CRIMPING, INTERCONNECTING CABLES, HARNESSES, …

1 NASA TECHNICAL NASA-STD STANDARD with Change 6. Approved: 1998-02-09. National Aeronautics and Space Administration Revalidation Date: 2008-07-25. Washington, DC 20546. Change 6 approved: 2011-03-29. crimping , INTERCONNECTING CABLES, harnesses , AND WIRING. Measurement System Identification: Metric (English). Requests for Relief from the requirements in this document are processed through the NASA Safety and Mission Assurance Technical Authority per NPR paragraph APPROVED FOR PUBLIC RELEASE DISTRIBUTION IS UNLIMITED. with Change 6. This page intentionally left blank. Page 2 of 114. with Change 6. DOCUMENT HISTORY LOG. Document Approval Status Description Revision Date Baseline 1998-02-08 Initial Release - Page iii: Update URL for accessing NASA Technical Standards. The correct URL is - Page iii: Update references to NASA (3J-1) and NASA (3M) to NASA-STD- and NASA-STD- respectively.

2 - Page iv: Insert Revisions page and renumber Table of Contents accordingly. - Para Change citation for NHB to NASA-STD- 6001 and change citation for NHB (V1) to NPR. - Para Delete NHB from Acronym List and Add NPR. to acronym list - Para No. 4: Change sentence to crimping . Stranded wire shall be used for crimping . crimping of solid wire is prohibited. crimping of solder tinned stranded wire is prohibited.. - Para : Change address for training center to: GSFC, Training Center, Code , 7000 Columbia Gateway Dr., Columbia, MD. 21046. Change 1 2006-01-27 - Para : Change sentence to read: All materials used in vacuum or low pressure shall not release greater than percent total mass loss (TML) and percent collected volatile condensable material (CVCM) when tested in accordance with ASTM-E-595.. - Para : Change NHB to NASA-STD-6001 in the second sentence. - Para No. 11 Change NHB to NASA-STD- 6001.

3 - Para : Change tape may be applied to bundle to shall be applied to bundle . - Para Change NHB to NPR - Para No. : For the Insulation Resistance (IR). Test, change for a minimum of 1 minute, or as specified in the test procedure to until a stabilized reading is attained not to exceed 1 minute, or as specified in the test procedure.. - Appendix C Update the address for submitting changes to NASA Technical Standards (WHBIII). Page 3 of 114. with Change 6. Document Approval Status Description Revision Date - Page v: Insert Revisions page entries - Page ix: Revise Table of Contents to reflect insertion of new Chapter 19 and renumbering of existing Chapter 19. to Chapter 20. - Page xi and xii: Revise list of Figures to reflect insertion of new figures as a part of the new Chapter 19. - Page xii: Revise List of Tables to reflect insertion of Change 2 2006-08-23. new tables as a part of the new Chapter 19.

4 - Pages 19-1 through 19-14: Inserted new Chapter on Splicing - Pages 20-1 through 20-10: Renumbered original Quality Assurance Provisions Chapter to accommodate the new Splicing Chapter (WHBIII). Correct page number formatting problem and add page Change 3 2006-09-05 numbers (no content changes). (WBHIII). Update references, add requirement' tags, and revalidate Change 4 2008-07-25. (JWL4). Editorial corrections to paragraphs , , , , and footnote #1 to Table 12-1. Addition of SMA. Change 5 2009-11-24. TA note on cover and VCS note below. (JWL4). Editorial corrections to Foreword and paragraphs and Format Page numbers. Add reference to NASA- Change 6 2011-03-29. STD in paragraphs and (JWL4). This document is subject to reviews per Office of Management and Budget Circular A-119, Federal Participation in the Development and Use of Voluntary Standards (02/10/1998) and NPD , NASA Engineering and Program/Project Management Policy.

5 Page 4 of 114. with Change 6. This page intentionally left blank. Page 5 of 114. with Change 6. FOREWORD. This Standard provides a baseline for NASA project offices to use when preparing or evaluating process procedures for the manufacture of mission hardware or mission critical ground support equipment. This Standard: a. Prescribes NASA's process and end-item requirements for reliable crimped connections, INTERCONNECTING cables, harnesses , and wiring. b. Establishes responsibilities for training personnel. c. Establishes responsibilities for documenting process procedures including supplier innovations, special processes, and changes in technology. d. For the purpose of this Standard, the term supplier is defined as in-house NASA, NASA. contractors, and subtier contractors. NASA Installations shall: a. Review and invoke the provisions of this Standard for procurements involving crimped connections, INTERCONNECTING cables, harnesses , or wiring of mission hardware and mission critical ground support equipment.

