wsp-3444 wire connections standard

WSP-3444

Wire Connections Standard

Revision 1.0 - 9/01/2012

WSP-3444 Revision 1.0 - 9/01/2012

Windstream Proprietary and Confidential ii

Copyright Notice

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WSP-3444 Revision 1.0 - 9/01/2012 Table of Contents

Windstream Proprietary and Confidential iii

Table of Contents

List of Figures ............................................................................................................................................... iv

List of Tables ................................................................................................................................................ iv

Document Purpose ........................................................................................................................................ v

Revision History ............................................................................................................................................. v

Areas Affected .............................................................................................................................................. vi

Approval ........................................................................................................................................................ vi

1. OVERVIEW ....................................................................................................................... 1

2. WIRE WRAPPING .............................................................................................................. 2

2.1. Wire-wrapped characteristics of acceptable wrapped connections include: .......................... 2

2.2. To Make a Wired-Wrapped Connection ........................................................................................ 3

2.3. Types of Wraps ............................................................................................................................... 3

3. WIRE-WRAPPED CONNECTION .................................................................................. 4

3.1.1. Shinning ............................................................................................................................................ 6

4. COAXIAL CONNECTIONS ................................................................................................... 8

4.1. Coaxial Shield Connections .......................................................................................................... 8

4.2. Tools needed for BNC Terminations ............................................................................................ 9

4.3. Coaxial Wire Stripper Alignment Process ................................................................................... 9

4.4. BNC Termination Process ........................................................................................................... 10

4.5. Test and verification of proper termination ............................................................................... 14

5. MECHANICAL CONNECTION ............................................................................................. 15

6. FIBER OPTIC CONNECTION ............................................................................................. 16

7. CAT-5 CABLE ................................................................................................................ 17

7.1. Procedure for Making a Cat-5 Cable ........................................................................................... 18

5. DEFINITIONS .................................................................................................................. 20

6. REFERENCES ................................................................................................................. 21

7. APPENDIXES .................................................................................................................. 22

8. ATTACHMENTS ............................................................................................................... 23

WSP-3444 Revision 1.0 - 9/01/2012 List of Figures

Windstream Proprietary and Confidential iv

List of Figures

NA

List of Tables

Table 1 – Skinning Length and Turns for Wrapped Connections .......................................................... 6

WSP-3444 Revision 1.0 - 9/01/2012 Document Purpose

Windstream Proprietary and Confidential v

Document Purpose

This document defines procedures and requirements of standards for wire terminations using wire-

wrapping, BNC and mechanical terminations, Ethernet and Fiber Optic connections. This document

should be used by the Network Engineer, Network Operations and by Installation.

Revision History

Version: 1.0 Release Date:

Summary of Changes:

Author:

Subject Matter Expert:

File Name:

WSP-3444 Revision 1.0 - 9/01/2012 Areas Affected

Windstream Proprietary and Confidential vi

Areas Affected

Network Engineering, Network Operations, Network Installation.

Approval

WSP-3444 Revision 1.0 - 9/01/2012 Overview

Windstream Proprietary and Confidential 1

1. OVERVIEW

This WSP document (Windstream Standard Practice) covers the requirements for wire

termination of loose wire or cable using wire wrapping, BNC coaxial, mechanical, and

Ethernet connections.

Cable termination tools used in the preparation of cables for wire connections shall be of the

type specified by the wire, cable and connector manufacturers and approved by Windstream.

The Installation Supervisor is responsible for ensuring that a current calibration sticker

identifies all crimping tools used.

Any problems encountered in wiring and termination operations that are not covered in this

document or the installation IPACK specification document should be referred to the

Windstream engineer and or Installation supervisor. Fiber connections can be reference in

WSP 6009.

WSP-3444 Revision 1.0 - 9/01/2012 Wire Wrapping


2. WIRE WRAPPING

Wire wrapped connections shall be installed and removed with an approved wrapping, and

unwrapping tool. The quality of the connection will be based on the correct number of turns

per wire gauge, clearances, tolerances, as well as the tension in which the connection was

made. A correct turn or wrap will begin at the point that the bare wire first contacts the

connection terminal.

2.1. Wire-wrapped characteristics of acceptable wrapped connections include:

� Mechanical stability.

� Metal to metal, gastight, corrosion free contact area.

� Approved terminal for wire wrapping.

� No overlapping turns.

� No bulged turns.

� No excessive space between turns.

NOTE: All 26awg – 32 awg wire-wrapped connections not meeting these requirements

must be re-skinned and reconnected.

26, 28, 30, 32 AWG wire requires one full wrap of insulation in addition to the required

number of wraps. The number of turns is counted from the point where the skinned wire

touches the first terminal corner.

