HarnWare™ V6.

3
HarnVis V2
User Guide

July 2020
© TE Connectivity Contents i

TABLE OF CONTENTS
Copyright 1

Overview 3

System Overview ................................................................... 3

HarnVis .................................................................................. 7
Training Courses .................................................................... 8
Part Selection Overview......................................................... 9
Harness Design Overview.................................................... 10
User Interface Overview ...................................................... 14
Opening Shapes ................................................................... 18
Error Handling ..................................................................... 19
Menus 23

File Menu ............................................................................. 23

Open Shape ............................................................ 23
Save Shape ............................................................. 24
Export Parts List .................................................... 25
Data Import ............................................................ 26
Print Document(s) .................................................. 26
Drawing Export Processor ..................................... 26
Purge Unused Visio Masters .................................. 27
Upgrade Document(s) ............................................ 28
Exit ......................................................................... 29
Edit Menu............................................................................. 29
ii User Guide HarnWare™ Version 6.3
Copy, Paste and View Part Data ............................ 29
Find Shape ............................................................. 30
Next / Previous Shape ............................................ 30
Rotate/Group Shapes ............................................. 31
Tools Menu .......................................................................... 31
Design Wizard ....................................................... 34
Database Search ..................................................... 34
Wiring Schematic/Schedule ................................... 35
Wire Route ............................................................. 36
Multi-Core Cable ................................................... 36
Parts List ................................................................ 37
Composite Parts List .............................................. 37
Marker Page & Data Export .................................. 38
Check Design ......................................................... 38
Compare Designs ................................................... 39
Labour Estimate ..................................................... 39
RELIABILITY GUIDE (Mean Time
Between Failures) Estimate ................................... 40
CoP, Materials & Equipment ................................. 41
RoHS ...................................................................... 41
Weight .................................................................... 42
Composite Weight ................................................. 42
HarnVis .................................................................. 42
Drawing Translator ................................................ 43
Create Shape .......................................................... 43
Calculator ............................................................... 44
Options Menu....................................................................... 44
© TE Connectivity Contents iii
Balloon Wires ........................................................ 45
Cable Cross-Section Labels ................................... 45
Retain Item Number Dialog ................................... 45
Units of Measure .................................................... 45
Display Options ..................................................... 46
Material Systems .................................................... 46
Wire and Band Strap Adaptor Source .................... 47
Master Database Folder ......................................... 48
Visio File Paths ...................................................... 48
Window Menu ..................................................................... 49
Help Menu ........................................................................... 52
Toolbar 55

Design Wizard ..................................................................... 55

Open Shape .......................................................................... 56
Save Shape ........................................................................... 56
Next / Previous Shape .......................................................... 56
Find Shape ........................................................................... 56
Rotate or Group Shapes ....................................................... 57
Database Search ................................................................... 57
HarnWare™ Help ................................................................ 58
EMI Shielding Advice ......................................................... 58
TE Product Catalogue .......................................................... 58
Short-Cut Keys 59

Drawing Hints & Tips 61

Drawing Pages ..................................................................... 61
iv User Guide HarnWare™ Version 6.3
Glue ...................................................................................... 62
Harness Legs ........................................................................ 64
Moulded Part Stencils .......................................................... 65
Multi-Cable Shapes .............................................................. 65
Connector References .......................................................... 65
Drawing Borders .................................................................. 66
Wire Line and Part Line Shapes .......................................... 68
HarnWare™ Shapes ............................................................. 68
Copying and Pasting Shapes ................................................ 69
Drawing Layers .................................................................... 69
Drawing Files ....................................................................... 70
Document Stencil ................................................................. 70
Cable Marker Shapes ........................................................... 70
Keyway Shape ..................................................................... 71
Design Wizard 73

Overview .............................................................................. 73

Method of Use...................................................................... 73
Toolbar Icon ......................................................................... 77
Set Properties ....................................................................... 77
Add/Delete Wires................................................................. 79
Material Systems Advice 81

Product Information 85

Product Catalogue ................................................................ 85

Product Information ............................................................. 85
© TE Connectivity Contents v

Wire List & Selection 89

Opening Wire Form ............................................................. 89

Number of Wires & From-To .............................................. 89
Wire Selection ...................................................................... 91
Wire Specification Selection ................................................ 93
Wire Gauge .......................................................................... 95
Wire Colour ......................................................................... 99
Fibre Optic Cable Selection ............................................... 100
Saving Data to the Wire Table ........................................... 101
Wiring Schematic 103

Overview ............................................................................ 103

Drawing ............................................................................. 106
Connector Parameters ........................................................ 108
Contact Assignments.......................................................... 110
Database ............................................................................. 112
Export Wiring & Schematic Schedule Data....................... 113
Wiring Schedule 115

Overview ............................................................................ 115

Drawing Analysis............................................................... 116
Schedule Output ................................................................. 118
Connector Parameters ........................................................ 118
Contact Assignments.......................................................... 119
Customising the Wiring Schedule...................................... 121
Export Wiring Schematic & Schedule Data....................... 122
vi User Guide HarnWare™ Version 6.3

Wire Routing 125

Overview ............................................................................ 125

Wire Lengths ...................................................................... 127
Repair Loops ...................................................................... 127
Wire Bundle Diameters ...................................................... 128
Potential Problems ............................................................. 129
Warning and Errors ............................................................ 130
Multi-Core Cable (EPD) Analyser 133

Overview ............................................................................ 133

Time Synthetics.................................................................. 133
Results Output .................................................................... 134
Saving Results .................................................................... 135
Analysis.............................................................................. 136
Worked Example ............................................................... 137
Multi-Core Cable (EPD) Search 139

Cable Database Set-Up ...................................................... 141

Database Selection ............................................................. 142
Braid &Tube 143

Opening Braid & Tube Form ............................................. 143

Cable Lay Design ............................................................... 144
Braid & Tube Selection...................................................... 145
Braid Termination .............................................................. 147
Multi-Core Cables (EPD)................................................... 147
Multi-Core Cable Details Form ......................................... 149
Lengths and Diameters....................................................... 149
© TE Connectivity Contents vii
Conduit............................................................................... 150
Cable Lay Design 151

Overview ............................................................................ 151

Filler Type .......................................................................... 153
Twisted Pairs ...................................................................... 154
Sub-Assemblies.................................................................. 154
Cable Cross-Section Drawings .......................................... 155
Component Spacing ........................................................... 155
Minimum Component Spacing ............................ 156
Maximum Component Spacing............................ 156
Rules and Limitations ........................................................ 157
Connectors 159

Opening Connector Form................................................... 159

Connector Selection ........................................................... 160
Connector Planforms & Part Number Construction .......... 163
Connector Planform Search ............................................... 166
Connector References ........................................................ 168
Connector Part Number Texts............................................ 168
Keyway Angles .................................................................. 169
Go To Adaptor/KTKK ....................................................... 170
Combined Connector/Adaptors.......................................... 170
Flying Leads....................................................................... 170
D Connectors ..................................................................... 170
GPR Rectangular Connectors ............................................ 171
ProBeam Fibre Optic Connectors ...................................... 172
RF Coax Connectors .......................................................... 173
viii User Guide HarnWare™ Version 6.3
Splices ................................................................................ 174
Devices 179

Adaptors 185

Opening Adaptor Form ...................................................... 185

Adaptor Selection............................................................... 186
Go To Connected Parts ...................................................... 188
Non-Preferred Adaptors ..................................................... 188
Code 18 Adaptors .............................................................. 188
Code 54 Adaptors .............................................................. 189
Code 79 Adaptors .............................................................. 189
Code 88 Adaptors .............................................................. 190
Tinel Adaptors ................................................................... 190
Band Strap .......................................................................... 191
Conduit Adaptors ............................................................... 191
Spin-Lock Adaptors ........................................................... 192
Hexashield.......................................................................... 192
Moulded Parts 197

Opening Moulded Part Form ............................................. 197

Moulded Part Selection ...................................................... 198
D Connector Boots ............................................................. 201
Boots Used as Transitions .................................................. 201
Bent Boots .......................................................................... 202
Go To Adaptor ................................................................... 202
Alternative Styles ............................................................... 202
Packing or Shimming ......................................................... 203
© TE Connectivity Contents ix
Braid Termination .............................................................. 205
Feedthroughs 209

Feedthrough Shapes ........................................................... 209

Opening Feedthrough Form ............................................... 209
Feedthrough Selection ....................................................... 209
Go To Leg .......................................................................... 212
TCFT Feedthroughs ........................................................... 212
KTKKs 215

Opening KTKK Form ........................................................ 215

KTKK Selection................................................................. 215
Go To Connected Parts ...................................................... 218
Code 18 KTKKs ................................................................ 218
Code 54 KTKKs ................................................................ 218
Code 79 KTKKs ................................................................ 219
Code 88 Adaptors .............................................................. 219
Spin-Lock Adaptors and Boots .......................................... 219
Packing or Shimming ......................................................... 220
Marker Sleeves 223

Opening Marker Sleeve Form ............................................ 223

Marker Sleeve Selection .................................................... 223
Cable Marker Text and Font .............................................. 226
Marker Page and Data Export ............................................ 227
Importing Data into WinTotal............................................ 229
Databus 231

Opening Databus Form ...................................................... 231

x User Guide HarnWare™ Version 6.3
Databus Coupler Selection ................................................. 232
Box Couplers ....................................................... 232
Micro and Flat-Pack Couplers ............................. 233
Space Application ................................................ 235
Database Search and Save Shape ......................... 235
Databus Connector Selection ............................................. 235
Space Application ................................................ 237
Database Search and Save Shape ......................... 237
Databus Miscellaneous Part Selection ............................... 237
Space Application ................................................ 239
Database Search and Save Shape ......................... 239
Conduit 241

Opening Conduit Form ...................................................... 241

Conduit Selection ............................................................... 241
Conduit Selection ................................................. 242
Braid and Tube Selection ..................................... 243
Lengths and Diameters ........................................ 244
Conduit Transition Selection ............................................. 245
Design Checker 247

Parts Listing 251

Overview ............................................................................ 251

Balloons ............................................................................. 252
User Balloons ..................................................................... 253
Non-Parts Listing Layer & Sub-Assemblies ...................... 255
Gap Shapes & Item Number Sequences ............................ 256
© TE Connectivity Contents xi
Retain Existing Item Numbers ........................................... 256
Wire List ............................................................................ 257
Balloons for Wires in Legs ................................................ 257
Cable Cross-Section Drawings .......................................... 258
Parts List Tables ................................................................. 258
Edit Parts List Format ........................................................ 260
Parts List Class Codes ........................................................ 262
Braid, Tube, Wire & EPD Lengths .................................... 263
Warnings ............................................................................ 265
Export Parts List ................................................................ 265
Standard Headers Option ................................................... 266
TE CBOM Headers Option ................................................ 268
Composite Parts Lists......................................................... 268
User Parts Library 271

Part Numbering Schemes ................................................... 271

Using the Parts Library ...................................................... 272
User Parts Library Database .............................................. 274
Weight Estimator 277

Overview ............................................................................ 277

Estimating the Weight of a Harness ................................... 278
User Weight Database........................................................ 280
Composite Weight.............................................................. 281
Labour Estimating 283
Overview ............................................................................ 283
Labour Estimate Page ........................................................ 284
xii User Guide HarnWare™ Version 6.3
Warnings ............................................................................ 285
Lengths............................................................................... 286
Solder and Crimp ............................................................... 286
Potential Problems ............................................................. 287
CoP, Tooling & Materials 289

Overview ............................................................................ 289

Generating CoP, Tooling Equipment & Assembly
Materials Lists .................................................................... 289
Drawing Translator 293

Overview ............................................................................ 293

Method of Use.................................................................... 294
Phrase Database Management............................................ 295
Extended Character Sets .................................................... 296
RoHS 297

Overview ............................................................................ 297

Background Information .................................................... 298
RoHS Code Definitions ..................................................... 299
Further Information ............................................................ 301
Compare Designs 303

Create Shape 305

Drawing Hints .................................................................... 307

Errors ................................................................................. 307
Miscellaneous Options 309
Rotate and Group Shapes ................................................... 309
© TE Connectivity Contents xiii
Rotate Shapes ....................................................... 309
Group Glued Shapes ............................................ 311
Multi-Cable Shapes ............................................................ 311
Copy, Paste and View Part Data ........................................ 312
Print Document(s) .............................................................. 314
Documents ........................................................... 314
Pages .................................................................... 315
Printing................................................................. 315
Data Import ........................................................................ 316
Connectors ........................................................... 316
Splices .................................................................. 316
Wire ..................................................................... 317
Processing ............................................................ 317
Pre-Processing Documents for Export ............................... 318
Documents ........................................................... 319
Pages .................................................................... 319
Processing ............................................................ 319
Arrange Dialog and Main Forms ....................................... 321
HarnVis 323

Overview ............................................................................ 323

Demonstration .................................................................... 326
Viewing .............................................................................. 327
Orbit, Centre View and Zoom.............................. 327
Background Colours ............................................ 328
Lighting ................................................................ 329
Perspective Angle ................................................ 330
xiv User Guide HarnWare™ Version 6.3
Smoothness .......................................................... 331
Pixel Formats ....................................................... 332
Bend and Twist Harness Legs ............................................ 334
Measuring Parts ................................................................. 335
Part Details and Dimensions .............................................. 337
Product Information ............................................. 339
Exposed Surface Area ........................................................ 341
Select in Visio or HarnWare™ .......................................... 342
Lay-Up Board Design ........................................................ 343
Copying and Saving Views ................................................ 345
Save As IGES .................................................................... 347
Save As HSF ...................................................................... 348
Model Part .......................................................................... 350
Miscellaneous .................................................................... 352
Multi-Cables ........................................................ 352
Viewing Quality and Speed ................................. 353
APPENDIX A 355

Support Contacts ................................................................ 355

APPENDIX B 357

Installation Guidelines ....................................................... 357

Visio Requirements .............................................. 357
HarnWare™ Installation ...................................... 357
Uninstalling .......................................................... 358
Start Up ................................................................ 359
Setup Problems .................................................... 360
HarnWare™ Key File ........................................................ 362
© TE Connectivity Contents xv

APPENDIX C 364

What’s New ....................................................................... 364

Version 5.3 ......................................................................... 364
Version 5.4.2 ...................................................................... 365
HarnWare™ V5.4.5 and HarnVis 1.2.6 ............................. 366
HarnWare™ V6 ................................................................. 367
HarnWare™ V6.1 .............................................................. 370
Index 372
© TE Connectivity Copyright 1

Copyright
The TE HarnWare™ and HarnVis systems were designed and
developed for TE Connectivity. (TE) by Roger Billsdon of ADE
Analysis & Design Engineering Ltd.

Each copy of HarnWare™ is registered to an individual user whose

name and company appears in the copyright splash screen shown
when the system is started:

Clicking the 'OK' command confirms your agreement to the

limitations and restrictions placed on you and your company in
relation to the acceptance and use of the TE Software Programs
entitled HarnWare™ and HarnVis.
© TE Connectivity Overview 3

Overview
System Overview
HarnWare™ will speed and simplify the process of selecting TE
products and designing electrical wiring harnesses. HarnWare™
enables the correct parts for a specific design requirement to be
selected from a database of preferred parts. The HarnWare™ PC
Harness Design System combines this functionality with a drag and
drop drawing interface. The design rules encoded into HarnWare™
have been developed from years of experience making this a powerful
interactive design application.

The HarnWare™ PC Harness Design System is a highly flexible and

easy-to-use system. For drawings HarnWare™ uses an off-the-shelf
package known as Visio which is now owned by Microsoft. All of the
functionality of Visio is available for users to create many types of
drawing in addition to TE wiring harness drawings.

A graphical or pictorial interface is the most effective way of creating

any new design. By dragging and dropping shapes representing TE
products into a drawing the correct parts for a specific requirement
can then be automatically selected. HarnWare™ can help you
generate drawings, wiring schematics, Bills of Materials or Parts
Lists, assembly time estimates, Code of Practice listings, list changes
introduced by a design revision, etc. Hence you will be able to
respond to customer enquiries more professionally, quickly and
reliably.

For further details on how to use HarnWare™ please refer to this User
Guide or the System Operating Procedures chapter in the online help
system. For guidance on harness design best practices including
selection of materials and components please refer to the Harness
Design Procedures and Reference chapters in the online help system
which include product descriptions and other useful harness design
4 User Guide HarnWare™ Version 6.3

information. Refer to Microsoft Windows documentation for details

on how to use Windows Help Systems.

HarnWare™ can be used for:

 Part selection. The best components for a given set of design

requirements can be selected.

 Harness design. A complete harness can be drawn, specified and

analysed.

Harness drawings created by HarnWare™ contain part numbers,

dimensions, materials and other key design data. Various analysis
options are provided to:

 Advise on the most suitable wire gauge relative to such parameters

as current and temperature rise.

 Advise on the most suitable materials relative to such parameters

as temperature and type of application.

 Automatically generate wiring schematics and wiring schedules

from simple wire list data. This data can also be exported to a text
file or the Windows Clipboard.

 Calculate wire lengths and bundle diameters.

 Advise on the most cost effective use of multi-core cables (EPDs)

and to search for suitable cables.

 Determine optimum lays for minimum cable diameters and

automatically produce cross-section drawings.

 Check harness designs against a variety of ‘best practice’ rules.

 Generate parts lists.

© TE Connectivity Overview 5

 Generate composite parts lists for a number of harness design

drawings.

 Export parts list data for use in other systems including spread
sheets, databases and the TE’ UK CBOM system.

 Produce labour estimates.

 Output listings of Restriction on Hazardous Substances (RoHS)

Codes.

 Compare two designs to identify changes introduced by a harness

design revision.

 Output listings of codes of practice references, tooling equipment

and assembly materials.

 Estimate the weight of a harness assembly and the total weight of

a number of harnesses.

 Translate drawing texts into a variety of western and eastern

languages.

 Import data from an Excel spread sheet to help create parts of a

harness design.

HarnWare™ normally runs alongside Visio. Drawings are produced

and edited using Visio. HarnWare™ analyses and saves design data in
Visio document files. However, if Visio is not installed on your
computer, HarnWare™ can still be used for database searching, part
selection and for accessing product data in the harness design help
system or the product catalogue.

A database contains details of TE harnessing components and

materials. If you have a copy of Microsoft Access, you can inspect the
contents of the HarnWare™ database. However, use a copy of the
database, as HarnWare™ is protected against changes to the database
and you will need to reinstall the system if the database is modified in
6 User Guide HarnWare™ Version 6.3

anyway. A separate User Parts Library database is provided for non-

standard parts and part numbering schemes.

