1、BS EN 16602-70-30:2014Space product assurance Wire wrapping of high-reliability electrical connectionsIncorporating corrigendum February 2017BSI Standards PublicationWB11885_BSI_StandardCovs_2013_AW.indd 1 15/05/2013 15:06BS EN 16602-70-30:2014 BRITISH STANDARDNational forewordThis British Standard
2、is the UK implementation ofEN 16602-70-30:2014. It supersedes BS EN 50389:2005 whichThe UK participation in its preparation was entrusted to Technical Committee ACE/68, Space systems and operations.A list of organizations represented on this committee can be obtained on request to its secretary.This
3、 publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. The British Standards Institution 2017.Published by BSI Standards Limited 2017ISBN 978 0 580 97531 8 ICS 49.140 Compliance with a British Standard cannot confer imm
4、unity from legal obligations.This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 November 2014.Amendments/corrigenda issued since publicationDate T e x t a f f e c t e d28 February 2017 Implementation of CEN Correction Notice24 December 2014:
5、Supersession details addedis withdrawn.BS EN 16602-70-30:2014EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16602-70-30 October 2014 ICS 49.140 English version Space product assurance - Wire wrapping of high-reliability electrical connections Assurance produit des projets spatiaux - Enveloppe
6、de fils pour connexion lectrique fiabilit leve Raumfahrtproduktsicherung - Umhllung von Kabeln fr hochzuverlssige elektrische Verbindungen This European Standard was approved by CEN on 11 April 2014. CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulat
7、e the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN and CENELEC member. This E
8、uropean Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN and CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
9、 CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lit
10、huania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels 2014 CEN/CENELEC All rights of exploitation in any form and by any means reserved wor
11、ldwide for CEN national Members and for CENELEC Members. Ref. No. EN 16602-70-30:2014 ESupersedes EN 50389:2005BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 2 Table of contents Foreword 5 1 Scope . 6 2 Normative references . 8 3 Terms, definitions and abbreviated terms 9 3.1 Terms defined in other s
12、tandards . 9 3.2 Terms specific to the present standard . 9 3.3 Abbreviated terms. 10 4 Principles 11 5 Requirements 12 5.1 Preparatory conditions 12 5.1.1 Hazards, health and safety precautions 12 5.1.2 Facilities 12 5.1.3 Tools and equipment . 13 5.1.4 Configuration of process and workpiece 15 5.1
13、.5 Wire-wrap process certification . 16 5.1.6 Requirements for new combinations of wire-wrap . 16 5.2 Material selection 17 5.2.1 Wire 17 5.2.2 Terminal post 19 5.3 Wire-wrap operation . 22 5.3.1 Preparation for wire-wrapping . 22 5.3.2 Process and criteria 22 5.3.3 Number of turns on terminal post
14、24 5.3.4 Wire routing. 25 5.3.5 Rework 25 5.4 Test methods 26 5.4.1 General . 26 5.4.2 Stripping force . 26 5.4.3 Unwrapping test 27 BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 3 5.4.4 Connection resistance . 27 5.4.5 Gas-tightness test . 28 5.4.6 Metallography . 28 5.4.7 Records of tests 29 5.5 W
15、orkmanship and acceptance criteria 29 5.5.1 Visual inspection . 29 5.5.2 Replacement and rework 30 5.5.3 Performance tests . 31 5.6 Quality assurance . 32 5.6.1 General . 32 5.6.2 Traceability . 32 5.6.3 Data 33 5.6.4 Nonconformance . 33 5.6.5 Calibration . 35 5.6.6 Workmanship standards 35 5.6.7 Op
16、erator and inspector training and certification . 35 5.6.8 Inspections 36 5.7 Document requirements 37 Annex A (informative) Procedure for wire-rapping 38 Bibliography . 46 Figures Figure 1-1: Single wire-wrapped connection to square terminal and reference corner 7 Figure 5-1: Minimum wrapping lengt
17、h on terminal post for each wire gauge . 21 Figure 5-2: Terminal post dimensions over minimum wrapping length for each terminal size 21 Figure 5-3: Position and regularity of wrap connection . 24 Figure 5-4: Wire-wrap rejection criteria which require reworking of the connection . 31 Figure 5-5: Guid
18、e to quality assurance during wire wrapping 34 Figure 5-6: Guide to quality assurance during wire wrapping 34 Figure A-1 : Examples of approved wire-wrapping tools . 39 Figure A-2 : Wire-wrap connection process 40 Figure A-3 : Hand unwrapping tools . 41 Figure A-4 : Example of a daily process contro