Minimum space between connections and adjacent metal work shall be 1/32 inch.

Minimum space between adjacent connection shall be 1/64 inch.

Separation between adjacent wraps will not exceed 0.005 inch for 20, 22, 24, and 26 AWG

wire.

Separation between adjacent wraps shall not exceed 0.003 inch for 28 and 30 gauge wire.

Any wire projection shall be less than 50% of the distance between terminals or 1/8 inch

maximum, whichever is less.

Wire insulation must be within 1/16 inch of the wiring terminal, unless a modified wrap is

being used.

WSP-3444 Revision 1.0 - 9/01/2012 Wire Wrapping


2.2. To Make a Wired-Wrapped Connection

� Select proper Bit and Sleeve, and Pre-Stripped Wire.

� Insert Wire into bit groove.

� Anchor wire on sleeve niche

� Insert terminal post into bit

� Finish connection by wrapping wire on post

2.3. Types of Wraps

� A “Regular” bit wraps the bare wire around the terminal.

� A “Modified” bit wraps a portion of insulation around the terminal in addition to the bare

wire. This increases the ability to withstand vibration.

WSP-3444 Revision 1.0 - 9/01/2012 WIRE-WRAPPED CONNECTION


3. WIRE-WRAPPED CONNECTION

All connections will be made as directed by job IPACK.

Connections will not deviate from the IPACK’s Cable Running List’s termination points

without authorization of Windstream engineer.

Connections will be terminated in such a way as to provide a good electrical connection A

sufficient length of service loop must remain in all wires after termination is completed so

that leads may be re-skinned and reconnected if necessary.

Connection will not be made with a previously wrapped lead or with used ends.

If an excessive amount of copper is visible on a partially tinned or scrapped wire, it must be

re-skinned and reconnected.

Insulation must be within an eight of an inch of the terminal. An exception would be wires

that use a modified wrap.

Soldered connections are not allowed in Windstream facilities. Exceptions MUST be

specifically authorized by job IPACK.

Figure 1



Figure 2

Figure 3.



3.1.1. Shinning

When skinning a wire, care should be taken not to scrap or nick the metallic wire.

An approved wire-skinning tool shall be used.

Connection will not be made with a previously wrapped lead.

Table 1 – Skinning Length and Turns for Wrapped Connections

Wire Gauge Skinned Length Minimum # of Turns

24 1 ½ inches 6

20 – 24 1 5/8 inches 20,22 – 5, 24 - 6

22, 24 1 5/8 inches 22 – 5, 24 – 6

26 – 30 2 inches 7

26 - 30 1 1/8 inches 7

Figure 4 – Wire-wrapping tools



Figure 5 – Wire shinning Figure 6 – Wire insertion

Figure 7 - Wire – wrapping unto wire block

WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections


4. COAXIAL CONNECTIONS

The crimping tool shall be of the approved type for the BNC connectors being used.

Use proper cap inserting squeeze tool for cap placement. The cap shall fit tightly, and be

smooth and free of any distortion.

All connectors shall be placed on the coax cable’s point of termination and shall have no

strain and twists.

The outer sleeve shall be ½ inch minimum in overall length.

The crimped portion of the sleeve shall be ¼ inch minimum measured along the axial

dimension.

The crimped outer sleeve shall show no signs of having a double crimp.

The crimped outer sleeve shall have no cracks or fractures.

The crimped outer sleeve should butt against the jack, but shall not exceed 1/32-inch space

between the sleeve and the jack body.

NOTE: Quick connect BNCs shall not be used in any Windstream facility.

4.1. Coaxial Shield Connections

The shield of a shield coax cable shall be connected to ground with paired inner and outer

sleeves that are crimped with an approved crimping tool.

NOTE: The shield shall not get soldered.

The crimp shall be of the type specified by the manufacture of the connector.

Figure 8 – Typical Coaxial Connections

Note: Round crimp with flare is not used in Windstream facilities.



4.2. Tools needed for BNC Terminations

Tools Needed for BNC Terminations

� Coaxial (manual or power) stripper

� Trompeter 12-point center pin crimp tool

� Trompeter hex sleeve crimp tool

� Flushed side cutters

� Coaxial cable cutter

Figure 9 – BNC Tool Kit Figure 10 – BNC Manual Stripper.

4.3. Coaxial Wire Stripper Alignment Process

There are seven parts that make up the stripping tool. The body, locking latch, cassette, slide,

V-block, groove, and set screws.

The main body provides several functions:

It pivots and will open by rotating the locking mechanism in a downward direction.