Select HarnWare™ from the Windows Start Menu to start

both HarnWare™ and Visio. If you already have a copy of
Visio running, you can use the Visio Tools>Run Add-On
© TE Connectivity Overview 7

menu (or in Visio 2010 use the add-ons option in the View
tab) to start HarnWare™.

Refer to:

 Please contact: [email protected] for the latest information and to

post any questions you may have.

 The ReadMe.txt file included on the HarnWare™ CD-ROM and

in the HarnWare™ folder on your hard disc for any late
information on the system.

 Appendix A for TE harness product and HarnWare™ system

support contacts.

 Appendix B for system installation and troubleshooting details.

 Appendix C for details on the changes introduced in this latest

version of HarnWare™.

HarnVis
HarnVis is a 3D harness design visualisation system which is
available for a small charge. It can be accessed via the HarnWare™
Tools menu, the <Ctrl>+H short-cut key, the Windows Start Menu or
the Visio add-ons menu.

Using HarnVis, to-scale 3D models of a HarnWare™ wiring harness

can be automatically generated and viewed from any angle. Views are
rendered in colour with lighting effects, which are very realistic.
These 3D models provide "virtual prototypes" of harnesses allowing
the user to see what a harness will look like with lengths, diameters
and parts shown to-scale. By simply clicking on a part, the user can
access such data as part numbers, materials, finishes, adhesives, etc.

These "virtual prototypes" reduce the potential for errors. 3D views

also have a more immediate impact than 2D schematic drawings,
especially for those who are not trained in reading engineering
8 User Guide HarnWare™ Version 6.3

drawings. 3D views can be saved to disc or pasted into other

programs such as Visio or Microsoft Word.

Harness lay-up boards (also known as nail, form and peg boards) can
be modelled and pegs can be automatically positioned along the
harness legs. When a long harness leg makes it necessary, legs can be
bent to fit a lay-up board.

3D models of harnesses and of TE parts can be exported from

HarnVis in the form of Hoops Streaming Files (HSF or OpenHSF) or
IGES files for use in other CAD systems.

Training Courses
HarnWare™ is intended for harness designers who have attended the
relevant HarnWare™ training courses. For new users the normal
HarnWare™ training course is 3 days while for those who are
proficient users of an earlier version of HarnWare™ there is a shorter
© TE Connectivity Overview 9

upgrade training course which only covers the new and improved
features.

For those wishing to tailor HarnWare™ to particular company

requirements there is an optional 1-day system administrator’s course.
This covers setting up company drawing borders, special connector
shapes, User Parts Library, cable databases, etc.

For those wishing to design Databus harnesses, there is a 1-day

specialist course which specifically addresses the requirements of
databus harness design and product selection.

For HarnVis there is a 1-day training course.

For further details on training courses please email [email protected]

Part Selection Overview

To select a single part for a given design requirement:

 Use the appropriate HarnWare™ Window>Parts menu option.

 Alternatively, if you have a shape in a Visio drawing, use the
double-click or right-click menu, or select Open Shapes from the
HarnWare™ menu in Visio to select the shape and open it in
HarnWare™. HarnWare™ will set up a form for the selected class
of part, including any known details such as part style and
dimensions. Use the F1 key to obtain context sensitive help on
how to use a particular aspect of the system.
 Enter any additional requirements, for example, part style, material
and finish requirements. When, for example, a combo-box
containing materials is selected, with the shift key held down,
press the F1 key. The <Shift>+F1 key combination is used to
obtain details on the particular style of part or material option. The
default harness material system is selected using the HarnWare™
Option menu or by clicking the current material system shown at
the right-hand end of the HarnWare™ status bar.
 Use the database search button in the HarnWare™ toolbar, the
Tools menu option or the <Ctrl>+D short-cut key. Part numbers
10 User Guide HarnWare™ Version 6.3

and dimensions for any part that match the requirement will be
output. Details of suitable alternative
parts can be viewed using the database
next, previous first or last record
buttons in the toolbar.
 If required, part number, dimensional and other design
data for your chosen part can be saved to the shape in the
drawing using the HarnWare™ Save toolbar button, the
File Menu option or <Ctrl>+S.
This process may be repeated by selecting another
shape in Visio or by using the Next or Previous
shape HarnWare™ toolbar icons.

Harness Design Overview

The key steps in the suggested harness design process include:

 Start a new drawing using the HarnWare™ imperial or metric

template and set the drawing size. Create the harness drawing by
dragging, dropping and gluing component shapes and harness
legs. Add dimensions to harness legs and references to connectors,
by clicking the shape and typing the required text.

 Use the HarnWare™ icon in the Visio toolbar (or in Visio

2010 use the option in the HarnWare™ tab) to pop
HarnWare™ to the front. Alternatively, you can use the Windows
<ALT>+<TAB> short-cut to swap between program windows or
you can use the HarnWare™ menu in Visio to directly select
options such as the Design Wizard.

 Click the design wizard toolbar icon to have HarnWare™

analyse your drawing. The design wizard leads you
through the design process and provides quick access to
information on each part in the harness. The list produced by the
wizard contains an icon indicating the type of part or operation
along with a brief description. As you move the mouse over the
list, more details and a picture of the particular style of part is
© TE Connectivity Overview 11

output. A black arrow to the left of the icon indicates the item to
which the descriptive detail relates and the black lines show
connections between shapes. The right-hand side of the wizard
form contains details on parts plus hyperlinks to further
descriptive details on materials, part styles, etc in the online help
system.

 Click Set Properties in the design wizard list. When an

item in the list is clicked, it is highlighted in green to
serve as a reminder of the last operation or part selected.
In the properties form specify the required harness material
system. Using Set Properties you can select the harness material
system, units of measure, etc.

 Click the add wires option to add or delete lines from the wire list
table in the drawing.
12 User Guide HarnWare™ Version 6.3

 Click the first wire in the wizard list. HarnWare™ will

select the appropriate page and shape in Visio and load
the wire selection form with information from the wire
line shape. Enter the number of wires and select the from-
to references from the lists of connector references.
Specify the necessary wire design parameters and select a
wire part number from the database. Save the data to the drawing
using the Save Shape option. HarnWare™ will return to the design
wizard form. Repeat this step for each wire.

 If you wish, you can now use the Wiring Schematic

option to have HarnWare™ automatically generate a
wiring schematic from the information entered in the
wire list and the position of the connector shapes in the harness
drawing. However, you do not need to rigidly follow the order of
operations in the Design Wizard and a schematic can be generated
at almost any stage in the harness design process.

 Click the Wire Route option to have HarnWare™

calculate routes, wire lengths and cable bundle diameters.
Close the wire route form or click the design wizard
toolbar icon to return to the Wizard.

 Click a harness leg in the Wizard to select it and load

the HarnWare™ braid and tube selection form. Use the
cable lay design command button if you wish to analyse or
produce a drawing of the cable cross-section. Select the
optimum braid and tube, using the part selection process
described in the previous section. Save the braid and tube
data to the leg shape in the drawing. Repeat this step for each
harness leg listed by the wizard.

 Click the first connector in the Wizard to select it and

load the HarnWare™ connector selection form. Enter
the connector requirements and use the database to
search for the required connector. If you wish the connector part
number and planform command can be used to help identify the
full connector part number and to add a planform into the drawing.
© TE Connectivity Overview 13

Save the connector code, shell size and other data to the shape in
the drawing.

 The Design Wizard groups connectors with their

associated adaptors and boots. This makes selection easier
than would be the case if all the connectors, then all the
adaptors and then all the boots were selected. Click the
adaptor in the Wizard to select the adaptor which is glued to the
connector and call up the HarnWare™ adaptor form. Choose and
save the adaptor data to the drawing.

 Click the boot in the Wizard to select the boot which is

glued to the adaptor and call up the HarnWare™
moulded part form. Choose and save the boot data to the drawing.

 Repeat the part selection process for all the other connectors,
adaptors, boots, transitions , KTKKs, feedthroughs and marker
sleeves in the drawing. Also add part numbers, quantities, etc. to
any user balloons included in the drawing.

 Click Design Checker in the Wizard. This optional step

performs a series of checks on your design and warns of
some common design problems.

 Click Parts List in the Wizard. The resulting parts list is

shown in the HarnWare™ form and is added to the parts
list page(s) in Visio. Parts list balloons are automatically
added to the drawing. If required, the HarnWare™ File, Export
Parts List option can be used to export the parts list data to a
spread sheet, database or the TE UK CBOM system.

 Click Labour Estimate in the Wizard to generate a labour

estimate in the Visio harness design document.

 If you wish, you can use various options in the HarnWare™ Tools
menu, for example, Wiring Schedule, Harness Weight, CoP,
Tooling Equipment and Assembly Materials, HarnVis, etc.
14 User Guide HarnWare™ Version 6.3

NOTE

The design sequence generated by the wizard is one that flows easily
from stage to stage. However, you can skip steps or re-iterate parts of
the design process to study alternative solutions. Alternatively, you
can use the part selection and analysis operations from the
HarnWare™ menus and toolbar rather than from the design wizard.
Some less commonly used options, for example, the drawing
translator, are not listed by the design wizard and must be accessed
via the menus.

User Interface Overview

The user interface is similar in style and function to many programs
that run under Microsoft Windows. After starting HarnWare™ the
main title bar, menu, toolbar and status box are displayed.

The blank area is used for forms associated with harness components
and design processes. Different forms are used for each class of
component, e.g., moulded parts and adaptors, and for different
processes, e.g., parts listing and labour estimating.

Forms can be closed, minimised and maximised using the form

control menu buttons. Some forms such as the design wizard, parts list
and wire route can be resized to show more items. The HarnWare™
Window menu indicates the forms that have been previously opened
with a check mark. If a form has been used before, clicking it in the
Window menu will cause it to be displayed with the previous data.
Otherwise a new blank form will be displayed. This is useful if you
need to search for an isolated part. However, when designing a
harness you will normally add a shape to the drawing and open it
using the design wizard, rather than using the HarnWare™
Window>Parts menu.
© TE Connectivity Overview 15

Before closing a form or opening another form, HarnWare™™ will

warn you if the form contains information that has not been
saved to the drawing. If a part selection form was accessed
from the design wizard, closing or using the Save Shape option will
return you to the design wizard form.

When HarnWare™ is searching the drawing for information, a

scrolling blue bar is displayed in the status bar to indicate that the
system is busy. Time consuming analysis processes can be stopped by
pressing the escape key. However, once HarnWare™ has completed
the initial analysis and has started to update the drawing for such
options as parts listing, the escape key will not allow the process to be
interrupted. During such processes, HarnWare™ locks Visio to
prevent changes being made while the active document is being
analysed.

Options from the toolbar are selected by clicking. Menu

items can be selected by clicking or by using <ALT> plus
the underlined key. For example, the <ALT>+F key
combination opens the File menu. In addition, some commands have
16 User Guide HarnWare™ Version 6.3

their own short-cut key combinations. For example, <Ctrl>+R can be

used as an alternative to selecting Rotate from the Edit menu or
toolbar.

As you move the mouse over command buttons and text boxes, a
short description of the control is output in a yellow tooltip. More
detailed help is available in the online help system. Either use the
Help menu or press the F1 key to obtain context sensitive help. For
example, when the wire routing form is displayed, pressing the F1 key
will display a help topic that explains the wire routing process.

When a list or combo-box containing such information as part style,

materials, finishes or adhesives has focus, hold the shift key down and
press the F1 key to obtain help on the item selected in the list. The text
contained in these pop-help items can be copied to the Windows
clipboard by pressing <Ctrl>+C. This text can then be pasted into
your harness drawing using the Visio paste command. Many pop-help
items contain links to the HarnWare™ web site and to the online
product catalogue where you can read more about the relevant TE
products and materials.
© TE Connectivity Overview 17

The currently selected units of measure and harness material system

are displayed in the HarnWare™ Status Bar. The Material Advice
form can be accessed by clicking this part of the Status Bar.

HarnWare™ normally works alongside Visio. It is easy to switch

between Visio and HarnWare™ by:

 Using the HarnWare™ toolbar icon in Visio. This pops the

HarnWare™ Window to the front of Visio.

 Double-clicking a HarnWare™ shape.

 Right-clicking a HarnWare™ shape and using the menu of

HarnWare™ shape options. These are generally open shape, rotate
shape and product information. If the menu includes the parts list
and wire route options, you have not selected a shape and Visio is
displaying the page right-click menu.

 Using one of the options in the HarnWare™ menu in Visio. These

allow you to initiate a number of options including the Design
Wizard, Parts Listing and Design Checker.

 With no shape selected, right-clicking the page and using the page
menu of HarnWare™ options. These are pop to HarnWare™,
parts list, wire route, labour estimate and drawing notes. If the
menu includes the rotate option, you have a HarnWare™ shape
selected and Visio is displaying the shape, rather than the page
menu.

 Using the standard Microsoft Windows <ALT>+<TAB> key

combination.

 Using the Windows task bar.

When a shape is 'opened' the shape is linked with HarnWare™ and

information can be exchanged between HarnWare™ and the selected
Visio shape.
18 User Guide HarnWare™ Version 6.3

If you save data to Visio or make other changes by mistake, you can
often reverse the action using the Undo option in the Visio Edit menu.
However, some HarnWare™ operations result in many Visio
command steps and you may find you cannot undo them all. The
number of actions that can be undone in Visio is 10 by default, but
may have been set to another number in the Visio>Tools>Options
menu. It is advisable to save your Visio drawing at regular intervals to
provide a backup in case of mistakes.

Part numbers and other data used by HarnWare™ are mostly stored in
the data1 fields associated with each shape. In Visio select a shape
and use the Format>Special menu option (or in Visio 2010 use the
‘Shape Name’ option in the developer tab) to inspect the data1 field.
You can make minor changes to part numbers in the data1 field.
However, making changes in this way may affect the operation of
HarnWare™ and is generally not advised.

NOTE

If the Visio Format>Special or Visio 2010 developer tab are not

visible, check the ‘Run in Developer Mode’ option in the Visio
advanced option menu.

Opening Shapes
HarnWare™ works alongside Visio. When a shape is 'opened',
HarnWare™ can exchange information with the selected Visio shape.
There are a number of alternative ways to Open Shapes:

Clicking a line in the Design Wizard list which references the part.
This selects the part in Visio and opens the appropriate HarnWare™
part selection form.

 Double-clicking a HarnWare™ shape in Visio.

 Right-clicking a HarnWare™ shape and using the HarnWare™
Open Shape option. If the right-click menu includes parts list and
© TE Connectivity Overview 19

wire route options, you have not selected a shape and Visio is
displaying the page menu.
 With a shape selected using the Open Shape option in the
HarnWare™ menu in Visio.
 With a shape selected, switch to HarnWare™ using either the
HarnWare™ icon in the Visio toolbar or the standard Microsoft
Windows <ALT>+<TAB> key combination or by clicking
HarnWare™ in the Windows task bar. This pops HarnWare™ to
the front of Visio. You can then use the 'Open Shape' toolbar icon
in HarnWare™.
After using one of these options the shape in the Visio drawing is
linked with the HarnWare™ form, enabling information to be
exchanged. This allows you to use HarnWare™ to identify parts and
save part numbers and associated design information to the shape in
the drawing. Data saved with drawing shapes can be used when
selecting mating parts, for parts listing, design checking, etc.

When a shape is opened, any part number and design data previously
saved with the shape is automatically loaded into the HarnWare™
form.

Error Handling
HarnWare™ is a complex system. Inevitably in a system of this size
and complexity, some errors will be present. You should check all
output from the system and report any inaccuracies to one of the TE
HarnWare™ system support contacts listed in Appendix A.

If you encounter a problem, please contact: [email protected].

If the HarnWare™ software fails an error file will be automatically

output and you will see a dialog box similar to:
20 User Guide HarnWare™ Version 6.3

If you see a dialog box like this, please save your Visio document file
and email the following items to TE HarnWare™ system support:

 The Visio VSD document file. If Visio is locked, try restarting

HarnWare™ as this will often unlock Visio and enable you to save
the document file.

 The HarnWare™ error file HarnWare™ Error File.txt This

contains diagnostic information to help us trace the cause of
certain types of error. On Windows XP this file is normally saved
in the "C:\Documents and Settings\<User Name>\Application
Data\Tyco Electronics\HarnWare™" folder or directory. On
Windows Vista and 7 the folder is normally "C:\Users\<User
Name>\AppData\Roaming\Tyco Electronics\HarnWare™"

 If the error is associated with the wiring schematic or schedule, a

copy of the Wiring.accdb file can also help us trace certain errors.
This file will be saved in the same folder as the error file.

 A note of the circumstances in which the error occurred. Most

errors will be due to a particular combination of circumstances
© TE Connectivity Overview 21

which we will need to replicate if we are to trace and cure the

problem. After making a safe copy of the Visio document file and
the HarnWare™ error file, try to reproduce the error and make a
note of the sequence of steps we can use to reproduce the error.
Also we would be grateful if you would eliminate unnecessary
detail from the Visio document. This will reduce the size of files
sent by email and help us focus on the problem more quickly. In
most cases only a few shapes in the harness drawing and the wire
list are all that is required to reproduce an error. For example,
delete unnecessary pages, shapes, large drawing borders, etc and
then use the HarnWare™ File>Purge Unused Visio Masters menu
option to reduce the Visio file size.

NOTE

Only by being informed of any errors that occur will we be able to fix
them and make HarnWare™ a better system for you and all other
users. We also welcome comments and suggestions for improvements
and system enhancements.
© TE Connectivity Menus 23

Menus
File Menu
The file menu contains the following options:

Menu Option Short-Cut Key

Open Shape <Ctrl>+O

Save Shape <Ctrl>+S

Export Parts List

Data Import

Print Document(s)

Drawing Export Processor

Purge Unused Visio Masters

Upgrade Document(s)

Exit <ALT>+F4

Open Shape

This option can be selected from the toolbar, file menu or <Ctrl>+O.

Visio is checked to see if a shape is currently selected. If not, or if the

currently selected shape is not a HarnWare™ shape, i.e. moulded part,
adaptor, etc., the message 'No HarnWare™ shape currently selected in
Visio' is displayed. If several shapes are selected they are all checked
and the first HarnWare™ shape, if any, is selected. Component style,
dimensions, part numbers, etc. are retrieved from the shape and
entered into the form.
24 User Guide HarnWare™ Version 6.3
Double-clicking a shape in Visio or right-clicking the HarnWare™
shape menu in Visio, pops-up HarnWare™ and performs the Open
Shape option in a single operation. Hence this method is normally
preferred to the three steps of selecting a shape in Visio, using
<ALT>+<TAB> to switch from Visio to HarnWare™ and then Open
Shape to load the part data.