6 B. Review and invoke the provisions of this Standard for in-house operations involving crimped connections, INTERCONNECTING cables, harnesses , or wiring of mission hardware and mission critical ground support equipment. c. Tailor specific provisions of this Standard to address program or unique contractual or mission requirements. d. Assure that NASA suppliers invoke this Standard on subcontractors, purchase orders, and on subtier suppliers where applicable. e. Furnish copies of this Standard in the quantities required to NASA suppliers and subtier suppliers. Questions concerning the application of this Standard to specific procurements shall be referred to the procuring NASA installation, or its designated representative. This Standard cancels NASA Assurance Standard (NAS) (3G-1), Workmanship Standard for INTERCONNECTING Cables, harnesses , and Wiring, and NASA Handbook (NHB) (3H), Requirements for crimping and Wire Wrap.

7 This Standard shall not be rewritten or reissued in any other form not approved by NASA. Other processes not covered by this standard may be required. The design, materials, and processes shall be defined in engineering documentation. Page 6 of 114. with Change 6. Comments and suggestions for improving this Standard may be submitted using the form NASA Technical Standard Improvement Proposal. A copy of this form is included at the end of this standard. This version supersedes: NASA-STD with Change 5 Frederick D. Gregory dated November 24, 2009 Associate Administrator for Safety and Mission Assurance NASA-STD Change 5 approved by: Michael G. Stamatelatos, on 29 March 2011. Page 7 of 114. with Change 6. NASA Technical Standards for Mission Hardware and Mission-Critical Ground Support Equipment NASA Technical Standards can be found on the World Wide Web at URL address Title Number Workmanship Standard for Staking and Conformal Coating of Printed Wiring Boards and Electronic Assemblies Workmanship Standard for Surface Mount Technology with Change 1.

8 Soldered Electrical Connections with Change 3. crimping , INTERCONNECTING Cables, harnesses , and Wiring with Change 5. Fiber Optic Terminations, cable Assemblies, and Installation with Change 1. NOTE: , Standard for Electrostatic Discharge Control (Excluding Electrically Initiated Explosive Devices), was referenced in earlier versions of this document as a NASA. Technical Standard for Flight Hardware Workmanship. It has been replaced with ANSI/ESD , Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices). Page 8 of 114. with Change 6. TABLE OF CONTENTS. 1. 16 Purpose .. 16 Applicability .. 16 2. APPLICABLE DOCUMENTS .. 17 Applicable Specifications .. 17 Other Documents: .. 17 3. DEFINITIONS AND ACRONYMS .. 18 Acronyms .. 18 19 4. GENERAL .. 23 General .. 23 Approval of Departures from this Standard .. 23 Principles of Reliable Cabling and Wiring.

9 23 Documentation .. 24 Rework .. 24 5. TRAINING AND CERTIFICATION PROGRAM .. 25 General .. 25 Vision 25 Certification Levels .. 25 Training Program Requirements .. 26 Documentation .. 26 Maintenance of Certification 27 Training Resources .. 28 6. FACILITIES, EQUIPMENT, MATERIALS, AND PARTS .. 29 Facility Cleanliness .. 29 Environmental Conditions .. 29 Tool and Equipment Control .. 30 Electrostatic Discharge Requirements .. 31 In-Process Storage and Handling .. 31 Wire Processing and Preparation Tools .. 31 Inspection Optics .. 32 Materials 32 Solvents and Cleaners .. 32 Page 9 of 114. with Change 6. Personnel Protection .. 33 7. DESIGN PRACTICES .. 34 General .. 34 Requirements Not Covered .. 34 Design Considerations .. 34 8. INTERCONNECTING cable /HARNESS FIXTURING .. 37 General .. 37 Mockup and Wiring Board Design Parameter .. 37 Temporary Identification .. 37 INTERCONNECTING cable and Harness Protection.

10 37 9. FORMING WIRES INTO CABLES AND harnesses .. 40 General .. 40 Lacing for Trunk, Branches, and Breakouts .. 40 Fabric Braid Sleeving (Prewoven) .. 43 Fabric Braid Directly Woven on INTERCONNECTING Harness or cable .. 44 Spiral Wrap Sleeving .. 46 Plastic Straps .. 46 Metal Braid Shielding .. 47 Insulation Sleeving/Tubing .. 47 Installation of Heat-Shrinkable Sleeving .. 48 Long Lengths of Shrinkable 49 Shrinkable Part Requirements and Installation .. 50 10. STRIPPING INSULATION FROM CONDUCTORS AND 52 Stripping Round 52 Stripping Jackets Over Shields .. 53 Stripping Flat Conductor cable .. 53 11. cable SHIELDING AND SHIELD TERMINATION .. 54 General RFI/EMI Practices .. 54 Shield 54 Terminating Overall Shielding Using RFI/EMI Adapters .. 54 Individual Shield Termination Using Heat Shrinkable Solder Sleeves .. 55 Individual Shield Termination Using Two-Piece Crimp Rings .. 55 Group-Grounding of Individual Shield Terminations.