At the top section inside the body, two metal rod springs are used to hold the V block, which

is a course adjustment devise that allows different gauge diameter cable to be stripped.

The adjustment slide is located on the top of the body and has five positions.

An extruded plastic groove on the side of the body is used to stabilize the end of the coaxial

cable to be terminated.

It houses a three-blade cassette inside the body.

On the bottom side, there are three fine allen head screws for adjusting the blade depth.

� Stripper blade #1 – Make sure that blade does not scar or nick the center conductor.

� Stripper blade #2 – Strip away first and second shielded braid leaving only a slight mark

on the dielectic.

� Stripper blade #3 – Strip away outside jacket leaving outer stranded shield intact.



� Inspect the first strip to see how deeply each blade has scored the cable.

� Adjust the stripper blade to match the coaxial cable’s size by turning the allen screws on

the bottom of the tool.

If the braid is twisting excessively, turn the allen screw for the braid cutting blade +90 degree

and the allen screw for cutting the jacket –90 degree.

If after repeated adjustments, most of the braid will not cut correctly, you may need to replace

the worn blades by reversing the blade cassette and use the new blade set.

4.4. BNC Termination Process

� Make a smooth flush 90 degree cut on the coaxial cable with proper cable cutter.

� Inspect cable end – it should be round not elliptical.

� Open BNC assembly package and inspect components for any defects

� Place crimp ferrule over the coaxial cable jacketing with the step milled index end first; it

will provide strain relief for the connector by firmly grasping cable jacketing. (figure 11).

USING A POWER STRIPPER:

• Strip coaxial cable to BNC connector manufacturer’s dimensions. Insert flush cable end

to be terminated into stripping tool until it hits bottom. Firmly hold the jacketing material

while depressing the motor switch engaging the blades to cut coaxial cable. Hold trigger

4 to 5 seconds. (figure 12).

USING A MANUAL STRIPPER: (For a 734 BNC)

• Insert the properly coded V-Block for the coax being terminated. (Use the Red V-Block

when using 734 coax cable). (Figure 13).

• Adjust slide to position #5

• Open tool by rotating locking latch in a downward motion.

• Hold the tool with the handle toward you and insert coax cable from the left into the

groove position, close and latch tool. (Figure 14).

• Push slide forward to proper start position. (Position #4 for 734 BNCs).

• Rotate tool around the coax cable four or five times until tool stripper rotates freely

around cable. Push slide position forward to position #3 and rotate tool again. Repeat the

previous steps for final position #2. (Figure 15).

• Return slide position back to position #5



� Remove first and second cut material from cable. This consist of the outer jacketing

material, the double braided shield material, leaving the dielectric material exposed.

Remove any loose or extended strands of shield to prevent a short between the shield and

the center pin.

� Work the jacketing material loose at the third and final cut and remove the outer

jacketing material from the cable. Take caution not to break any of the shield material or

disturb the braid pattern, or it will make placing the ferrule over the stranded shield

difficult. (figure 17).

� Place center pin over center conductor. Verify center conductor pin length is correct by

using the visual inspection hole to see if the conductor is past the inspection hole.

� Using the 12-point crimping tool, fully insert center pin with center conductor into tool

opening, Crimp center pin on center conductor. The end of the center pin should be flush

against the dielectric; there should be no gap. Remove tool and tug on center pin to make

sure the pin is tightly secured. (Figure 18).

� Take the plug body and partially insert the center pin into the plug body and rotate the

plug body to move the entire shield away from the dielectric. Push the plug body all the

way over the center pin locking the center pin into the plug body. You will feel a snap as

the pin locks into the plug body. If the pin does not lock into position, check for incorrect

strip dimensions or contaminants in the connector. If the pin and plug will not snap, use

another connector. (Figure 19)

� With center pin and plug properly in place, position the metal stranded shield material

back to its natural position around the stem of the BNC body. Try not to disturb the

weave pattern of the shield by straightening it out since this action makes pulling the

crimp sleeve into position difficult.

� Bring the crimp sleeve up over the outside of the shield. If there is any exposed shield

once the sleeve is butted up against the plug body, pull the sleeve back down and trim the

excess shield material away, and then place the crimp ferrule back to the plug body.

� With no exposed strands showing, take the crimping tool and place around the crimp

sleeve making sure the sleeve is tightly butted up against the plug body, then crimp the

sleeve. The crimp tool will release when the cycle is completed and the ferrule is

crimped. (Figure 20).

Figure 11 Figure 12



Figure 13 Figure 14

Figure 15 Figure 16



Figure 17. Figure 18.


Figure 21.



4.5. Test and verification of proper termination

Lightly tug on the BNC connector’s body to make sure that the internal spring is working

properly.