Open Shape is similar to:

 Clicking an item in the Design Wizard.

 Selecting a part form from the HarnWare™ Window>Parts menu.

The Design Wizard and Open Shape options link the form with a
shape in the drawing and transfer data from the shape into the form
whereas the HarnWare™ Window>Parts menu options do not
establish any link with the drawing unless the menu option is checked.
In this case the Window>Parts menu calls up a form with previously
entered data which, if previously established, may have a link with a
shape in Visio.

Forms that are linked to a shape contain the shape name in the title
bar. The shape name comprises the master shape name and number, if
there are more than one in the drawing. In the case of connectors, the
connector reference is added to the form title.

Save Shape

This option can be selected from the toolbar, file menu or by

using the <Ctrl>+S short-cut key combination. It is intended
for saving part data to the relevant shape in the drawing. However, if,
when this option is selected, the parts list, wire router or labour
estimating form is active, this option will return you to the design
wizard form.

When a harness part selection form is active, this option first checks
Visio to see if a shape in the current Visio page is linked to the form.
If not, you have the option to drop a new shape at the lower left corner
of the drawing page.
© TE Connectivity Menus 25
If a shape is linked to the form, the system replaces it with a new
shape when the style of part has changed to one with a different
shape. When HarnWare™ changes the style of a shape, you will often
have to move the shapes to re-glue them. Normally the shape is not
changed and only the part number, dimensions and other design data
associated with the shape are updated with details from the harness
part form. The shape is selected in Visio to highlight it and the
harness part form is updated to include any change in the title bar and
drawing part number.

Part numbers and other data used by HarnWare™ are stored in the
data1 fields associated with each shape. In Visio select a shape and
use the 'Format, Special' menu (or in Visio 2010 use the shape name
option in the developer tab) to inspect the data1 field contents. You
can make minor changes to part numbers in the data1 field. However,
making changes in this way may affect the operation of HarnWare™
and is not generally recommended.

If a part selection form was accessed from the design wizard, Save
Shape will return you to the design wizard form.

NOTE

If the Visio Format>Special or Visio 2010 developer tab are not

visible, check the ‘Run in Developer Mode’ option in the Visio
advanced option menu.

Export Parts List

These options allow parts lists contained in the current Visio

document or a selected set of documents to be exported to the
clipboard or a text file. This data can then be used in a spread sheet,
database, or the TE UK CBOM System.

Before using this option, a parts list should have been added to the
document(s) with the Tools>Parts List or Composite Parts List menu
option.
26 User Guide HarnWare™ Version 6.3
For further details refer to the section entitled Parts Listing or to the
online help system topic Analysis Operations>Parts List>Export Parts
List(s).

A separate Part Number Translator program is available to convert the

part numbers in HarnWare™ parts lists into standard reference
numbers or into customer in-house part numbers. Refer to the system
support contacts in Appendix A, if you are interested in discussing
this option.

Data Import

This option is used to import data from an Excel spread sheet to help
create parts of a harness design. Three example Excel spread sheets
named 'DataImportExample*.xls' are contained in the HarnWare™
Sample folder. These examples can be used as a basis to create your
own spreadsheets.

For further details refer to the section entitled Miscellaneous Options

or to the online help system.

Print Document(s)

This option prints selected pages from the current document or from a
selected set of Visio document files. By comparing the height and
width of each page HarnWare™ selects the most appropriate
orientation for printing, either portrait or landscape. Recent versions
of Visio now include various options for setting different print options
for each page in a document and so the HarnWare™ print option is
not so often required.

For further details refer to the section entitled Miscellaneous Options

or to the online help system.

Drawing Export Processor

This option processes selected pages from the current document or

from a selected set of drawing files. Certain options in Visio are not
implemented in other CAD systems, such as AutoCAD, and therefore
© TE Connectivity Menus 27
HarnWare™ drawings transferred into other CAD systems via DXF,
or other file formats can require some editing. This option makes
various modifications to allow HarnWare™ drawings to transfer in a
more acceptable manner.

For further details refer to the section entitled Miscellaneous Options

or to the online help system.

NOTE

After using the Drawing Export Processor do not save the Visio
document. When a document has been processed for export, it is no
longer suitable for use with HarnWare™

Purge Unused Visio Masters

This option can significantly reduce the size of your Visio document
files. This can save disc space and the time required to send Visio files
via email.

When you drag and drop shapes into a Visio drawing, a copy of the
master is added to the document stencil. Even if you later delete the
shape, the master will remain in the document stencil, increasing the
file size. This HarnWare™ option deletes all these unused masters
from the document stencil.

Alternatively you can use the Visio Window>Show Document Stencil

option to view the masters. You can then select and individually
delete any unused masters, Visio will display a warning if a master is
used in the document.

In Visio 2010 the File tab contains a 'Remove Personal Information'

command button which now provides an alternative for the
HarnWare™ 'Purge Unused Visio Masters' option.
28 User Guide HarnWare™ Version 6.3

NOTE

Use the Visio File>Save menu to save the drawing to disc before
using this option. In the event of a problem occurring this will ensure
a copy of your drawing is safe.

Upgrade Document(s)

Drawings for versions of HarnWare™ up to and including V5.4 used

a different mechanism for the Visio/HarnWare™ interface. The menu
options affected include right-click menus in HarnWare™ document
pages and shapes and shape double-click menus for such options as
"Pop HarnWare™", "Parts List" and "Rotate".

Many users rely upon the HarnWare™ Design Wizard, toolbars, etc
and do not use these Visio right-click and double-click menu options.
However, if you do use these Visio right-click and double-click menu
options you will encounter a warning message advising that you may
wish to upgrade the drawing.

This "Upgrade Document(s)" option in the HarnWare™ file menu

enables all the shapes and pages in selected Visio documents and
stencils to be converted between the before and after HarnWare™
V5.4 standard. Normally the "upgrade" option will be selected, but if
you need to share drawings with someone still using an early version
of HarnWare™ up to and including V5.4, the "downgrade" option
should be selected.

HarnWare™ opens and processes each selected Visio document, but

does not save the changed document thus providing you with the
option to accept or reject the changes made to each document.

When downgrading a V6 drawing the shell size for any D-Connectors

are changed to the number of contacts which was the format used
prior to HarnWare™ V6.
© TE Connectivity Menus 29

Exit

Use this option to exit from HarnWare™. As with most programs that
run under Microsoft Windows, <ALT>+F4 or double clicking the
application control menu can also be used to exit from the system.

After exiting HarnWare™, Visio will remain running and can

continue to be used. If you wish to restart HarnWare™:

 click HarnWare™ in your Windows Start Menu, or;

 use the Visio Tools>Run Add-On menu.

Edit Menu
The edit menu contains these options:

Menu Option Short-Cut Key

Copy Part Data

Paste Part Data

View Part Data

Previous Shape <Ctrl>+P

Next Shape <Ctrl>+N

Find Shape <Ctrl>+F

Rotate Shapes <Ctrl>+R

Copy, Paste and View Part Data

These options are mainly used when a number of wires are identical,
except for colour, or when two harness legs with identical braid and
tube are required either side of a feedthrough. Alternatively the copy
and view options can provide a simple notepad or reminder of options
selected for a previously specified part.
30 User Guide HarnWare™ Version 6.3
With any HarnWare™ part form active you can use the copy option to
make a temporary copy of the part numbers, diameters, material
options, etc. contained in the form. Individual items of data can be
copied from the view part data form by dragging the mouse over the
text to highlight it and then using the normal Windows <Ctrl>+C key
combination to copy the text to the Windows clipboard. This text can
then be pasted using <Ctrl>+V.

For further details refer to the section entitled Miscellaneous Options

or the online help system.

The product information command button in the View Part Data form
allows you to access more information on the relevant TE products
and materials.

NOTE

The paste option should be used with care as it overwrites diameters,

part numbers, material options etc. Before using this option it is
advisable to use the view part data option and study the temporary
data alongside the current form to see if you really do want to change
all the data.

Find Shape

The find shape option can be initiated using the toolbar icon,
the edit menu or <Ctrl>+F.

This option tries to find a shape associated with the current

HarnWare™ form. If a shape is found, it is selected in Visio.

Next / Previous Shape

These options and toolbar icons change the selected

shape in Visio and perform an Open Shape
operation. If a harness part form is active the drawing is searched for
shapes of the same class, i.e. moulded part, adaptor, etc. If not, the
drawing is searched for the next HarnWare™ shape of any class.
© TE Connectivity Menus 31
The <Ctrl>+N and <Ctrl>+P short-cut keys are provided as
alternatives to using the toolbar or menu.

Rotate/Group Shapes

This option can be initiated using:

 The toolbar icon.

 The HarnWare™ Edit, Rotate menu option.

 The <Ctrl>+R short-cut key combination.

 Right clicking a HarnWare™ shape in Visio and selecting the

rotate menu option.

The rotate form provides two options: rotate and group glued shapes:

 Rotate: The selected shapes in Visio are rotated clockwise or anti-

clockwise by the angle you enter.

 Group: All shapes that are glued to the selected shapes, including
any associated balloons that were added by the parts lister are
grouped. This is useful when a harness leg formed by several
components needs to be moved.

For further details refer to the section entitled Miscellaneous Options

or to the online help system.

Tools Menu
The tools menu contains these options:
32 User Guide HarnWare™ Version 6.3

Menu Option Short-Cut Key

Design Wizard

Database Search <Ctrl>+D

Wiring
Schematic/Schedule

Wire Route <Ctrl>+W

Multi-Core Cable

Parts List <Ctrl>+L

Composite Parts List

Marker Page & Data

Export

Check Design

Compare Designs

Labour Estimate <Ctrl>+E

CoP, Materials & <Ctrl>+T

Equipment

RoHS

RELIABILITY
GUIDE Estimate

Weight

HarnVis <Ctrl>+H

Drawing Translator

Create shape

Calculator <Ctrl>+K
© TE Connectivity Menus 33
34 User Guide HarnWare™ Version 6.3

Design Wizard

The Design Wizard is initiated using the Tools menu option or

the toolbar icon. The wizard can:

 Lead you through the harness design process. You can quickly
step through the list of operations and part selections to produce a
design. The steps listed by the wizard can also be repeated or done
in almost any order when, for example, there are alternative design
solutions to investigate.

 Provide quick access to information stored with each shape and

show connections. When the mouse is moved over the wizard list,
HarnWare™ displays details on the shape and any connections.
This is useful for gaining a quick understanding of an existing
design. The information displayed on the right of the design
wizard form contain hyperlinks to product information in the
online help system. Product information links also provide access
more information on relevant TE products and materials.

For further details refer to the subsequent section entitled Design

Wizard or to the online help system.

Database Search

If a harness part form is active, the HarnWare™ database is searched

for parts that meet the specified design criteria. Different methods are
used for the various classes of harness parts, for example:

Adaptors
Braid and Tube
Conduit
Connectors and Splices
Databus
Feedthroughs
KTKKs
Markers
Moulded Parts
Wire
© TE Connectivity Menus 35
The first part shown is normally the one best suited to the particular
situation. The next, previous, first and last database record toolbar
icons allow you to view any other parts in the database that meet the
specified design criteria.

The database search option is initiated

using the Tools menu, the toolbar icons or
<Ctrl>+D.

Wiring Schematic/Schedule

The wiring schedule option automatically generates a wiring schedule

including wire and connector contact details along with marker and
solder sleeve item numbers. This option is normally used toward the
end of the harness design process after a parts list has been generated.

For further details refer to the subsequent section entitled Wiring

Schedule or the online help system.

The wiring schematic option can be initiated from the Design Wizard
or the HarnWare™ Tools menu. It automatically generates a wiring
schematic drawing including connector schematic symbols and lines
for each wire running between the connectors. The drawing is
constructed using groups and glued connections so that it can be
easily rearranged into the required layout. Before using this option
you should:

 Drop connectors into the harness drawing and add connector

references.

 Build the wire list so that the system knows where the wires run
and which are twisted or shielded.

For further details refer to the subsequent section entitled Wiring

Schematic or to the online help system.
36 User Guide HarnWare™ Version 6.3

Wire Route

Use this option to have HarnWare™ trace the routes of wires through
the harness in order to calculate adjusted lengths for each wire and
cable bundle diameters for each harness leg in the harness design.
Before using this option you should:

 Draw the harness ensuring the shapes are properly glued so

HarnWare™ will be able to trace around the connectivity of the
harness.

 Add connector references to the connector shapes and splices.

 Add dimensions to the harness legs.

 Enter the connector from - to references and wire diameters in the

wire list table, using the wire selection option.

The HarnWare™ Tools Menu, Design Wizard or <Ctrl>+W short-cut

key or the Visio HarnWare™ menu or the right-click Visio page
menu can be used to initiate the wire route option. For further details
refer to the subsequent section entitled Wire Routing or to the online
help system.

Multi-Core Cable

Multi-core cables or EPDs (an acronym used in TE to describe multi-

core cables) can be used as an alternative to hand laying wires and
assembling the braid and tube to form the legs in a harness. Multi-core
cables can save time, cost and improve harness quality.

The Multi-Core Cable Analyser can be accessed via the Tools menu
or the Design Wizard. This option analyses all the multi-core cable
configurations that could be used to build the harness and sorts them
into order of estimated assembly time savings. HarnWare™ can then
flag the leg(s) in the harness drawing that will then be defined as
multi-core cables when you select braid and tube for them. For further
details refer to the section entitled Multi-Core Cable Analyser or to
the online help system.
© TE Connectivity Menus 37
The Multi-Core Cable Search option is accessed via the Tools menu
or a command button in the Braid and Tube selection form. This
option is used to search a database for multi-core cables that match a
requirement exactly, or match with spare wires, or have similar
diameter wires or have different wire types. Full details and cross-
section drawings of matching cables can be displayed. When accessed
from the braid and tube form, the quantity and part numbers of the
wires routed through the selected leg are automatically extracted from
the wire list and entered into the multi-core cable search form. For
further details refer to the subsequent section entitled Multi-Core
Cable Search or to the online help system.

The Set Cable Database menu option enables you to switch between
different databases which can be useful when different sets of multi-
core cables are used on different design projects. The default database
is ‘Cable.accdb’. Other alternative cable databases installed by
HarnWare™ include 'StandardCableRange.accdb' and 'VG95218 Part
28.accdb'.

Parts List

The parts list option analyses the drawing and wire list to produce a
sorted and totalized list of parts. The resulting list is displayed in
HarnWare™ and a parts list table is generated in the drawing.
Balloons are also added to drawing shapes to cross-reference them to
the parts list.

This option is initiated via the Design Wizard, Tools menu, <Ctrl>+L,
the right-click drawing page menu in Visio or the HarnWare™ menu
in Visio. For further details refer to the subsequent section entitled
Parts Listing or to the online help system.

Composite Parts List

This option generates a composite parts list for a number of drawings

that have already been parts listed. HarnWare™ searches each
selected drawing for the data contained in the parts list table. If
required, quantities for each drawing and the total number of kits can
be adjusted. This data is then sorted, totalized and the resulting
38 User Guide HarnWare™ Version 6.3
composite parts list is output to the HarnWare™ parts listing form and
to the parts list page in the current drawing.

For further details refer to the subsequent section entitled Parts Listing
or to the online help system.

Marker Page & Data Export

This option can generate:

 A marker sleeve drawing page. This contains the manufacturing

information required for each cable marker used in the harness
design.

 Cable marker text and formatting details in an '.xmt' or COMMS

file that is suitable for import into the TE TMS Total and
WinTotal labelling software.

 Cable marker text in a comma delimited format output to a file or

to the Windows clipboard. This data can be imported into other
labelling software systems.

Further details are contained in the section entitled Marker Page and
Data Export.

Check Design

The Design Checker option is initiated via the Tools menu or the
Design Wizard. The Design Checker compares certain harness design
features against a set of predefined rules and, when necessary,
warnings are output. In addition, some general warnings are always
output.

Where warnings relate to a particular shape, a yellow warning can be

added onto it in the drawing. A table listing the warnings can also be
added to the drawing. All warnings are linked to appropriate topics in
the online help system. Click a message in the form and use
<Shift>+F1 to access the pop help topic. The Visio shapes used to
© TE Connectivity Menus 39
construct the table of warning messages and the yellow warning
shapes also have right-click shape help topics.

For further details refer to the subsequent section entitled 'Design

Checker', 247 or to the online help system.

Compare Designs

This option is initiated from the HarnWare™ Tools menu and is used
to analyse the changes between two HarnWare™ Visio design
documents, typically two different revisions of a harness design or
two similar designs.

Check boxes allow the parts lists, wire lists, cable marker text and
labour estimates to be included or excluded from the design
comparison.

For further details refer to the subsequent section entitled 'Compare

Designs', 303 or to the online help system.

Labour Estimate

The labour estimate option analyses the drawing and wire list to
produce a labour estimate. Summary information is presented in
HarnWare™ and data is added to the Labour Estimate page in Visio.
This page acts as a spread sheet so you can easily amend the times and
quantities in the estimate.

This option is initiated via the HarnWare™ Design Wizard, the Tools
menu, <Ctrl>+E. To initiate the labour estimating option from Visio
use the HarnWare™ menu or the right click page menu option. Until
the time when HarnWare™ starts to add information to the harness
drawing you can press the escape key to interrupt the labour
estimating process.

For further details refer to the subsequent section entitled Labour

Estimating or to the online help system.
40 User Guide HarnWare™ Version 6.3

RELIABILITY ANALYSIS (Is a guide for Mean

Time Between Failures) Estimate

The RELIABILTY ANALYSIS is only a guide and you should refer

to documents such as MIL-HDBK-217F for a more accurate analysis.

The RELIABILITY ANALYSIS assumes a value of 1 for the

following:

 Wire

 Filler

 Marker sleeves

 Tubing

 EPD/Multi-core cables

The RELIABILITY ANALYSIS will simply count the total number

of each of the following types of part in the harness:

 Moulded parts

 Filler plugs

 Solder devices

 Adaptors - Tinel

 Adaptors – Band strap

 Adaptors – Other

 Braid – number of pieces in the harness not length

© TE Connectivity Menus 41
The RELIABILITY ANALYSIS is calculated on the number of
populated contacts, number of active contacts, type of contact (crimp
or solder).

For connections or contacts the calculation is:

 λb (base failure rate) x πQ (quality factor) x πE (environment

factor)

For connectors the calculation is:

λb (base failure rate) x πK (mating/unmating factor) x πP

(active pins factor, also known as the rate multiplier) x πE
(environment factor)

RELIABILITY ANALYSIS values are quoted as failures in Years

The RELIABILITY ANALYSIS is for Guidance ONLY. It is

intended to act as a basis for the user to produce their own
calculations which they should verify as being suitable for their
particular design and service situation.

