Cable Dressing and Wiring Workmanship Standard

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Katrina Banks
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2 Page 2 of 7 Revision * A M D Page No. REVISION LOG Paragraph No. Revision Date Affected CRB Control No. (CN) Original Issue 817 Enterprise Content Management Submit No. This log identifies parts of this document that have been revised since the original issue. *A ADDED *M MODIFIED *D DELETED NOTE: Add rows as needed. All trade names, trademarks, or registered trademarks are trade names, trademarks, or registered trademarks of their respective companies. The owner of this document is the Manufacturing Engineering department. Cable Dressing and Wiring s is controlled by ISO 9001: Control of Documents.

3 Page 3 of PURPOSE The purpose of this document is to provide a consistent standard for workmanship detailing the general guidelines that assembly operators are to use when building, wiring, routing and dressing cables and harnesses in assemblies that are built in enclosed cabinets, tables and trailers. The primary purpose is to assure adequate strain relief at all mating connectors. This document will be superseded by individual assembly Work Instructions and schematics or wiring diagrams. The goal is to standardize the techniques used by the operators to create a quality product with repeatable results using best practices as they apply to our products. 2.0 SCOPE This workmanship standard is applicable to those departments and personnel who are involved in the manufacturing, testing and inspection of cabinets, tables, trailers, LEGOS assemblies, final assemblies and final system assemblies. 3.0 MASTER PROCESS FLOWCHART / PROCEDURE PFC PT SYSTEMS INTEGRATION TESTING PFC AS ASSEMBLY PROCESS WI QA MANUFACTURING WORKMANSHIP STANDARD WS AS PRODUCTION OPERATONS ESD STANDARD 11533XX-X VCOT C4 TRAILER CHECKLIST ASSEMBLY PROCEDURE IPC WHMA-A-620A REQUIREMENTS & ACCEPTANCE FOR CABLE/WIRE HARNESS ASSY IPC J-STD-001D REQUIREMENTS FOR SOLDERED ELECTRICAL ASSY IPC A-610D ACCEPTABILITY OF ELECTRONIC ASSY 4.0 ACRONYMS LEGO Largest End Items that Goes on Shelf

Page 4 of 7 5.0 CABINET WIRING STANDARD 5.1 Label Placement 5.1.1 Labels on all harnesses and cables must be applied 2.0 +/- ½ back from the connector or the rear most connector accessory, I.E. backshell or boot, on each end to allow for a smooth bend to provide strain relief.

If some crossover and twist is mandatory bundle should remain uniform in diameter. Reference examples below. ACCEPTABLE BUNDLE NOT ACCEPTABLE BUNDLE 5.3

4 Page 4 of CABINET WIRING STANDARD 5.1 Label Placement Labels on all harnesses and cables must be applied 2.0 +/- ½ back from the connector or the rear most connector accessory, I.E. backshell or boot, on each end to allow for a smooth bend to provide strain relief. 5.2 Routing Cables Parallel wires in a bundle must not twist or crossover but lay uniformly together (IPC 620; 14.3 Routing). If some crossover and twist is mandatory bundle should remain uniform in diameter. Reference examples below. ACCEPTABLE BUNDLE NOT ACCEPTABLE BUNDLE 5.3 Signal Separation Harnesses with different signal types must be routed close to each other it is desirable to have them cross each other at 90 degrees as opposed to running them along the same path and direction When possible cables will be routed in bundles with like signals. Example: Power, audio, network, video, USB, serial, etc Wire lay is essentially parallel to the axis of the bundle with no crossover (IPC 620; 14.3).

Page 5 of 7 5.3.1: 90 angle between power and data cables. 5.3.2 5.3.2 5.4

1.3 Target). 5.4.3 Routing bundles around equipment or bends will demand less space between tie points. 5.5 Harness Securing Methods 5.5.1 Restraining devices are placed in a manner that maintains the desired form and location and does not stress wires or cables at the termination point.

5 Page 5 of : 90 angle between power and data cables Tie Wrap Spacing Unless otherwise specified, tie wraps are spaced evenly and at an increment that maintains the bundles desired form (IPC 620; Acceptable) Spacing from the rearmost connection or between tie wraps is 3 diameters of the wire bundle or 4 inches, whichever is less (IPC; Target) Routing bundles around equipment or bends will demand less space between tie points. 5.5 Harness Securing Methods Restraining devices are placed in a manner that maintains the desired form and location and does not stress wires or cables at the termination point Tie wraps, Industrial Velcro and TC105 are Raydon Corporation standard harness securing methods. 5.6 Strain Relief Cables must conform to a minimum bend radius of any individual cable (IPC 620; Bend Radius) Cables must not be bent at a sharp angle from the connector. See Figure Cables are installed with enough stress relief to ensure and maintain the integrity of the connection. See Figure Minimum bend radius requirements for unshielded and shielded wire and/or cable must be 5X OD.

Page 6 of 7 Unacceptable bend radius Acceptable bend radius Figure 1 Figure 2 5.

necessary cable routing without interfering with equipment located behind the panel when

6 Page 6 of 7 Unacceptable bend radius Acceptable bend radius Figure 1 Figure Interface Panels Interface panels should be arranged in order to allow for necessary cable routing without interfering with equipment located behind the panel when possible (IPC; 620;1.13 Electrical Clearance). 5.8 Rework Access Panels and assemblies that are removable should be wired with enough strain relief in the mating harnesses to allow the panel to be disconnected and laid on the work surface to allow rework or cable replacement

7 Page 7 of Slide Rails Ensure slide rails maneuver with ease and do not have to be forced into place There must be enough strain relief to allow the slide rails to be fully extended without pressure being applied to cable connections Inspection Criteria No cosmetic issues (scratches, dings, nicks) Check for lose or missing hardware Check for proper labeling and placement should not interfere with bend radius of cables, should be legible, no smears and aligned straight Check wire harnesses for strain relief and proper bundling Ensure slide rails or pull out trays move freely and do not bind with cabling Ensure cables tied to rails are not too tight that could cause rubbing or cuts to the insulation

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