-1255-04 — 200°C 150°C Thermoplastic Two-part thermoset Thermoplastic S-1125 — S-1030 /180 80°C S-1048 /86 120°C Two-part thermoset S-1125 — 150°C Two-part thermoset S-1125 — 150°C Thermoset tape S-1255-04 — 200°C Thermoset tape S-1255-04 — 200°C System 770 — S-1264 — — System 780 Thermoset tape S-1255-04 — 200°C System 790 Thermoset tape S-1255-04 — 200°C 2-12 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Step 3. Determine the Level of EMI Shielding Required. Introduction This section is intended as a guide for the use of harness designers who are required to achieve a level of EMI control in their design practices. It is not intended that it should be a definitive statement on all aspects of EMI control for harnesses. In case of difficulty contact us for further clarification or consultancy. For well-designed EMI control of electrical systems it is essential that a detailed knowledge of the system requirements and susceptibility be obtained. The chosen level of shielding will be dependent on the: n Susceptibility of electrical system. n Types of components used. n Physical layout of the system. n Equipment practices adopted. n Anticipated EMI threat. For the most cost effective design of harnesses, which offer a long-term stability in performance, the system should be designed to achieve a balance of component characteristics. Components should only be used if they are qualified to a minimum level of EMI performance and the performance and test method should be applicable to the design technique being used. For quality assurance purposes minimum EMI characteristics should always be specified and for critical harnesses the complete performance should be measured. The technique to be adopted should always be specified. Finally the inter-relationship between harnesses and the protection, termination and grounding of equipment boxes is vital for good system performance against EMI. All components form part of the external shield on the system and therefore should be considered in the overall EMI design process. Subjects covered in this topic are: n Harness Types - point to point and branched n Shielding Levels calculations Harness Types Harnesses are divided into two types, point-to-point and branched. The advantages and disadvantages of each from an EMI control standpoint are described below. No attempt has been made to analyze their relative merits in mechanical or installation terms. 2 Electrical Interconnection System Design TE offers several methods and technologies for controlling electromagnetic interference (EMI) and noise in cable harnesses. Developed in response to well-established threats in military and other harsh environments, these technologies can be employed in compatible shielding (screening) systems to achieve the level of shielding required for a harness system. Table 5 on page 2-15 outlines the shielding requirements for various types of threat and levels of interference. Point To Point: The three major components of this type of harness are: connectors, cable, and connector accessories. Connectors There are many different types of circular military connectors. However, for a well-shielded harness only those connectors having a guaranteed performance level should be used e.g. MIL-C-26482 Series II and MIL-C-38999 series 1 and 2, and series 3 and 4. Cable Cable used in this type of harness is generally machine made. Hand laid cables may also be used but generally the shields incorporated in these harnesses vary in consistency of performance. In the case of machine made cables all shields should be designed for optimum shielding effectiveness at radio frequency. 2-13 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Connector Accessories Transitions Connector accessories, such as Raychem brand adapters, are available in many styles and therefore their performance varies with construction. For a level of consistency in performance it is essential that, as with connectors, a guarantee in performance level be achieved. Transitions, as with accessories, are very susceptible to performance variability with construction type. Fittings not specified in this way may significantly degrade the overall system performance. Branched In addition to those components described above, branched harnesses include transitions. This type of harness is usually made by hand and it is therefore difficult to incorporate accurately made machine fabricated shields. The implications of this are: Shields Cable shields may be put on by hand or by feeding through a braiding machine. However, as braid optimization depends on all the constructional parameters of the braid being accurately specified, unless braid is well constructed the shielding performance can suffer dramatically. Reductions in shield performance of 20-40 dB have been measured on badly made branched harnesses. The alternative method is to use pull on braids. If the cable bundle diameter is known the braid may be designed for optimized performance. For high performance harnesses these components should also have a guaranteed performance. In general the use of techniques such as hand soldering or the use of butted tape wraps are not recommended except where only a low performance of less that 40dB is required. Shield performance is specified in two ways, either as a power relationship in decibels (dB) or as an absolute measurement of the shield performance in terms of the surface transfer impedance. Except for very specific low frequency problems it is general to specify the performance at frequencies in the range 0.1MHz to 100MHz. Shielding Levels and Component Performance System Performance To specify the overall requirements of a complete electronic system in terms of its EMI characteristics it is necessary to consider the performance of the individual components parts. The harnesses form one of the major entry points for interference and this as such can degrade a complete system performance by a significant amount. In general terms, assuming that a shielded harness system is used, with the available components on the market the overall harness system performance and typical applications may be as below. n 40 to 50 dB Standard shielded systems for insensitive systems. n 50 to 60 dB Military standard shielded systems for general applications. n 60 to 80 dB As above but where full threat EMP & TEMPEST protection is required. n 80 to 100 dB Severe TEMPEST and very sensitive systems. n Over 100 dB Exceptional shielding requirements only. 2-14 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Connectors As with all designs EMI system design should not be performed to the “limit of performance safety margin