CoP, Materials & Equipment

This option analyses the drawing and wire list. Codes of Practice,
tooling equipment and assembly materials that are relevant to the parts
contained in the harness design are listed. You can add and delete
from the lists and then output the information to the drawing.

This option is initiated via the Tools menu, <Ctrl>+T or the right-
click drawing page menu in Visio. For further details refer to the
subsequent section entitled CoP, Tooling Equipment & Assembly
Materials or to the online help system.

RoHS

The HarnWare™ Restriction on Hazardous Substances (RoHS)

option analyses the parts referenced in the drawing and wire list. A list
42 User Guide HarnWare™ Version 6.3
of RoHS compliance codes for each part is presented in the
HarnWare™ form and the list may also be added to a page in the
Visio document. This option is accessed via the HarnWare™ Tools
menu.

Where parts are listed as non-RoHS compliant, alternatives are

usually available in the parts listed in the relevant HarnWare™ part
selection form. Alternatively please contact TE Product Management
for more information.

For further details refer to the subsequent section entitled RoHS or to

the online help system.

Weight

The HarnWare™ Tools>Weight menu option provides a means of

estimating the weight of a harness. The accuracy of the estimate is
constrained by a number of factors including the availability of
component weight data. Where component weight data is not
available, especially in the case of connectors, you can enter the
relevant data and a user weight database is provided for you to store
weights of frequently used part numbers.

This option analyses the current HarnWare™ Visio document in a

similar manner to that used for the parts listing process.

Composite Weight

The Composite Weight menu option provides a means of estimating

the total weight of a number of harnesses. For further details refer to
the subsequent section entitled Weight Estimator or to the online help
system.

HarnVis

HarnVis is a 3D harness design visualisation system. This option is

available for a small charge. It can be accessed via the Tools menu,
the <Ctrl>+H short-cut key, the Windows Start Menu or the
© TE Connectivity Menus 43
Visio>Tools>Macro menu (or in Visio 2010 use the add-ons option in
the View tab).

Using HarnVis, to-scale 3D models of a HarnWare™ wiring harness

design can be automatically generated and viewed from any angle.
Views are rendered in colour with lighting effects. These 3D models
provide "virtual prototypes" of harnesses allowing the user to see
what a harness will look like with lengths, diameters and parts shown
to-scale. By simply clicking on a part, the user can access such data as
part numbers, materials, finishes, adhesives, etc. For further details
refer to the section entitled HarnVis or to the HarnVis online help
system.

Drawing Translator

The translator searches through selected pages in Visio documents for

recognised harness design phrases. These phrases are replaced with
translations for the selected language. The translation process is
phrase, rather than word, based in order to achieve better grammatical
results.

Options are provided for adding and editing the phrases and
translations stored in the HarnWare™ translator database. The
translator can handle languages that include extended character sets,
for example, Korean and Japanese. Extra languages can be added
simply by inserting a new field in the database and loading it with
translations for each of the stored English phrases. For further details
refer to the subsequent section entitled Drawing Translator or to the
online help system.

Create Shape

The create shape menu option assists with certain aspects of creating
your own shapes for use with HarnWare™. For further details refer to
the subsequent section entitled Create Shape or to the online help
system.
44 User Guide HarnWare™ Version 6.3

Calculator

This menu option or the <Ctrl>+K short-cut key starts or activates the
Microsoft Windows Calculator applet. This can be a useful alternative
to a normal desktop calculator.

Options Menu
This menu contains options for:

 Choosing whether balloons should be added for wires in each

harness leg.

 Choosing whether cable cross-section drawings should be

numbered with item or wire list numbers or have no labels.

 Retain Item Number Dialog.

 Setting the units of measure.

 Selecting the harness material system and selecting whether

material systems 30 and 7xx should be included in the list of
available systems.

 Turning tool tips on or off.

 Choosing whether the HarnWare™ window should always be on

top.

 Selecting the TE plant in the UK or USA as the supplier for wire

and Band Strap adaptors.

 Master database folder to enable users to share certain databases

stored on a network disc drive.

 Visio file paths.

© TE Connectivity Menus 45
The options you choose from this menu are saved on disc and remain
set until you change them. Most of these options can also be set using
the Set Properties form which is accessed from the Design Wizard.

Balloon Wires

If the ‘balloon wires’ option is selected, parts listing will add balloons
for each different wire part number in each harness leg. In the case of
link wires, balloons are added to the connector shape.

When a harness contains many different wires, choosing this option

may result in too many balloons.

Cable Cross-Section Labels

If the item numbers option is selected, both wire and filler in cable
cross-section drawings will be numbered by the parts lister. If the wire
list option is selected, wires will be numbered with their number in the
wire list. Alternatively use the 'None' option if you do not wish cable
cross-section drawings to be labelled.

Retain Item Number Dialog

If the 'Retain Item Number Dialog' option is selected, each time the
parts lister is used you will be offered the option of having new item
numbers assigned or retaining the existing item numbers. If you do
not need to use this option deselect this menu item.

Units of Measure

Either inch or mm can be selected as the units of measure. Generally,

mm are output to two, and inches to three decimal places. Larger
dimensions, e.g. wire lengths, are output in metres or feet.

When you change the units of measure, any forms that are open in
HarnWare™ are closed. This ensures the dimension text boxes and
labels are reloaded.
46 User Guide HarnWare™ Version 6.3
The drawings installed in the HarnWare™ SAMPLE folder are metric
drawings.

The currently selected units of measure is displayed in the

HarnWare™ status bar.

NOTE

You must not mix inch and metric units in the same drawing. You
should select inch or metric units before starting work on a harness
design.

Display Options

As you move the mouse over command buttons and text boxes, a
short description of the control is output in a small yellow tool tip. If
you find these tool tips distracting use this menu to turn tool tips off.
Changes to this option will be applied the next time HarnWare™ is
started.

If you choose the always on top option, the HarnWare™ form will
always appear on top of all others, including Visio. This option is
most suitable if you are working on a large screen running at a high
resolution. Dialog forms always stay on top to prevent them being
hidden behind Visio or the main HarnWare™ form. The F8 function
key can be used to arrange all open dialog forms and the main
HarnWare™ form.

Material Systems

Harness Material Systems 10, 20, 25, 30, 100, 200, 300, 770, 780 or
790 can be selected from the options menu. This controls the
materials, finishes and adhesives that are offered as the preferred
choices when selecting parts. For example, if Material System 25 is
selected, the moulded part form will list -25 material and /225 and
S1125 adhesives. These are the preferred choices for Material System
25, although HarnWare™ will not stop you selecting non-standard
materials if you wish.
© TE Connectivity Menus 47
The options menu also allows you to select whether material systems
30 and 7xx should be included in the list of available systems.

Use the Advice option if you would like help from HarnWare™ to
select the most suitable material system. Also, the online Harness
Design Help System contains further guidance on material systems
and the factors you should consider when selecting parts, materials,
adhesives, etc.

The currently selected harness material system is displayed in the

HarnWare™ Status bar. The Material Advice form can also be
accessed by clicking this part of the status bar.

When a list or combo-box containing such information as part style,

materials, finishes or adhesives has focus, use <Shift>+F1 to obtain
help on the item selected in the list. The text contained in these pop-
help items can be copied to the Windows clipboard using <Ctrl>+C.
This text can then be pasted into your harness drawing using the Visio
paste command.

For further details refer to the section entitled 'Material Systems

Advice', 81 or to the online help system.

NOTE

When you change the selected material system, any open forms in
HarnWare™ are closed. This ensures each material, finish and
adhesive coating combo-box is reloaded with options that are valid for
the newly selected material system.

Wire and Band Strap Adaptor Source

TE manufacture TE wire both in the UK and USA The two plants

have different policies controlling the particular wires and colours that
are kept in stock or that are made-to-order. When using the colour
advice command in the wire form or saving data to the wire list, the
selected wire part number is checked against the stocking policy for
the UK or USA plant which is held in the HarnWare™ database.
48 User Guide HarnWare™ Version 6.3
A similar option is provided to set the Band Strap adaptor source to
the UK or USA.

Master Database Folder

Normally HarnWare™ uses the database files that are saved in the
installation folder. However, those databases which can be modified
maybe held on a shared network disc drive to help distribute changes
and ensure all users are using the same data. When a folder other than
the installation folder is specified, on start-up HarnWare™ checks the
specified folder for:

 Translat.accdb drawing language translator database.

 User Parts Database.accdb and, if this database file exists, all the
other files in the User Parts Library folder. Note: The shared folder
must include a User Parts Library\User Parts Database.accdb

 Weight.accdb estimated weights for parts not held in the main

HarnWare™ database.

If the specified master database folder contains one of the above files

and if it is different to that which already exists in the user's

application folder, then the file is copied into the user's application
folder. Up to 10 backup copies of previous file versions are
maintained to help guard against loss of information.

Changes to these master database folder settings will be applied the

next time HarnWare™ is started.

When the Translat or Weight databases in a master database folder are

used, the options to delete or update records in these databases are
disabled.

Visio File Paths

During the installation process, extra file paths are added to Visio. If
the HarnWare™ path settings are not included the HarnWare™
© TE Connectivity Menus 49
stencils and templates won't appear in the Visio File Open list and
double-clicking or right-clicking a HarnWare™ shape in Visio will
not 'open' the shape in HarnWare™.

Window Menu
The window menu is similar to that provided in many programs that
run under Microsoft Windows like Word and Visio. However, in
HarnWare™ different forms are used for the various classes of
component and operations. The forms used to help search and select
the different classes of component are grouped under the
Window>Parts sub-menu:

 Adaptor

 Braid and Tube. This form allows you to select braid and tube for
a harness leg. It also provides access to the cable lay design and
filler selection option.

 Conduit. Calls up form for selecting conduit and conduit

transitions.

 Connector. This form allows you to select connectors, splices and

combined connector/adaptors. It also provides access to the form
used for selecting solder sleeves, wire markers, contacts, insulation
caps and insulation sleeves used on wire ends.

 Databus. This form is used for selecting databus couplers, cable,

connectors, contacts, etc. Databus design is a separate option
within HarnWare™. This option is only available to those who
have attended the 1-day specialist databus harness design training
course.

 Feedthrough.

 KTKK. These are adaptor/boot assemblies.

50 User Guide HarnWare™ Version 6.3

 Marker Sleeves. This form helps with the selection of cable

markers and protection sleeves and with the layout of marker
sleeve text.

 Moulded part. This form allows you to select boots and transitions.
When required, packing can also be selected to improve the degree
of fit. It also provides access to the form used for selecting solder
and protection sleeves required for braid termination.

 User Balloon and Parts Library. This form is for adding data into
user parts list balloons, rather than those added automatically by
the parts lister. It also gives access to the User Parts Library.

 Wire. This form helps with the selection of wires and fibre optic
cables and setting up the wire list. It also provides access to the
form used to advise on wire gauges.

The following forms are those used for HarnWare™ operations:

 Design wizard

 Design checker

 Wire route

 Parts list. The form used for parts lists and composite parts lists.

 Labour estimate

 Codes of Practice (CoP), tooling equipment and assembly

materials.

 RoHS The form used to list Restriction on Hazardous Substances

(RoHS) codes.

 Weight. The form used for harness weight estimates.

If a form has previously been used, a check mark is added to the

Window menu. Clicking the menu will maximise the form to show the
© TE Connectivity Menus 51
previous data. If the form is a part selection form linked to a drawing
shape, the link will still be valid.

If the form is not checked in the Window menu, the option will
display a new blank form. If the form is one used for part selection,
the form will not be linked with any drawing shape. This is useful if
you wish to search for a part independently of any shape in the Visio
drawing. If you then select a part and use Save Shape HarnWare™
will offer the option of dropping a new shape at the lower left corner
of the drawing.

Forms can be minimised. Unless you need to use a form again, it may
be better to close the form after use. Double-click the form control
box or use <Ctrl>+F4 to close a form. HarnWare™ will warn you if
the form contains information that has not been saved to the drawing.

Clicking an option in the design wizard or using Open Shape or

double-clicking a shape in Visio, or choosing the HarnWare™ option
from the right click menu, automatically pops up HarnWare™ and
opens the appropriate form for the type of part. The Tools menu
options automatically open the appropriate form and initiate the
required operation. Therefore, in most circumstances there is no need
to use the window menu.

The following options help arrange forms and icons:

 Close all forms.

 Cascade. Provides a cascaded display of all open forms

 Tile. Arranges all open forms in a tiled display

 Arrange icons. Tidies up icons of any minimised forms

When a dialog form is open the F8 function key can be used to move
all other dialog forms and the main HarnWare™ form to the same
position.
52 User Guide HarnWare™ Version 6.3

Help Menu
This menu provides access to the HarnWare™ help system and
contains the following options:

 Contents: Accesses the help topics dialog which lists the contents
and key word index.

 System: Describes how to use HarnWare™.

 Harness Design: Harness design advice and data.

 Shielding: A guide for harness designers who are required to

achieve a level of EMI control in their designs.

 Support Contacts: Contacts for HarnWare™ system and TE

product support.

 Product Information. Details of TE harnessing products and

materials can be listed in full. Alternatively, the products and
materials that are relevant for the selected HarnWare™ shape can
be listed.

 Glossary: Definitions of system and harness design terms.

 Product Catalogue: This lists the sections in the TE Wire and

Cable, Harnessing and Protection Products catalogue. This and the
TE Adhesives Selection Guide are installed with HarnWare™ in
the form of Adobe Acrobat pdf files. To view these files you will
need a copy of the Adobe Acrobat Reader installed on your
computer.

 How to use help: Details on how to use Microsoft Windows help

systems.

 About: HarnWare™ copyright and system release details.

© TE Connectivity Menus 53

Context sensitive help can be obtained by pressing the F1 function

key. This will display the help topic that is most relevant to your
current task.

When a list or combo-box containing such information as materials,

finishes or adhesives has focus, you can hold the shift key down and
press the F1 key (<Shift>+F1) to obtain help on the item selected in
the list.
© TE Connectivity Toolbar 55

Toolbar

The HarnWare™ Toolbar provides access to the options outlined in

the following sections. As you move the mouse over the toolbar icons,
the icon is highlighted, and a short description of the tool is output in
a yellow tool tip.

Design Wizard
The Design Wizard is initiated using the Tools menu or the
toolbar icon. The wizard can:

 Lead you through the HarnWare™ harness design process. You

can quickly step through the list of operations and part selections
to produce a completed design. The steps listed by the wizard can
be repeated or used in almost any order when, for example, there
are alternative design solutions to investigate.

 Provide quick access to the information stored with each shape

and show how they are connected. When the mouse is moved over
the wizard list, HarnWare™ displays details on the shape and any
connections. This is useful for gaining a quick understanding of an
existing design. The information displayed on the right of the
design wizard form contains hyperlinks to product information in
the online help system. Product information links also provide
access more information on relevant TE products and materials.

If the Design Wizard form has not previously been opened the wizard
toolbar icon opens the form, analyses the drawing and sets up the
56 User Guide HarnWare™ Version 6.3
Design Wizard. If the form is open but is not currently maximised, the
toolbar icon maximises the form. If the form is already maximised, the
toolbar icon reanalyses the drawing for the Design Wizard.

For further details refer to the section entitled Design Wizard or to the
online help system.

Open Shape
This option can be selected from the toolbar, file menu or <Ctrl>+O.
Data from the shape selected in Visio is extracted and entered in the
form for the appropriate class of part. For further details, refer to the
Open Shape or to the online help system.

Save Shape
This option can be selected from the toolbar, file menu or
<Ctrl>+S. Part number and dimensional data contained in
the current form are saved into the appropriate shape in the Visio
drawing. For further details, refer to the Save Shape section or to the
online help system.

Next / Previous Shape

The toolbar icons either side of the find shape icon,
change the selected shape in Visio. If a harness part
form is active the drawing is searched for shapes of the same class,
e.g. moulded part, adaptor, etc. For further details, refer to the Next /
Previous Shape or to the online help system.

Find Shape
The find shape option can be initiated using the toolbar icon,
the edit menu or <Ctrl>+F. This option tries to find a shape
associated with the current form. If a shape is found, it is selected in
Visio. For further details, refer to the Find Shape section or to the
online help system.
© TE Connectivity Toolbar 57

Rotate or Group Shapes

The rotate or group shapes option can be initiated using the
toolbar icon, the edit menu or <Ctrl>+R. The selected shapes
in Visio are rotated clockwise or anti-clockwise by the angle you
enter. An option to group shapes is also provided.

For further details refer to the section entitled Rotate and Group
Shapes or to the online help system.

Database Search
If a harness part form is active, the
database is searched for parts that meet the
specified design criteria. Different methods are used for the various
classes of harness parts:

Adaptor
Braid and Tube
Cable Marker
Conduit
Connector
Databus
Feedthrough
KTKK
Moulded Part
Wire

This option can also be initiated using the tools menu or the <Ctrl>+D
short-cut key.

The next, previous, first and last toolbar icons allow you to view
database records for all parts that meet the design criteria specified in
the current form. If you haven’t used the database search option
before clicking one of these icons, the database search option is
automatically invoked.
58 User Guide HarnWare™ Version 6.3

HarnWare™ Help
The help toolbar icon provides a convenient one-click method
of accessing the HarnWare™ help system.

EMI Shielding Advice

This toolbar icon provides access to the Shielding topics in the
HarnWare™ Help System. This provides guidance for harness
designers who are required to achieve a level of EMI control in their
designs. It is not intended that it should be a definitive statement on all
aspects of EMI control for harnesses. In case of difficulty please
contact TE HarnWare™ system support for further clarification or
consultancy, contact details are contained in Appendix A

TE Product Catalogue
This toolbar dropdown list provides links to sections in the TE
Wire and Cable, Harnessing and Protection Products catalogue. This
and the TE Adhesives Selection Guide are installed with HarnWare™
in the form of Adobe Acrobat pdf files. To view these files you will
need a copy of the Adobe Acrobat Reader installed on your computer.
© TE Connectivity Short-Cut Keys 59

Short-Cut Keys
Short-cut keys are a quick alternative using the HarnWare™ menu or
toolbar: whenever HarnWare™ is the active application program.
Short-Cut Key Menu / Toolbar Option
<Ctrl>+C Copy Text
<Ctrl>+D Query Database
<Ctrl>+E Labour Estimate
<Ctrl>+F Find Shape
<Ctrl>+H Start/Switch to HarnVis
<Ctrl>+K Calculator
<Ctrl>+L Parts List
<Ctrl>+N Next Shape
<Ctrl>+O Open Shape
<Ctrl>+P Previous Shape
<Ctrl>+R Rotate Shape
<Ctrl>+S Save Shape
<Ctrl>+T CoP, Tooling Equipment and
Assembly Materials
<Ctrl>+V Paste Text
<Ctrl>+W Wire Route
F1 Context Sensitive Help
<Shift>+F1 Material, product, finish and
adhesive combo-box help
F8 Arrange dialog & main forms
<Ctrl>+F4 Close form
ALT F4 Exit
60 User Guide HarnWare™ Version 6.3
Short-cut keys for your particular version of Visio are listed in the
Visio on-line help system. NB Some short-cut keys changed in Visio
2010.
© TE Connectivity Drawing Hints & Tips 61

Drawing Hints & Tips

The following paragraphs detail some hints and tips that are
particularly relevant to HarnWare™.