19、l sheet for test samples 43 Figure A-5 : Stripping force test fixture . 44 Figure A-6 : Connection resistance test 44 Figure A-7 : Typical cross-section of wire-wrap (64) . 45 BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 4 Figure A-8 : Gas-tightness test result . 45 Tables Table 5-1: Wire size to t
20、erminal post combinations . 22 Table 5-2: Minimum number of wire turns on terminal post 25 Table 5-3: Minimum stripping force 27 Table 5-4: Test current for connection resistance . 28 BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 5 Foreword This document (EN 16602-70-30:2014) has been prepared by Te
21、chnical Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN. This standard (EN 16602-70-30:2014) originates from ECSS-Q-ST-70-30C. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest
22、by April 2015, and conflicting national standards shall be withdrawn at the latest by April 2015. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such pat
23、ent rights. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association. This document has been developed to cover specifically space systems and has therefore precedence over any EN covering the same scope but with a wider domain o
24、f applicability (e.g. : aerospace). According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugosla
25、v Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 6 1 S
26、cope This Standard specifies requirements for preparing and assembling parts to be joined by wire wrapping, as well as the selection, calibration, use and certification of wire wrapping tools. The covered wire-wrapped connections are illustrated in Figure 1-1. This type of connection is similar to “
27、Class A preferred” or “modified” connection detailed in MIL-STD-1130, and NASA NHB 5300.4(3H). Only previously tested and qualified wire-wrapped connections are covered by this Standard, which includes four wire sizes from 24 AWG to 30 AWG, and three terminal post sizes up to 1,78 mm maximum diagona
28、l. A step-by step procedure is covered in the informative Annex A. The use of heavier gauge wire and larger terminals is not generally prohibited, but it is considered unlikely that for such dimensions the method of wire-wrapping would be chosen as the electrical interconnection technique. Instead i
29、t is assumed that wire larger than 24 AWG will be multi-stranded and terminated by soldering in conformance with ECSS-Q-ST-70-08, or by crimping in conformance with ECSS-Q-ST-70-26. Training and certification requirements for operators and inspectors are defined in clause 5.6.7 and in ECSS-Q-ST-20.
30、With effect from the date of approval, this Standard announces the adoption of the external document on a restricted basis for use in the European Cooperation for Space Standardization (ECSS) system. This standard may be tailored for the specific characteristic and constraints of a space project in
31、conformance with ECSS-S-ST-00. BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 7 Terminal post End tail Uninsulated wire turns Insulated wire Reference corner (and at 1 below) 1 2 3 1 2 3 4 Shows either 3 or 4 corners of contact of insulation minimum turn of insulated wire Figure 1-1: Single wire-wrap
32、ped connection to square terminal and reference corner BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 8 2 Normative references The following normative documents contain provisions which, through reference in this text, constitute provisions of this ECSS Standard. For dated references, subsequent amen
33、dments to, or revisions of any of these publications do not apply. However, parties to agreements based on this ECSS Standard are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references the latest edition of th
34、e publication referred to applies. EN reference Reference in text Title EN 16601-00-01 ECSS-S-ST-00-01 ECSS system Glossary of terms EN 16602-20 ECSS-Q-ST-20 Space product assurance Quality assurance EN 16602-70-02 ECSS-Q-ST-70-02 Space product assurance Thermal vacuum outgassing test for the screen
35、ing of space materials EN 16602-70-38 ECSS-Q-ST-70-38 Space product assurance High-reliability soldering for surface-mount and mixed technology ESSCC Generic specification 3903 Solid wires, electrical 350V, for wire wrapping BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 9 3 Terms, definitions and ab