should always be incorporated when determining the minimum shielding level appropriate for consistent operation of the system. A study of those connector specifications having an EMI test shows that they are generally specified in the frequency band 100MHz to 1GHz. For an assessment at lower frequencies the low frequency performance as dictated by the d.c. resistance of the connector is required. These two parameters enable the EMI characteristic to be made of the complete connector performance. Typical values for standard connectors are 65dB (MIL-C-26482 Series II) and 90dB (MIL-C-38999 Series III) connectors. The inter-relationship of shielding effectiveness measured in decibels and the surface transfer impedance in ohms presents the designer with a conversion difficulty. External harness circuits vary, as do the coupling characteristics and it is therefore only possible to give an approximate conversion. The normal conversion from decibels to ohms and vice versa is to a reasonable approximation: 2 Electrical Interconnection System Design Safety Margins Screening Effectiveness (dB) = 36 – 20 log 10 (ZT (Ohms)) The constant term is developed from the expressions for the characteristic impedance of the line formed by the harness shield and the ground plane and the internal characteristic impedance of the inside of the harness. The translation from shielding effectiveness to surface transfer impedance is shown below in Table 5 for S.E. from 20 to 105dB. Table 5 - Screening Effectiveness (SE)/Surface Transfer Impedance (Zt) Relationships S.E. (dB) ZT (ohms) S.E. (dB) ZT (ohms) 20 25 30 35 40 45 50 55 60 6.309 3.548 1.995 1.122 0.631 0.355 0.200 0.112 0.063 65 70 75 80 85 90 95 100 105 0.0355 0.0200 0.0112 0.0063 0.0036 0.0020 0.0011 0.0006 0.0004 2-15 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Cable In accordance with most common cable specification the shielding performance of a cable is specified at 30MHz. It is also well into the band where inductive leakage is the primary penetration characteristic. For frequencies above or below 30Mhz, approximations, as for connectors, must be made. It should be noted that the performance specified at 30MHz in Table 6 for different cable types is the maximum that is allowed using TE’s standard Q.C. values. Actual performance may be up to 20dB better. Connector Accessories and Transitions In constructional terms the performance of the connector accessory includes both the resistive terminations to the cable shield and the connector. However, it is most unusual to specify the performance of an accessory and this is a distinct weakness in the design of harnesses. The reason is that the performance is extremely variable as accessories have to fit a variety of different cable sizes and shapes. Where specified at all the relationship between the test method and the coupling mechanism for the EMI must be considered. Table 6 - Cable Performances Type of Screen Single optimized braid Double optimized braid Superscreened (2 braids + 1 wrap) Diameter under screen Surface transfer Impedance Zt (mm) Up to 7.5 7.6 and up Up to 7.5 7.6 and up Up to 7.5 7.6 and up @ 30 Mhz (maximum) 100 milli ohms/metre 50 milli ohms/metre 10 milli ohms/metre 5 milli ohms/metre 100 micro ohms/metre 50 micro ohms/metre 2-16 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Connector Terminator Splice Transition Feedthrough 2 Electrical Interconnection System Design Cable Braid Complete Harness When considering the complete harness the coupling calculations are relatively simple. In general terms they are the addition of all the individual leakages within the system from connector to connector. The analysis route is therefore as follows: 1. Convert all decibel values at the desired frequency to surface transfer impedance. 2. Choose components for a ‘balanced’ system, i.e. the components should have approximately the same performance. 3. Add the values determined for surface transfer impedance of the components at the frequency chosen. 4. Reconvert to decibels if necessary. (Table 5 can be used for this purpose) As a guide to the shielding performance that can be expected from a harness that is constructed using Raychem brand components, Table 7 on the next page has been compiled to help in the product selection process. For branched harnesses it is necessary to determine whether every branch has the same susceptibility requirements or carries the same signals of power. The performance requirement of each branch is then determined and the matrix for the harness established. This is a more complex subject and not discussed here. System improvements may be achieved by changing either the connectors or cable. In general terms changing from a single to a double optimized braid improves the performance of that component by 20-25 dB. A similar advantage is achieved by changing from MIL-C-26482 Series II to MIL-C-38999 Series I connectors. However, the relative significance, as part of the system, of each component must be considered to determine the true weighting effect. For the optimum in system design a balance of component performances should be achieved wherever possible such that each of the components is of similar performance level. General Considerations Although cables and harnesses are considered to be the most significant in terms of coupling into systems the construction of equipment boxes can play an important part in the overall EMI performance of a system. With the increasing use of high speed digital circuits and the generation of harmonics having high energy content relatively short printed circuit board tracks can radiate or pick up energy as efficiently as cables. If the boxes themselves are not adequately protected these circuits may constitute an EMI threat. There is a further area of significance in the EMI protection of the boxes and this is the connector/ box interface. The junction may be considered to be a part of the harness system and any degradation in it may cause an overall harness degradation. 2-17 Catalog 1654025 Revised 3-13 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 800 522 6752 Asia Pacific: +86 0 400 820 6015 UK: +44 800 267 666 For additional support numbers please visit www.te.com Electrical Interconnection System Design Integrated Military Harness Systems (Continued) Table 7 - Screen System Guide Adapter Styles Shielding Level Required Connector Band Strap Braided Harness System Components Termination Cable Braid (max. length in m/ft) TinelRayaten cable construction) (by Lock Assembly SO DO SSS System NO VG95328 VG95234 n n n — 60 to 80 dB MIL-C-26482 Series 2 VG96912 Series 1 — — n — — 80 dB MIL-C-38999 — — — n — —