Drawing Pages
The metric and imperial HarnWare™ templates contain four pages
that are used in any new document based on them:

Harness Drawing
Parts List 1
Wire List 1
Labour Estimate

Separate templates are used for Databus, HexaShield and Conduit

harness designs.

When using options such as the CoP, tooling equipment and assembly
materials option, HarnWare™ adds pages to the Visio document.

Many HarnWare™ options including wire routing and parts listing

expect the drawing to be contained in the page named ‘Harness
Drawing’ and the wire list to be contained in pages with names
including the words ‘Wire List’, e.g. 'Wire List' 'Wire List 1' and
'Wire List 2'. Any parts included in pages named other than 'Harness
Drawing' will not, for example, be included in a parts list.

The 'Add Wire' option in the Design Wizard automatically names

pages 'Wire List 1', 'Wire List 2', etc. When the standard borders from
the HarnWare™ stencils or templates are used, parts and wire lists
and wiring schedules are automatically generated to fit on one or more
pages. Named connection points in the border shapes are used to
control the start and end points in each page.
62 User Guide HarnWare™ Version 6.3
The labour estimate page uses about 40 kbytes of disc space. If your
design does not need a labour estimate you can delete this page.

HarnWare™ documents include pages of varying sizes and

orientations. Use the HarnWare™ File>Print Document menu option
rather than printing each different page layout individually in Visio.
Use the Visio File>Page Setup>Print Setup menu option to set
parameters other than orientation prior to using this print option.

Glue
Many HarnWare™ functions check for glue between shapes to find
connected and related parts. For example, the wire routing option will
not be able to route wires between connectors if any of the shapes in
the path are not glued.

Do not glue more than one harness leg to the same point such as a
moulded part opening. If you do, the wire routing option may generate
incorrect wire lengths and the component selection systems may not
retrieve the correct leg diameters.
© TE Connectivity Drawing Hints & Tips 63

NOTE

To unglue shapes you must move the shapes in the reverse order to
which they were glued. The order can be established by selecting each
shape with the Visio rotate tool. The shape to move is the one with the
glue shown in red. If you move the other shape you will distort the
drawing. An alternative is to cut and paste the shape back into the
drawing using the standard <Ctrl>+X and <Ctrl>+V Windows short-
cut keys.

Because of the way in which HarnWare™ shapes are set up, it is

usually best in the Visio 'Tools Snap and Glue' dialog box to have:

 Glue to connection points and no other options checked

 Snap to connection points and to grid options checked

 Connection point strength set at a higher value than the other

settings
64 User Guide HarnWare™ Version 6.3

Harness Legs
The kinked leg shapes in the
miscellaneous stencil can provide a
quicker way of drawing harnesses than
rotating legs and parts to transition
angles. The right-click menu for the
kinked legs include standard transition angles and options to
increment the current angle by +/- 7.5°. The end points of the leg
maybe moved to change the relative lengths of the angled and the
horizontal or vertical lines.

The Visio page rotation option provides an alternative method of

drawing angled harness legs.

Harness leg shapes comprise a group of two shapes. After adding

dimension text to a leg, and hitting the escape button, you will notice
that the top shape of the group is sub-selected. That is the selection
handles are light green or blue rather than the normal darker colours.
To open a harness leg shape in HarnWare™ the leg must be selected
with the normal darker coloured handles. Click on a blank part of the
drawing and then click the harness leg again to ensure the leg group is
selected.

The straight and kinked harness leg shapes are set up so that the text
box automatically sizes to number of characters in the dimension text.
Also as you rotate or mirror the leg shapes, the text and text box
automatically flip so that the text is readable from the bottom or right
of the drawing.

Leg dimensions should be a single line of text that evaluates to a

numeric value. HarnWare™ will issue a warning if it finds a non-
numeric harness leg dimension. Alternative harness leg shapes with
non-printing dimension text and boxes are included in the
HarnWare™ miscellaneous stencils.
© TE Connectivity Drawing Hints & Tips 65

Moulded Part Stencils

Some moulded part styles are only available in certain materials and
are therefore unsuitable for use with some harness material systems.
To help with the selection of moulded parts, separate moulded part
stencils are provided for each harness material system. These include
only those moulded part styles that are suitable for use with the
particular harness material system. A stencil containing all moulded
part styles is also provided.

Multi-Cable Shapes
Multi-cable shapes allow two or more
harness legs to be associated with one
opening in a moulded part, adaptor, KTKK
or feed-through. The HarnWare™ stencil
contains shapes catering for 2, 3 and 4 legs
to be associated with one opening. If more
than 4 legs are required, glue the multi-
cable shapes end to end.

When a multi-cable shape is used, HarnWare™ searches for the

expected number of harness legs. For example, if a 3-way shape is
used HarnWare™ will search for 3 legs, or multi-cable shapes glued
to the shape. A warning is given if fewer legs are found.

Connector References
Connector references should not contain carriage returns. That are the
references should comprise a single line of text. HarnWare™ will
issue a warning when it finds a connector reference containing a
carriage return.
66 User Guide HarnWare™ Version 6.3

Drawing Borders
HarnWare™ drawing borders automatically centre on the page as they
are dropped. The following texts in drawing borders as supplied with
HarnWare™ are automatically set:

 Creator The name of the user in Visio.

 Title The title given to the file.

 Date The date the file was created.

 Pages The number of pages in the document.

 Date and Time When the file was lasted printed.

 File The Visio VSD filename.

To change the name of the user, use the Visio Options menu:
© TE Connectivity Drawing Hints & Tips 67

We recommend you leave the ‘Prompt for Document Properties on

Save’ checked so you can set the drawing title when saving a new
drawing. To change the title or other properties of an existing file, use
the Visio File>Properties menu.

It is good practice to fully complete these properties as they can help

you locate drawings. The ‘Save Preview Picture’ option is also useful
in this regard. However, when this option is selected drawing files
will be larger and take somewhat longer to save on disc.

A document 'Creating drawing borders in Visio for use with

HarnWare™' is available on request from HarnWare™ system
support. This contains details on how to change the HarnWare™
templates and stencils to suit your own particular requirements.
68 User Guide HarnWare™ Version 6.3

Wire Line and Part Line Shapes

HarnWare™ recognises the data contained in the wire list and parts
list by position and the tabs used to separate each data item. Use the
HarnWare™ wire selection and parts listing systems rather than
editing the wire line or parts list line texts directly. Other information
is stored in the data1 field associated with each line in the wire and
parts lists.

HarnWare™ Shapes
To make HarnWare™ shapes easier to glue and position in harness
drawings, most have been set-up as 1D shapes. That is the Visio
Format>Behaviour menu option (or in Visio 2010 the 'behaviour'
option in the developer tab) has been used to set 1 dimensional, rather
than 2 dimensional, behaviour. In addition most HarnWare™ shapes
are fixed size and do not scale, unlike many of the standard Visio
shapes.

You can set up your own shapes. If you wish HarnWare™ to

recognise your shape in the part selection, wire routing and parts
listing processes you will need to add the correct information to the
data1 field. Drag and drop a HarnWare™ shape and use the Visio
'Format Special' menu option (or in Visio 2010 the 'Shape name'
option in the developer tab) to inspect the data1 field. If you copy and
paste the data1 field into your shape, most of the HarnWare™ options
will recognise your shape. Moulded part transitions are, however,
more complicated to set up because opening names have to be related
to connections—contact HarnWare™ system support for further
advice.

New in HarnWare™ V6 is an option that helps with certain aspects of

creating your own shapes, please refer to the section Create Shape.
© TE Connectivity Drawing Hints & Tips 69

Copying and Pasting Shapes

Part numbers, dimensions, and other data used in the selection of parts
are stored in the shape's data1 field or custom properties. If a number
of shapes or balloons relate to the same part number, you may find it
quicker to add one shape to your harness drawing and use the
HarnWare™ selection option for that shape. Then, after saving the
HarnWare™ data to the shape, copy and paste the shape in Visio. The
parts lister will accumulate the total number of parts in the drawing.

If the wire router has already been used on a drawing, always rerun
the router after copying and pasting a harness leg, or changing a
connector reference or changing the wire list. The wire router stores
wire list numbers with the harness leg shapes and options such as the
parts lister need this information to be consistent with that contained
in the wire list.

Drawing Layers
HarnWare™ shapes are usually added to special drawing layers. For
example, moulded part and adaptor. With the Visio View>Layer
Properties menu option (or in the Visio 2010 home tab the
Layers>Layer Properties option) you can selectively turn layers on
and off and you can change the colour of all shapes on selected layers.
By clicking the column headed with a # sign you can also find the
numbers of shapes on each of the layers.

Layers that are locked or invisible can prevent some HarnWare™

options from functioning. For example, the parts lister may not be
able to finish if the Part Line or Warning layers are locked or
invisible.

You can use the Visio Edit>Select Special menu (or in the Visio 2010
home tab the Select>Select by Type option) to select all HarnWare™
warnings and delete them in a single operation.
70 User Guide HarnWare™ Version 6.3

Drawing Files
The Visio file preview option is a useful feature when searching
through a number of drawings. However, using the Save File Preview
option in Visio uses more disc space and makes file saving slower.

Meaningful directory or folder and file names may help avoid the
need to save file previews. By default drawings will be saved in your
‘My Documents’ folder. You should create sub-folders to sub-divide
your drawings into logical groupings such as projects or customers.

Document Stencil
When you drag and drop a shape into a Visio drawing, a copy of the
master is added to the document stencil. Even if you later delete the
shape, the master will remain in the document stencil, increasing the
file size.

Use the Visio Window>Show Document Stencil option (or in Visio

2010 the More Shapes>Show Document Stencil option) to view the
masters. You can select and delete any unused masters, Visio will
display a warning if a master is used in the document. A quicker
alternative is to use the HarnWare™ File>Purge Unused Visio
Masters option or, in Visio 2010, the File tab>Info>Remove Personal
Information command.

The document stencil window is also useful if you want to apply

formatting to all instances of a given shape in the drawing. For
example, you may wish to use a heavier line style to emphasise a
certain style of moulded part used in your harness design.

Cable Marker Shapes

Some cable marker sleeve shapes have a control handle to set the
position of the text label. The text box automatically sizes to fit the
text you enter.
© TE Connectivity Drawing Hints & Tips 71
The end points are set outside the marker sleeve shape and should be
glued to a moulded part connection point when dropping the marker
sleeve. This ensures the shape is located accurately on the leg. The
shape can be rotated and then the position control handle can be used
to slide the shape up and down the leg.

Keyway Shape
A keyway shape is included in the two
miscellaneous stencils. The keyway angle is set by
double-clicking or right-clicking the shape to
access the angle property.

The HarnWare™ Connector selection form also

has an option for adding keyway shapes to the drawing. If the selected
connector has anti-rotation teeth and a particular angle of orientation
relative to the master keyway is required for angled adaptors, the
keyway command button automatically calculates the achievable
angles.
© TE Connectivity Design Wizard 73

Design Wizard
Overview
The wizard can:

 Lead you through the HarnWare™ harness design process. You

can quickly step through the list of operations and part selections
to produce a completed design. The steps listed by the wizard can
also be repeated or done in almost any order when, for example,
there are alternative design solutions to investigate.

 Provide quick access to the information stored with each shape

and show how they are connected. When the mouse is moved over
the wizard list, HarnWare™ displays details on the shape and any
connections. This is especially useful as a means of gaining a
quick understanding of an existing design. The information
displayed on the right of the design wizard form contains
hyperlinks to product information in this help system. Product
information links also provide access more information on
relevant TE products and materials.

Method of Use
Having produced all or part of a harness design drawing, use
the toolbar icon or the HarnWare™ tools menu option to
initiate the wizard. The drawing is analysed and the shapes and design
operations are sorted into the normal design sequence:

 Analyse drawing

 Set properties

 Add wires
74 User Guide HarnWare™ Version 6.3

 Databus parts

 Wires

 Wiring Schematic

 Wire route. This option is not included if there is no wire list in the
drawing, as would be the case for a Databus harness.

 Multi-core cable analyser

 Harness legs

 Connectors. After each connector is placed the associated adaptor,

boot or KTKK.

 Any remaining adaptors, KTKK's and moulded parts that are not
glued to a connector.

 Feedthroughs

 Conduit and conduit transitions

 Cable markers

 User balloons and user part library parts

 Design Checker

 Parts list

 Labour estimate

 Marker page
© TE Connectivity Design Wizard 75

The list produced by the wizard contains icons to indicate the type of
part or operation and texts giving the operation name, style of part,
part number, connector reference or harness leg length. As you move
the mouse over the list, more details and a picture of the particular
style of part is output. A black arrow to the left of the icon indicates
the item to which the descriptive detail relates. If the description is too
long for the space in the form, a vertical scroll bar is enabled. The
black lines, also drawn to the left of the icons, show connections
between the shapes. If you need to scroll the display to view other
parts linked by the connection line, move the mouse horizontally off
the list, so that the black arrow remains on the same item, then use the
scroll bar. The design wizard form can be maximised in order to view
more information thus reducing the need to scroll through the list of
operations and parts.

When you click an item in the list, the text is highlighted with a green
box:
76 User Guide HarnWare™ Version 6.3

 If the item is an operation, for example parts listing, HarnWare™

starts the operation. When it is complete, close the form, use the
design wizard toolbar icon or the window menu to return to the
design wizard form.

 If the item is a part, HarnWare™ turns to the required page in

Visio, selects the shape, opens the appropriate part selection form
and loads it with the part data. After choosing the best part and
saving the data to the drawing, the wizard form is automatically
brought up. Alternatively you can close the part form, use the
design wizard toolbar icon or the window menu to return to the
wizard.

Clicking a user parts list balloon item works in the same

manner as for other HarnWare™ parts. Balloons added by
the parts lister are not included by the wizard; only balloons
that were added by the user or have since had a part number
added by the user are listed by the wizard.

Clicking the 'Set Properties' item displays a form used to set various
design properties. If either the material system or units of
measurement are changed, any open part selection forms are closed so
that they are not left with invalid data.

The 'Add Wires' option allows you to add or delete lines from the wire
list table in the drawing.

The text remains highlighted with the green box to show which
operation or part was clicked last. The details displayed alongside the
highlighted item when the mouse is moved over it are updated.

Click the 'Analyse Drawing' operation after adding, deleting or

moving shapes in the Visio drawing or after changing any
HarnWare™ Option menu settings. This will update the wizard list
and the information associated with each item in the list.

Operations such as the Multi-Core Cable (EPD) Analyser, Wiring

Schematic, Wire Router, Design Checker, Parts Lister and Labour
Estimator lines, only have information associated with them after you
© TE Connectivity Design Wizard 77

have used the operation. This information is cleared by 'Analyse

Drawing'. The Multi-Core Cable (EPD) Analyser, Wiring Schematic
and Wire Router options are not included if there is no wire list in the
drawing, as would be the case for a Databus harness.

Toolbar Icon
If the Design Wizard form has not previously been opened the
Design Wizard toolbar icon opens the form, analyses the
drawing and sets up the Design Wizard. If the form is open but is not
currently maximised, the toolbar icon maximises the form. If the form
is already maximised, the toolbar icon reanalyses the drawing for the
Design Wizard.

Set Properties
This option, selected by clicking the 'Set Properties' item in
the Design Wizard, is used to set:

 The material system.

 Whether systems 30 and 7xx should be listed in the available

harness material systems.

 Units of measure.

 Whether repair loop allowances are to be included in wire and

braid lengths by the router and parts lister.

 Whether item numbers or wire list numbers are added to cable

cross-section drawings by the parts lister.

 Whether balloons are to be added for wires in harness legs by the

parts lister.
78 User Guide HarnWare™ Version 6.3

If either the material system or units of measurement are changed, any

open forms are closed so that they are not left with invalid data.

Use the Material Systems Advise command button if you would like
help from HarnWare™ to select the most suitable material system.

The Drawing Properties button enables any custom properties in the

drawing border shape within the "Harness Drawing" page to be
queried and edited. Any edits are also applied to all other drawing
border shapes found in any page in the document.
© TE Connectivity Design Wizard 79

Add/Delete Wires
This option is selected by clicking the 'Add/Delete Wires'
item in the Design Wizard and allows you to add or delete
lines from the drawing wire list table.

You are prompted to enter the number of wires to add or delete, enter
a negative number to delete wires. If you enter a negative number
HarnWare™ asks you to confirm that you do actually wish to remove
lines from the wire list table in the drawing. Provided not too many
wire lines were deleted, you can use the Visio>Edit>Undo option to
reverse the action. You will need to use the design wizard to reanalyse
the drawing after changing the wire list in Visio.

Wire lists are created using the wire list line shape from one of the
two miscellaneous stencils. If one or more wire list lines are found in
the set of pages for the active Visio document, the line at the lowest y
co-ordinate is used to position further lines when required. If no wire
lines are found in the drawing, HarnWare™ adds a new page named
'Wire List 1'. If the wire list border from the HarnWare™ Metric or
Imperial stencils or the standard HarnWare™ templates is used,
HarnWare™ will automatically start a new page, named 'Wire List 2',
when the first page is full. The start and end positions for wire lists are
indicated by named connection points in the wire list border shapes.

If you need to delete a Specific wire line, go to the Wire List page in
Visio, Select the Wire Line to be deleted then use the Delete Button
to delete this line. Remember to run the Design Wizard to update
HarnWare™.
© TE Connectivity Material Systems Advice 81

Material Systems Advice

This option is accessed from the HarnWare™ Options menu or from
the Set Properties form used in the Design Wizard or by clicking the
harness material system displayed in the HarnWare™ status bar.

By choosing the harness application, maximum and minimum

operating temperatures, exposure to fluids and DEF, Mil or VG
standards, HarnWare™ will suggest the harness material system(s)
that may be suitable. As each design requirement is selected, a brief
description is output and the list of applicable harness material
systems is adjusted.