36、breviated terms 3.1 Terms defined in other standards For the purpose of this Standard, the terms and definitions from ECSS-S-ST-00-01 and ECSS-Q-ST-70-38 apply. In particular from ECSS-Q-ST-70-38 the following term: process identification document (PID) NOTE The content of the PID is specified in EC
37、SS-Q-ST-70-38. 3.2 Terms specific to the present standard 3.2.1 a turn of wire a wrap consisting of one complete single helical ring of wire wrapped 360 degrees around the terminal post, touching all four corners of the post. NOTE For the purpose of counting turns, the number of times the wrapped wi
38、re passes and intercepts the reference edge of the terminal post after the first intercept of uninsulated wire and terminal post, constitutes the number of turns of uninsulated wire in the connection. 3.2.2 end tail end of the last turn of wire on the terminal post which can extend in a tangential d
39、irection instead of resting against the post 3.2.3 gas-tight area contact area between the terminal post and wire which excludes gas fumes 3.2.4 reference corner corner of the terminal post at which the first turn of uninsulated wire contacts, and from which the number of turns of the wrapped wire a
40、re counted. 3.2.5 terminal post post of square or rectangular section onto which the interconnection wire is wrapped. BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 10 3.2.6 wire-wrapped connection connection consisting of a helix of continuous, solid, non-insulated wire tightly wrapped around the te
41、rminal post to produce a mechanically and electrically stable connection. NOTE 1 The number of turns required will depend on the gauge of wire used. NOTE 2 All completed wraps have an additional minimum of 3/4 turn of the insulated wire that is in contact with at least three corners of the terminal
42、post (see Figure 1-1). 3.3 Abbreviated terms For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01 and the following apply: Abbreviation Meaning AWG American wire gauge ETFE ethylene-tetrafluorethylene (Tefzel) NCR nonconformance report PFA perfluoroalkoxy PID process identifi
43、cation document PTFE polytetrafluorethylene PVDF polyvinylidene fluoride (Kynar) QA quality assurance RFA request for approval RH relative humidity BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 11 4 Principles The production of wire-wrapped connections is a relatively simple yet precision method of
44、fusion. Its use for high reliability space conditions affords high skills of operators and inspectors as well as tooling and environmental controls to produce continued high level quality. The following principles are laid down in this Standard: Each tool is certified for each wire to post configura
45、tion; regular calibration is mandatory. All material, including wire and post, requires approval and rigorous inspection. A well-defined and documented process control document (PID) to ensure consistency of production over extended periods. Operators and inspectors need experience and regular train
46、ing and certification. Frequent inline inspection and testing of wire-wraps validate continued quality levels for the intended high reliability application. Formal Quality Assurance and documentation will substantiate the achieved level of compliance to the requirements within this Standard. It is i
47、mportant to perform the work taking into account health and safety regulations and in particular the national standards on this subject. BS EN 16602-70-30:2014EN 16602-70-30:2014 (E) 12 5 Requirements 5.1 Preparatory conditions 5.1.1 Hazards, health and safety precautions a. Components, tools and co
48、ntrols shall be so located that personnel are not exposed to hazards such as electric shock, cutting edges, sharp points or toxic atmospheres. b. Pneumatic air-powered wire-wrapping tools shall be connected to a regulated, lubricated and filtered air supply, and disconnected when not in use. 5.1.2 F
49、acilities 5.1.2.1 Facility cleanliness a. The supplier shall provide for a work environment in conformance with the following: NOTE Those requirements are in general met by using cleanrooms. It is not, however, mandatory to use a cleanroom. 1. The areas in which wire-wrapping is carried out are maintained in a neat orderly fashion, with no loose material that can cause contamination of the wire-wrapped connection. NOTE For example: Dirt, dust, oils or clipped wires. 2. Furniture is kept to a minimum in the work areas and be arranged to allow easy and tho
