wsp-3444 wire connections standard
TRANSCRIPT
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
Copyright © 2002 Windstream® Incorporated. All rights reserved. The entire contents of this document are protected under the United States copyright laws.
You may print and download portions of material from this document for your own internal, non-commercial use. For any other copying, redistribution, retransmission or publication of any downloaded material, you must have the express written prior consent of Windstream Incorporated.
“Windstream”, the Windstream logo, and all related products and service names, marks, and slogans are trademarks of Windstream Incorporated. Other product and company names mentioned herein may be trademarks of their respective companies.
Misuse of the trademarks or any other content in this publication is strictly prohibited.
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
Windstream Proprietary and Confidential 2
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
Windstream Proprietary and Confidential 3
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
Windstream Proprietary and Confidential 4
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
WSP-3444 Revision 1.0 - 9/01/2012 WIRE-WRAPPED CONNECTION
Windstream Proprietary and Confidential 5
Figure 2
Figure 3.
WSP-3444 Revision 1.0 - 9/01/2012 WIRE-WRAPPED CONNECTION
Windstream Proprietary and Confidential 6
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
WSP-3444 Revision 1.0 - 9/01/2012 WIRE-WRAPPED CONNECTION
Windstream Proprietary and Confidential 7
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
Windstream Proprietary and Confidential 8
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.
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 9
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.
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 10
� 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
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 11
� 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
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 12
Figure 13 Figure 14
Figure 15 Figure 16
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 13
Figure 17. Figure 18.
Figure 19. Figure 20.
Figure 21.
WSP-3444 Revision 1.0 - 9/01/2012 Coaxial Connections
Windstream Proprietary and Confidential 14
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
Windstream Proprietary and Confidential 15
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
Windstream Proprietary and Confidential 16
6. FIBER OPTIC CONNECTION
Reference: WSP 6009
WSP-3444 Revision 1.0 - 9/01/2012 Cat-5 Cable
Windstream Proprietary and Confidential 17
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.
WSP-3444 Revision 1.0 - 9/01/2012 Cat-5 Cable
Windstream Proprietary and Confidential 18
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
Figure 24. Figure 25.
WSP-3444 Revision 1.0 - 9/01/2012 Cat-5 Cable
Windstream Proprietary and Confidential 19
Figure 26. Figure 27.
Figure 28. Figure 29.
WSP-3444 Revision 1.0 - 9/01/2012 Definitions
Windstream Proprietary and Confidential 20
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
RJ12 6 pin cable plug
RJ11 4 pin cable plug
WSP-3444 Revision 1.0 - 9/01/2012 References
Windstream Proprietary and Confidential 21
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
Windstream Proprietary and Confidential 22
7. APPENDIXES
NA
WSP-3444 Revision 1.0 - 9/01/2012 Attachments
Windstream Proprietary and Confidential 23
8. ATTACHMENTS
NA