Unlike the other list and combo-boxes where only one selection is
allowed, none, one or more standards can be selected in the Standards
list box. Use the standard Windows click, control and shift key
combinations to select multiple items in the Standards list box. If you
82 User Guide HarnWare™ Version 6.3
select 'None', the first item in the list, all the other standards will be
deselected.

When one of the list or combo-boxes has focus, with the shift key
held down, press the F1 key (<Shift>+F1) to obtain help on the item
selected in the list.

If two conflicting requirements are selected, the applicable harness

material systems list will contain 'None Suitable'. For example, if the
application is set to 'Fire' and the temperature is set to 200°C, no
suitable harness material system is available for this combination of
requirements. When 'None Suitable' appears try reducing one of the
criteria or deselecting one or more standards by clicking with the
control key held down.

If the system 30 and 7xx options are checked in the Options menu,
they will be included in the list of alternative harness material
systems.

Click your preferred harness material system and then click OK to

select it. If 'None Suitable' is displayed in the Applicable Harness
Material Systems list box, clicking OK will simply leave the selected
© TE Connectivity Material Systems Advice 83
material system at its previous setting. The selected material system is
displayed in the status bar.
© TE Connectivity Product Information 85

Product Information
Product Catalogue
The TE Wire and Cable, Harnessing and Protection Products and the
TE Adhesives Selection Guide catalogues are installed with
HarnWare™. The catalogues are held in the form of Adobe Acrobat
pdf files. To view these files you will need a copy of the Adobe
Acrobat Reader installed on your computer. If you do not already
have this software installed it can be downloaded without charge
from: www.adobe.com/acrobat

The HarnWare™ toolbar dropdown list and the Help>Product

Catalogue menu list the sections in the catalogue, including tubing,
moulded parts, etc. These menu options provide direct access to the
sections in the catalogue. Alternatively the Help>Product Information
menu and command options list those TE products and materials that
are relevant to the current HarnWare™ form or selected shape in
Visio or harness design. Many of the products and materials are
hyperlinked directly to the relevant page in the product catalogue.

Please note that Product Catalogue dimensions and other details are
for reference only. For controlled documents please refer to TE

Product Information
TE harnessing product and material information that is relevant to the
current HarnWare™ form or shape can be obtained by using the:

 Right-click HarnWare™ shape menu in Visio

 Product information hyperlinks in the Design Wizard form
 Product information command button in the view copied part data
form
 Help>Product Information>For Selected Visio Shape menu option
86 User Guide HarnWare™ Version 6.3

This option lists all the products and materials that are relevant to the
current form or shape and, if the Design Wizard contains a list of
parts, to the parts in a harness design. Finally a full list of products
and materials contained in the database can be displayed - those that
are used in the current form, shape or harness design are highlighted
in a cyan colour.

Clicking any product or material description displays a pop-help.

Most of the pop-help topics contain hyper-links to further information
on the www.HarnWare™.com internet web site and the online
product catalogue.
© TE Connectivity Product Information 87
In the case of some products, a small image is displayed when an item
is clicked in the treeview listing of product descriptions.

If the Visio document name has changed since the current Design
Wizard part listing was generated a warning note will be included in
the Product Information form.
© TE Connectivity Wire List & Selection 89

Wire List & Selection

Opening Wire Form
Obtain the wire form using one of the methods described in the Open
Shapes section, for example:

 Click a wire line in the Design Wizard list, double-click a

line in the wire list table in Visio to select the wire line,
switch to HarnWare™ and load the wire line data into the
HarnWare™ form.

 If you do not wish to save data to a Visio drawing, select 'wire'

from the HarnWare™ Window>Parts menu. If the menu item is
checked, the form will contain previous data, otherwise a new
blank form will be displayed.

There is no need to use the wire selection option for Databus

harnesses.

Number of Wires & From-To

Enter the number of wires in the 'No Off' text box.

Select the connectors or splices between which the wire(s) are

required from the lists in the 'From' and 'To' combo-boxes.
HarnWare™ loads these boxes with the references from all the
connectors and splices in your harness drawing. If a reference is not
found in the drawing a warning message is output.
90 User Guide HarnWare™ Version 6.3

If you have added or changed a connector or splice reference in Visio,

you have the option of refreshing the list of references in the 'From'
and 'To' combo-boxes when opening another wire line shape.
Alternatively click the refresh command button (located in the
same frame as the from and to combo-boxes) to reload the
connector and splice references.

Only the page named 'Harness Drawing' is searched for connector

references. Connector and splices on any other page will be ignored.

NOTE

Connector references should comprise a single line of text.

HarnWare™ will replace any carriage returns found in connector
references with a space. But to avoid confusion you should ensure
connector references are contained on a single line.
© TE Connectivity Wire List & Selection 91
The wire number and length are automatically added into the wire list
by the wire router. You will not normally need to change the value in
the length text box.

Link wires that connect two contacts within the same connector, may
be defined by setting the from and to connector to the same reference.

Wire Selection
The harness material system set in the HarnWare™ Options menu
determines the wire specifications that are displayed by default.
Choosing ‘All’, rather than the ‘Preferred’ option button, will cause
the wire specification combo-box to be filled with all the wire
specifications held in the database. Details on the harness design
aspects of selecting the best type of wire are contained in the harness
design section of the online help system. When the wire specification
combo-box is selected, <Shift>+F1 pops-up brief details of the
particular wire specification which may include links to further
product information on the Internet or in the TE Product Catalogue.

Click the information command button in the wire spec frame

if you need guidance on selecting the most appropriate wire
92 User Guide HarnWare™ Version 6.3
specification. If you are not familiar with the TE wire part numbering
schemes, this option can also help to specify other details such as
shield, jacket and voltage for wire or core diameter, etc for fibre optic
cable. Refer to the Wire Specification Selection section for further
details on this option.

On selecting a wire specification, various combo-boxes will be set up.

For example, 44, 55 and 99 wire are defined by type, construction,
class, number of conductors, conductor m

aterial and gauge whereas some power cable is defined simply by wire
size. Selecting the wire specification also causes the wire colour
selection box to be loaded with the colours appropriate to that
specification. If there is only one colour available for a wire
specification, it is loaded into the wire colour text box for you to
accept as a default.

When you select a wire specification, the lists in the other combo-
boxes are changed to the relevant data and defaults are selected for
that specification. As you click on data in these combo-boxes a
description of the selected item is output to help you interpret that
element of the wire part number. Each combo-box contains a blank at
the top of the list which you can use to search the database when you
are unsure of any of the requirements.

Use the database search option to check if

any wires are available to match the
specified criteria. HarnWare™ will output the number of wires found
in the database and, for the first one found, the nominal wire diameter
and a picture of the wire style. If no wires are found to match the
specified criteria, HarnWare™ will inform you if alternatives are
available to match all except one of the specified criteria. If no wires
are found then, it is suggested that you try blanking one or more of the
combo-boxes and search again. Alternatively if the specific wire
requirements are essential, enter the part number, wire diameter and
contact Product Management to check the delivery, minimum order
quantity and price implications.
© TE Connectivity Wire List & Selection 93

Wire Specification Selection

This option helps to identify the type of wire that is most
appropriate for a given set of requirements. It is accessed using
the 'Wire Selection' command button alongside the wire
specification combo-box in the HarnWare™ wire form.

As the wire selection form is loaded, settings in the wire form are
transferred to reduce the number of check box, combo-box and option
button settings that you have to make.

The wire type option buttons enable you to search for equipment,
coaxial and power wire. When equipment wire is selected, further
options are enabled in the equipment frame. If AWG and metric
conductor wires are available for the selected wire type, the two size
option buttons are enabled.

For guidance on the most appropriate size of equipment or power wire

for given current and operating temperature conditions click the
94 User Guide HarnWare™ Version 6.3
information button alongside the size combo-box. Refer to the Wire
Gauge section for further details on this option.

When the 'Preferred' material option is used only wire specifications

that are appropriate for the currently selected harness material system
are listed. If no suitable wire is available, use the 'All' material option
to widen the search, but be careful to ensure the specification is
suitable for the operating temperature and environment in which the
harness will be used. Before using this option you would normally
consider other options such as larger wire sizes.

As you click the various option buttons, combo-boxes and check

boxes HarnWare™ searches the database to determine how many
alternative wires suit the specified criteria. The alternative wire
specifications and the number of standard wire part numbers are
listed. The total number of alternative wire part numbers is also noted.

If no standard wire part numbers are found, HarnWare™ checks the

database for alternatives in larger sizes, AWG or metric conductor
sizes, higher voltage rating, with a shield or in other material systems.
A message notes any such alternatives that might be suitable. If no
suitable wire is found in the database please contact Product
Management to establish whether a non-preferred wire is available to
suit your requirements.

Clicking a wire specification in the list box causes a brief description

to be output. Further details can be obtained by pressing <Shift>+F1.
Details on the harness design aspects of selecting the best type of wire
are contained in the harness design section of the online help system.

When you have selected a wire specification in the list box click 'OK'
to select that specification in the main HarnWare™ wire form. Chosen
options such as size, number of conductors, shield and jacket are also
transferred into the wire form. Other options such as conductor
material are blanked to provide an indication of the other options you
may need to set.

If you then search the database from the wire form you may find that
the number of alternative wire part numbers reported is less than
indicated in the wire specification selection form. This indicates that
© TE Connectivity Wire List & Selection 95
there are more than one alternative setting for options such as shields,
jacket and voltage. The setting selected is the first option in each of
the part number combo-boxes that meets all the criteria. For example,
with 55 wire, both constructions '1' and '5' are shielded and jacketed,
therefore, '1' will be selected when you search for this type of
construction.

Wire Gauge
General guidance on the most appropriate size of equipment
and power wire to use for given current loading and
temperature conditions can be obtained using the 'Advice on
Wire Gauge' command buttons (located in the size frame in the wire
and wire specification forms).

The estimated temperature rises, operating temperatures and

voltage drops calculated by this option are for general
guidance only. The calculations are based on a number of
assumptions which may not be valid for your particular design. For
critical design situations refer to standards such as IEC 60287-*-*
(previously IEC 287) and SAE-AS-5088-1 (previously MIL-W-
5088L) and contact TE Product Management to obtain exact values
for conductor resistance and temperature rise vs current for the
particular wire type and size.
96 User Guide HarnWare™ Version 6.3

The form is initially loaded with the length, number of cores and
gauges from the wire form. Adjust the number of cores to the
maximum of wires that will run together in any leg of your harness.
The calculations assume all wires are carrying the same current. Enter
the continuous current in amperes, the maximum altitude and the
maximum ambient temperature in which your harness will operate.

When the above data is entered or changed, HarnWare™ will estimate

the temperature rises for each size of wire that is available for the type
of wire selected in the wire form. If possible, the smallest gauge that
might achieve a temperature rise of 30°C or less is selected in the
combo-box. Select other gauges in the combo-box if you wish to
check the temperature rises for other sizes of wire. Estimated
© TE Connectivity Wire List & Selection 97
temperature rises that exceed 50°C are highlighted in red. Estimated
temperature rises that are less than 0.01°C are set to 0.01°C and a
maximum limit of 1,000°C is placed on the calculation.

The operating temperature for the wire is also calculated by summing

the ambient temperature and the estimated temperature rise due to the
heating effect of the current loading. If the operating temperature
exceeds the limit for the type of wire selected in the wire form, it is
highlighted in red.

If a maximum wire length is specified, HarnWare™ will also estimate

the voltage drop for that wire length and temperature. The wire
resistance is adjusted for the ambient and estimated temperature rise
due to the heating effect of the current loading. The voltage drop is
output in milli-volts, (1mV = 1/1000 volt). Again by selecting other
gauges in the combo-box you can check the volt-drops and
temperatures for other sizes of wire. If the estimated voltage drop is
calculated to be less than 0.0001mV, it is rounded up to 0.0001mV. A
limit of 1,000,000mV (1,000 volts) is placed on the volt drop
calculation.

The Visio drawing named TempRise, stored in the

\HarnWare™\Samples folder, contains sample graphs illustrating the
relationship between temperature rise, current, number of cores and
ambient temperature. The estimates calculated by HarnWare™ will
not exactly match the values in these graphs.

Click the 'OK' command button if you wish to return to the wire form
and change the wire gauge to that currently selected in the combo-
box. Click 'Cancel' if you just wish to return to the wire form without
changing the gauge selected there.
98 User Guide HarnWare™ Version 6.3
© TE Connectivity Wire List & Selection 99

Wire Colour
TE manufacture wire both in the UK and USA. The two plants have
different policies controlling the particular wires and colours that are
preferred and non-preferred. The HarnWare™ Options menu is used
to select the UK or USA plant as the wire source.

The 'Advice on wire colours' command in the wire selection

form, lists the required colour code format and the
preferred/non-preferred colours for the particular wire part
number.

As colours are selected in the treeview, the colour textbox and colour
description are output and a coloured drawing is produced. Any wire
or jacket colours not specified are indicated with an '*' in the text box
and a red cross-hatch pattern in the drawing.
100 User Guide HarnWare™ Version 6.3
With twisted pairs, triples, etc. wire colours are specified in ascending
order. For example, 2/4 rather than 4/2. Therefore, if you select 4 for
the first wire, the list of colours from which you can choose for the
second wire starts at 4.

Click OK when you have selected the required colour to transfer the
colour into the wire selection form. HarnWare™ will warn you if no
colour is selected or if the colour is not properly specified.

Colour code formats are reported in forms like '0/2-9,2/4-9'. This

would relate to a jacketed twisted pair and means that the jacket
colour must be 9 (white) and the wires could be either 0/2 (black and
red) or 2/4 (red and yellow). Slashes '/' separate the colours of
individual wires and a dash '-' is inserted before the jacket colour
code. Colour codes are usually single numbers, 0 to 9, except for
colours such as '2L' pink or '9X' translucent white and stripped wire
colours such as '45' yellow and green.

In the main HarnWare™ Wire form, colour codes may be constructed

using the colour table and text box. As you move the mouse over the
colour table HarnWare™ outputs the colour code and description.
Also included in the colour table for 44, 55 and 99 wire are the '/' and
'-' characters that are used to separate the colours for each primary
wire and the jacket.

By clicking on the colour table the appropriate code is added to the

proposed colour text box. After adding a code you can use the
backspace key to delete the last one or two (for example, 2L Pink or
45 yellow and green) character code from the text box. If you prefer
you can enter a colour code directly into the colour text box rather
than clicking on the colour table.

Fibre Optic Cable Selection

This option helps to identify the fibre optic cable that is most
appropriate for a given set of requirements. It is accessed using the '?'
command button in the HarnWare™ wire form Spec frame.
© TE Connectivity Wire List & Selection 101
As the Fibre Optic Cable Selection Guide form is loaded, settings in
the wire form are, where possible, used to select the most appropriate
options for application, number of cores and mode.

As you change selections in the list boxes for application, number of

cores and mode a description of the option is output and the fibre
optic cable part number(s) that meet all your selections are listed.
Please note that fibre optic cables may not be available to meet certain
combinations of options. If no suitable fibre optic cable is found in the
HarnWare™ database, please contact TE Product Management to
establish whether a non-preferred cable is available to suit your
requirements or if a custom designed cable is feasible.

As you click an available fibre optic cable part number a brief

description of the cable is output and a cross-section drawing of the
cable construction.

When you have selected a fibre optic cable part number in the list box
click 'OK' to select the appropriate options and the cable part number
in the main HarnWare™ wire form.

Certain fibre optic connectors and cable designs were at a preliminary

design status at the time of this HarnWare™ release. Therefore, you
are advised to check all fibre optic designs and component choices
with TE product management to confirm their suitability for your
particular design application and requirements.

Saving Data to the Wire Table

Wire data is saved to the wire table in the Visio drawing using one of
the normal save shape alternatives:

 Save shape toolbar icon

 File, Save shape menu option

 <Ctrl>+S short-cut key

102 User Guide HarnWare™ Version 6.3
If the HarnWare™ wire form is associated with a line in the wire list
table, the line is updated. If not, HarnWare™ offers you the option of
adding a new line to the drawing. If any wire lines are found in the
current Visio page the new line is added under the lowest line.
Otherwise the line is added at the lower left corner of the page.

When saving data from a wire form HarnWare™ checks for various
errors in the colour code. For example, you are warned if there are
insufficient colour codes for the number of wires specified in the wire
construction or if a jacket colour is not specified for a jacketed cable.
Also, if the wire part number is contained in the database, the colour
code will be checked. If the colour is non-preferred in the UK or USA
wire plant, as specified in the Options menu, HarnWare™ will inform
you of any available preferred or non-preferred alternatives.

The text in the wire list table is formatted with a tab character before
each item, i.e., <TAB> Wire No <TAB> Item No <TAB> From
Connector Reference <TAB> To Connector Reference, etc.
Additional information is held in the wire line shape's data1 field. It is
not advisable to edit the wire list table using the standard Visio text
tools, as the text must correlate to the data1 field information and the
tabs must be correctly positioned and fields such as wire diameter,
must contain numeric values. See the drawings held in the
HarnWare™ Samples folder.

If you wish you can easily change the format of the wire list table
format that HarnWare™ constructs in Visio. The procedure is similar
to that described for changing the format of the HarnWare™ parts list
table in the section Edit Parts List Format.

Wire lists should be held in pages named 'Wire List' or 'Wire List 1',
'Wire List 2', etc.
© TE Connectivity Wiring Schematic 103

Wiring Schematic
Overview
This option automatically generates a wiring schematic drawing
including connector schematic symbols and lines for each wire
running between the connectors. As the drawing is carefully
constructed using groups and glued connections, you can easily use
Visio to rearrange the drawing into the required layout. Wiring
schematic data can also be exported to a text file or to the Windows
Clipboard in a form that can be used by other systems such as
automatic test equipment.

Users of versions of HarnWare™ up to and including V4.5 will find

that the Wiring Schematic option has been extensively enhanced.
However, changes to the user interface have been kept to a minimum
in order to ease the transition for existing users.

HarnWare™ does not require a wiring schematic for any other option
such as part selection or wire routing. Therefore, you can omit this
step altogether or use it at a later stage of the harness design process.

This option is initiated from the design wizard or the HarnWare™

Tools menu.

A similar alternative which generates wiring schedules is also

available. Wiring schedules are usually used as a production
document and, therefore, they tend to be produced later in the harness
design process.

Before using the wiring schematic option you should:

 Drop the connectors into the harness drawing and add connector
references. The same positions are used for the connector shapes
in the wiring schematic drawing.
104 User Guide HarnWare™ Version 6.3

 Build the wire list so that the wiring schematic option knows
where the wires run and which are twisted or shielded.

You don't need to run the wire router or have any legs or transitions in
the harness drawing to be able to generate a wiring schematic.