Rotate the BNC connector’s collar on the plug body to make sure it rotates freely

After both ends of cable have been terminated, test cable with a Windstream approved cable

tester.

NOTE: Refer to WSP 3442 for testing procedure.

Figure 22.

WSP-3444 Revision 1.0 - 9/01/2012 Mechanical Connection


5. MECHANICAL CONNECTION

Mechanical connections may only be used when the manufacture’s specification and design

require a mechanical connection.

Connection shall be tight and torque to manufacturer’s specification.

Connection shall not have more than 1/16 of an inch shiner.

A used wire end shall not be used. It will be re-skinned and reconnected.

WSP-3444 Revision 1.0 - 9/01/2012 Fiber Optic Connection


6. FIBER OPTIC CONNECTION

Reference: WSP 6009

WSP-3444 Revision 1.0 - 9/01/2012 Cat-5 Cable


7. CAT-5 CABLE

When making Cat-5 cable, especially when using it in a 10BaseT/100BaseT, it is always best

to follow the color scheme of the EIA/TIA 568B and 568A cabling standards, unless

otherwise specified in the IPACK. The effective length of Cat-5 cable depends on the

speed of the circuit being used, with a maximum 300 feet at any speed. The twisted pairs

carry a signal in one direction on one wire and its return on the other wire of the pair. It is

necessary for the signal and return to be part of the same twisted pair for the Ethernet to

function as it was designed. The 568-B pin-out is the most common cable used, most pre-

manufactured cables come in the 568B standard.

568A 568B

Pin Color Pin Color

1 white-green 1 white-orange

2 green 2 orange

3 white-orange 3 white-green

4 blue 4 blue

5 white-blue 5 white-blue

6 orange 6 green

7 white-brown 7 white-brown

8 brown-white 8 brown-white

Tools and Materials needed to make a Cat-5 cable

� Appropriate length of Cat-5 cable

� Cable stripper

� RJ45 jacks

� RJ45 crimping tool

� Cable tester

� Scissors

Figure 23.



7.1. Procedure for Making a Cat-5 Cable

� Remove approximately 11/4 inch to 1-1/2 of an inch off the outer cable jacket from the

cable end that is to be crimped. Be careful not to cut or nick the twisted wire pairs inside.

Use your fingers to un-twist and straighten all of the wires. (Figure 24).

� Using the pin-out for the requested circuit type in the IPACK, arrange the color-coded

wires as required. Recheck wires to make sure that all wires are in the proper color coded

order and shall be free of any kinks, nicks bends, etc. (Figure 26).

� Hold the color sorted wires tightly together, and using a sharp scissors cut all of the wires

in a neatly 90 degree angle approximately ½ inch from the end of the cable jacket. It is

important to make a straight clean cut to ensure that the wires make proper contact when

inserted into the RJ45 connector. (Figure 27).

� The wires shall all be in a straight 90-degree cut, approximately a ½ inch expose out from

the cable jacket. Hold the RJ45 connector with the pins facing up and the tab facing

down.

� Firmly insert the wires into the RJ45 until they reach the end of the connector. Ensure

that the wires are inserted in the correct color code and fully inserted into the end of the

connector. The cable shall also have approximately 3/16 of an inch of the cable jacket

inserted into the RJ45 connector.

� Using an approved Windstream RJ45 crimp tool insert the connector into the crimp tools

die. Firmly squeeze until the ratchet mechanism completes a full crimp.

� Repeat the procedure to the other end of the cable and test with a cable tester to ensure a

good connection and proper continuity.

If the continuity test fails, check to make sure that both ends followed the proper color

code, examine the conductors and verify that they are fully seated at the end of the jack.

Remove the suspected connector and repeat the steps above


WSP-3444 Revision 1.0 - 9/01/2012 Definitions


5. DEFINITIONS

Term/Acronym Definition

Abam Multiple pair cable with a foil protective shield

AWG American Wire Gauge

DC Direct Current

Dielectric Insulating material which will store but not conduct electricity

DSX Digital Signal Cross-Connect

ESD Electrostatic Discharge

RJ45 8 pin cable plug



WSP-3444 Revision 1.0 - 9/01/2012 References


6. REFERENCES

Ameritech Standard Practice, AM-TR-EEN-000011, Issue H. August 1999

Ciena Installation Workmanship Standard, P/N 009-7003-000

Telecordia.com

WSP 3442

WSP 6009

WSP-3444 Revision 1.0 - 9/01/2012 Appendixes


7. APPENDIXES

NA

WSP-3444 Revision 1.0 - 9/01/2012 Attachments


8. ATTACHMENTS

NA

wsp-3444 wire connections standard

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