This is one of the largest single HarnWare™ modules and because of

the drawing activity it is the most demanding upon the computer.
Large drawings require a reasonable amount of memory and a fast
processor to achieve acceptable response times. A high resolution
colour graphics screen is also required.

You can interrupt the schematic drawing process using the escape
key. When the wiring schematic form is open you can move it and
reposition the main HarnWare™ form using the F8 function key
arrange forms option. The form size can also be adjusted to suit the
amount of data.

If, when the wiring schematic option is first chosen from the Tools
menu or Design Wizard, an existing wiring schematic drawing is
found, HarnWare™ will extract connector positions and contact
assignments from the schematic. If there is no existing schematic, but
there is an existing wiring schedule, HarnWare™ will offer the option
of using data from the schedule.

If changes have been made to the wire list since the schematic or
schedule was produced, HarnWare™ can, if you wish, attempt to
incorporate these changes into the data obtained from the existing
schematic or schedule. If the changes are simple, for example, a single
wire has been added to the wire list, this process should be reliable
and can save re-entering all your previous contact reference changes,
etc.

NOTE

It is safer to load data from the wire list. If you select one of the other
options always carefully check your schematic and schedule.
© TE Connectivity Wiring Schematic 105
If the Visio document contains neither a schematic or a schedule,
HarnWare™ uses information from the assembly drawing and wire
list. If a connector planform has been specified for a connector shape,
the contact references for the planform are used. Alternatively
contacts are assigned numeric references. HarnWare™ offers the
alternative of assigning contacts for shields. If few shields are
terminated or if they are terminated to connector shells or daisy-
chained to a single contact, you may find it easier to insert extra
contacts for the shields rather than remove the excess contacts which
would be included if HarnWare™ assigned contacts for all shields.

A database is used to manage wiring schematic and schedule data. A

menu option allows you to load data from this database, rather than
the drawing so that you can recover any unsaved changes. The
database may also be useful for exporting pin-out data to other
systems such as automatic test equipment.

This wiring schematic option is not relevant to Databus harnesses.

106 User Guide HarnWare™ Version 6.3

Drawing
When you click the draw command a number of options are offered.

Two alternative styles of schematic can be chosen:

 A connected style of schematic that includes lines for wires

between each connector.
 A disconnected style where separate connector shapes are drawn
with short lines and labels showing the connector and contact
references for the destination. The length of the lines can be
changed using a right-click menu for each connector shape.
You can choose from three alternative wire lines:
A three line wire shape. This shape uses a modified version of the
Visio Universal Connector, which usually kinks correctly however
you move or rotate the connectors. The right-click menu for these
wire shapes allows you to position the text on the beginning, middle
or end line segment. The angle of the text is automatically set.
© TE Connectivity Wiring Schematic 107

 A line shape that automatically includes line jumps where wires

cross-over. This uses another version of the Visio Universal
Connector, which is more flexible but which requires re-
positioning more often than the 3 line shape option. The right-
click menu for these wires allows you to quickly change the text
angle. Using the shift and control keys to drag parts of wire shapes
allows you to add steps and extra points into the wire line. The
format of line skips, where wires cross over each other can be
modified using the Visio Page SetUp menu. Refer to the Visio
Shape Help for more details on using Universal Connectors.
 A straight-line. This option is intended to help determine the
connector contact order which minimises the number of wire
cross-overs. When wires are drawn with the other two shapes,
wires that cross-over are often drawn on top of each other.
You can elect whether or not to include unused connector contacts in
the schematic drawing. You can also elect whether to have wire
descriptions added to the wire line shapes.

By default HarnWare™ rotates and flips the connectors and assigns

wires and shields to contacts so that:

 As few wires as possible cross-over each other.

 Twisted groups of wires and shields are kept together.

The connector shapes are generated as a group including the twist and
shield symbols and the braid shape. You can move, rotate, flip, stretch
and shrink the connector shapes. You can manipulate the connectors
like this, because all the wires are glued.

HarnWare™ sets the minimum grid on the wiring schematic drawing

page to 5mm or 0.25 inches so that it's easy to snap the connectors
into position to make wires into straight lines.

To edit the contacts or other details of a schematic connector, select

the shape and use the Visio Edit, Open Group menu option (or in
Visio 2010 the shape right-click group>open group option) to access
the shapes included in the connector group. The right-click menu for
the shield, coax and braid shapes can be used to select alternatives for
108 User Guide HarnWare™ Version 6.3
shields that are not terminated, daisy chained, terminated to a contact,
etc. Control handles in the braid, shield and coax shapes allow
adjustments to be made to the shape width, shape length (to allow
more wires to be encased) and to the connection position.

The right-click menu for schematic connectors allows the connector

and all the wires glued to the shape to be coloured red, blue, cyan or
magenta. If the connector or any of the connected wires are already
set to a colour, they are changed to green. This option can also be
accessed using the colour command in the HarnWare™ Wiring
Schematic form. Colouring the schematic can help you understand the
interconnection of wires and therefore help achieve the best schematic
layout.

Generally the best sequence of operations to rearrange the drawing is

to:

 Move, rotate and flip the connectors. Rotating connectors in an

anti-clockwise direction (left) is preferable to clockwise. Rotating
connectors is also a quick method of untangling any wire cross-
overs.

 Move any wire bends if you need to change their shape or the text
positions.

If you wish to scale the whole schematic drawing:

 Select all the shapes in the wiring schematic.

 Group them, using the Visio Shape, Group menu option.

 Scale the group to the required size. You may need to use the
Visio Format menu to changed the text size.

Connector Parameters
In the HarnWare™ wiring schematic form, parameters for each
connector can be viewed by selecting the connector reference in the
connector combo-box. Splice references are not included in the
© TE Connectivity Wiring Schematic 109
combo-box, as there are no contact assignments, or connector options
that can be set for splices.

You can change certain connector parameters using the options in the
Contacts frame and the braid combo-box and then clicking the Apply
command button. These parameters are:

 The default contact style used to construct the connector shape can
be changed to a pin, socket or block shape.

 Contact labels can be changed from the numeric default to various

lettering sequences. Selecting the planform option, allows you to
automatically load the contact references for a connector planform.

 The number of contacts can be increased. You can only decrease

the number of contacts if those with the highest references are not
assigned. The minimum number of contacts is the number of
conductors plus the number of shields, even if some conductors or
shields are unterminated. In this case the number of contacts
actually drawn will be determined by the assignments in the
listview rather than the quantity of contacts shown in the
connector frame.

 The number of layers of braid can be changed from the default of

1 to either 0 or 2. This controls the type of braid symbol added to
the connector shape.

After changing any of the above parameters, only when the Apply
command button is clicked are the changes saved. Contact references
from connector planforms are an exception to this rule. If you make
some changes and forget to use the Apply command, HarnWare™
will warn you that the changes have been discarded if you select
another connector or make any contact assignment changes.

Contacts can be assigned or unassigned for shields or unassigned for

all the wires and shields associated with the current connector using
the ‘Assign or Unassign’ command button.
110 User Guide HarnWare™ Version 6.3

Contact Assignments
The form lists contact assignment details for the selected connector. .
A variety of different icons are used for contacts that are associated
with a single wire or shield and for daisy chained shields, un-
terminated shields, un-terminated wires, spliced wires, unused
contacts with the same reference as another assigned contact. Unused
contacts are shown without an icon.

The individual columns of the list can be resized to fit longer

descriptions by moving and dragging the mouse over the column
headings. The wiring schematic form can be maximised or resized so
that more contact details are visible.

Extra contacts can be added to the end of the list by increasing

the number in the Connector frame and clicking the Apply
command. Alternatively, using the ‘Add Contact’ command,
up to 9 extra contacts can be inserted before or after the one selected
in the list. Contacts with the highest references that have no wires or
shields connected to them can be deleted by reducing the
number of contacts in the Connector frame. Alternatively if
the selected contact is unused, it can be deleted using the
delete command button.

Contact references for the selected wire or shield line in the

list can be changed by selecting or typing into the two contact
combo-boxes and using the Update command button. The
Update command ensures contact references are maintained. If
you type a contact reference that is not already used, the combo-box is
highlighted in yellow. When you use the Update command a new
contact is added for the old contact reference unless another contact is
already using the old reference. If the new contact reference was
already assigned to an unused contact, the Update command deletes
that contact.
© TE Connectivity Wiring Schematic 111
As references in the two contact combo-boxes are changed for each
end of the selected wire or shield, HarnWare™ indicates the contact
assignment changes that the Update command would make.
You may need to increase the width of the schematic form to
see all of the contact assignment message. Changes made to the
contact assignments are only saved by clicking the Update
command. Any unsaved changes will be lost if you select
another contact in the list or another connector in the connector
combo-box. HarnWare™ will warn you that the changes have
been discarded if you select another contact or make any
connector parameter changes.

Contacts can be moved up and down the list using the four
move first, move up, move down and move last commands.
The list controls the order in which the contacts are drawn in
the schematic. The move commands simply alter the order of the
contacts, they do not swap wire or shield connections.

The sort command reorders contacts to group together wires or shields

with the same contact reference and wires with their associated shields
and sets of wires that have daisy chained shields. This
command can either be used for the currently selected
connector or the grouping operation can be applied to all
connectors in a single operation. Also associated wires can either be
pulled up or pushed down the list of contacts. Working down the list
of contacts each wire is examined for associated wires and shields. If,
for example, the wire is one of a twisted pair the other wire is either
pulled up the list into the next position or the first wire is pushed
down the list to the contact just before the other wire. After this re-
ordering has been completed any shields are then moved to the
contact just below the last of the shielded wires.

The default descriptions added to all wires in the schematic can be

selected from a list of options in the wire description combo-box. The
options include colour, gauge and part number. Individual wire
descriptions can be changed by clicking a wire in the list, editing the
text in the description text box and using the Update command.
Descriptions apply to wires not connectors, so that the updated wire
description will be seen when you select either of the two connectors
112 User Guide HarnWare™ Version 6.3
between which the wire is routed. The description text box is disabled
when an unused contact or one used for a shield is selected in the list.

The shields for two or more sets of shielded wires can be assigned to
the same contact, when the shields are daisy chained together. Two or
more wires that are spliced together can also be assigned to the same
contact reference.

Database
The HarnWare™ wiring schematic and schedule options use a
database to store information on connectors, wires, etc. The
information is initially extracted from the Visio document and is
modified as you make changes to contact references, wire
descriptions, etc. The database files are compatible with Microsoft
Access 97 and are stored in the HarnWare™ folder which is normally
named Program Files\Tyco Electronics\HarnWare™ V6.

The Wiring Blank.accdb is a blank database, a copy of which is used

as a template for each new schematic or schedule that is produced.
The working database is Wiring.accdb. Before creating a new
Wiring.accdb database file, HarnWare™ renames any existing file of
this name to Wiring Old.accdb Error messages are output if
HarnWare™ is unable to create, delete or rename any of these files.
Normally this will be caused by file protection problems.

A HarnWare™ menu option allows you to load data from this

database, rather than the drawing so that you can recover any unsaved
changes. For example, if you clicked the Done rather than the Draw
command in the HarnWare™ schematic or schedule form you can use
this menu option to retrieve all the edits made to contact references,
etc.

The database may be useful for exporting contact-out data to other

systems such as automatic test equipment. Please contact HarnWare™
system support if you would like further details on the database
structure.
© TE Connectivity Wiring Schematic 113

Export Wiring & Schematic

Schedule Data
Command buttons in the Wiring Schematic and Schedule forms allow
data to be exported to a text file or to the Windows Clipboard. This
data can then be used in other systems, for example, automatic test
equipment or other electrical design software. For further details
please refer to the Export Wiring Schedule & Schematic Data section.
© TE Connectivity Wiring Schedule 115

Wiring Schedule
Overview
This option can be initiated from the HarnWare™ Tools menu. It
automatically generates a wiring schedule including wire and
connector contact details along with marker and solder sleeve item
numbers. A similar alternative which generates wiring schematic
drawings is described in the previous section.

This option is normally used toward the end of the harness design
process when wire markers and solder sleeves have been selected and
a parts list has been generated. The wiring schematic alternative is
often used at an earlier stage. Wiring schedules are mainly intended as
a production document whereas schematics can also be useful during
the design process.

Users of previous versions of HarnWare™ up to and including V4.5

will find that the Wiring Schedule option has been extensively
enhanced. However, changes to the user interface have been kept to a
minimum in order to ease the transition for existing users.

This is one of the largest single HarnWare™ modules and because of

the drawing activity it is the most demanding upon the computer.
Large drawings require a reasonable amount of memory and a fast
processor to achieve acceptable response times.

You can interrupt HarnWare™ when it is generating a wiring

schedule using the escape key. When the wiring schedule form is
open you can move it and reposition the main HarnWare™ form
using the F8 arrange forms option.
116 User Guide HarnWare™ Version 6.3

This wiring schedule option is not relevant to Databus harnesses.

Drawing Analysis
If, when the wiring schedule option is first chosen from the Tools
menu, an existing wiring schedule is found, HarnWare™ will extract
connector contact assignments, wire details and item numbers from
the schedule. Edits that have been made to the remarks or item
numbers contained in the wiring schedule will be re-used. Edits to
other data in the wiring schedule will not be re-used as for reasons of
data integrity HarnWare™ the data1 field associated with each line of
the schedule is used to store such data as the connector and contact
references for each wire.

When there is no existing schedule, but there is an existing schematic,

HarnWare™ will offer the option of using data from the schematic. If
changes have been made to the wire list since the schematic or
© TE Connectivity Wiring Schedule 117

schedule was produced, HarnWare™ can, if you wish, attempt to

incorporate these changes into the data obtained from the existing
schematic or schedule. If the changes are simple, for example, a single
wire has been added to the wire list, this process should be reliable
and can save re-entering all your previous contact reference changes,
etc.

NOTE

It is safer to load data from the wire list. If you select one of the other
options always carefully check your schematic and schedule.

If the Visio document contains neither a schematic or a schedule,

HarnWare™ uses information from the assembly drawing and wire
list. If a connector planform has been specified for a connector shape,
the contact references for the planform are used. Alternatively,
contacts are assigned numeric references. HarnWare™ offers the
alternative of assigning contacts for shields. If few shields are
terminated or if they are terminated to connector shells or daisy-
chained to a single contact, you may find it easier to insert extra
contacts for the shields rather than remove the excess contacts which
would be included if HarnWare™ assigned contacts for all shields.

By default, HarnWare™ assigns connector contacts so that twisted

groups of wires and shields are kept together. Contact numbers are
assigned in the same default sequence that is used in the wiring
schematic option.

A database is used to manage wiring schematic and schedule data. A

menu option allows you to load data from this database, rather than
the drawing so that you can recover any unsaved changes. The
database may also be useful for exporting pin-out data to other
systems such as automatic test equipment.
118 User Guide HarnWare™ Version 6.3

Schedule Output
Two options are offered for generating schedules either as a
continuous list or to start a new page for each connector. In the latter
case each wire appears twice in the lists for each of the connectors
that it is routed between.

Connectors with the greatest number of assigned contacts are output

first. The order of wires is then related to the order that they appear in
the wire list. Before the first contact of a connector is output, a line is
added to the schedule indicating the number of layers of braid.

HarnWare™ fixes the grid on the wiring schedule drawing page to

5mm or 0.25 inches so that it's easy to arrange the lines into a table.

If more than one wire or shield is connected to a contact, you may

need to edit the schedule. Even when shields are daisy-chained to a
single contact, HarnWare™ outputs a schedule line for each shield.
This apparent duplication of information is necessary to ensure
information is not lost when, for example, shields are daisy-chained at
one end and terminated to separate contacts at the other. A line is also
included for shields that are not terminated at either end.

Unused connector contacts are not included in wiring schedules.

If you wish to scale the whole wiring schedule:

 Select all the shapes in the wiring schedule.

 Group them, using the Visio Shape, Group menu option.
 Scale the group to the required size.

Connector Parameters
In the HarnWare™ wiring schedule form, parameters for each
connector can be viewed by selecting the connector reference in the
connector combo-box. Splice references are not included in the
© TE Connectivity Wiring Schedule 119

combo-box, as there are no contact assignments, or connector options

that can be set for splices.

You can change certain connector parameters using the options in the
Contacts frame and the braid combo-box and then clicking the Apply
command button. These parameters are:

 Contact labels can be changed from the numeric default to various

lettering sequences. Selecting the planform option, allows you to
automatically load the contact references for a connector planform.
 The number of contacts can be increased. You can only decrease
the number of contacts if those with the highest references are not
assigned.
 The number of layers of braid can be changed from the default of
1 to either 0 or 2.
After changing any of the above parameters, only when the Apply
command button is clicked are the changes saved. Contact references
from connector planforms are an exception to this rule. If you make
some changes and forget to use the Apply command, HarnWare™
will warn you that the changes have been discarded if you select
another connector or make any contact assignment changes.

Contacts can be assigned or unassigned for shields or unassigned for

all the wires and shields associated with the current connector using
the ‘Assign or Unassign’ command button.

Contact Assignments
The form lists contact assignment details for the selected connector. A
variety of different icons are used for contacts that are associated with
a single wire or shield and for daisy chained shields, unterminated
shields, unterminated wires, spliced wires, unused contacts with same
reference as another assigned contact. Unused contacts are shown
without an icon.

The individual columns of the list can be resized to fit longer remarks,
part numbers, etc. by moving and dragging the mouse over the
120 User Guide HarnWare™ Version 6.3

column headings. The wiring schedule form can be maximised or

resized so that more contact details are visible.

Extra contacts can be added to the end of the list by increasing

the number in the Connector frame and clicking the Apply
command. Alternatively, using the Add Contact command, up to 9
extra contacts can be inserted before or after the one selected in the
list. Contacts with the highest references that have no wires or
shields connected to them can be deleted by reducing the
number of contacts in the Connector frame. Alternatively, if
the selected contact is unused, it can be deleted using the delete
command button.

Contact references for the selected wire or shield line in the

list can be changed by selecting or typing into the two-contact
combo-boxes and using the Update command button. The Update
command ensures contact references are maintained. If you type a
contact reference that is not already used, the combo-box is
highlighted in yellow. When you use the Update command a new
contact is added for the old contact reference unless another contact is
already using the old reference. If the new contact reference was
already assigned to an unused contact, the Update command deletes
that contact.

As references in the two-contact combo-boxes are changed for each

end of the selected wire or shield, HarnWare™ indicates the contact
assignment changes that the Update command would make. You may
need to increase the width of the schedule form to see all of the
contact assignment message. Changes made to the contact
assignments are only saved by clicking the Update command. Any
unsaved changes will be lost if you select another contact in the list or
another connector in the connector combo-box. HarnWare™ will
warn you that the changes have been discarded if you select another
contact or make any connector parameter changes.

Contacts can be moved up and down the list using the four move first,
move up, move down and move last commands. The list controls the
order in which the contacts would be drawn in a schematic. This
ordering has no effect on wiring schedules which are drawn in wire
© TE Connectivity Wiring Schedule 121

list order. The move commands simply alter the order of the contacts,
they do not swap wire or shield connections.

The sort command reorders contacts to group together wires or

shields with the same contact reference and wires with their
associated shields and sets of wires that have daisy chained
shields. This command can either be used for the currently
selected connector or the grouping operation can be applied to
all connectors in a single operation. Also associated wires can
either be pulled up or pushed down the list of contacts.
Working down the list of contacts each wire is examined for
associated wires and shields. If, for example, the wire is one of
a twisted pair the other wire is either pulled up the list into the
next position or the first wire is pushed down the list to the
contact just before the other wire. After this re-ordering has
been completed any shields are then moved to the contact just
below the last of the shielded wires.

Any wire marker item numbers associated with the connector shape in
the assembly drawing are listed against each wire. Solder sleeve item
numbers associated with the connector shape are listed against each
shield.

Wire part numbers are included for reference purposes, they are not
output to the wiring schedule. Item numbers, remarks, wire colour and
size are all output to the wiring schedule and can be edited in the
form.

The shields for two or more sets of shielded wires can be assigned to
the same contact, when the shields are daisy chained together. Two or
more wires that are spliced together can also be assigned to the same
contact reference.

Customising the Wiring

Schedule
The shapes used for the wiring schedule border and lines in the table
are contained in the sheets and miscellaneous stencils. Different
122 User Guide HarnWare™ Version 6.3

shapes are used depending upon whether the drawing was created
using a HarnWare™ metric or imperial template.

These shapes can be customised to suit different company standards.

For example, column widths can be altered, the order of columns can
be changed, and selected columns can be removed.

The schedule line shape comprises a group of shapes. Shapes used for
the various data items in the wiring schedule contain a setting in their
data1 field that determines the data for which the shape will be used.

The wiring schedule drawing border contains two connection points

that determine the positions of the first and last line in the schedule.
Wiring schedule pages are automatically named 'Wiring Schedule 1',
'Wiring Schedule 2', etc.

Export Wiring Schematic &

Schedule Data
Command buttons in the Wiring Schematic and Schedule forms allow
data to be exported to a text file or to the Windows Clipboard. This
data can then be used in other systems, for example, automatic test
equipment or other electrical design software.
© TE Connectivity Wiring Schedule 123

The Export Wiring Schematic and Schedule forms are similar and
allow you to select the data to export. For example, if you only want
to include connector and pin references, just check these two options.
A note of the columns you select is saved in the HarnWare™ INI file.
When you next use the export wiring schematic or schedule option,
the same column options are checked as the form is displayed.

Another check box allow you to select whether lines are included for
any shielded wires.

You have the option of entering four headers for output as the first
line in the export file. If any of the header text boxes contain some
text the first line of the output file will contain <TAB> Part Number
<TAB> Project Number <TAB> Customer Drawing Number <TAB>
Issue. These headers can be up to 25, 8, 25 and 6 characters
respectively.
124 User Guide HarnWare™ Version 6.3

If you check the Clipboard option, the file name frame will be
disabled. Un-check the box to reactivate the frame.

The folder or directory and file name will normally default to that of
the current drawing, except the file extension is changed from .VSD
to .TXT

If you check Set Default Directory, the folder or directory path name
will be saved in the HarnWare™ INI file. When you next use the
export wiring schematic or schedule option, this same folder or
directory path will be selected as the default and the check box will be
set. If you uncheck the box and click OK to export data, the system
will offer the drawing folder or directory path as the default when you
next use the option.

Both wiring schematic and wiring schedule data is output in the order
that would be used for a continuous wiring schedule. Lines are not
included for blank connector contacts or for any overall braid.
© TE Connectivity Wire Routing 125

Wire Routing
Overview
Use this option to have HarnWare™ trace the routes of wires through
the harness in order to calculate:

 Adjusted lengths for each entry in the wire list table.

 Cable bundle diameters for each harness leg in the drawing.

This option can be initiated from the design wizard, the HarnWare™
tools menu, the <Ctrl>+W short-cut key combination, the Visio
HarnWare™ menu or the right-click Visio page menu. Before using
this option you should:

 Draw the harness ensuring the shapes are properly glued so

HarnWare™ will be able to trace around the connectivity of the
harness.

 Add references to the connector and splice shapes and dimensions

to the harness legs.

 Enter the connector from - to references and wire diameters in the

wire list table, using the wire selection option described earlier.

You can, if you wish, generate a wiring schematic drawing before

using this wire routing option.

Until the time when HarnWare™ starts to add information to the

harness drawing the escape key will stop the wire routing process.

The same drawing analysis method and wire router form is used by
the HarnWare™ Multi-Core Cable (EPD) Analyser.
126 User Guide HarnWare™ Version 6.3
A new wire router algorithm was introduced in HarnWare™ V6. This
allows very rapid analysis of much more complex harness designs
including many harness legs and alternative wire routes.

There is no need to use this wire routing option for Databus harnesses.

The wire route form can be maximised in order to view more

information without the need to scroll through the rows in each list.

NOTE

The harness drawing and wire list table should be on separate

drawings pages named ‘Harness Drawing’ and names including the
words 'Wire List', e.g. 'Wire List', 'Wire List 1', 'Wire List 2', etc. The
drawing can include two or more harnesses.
© TE Connectivity Wire Routing 127

Wire Lengths
If two or more alternative routes exist for a wire route, HarnWare™
identifies the shortest route.

Wire lengths are calculated by summing the harness leg lengths plus a
10% lay loss allowance. This is increased to 20% for legs where the
calculated bundle diameter is greater than 15mm (0.59”).

Wire length adjustments are also made for adaptors, KTKKs and
moulded parts in the wire route. For example, a greater allowance is
made for right angled, rather than straight, boots. The adjustments for
each style of adaptor, KTKK and moulded part are held in the
HarnWare™ database.

Any wire lengths that are calculated to be less than 150mm (6") are
rounded up to these values. This will, for example, apply to link wires
and wires running from a connector to a splice in the adjacent boot.

Calculated wire lengths are added to the wire list table and wire
numbers are automatically set. Item numbers are set when you
subsequently use the HarnWare™ parts listing option.

Any wire lengths that are calculated to be less than 150mm (6") are
rounded up to these values. This will, for example, apply to link wires
and wires running from a connector to a splice in the adjacent boot.

Repair Loops
Extra length allowances can be made for repair loops when the wire
routing option calculates wire lengths and when the parts listing
option calculates braid and EPD lengths. By default HarnWare™
allows for repair loops.

Use the set properties option in the design wizard to change the repair
loop setting. Alternatively:
128 User Guide HarnWare™ Version 6.3

 Click on a blank part of the Visio harness drawing page to ensure

no shapes are selected.

 Use the Visio Shape, Custom Properties or shape data menu or the
right click , Custom Properties or shape data menu. In Visio 2010
check the 'Show/Hide Shape Data Window' checkbox in the Data
tab.

 Select either Yes or No to specify whether repair loops are

required or not.

If the 'Repair Loops' custom property is set to 'Yes', HarnWare™ will

add 20mm (0.79”) per end for each wire that is smaller than 18AWG.
It is not normally possible to loop larger wires.

After using the wire routing or parts listing options HarnWare™

outputs a prompt indicating whether allowances have been made for
repair loops.

Wire Bundle Diameters

Estimated wire bundle diameters are added to each harness leg. If all
the wires in a leg are the same diameter, a standard wire lay chart
diameter factor is used to calculate the diameter. If the wire diameters
in a leg vary, the bundle diameter is estimated using the formula:

1.2 * N1 * D12  N 2 * D 2 2  N 3 * D32...

It is a feature of this formula that the accuracy diminishes as the

variation in wire diameter increases. HarnWare™ outputs the
minimum and maximum wire diameters to make you aware of the
variation in wire diameters in each leg.
© TE Connectivity Wire Routing 129

NOTE

The cable lay design option in the braid and tube form analyses the
lay of wires in each leg in much more detail. The bundle diameters of
mixed diameter wires calculated by this option are generally more
accurate.

The numbers in the wire list table for wires passing through each
harness leg are also saved in the drawing. The bundle diameter and
the wire list numbers are shown in the braid and tube form.

If, when saving wire route data to the drawing, HarnWare™ finds a
leg with a multi-core cable (EPD), braid, tube or fillers specified
where the cable diameter has changed, a warning message is output.
You may need to use the braid and tube selection option again to
change the braid and tube. This in turn may affect any previous
choices you have made for moulded parts, adaptors, etc. Normally this
situation will arise after changes are made to the wire details.
However, the cable lay design command can, especially if fillers are
added, result in bundle diameters sufficiently different to those
estimated by the wire router formula, to cause this warning message.

Potential Problems
The system will warn of such errors as:

 Duplicate connector references. The same reference has been

found on two or more connector or splice shapes in the harness
drawing.

 Blank connector reference. One or more connector shapes have

been found with a blank connector reference. Click the connector
shape, enter a reference and press the escape key to set the
connector shape text to the required reference.

 Connector references that include a carriage return. You should

change the connector reference in the drawing so that it is
130 User Guide HarnWare™ Version 6.3
contained on a single line of text. The wire router will try to
continue using a space in place of the carriage return in the
connector reference.

If the system reports one or more wire routes that can't be found,
check the gluing of shapes, as this is normally the cause of such
problems. Connections between glued shapes highlight in a red square
when selected in Visio 2010.

NOTE

Always rerun the router after making drawing changes such as

copying and pasting a harness leg, or changing a connector reference
or changing the wire list. The wire router stores wire list numbers with
the harness leg shapes and options such as the parts lister need this
information to be consistent with that contained in the wire list.

To save time only pages named 'Harness Drawing' and those

containing the words 'Wire List' (e.g. Wire List, Wire List 1, Wire List
2, etc.) are analysed when HarnWare™ is collecting information for
wire routing. You should use the standard pages in the HarnWare™
template for the specified purposes to avoid problems.

Warning and Errors

th
When HarnWare™ generates warnings or errors

ng
le
during the wire routing process a yellow

g
le
s
warning shape is placed in the drawing on the es
rn
ha

shape or line in the wire list table where the

ic
er
um

problem was encountered. You do not need to

-n
on
N

delete these warnings as they will be cleared

when you use an option such as wire routing,
parts listing or labour estimating. However, if you wish you can delete
all the warnings using the Visio Edit, Select Special menu option to
select all shapes on the 'Warning' layer.
© TE Connectivity Wire Routing 131
A brief description of the problem is added to the yellow warning
shapes. Further details can be obtained by right-clicking the warning
shape in Visio, and selecting the help menu option.

The wire list table is generated using the wire lines in the order they
were added to the drawing. If you find the wire numbers are out of
sequence in the table, move the lines so that the numbers are in
sequence and if you use the wire routing option again, the numbering
of wires will be correct.
© TE Connectivity Multi-Core Cable (EPD) Analyser 133

Multi-Core Cable (EPD)

Analyser
Overview
EPD stands for 'Engineering Product Design', an acronym used in TE
to describe multi-core cables. These assemblies can be used as an
alternative to hand laying wires and assembling the braid and tube to
form the legs in a harness. Multi-core cables can save time, cost and
improve harness quality.

This HarnWare™ Tools menu option analyses all the multi-core cable
configurations that could be used to build the harness and sorts them
into order by the estimated amount of assembly time saving.
HarnWare™ can then flag the leg(s) in the harness drawing that will
then be defined as multi-core cables when you select braid and tube
for them. The Multi-Core Cable (EPD) Analyser can also be initiated
from the Design Wizard.

Many harness designs do not use multi-core cables and in others, such
as point-to-point harnesses the required multi-core cable construction
is obvious. Therefore, for many harness designs this option is
unnecessary. Also this option is not relevant to Databus harnesses.

Time Synthetics
The aim of the Multi-Core Cable (EPD) Analyser is to identify the
multi-core cable configuration for a particular harness design that
offers the maximum potential time savings. Therefore, it is the relative
values rather than the actual time synthetics that is important.
Estimating the actual assembly time for any particular configuration is
better handled by the HarnWare™ Labour Estimator which
undertakes a much more detailed analysis.
134 User Guide HarnWare™ Version 6.3
The Multi-Core Cable (EPD) Analyser form allows you to set various
time synthetics. In most cases the default values should provide
acceptable results. However, if for example your harness design
includes large leg diameters, you may wish to increase the time
required to add braid and tube.

When you click the OK button the time synthetics are saved to a
HarnWare™ INI file on disc and these are reloaded when you next
use the Multi-Core Cable (EPD) Analyser. The standard default time
synthetics can be reloaded using the Default command
button. The lay wires time synthetic is per metre wire length.
All the other time synthetics are per metre harness leg length.

Results Output
HarnWare™ draws the configuration which has the greatest potential
assembly time saving first. Other alternatives can be viewed in
descending order of potential time saving. The number of available
alternatives is presented in the usual format, e.g., '1 of 8'. The
minimum number of harnesses needed to achieve a 100 metre
minimum multi-core cable order quantity is also calculated. If a zero
© TE Connectivity Multi-Core Cable (EPD) Analyser 135
multi-core cable length is encountered '***' is entered as the minimum
order quantity.

The number of multi-core cables in the current configuration is

displayed along with the estimated time saving in minutes. This
estimate is the difference between the time required to assemble the
harness legs using multi-core cables and the time required for a purely
hand lay method of construction. The saving can become negative for
EPD configurations that are estimated to take longer to assemble than
the fully hand laid alternative.

The sketch shows the harness legs, leg lengths, connector references,
transitions and multi-cables in black. Each multi-core cable is then
drawn offset to the right and up from the black harness leg lines. A
colour code is used to represent the different situations:

 Where all the wires in a leg are contained in a multi-core cable, it

is drawn in green.

 Where a multi-core cable is stripped back to a transition, the

stripped portions are drawn in red.

 Where a multi-core cable is bundled with other wires or multi-core

cables, blue is used.

Where a configuration contains two or more multi-core cables the

parts of each are drawn at the same offset from the black harness leg
line. Therefore, the various parts of each multi-core cable can be
related by comparing the offsets for each leg.

Other multi-core cable configurations can be

inspected using the next, previous and minimum
time command buttons.

Saving Results
If you click the OK button:

 The time synthetics are saved on disc in a HarnWare™ INI file.

136 User Guide HarnWare™ Version 6.3

 Multi-core cable references ('EPD1', 'EPD2', etc.) are added to

each harness leg in the drawing that is to be specified as a multi-
core cable. If any multi-core cable references are already included
for any legs, these are overwritten. When using the braid and tube
selection form, change the 'EPDn' flags to the actual multi-core
cable references.

The multi-core cable database search option can be accessed via a

command in the braid and tube form or using the HarnWare™
Tools>Multi-core cable>Search menu. This option may help you
identify a suitable multi-core cable.

If you click the Cancel button, the time synthetics are not saved and
no changes are made to harness legs in the drawing.

Analysis
The drawing analysis is the same as is used by the wire routing
option. Similar error checks and messages are output. The wire router
form is displayed as an aid to understanding the multi-core cable
options presented.

HarnWare™ analyses all the possible configurations of multi-core

cables. Those with only one wire are eliminated from consideration.
The number of possible alternative configurations grows rapidly with
the number of legs in a harness. For example, there are 13 potential
configurations for a harness with three legs before invalid options are
excluded, but over 30 million for a harness with 13 legs. Therefore,
the maximum number of legs that this option will analyse is currently
limited to 15.

The assembly time is estimated for each alternative and compared

with the hand laid alternative. In doing so multi-core cable lengths are
taken as the maximum length of any wire included in the multi-core
cable, as calculated by the wire routing process. The sum of the leg
lengths through which the multi-core cable is routed is compared with
this length so that some time is included for end stripping. This
calculation also takes account of cases where a cable is striped back to
a transition.
© TE Connectivity Multi-Core Cable (EPD) Analyser 137
For legs where a multi-core cable is bundled with other wires or
multi-core cables, the time to strip the cable and the times required to
hand lay the leg is applied.

Worked Example
To illustrate the calculations made by the Multi-Core Cable (EPD)
Analyser consider the following branched harness in which there are
10 wires connecting PL1 to PL2 and 20 from PL1 to PL3. The wire
lengths calculated by the router are 2,860mm and 2,750mm, i.e. the
leg lengths plus 10% lay loss and no additional amendments for
moulded parts, adaptors or repair loops.

600
PL2

2000
PL1

500
PL3

The following worked example uses these time synthetics:

Add Braid and Tube 13 mins per metre

Lay Wires 2 mins per wire per metre

Strip EPD 5 mins per metre

Prepare EPD 2 mins per metre

There are 4 valid alternative multi-core cable configurations for this

harness design. The configuration offering the largest potential
assembly time savings is, somewhat obviously, a multi-core cable for
the main leg leading from PL1. The estimated time saving is 136
minutes which is calculated as follows:

 The assembly time for the hand lay production method is first
calculated as a basis to compare all the multi-core cable
138 User Guide HarnWare™ Version 6.3
alternatives. This is the sum of the braid and tube time synthetic
multiplied by the sum of the leg lengths plus the number of wires
in each leg multiplied by the leg length multiplied by the lay wires
time synthetic:

(2 + 0.6 + 0.5) * 13 + (30 * 2 + 10 * 0.6 + 20 * 0.5) * 2 = 192.3

 The estimated time for the preferred multi-core cable configuration

is calculated:

Add braid and tube (0.6 + 0.5) * 13 = 14.3

Lay wires (10 * 0.6 + 20 * 0.5) * 2 = 32

EPD Strip Back (2.86 - 2) * 5 = 4.3

EPD Preparation 2.86 * 2 = 5.72

Total Time 14.3 + 32 + 4.3 + 5.72 = 56.32

Time Saving 192.3 - 56.32 = 136 minutes

To develop a better understanding of the Multi-Core Cable (EPD)

Analyser, examine the effects of changing the time synthetics, leg
lengths, wire routing and number of wires in a sample design. For
example, in the above design trying changing the 600mm leg length to
1000mm. The best configuration then becomes two multi-core cables
for the PL2 and PL3 legs as this alternative avoids the need to strip
back and relay the wires in over a metre of multi-core cable. However,
before committing to such an option it would be advisable to:

 Analyse the assembly times in more detail with the labour

estimator.

 Consider the relative material costs for the multi-core cables and
the component wire, braid and tube.
© TE Connectivity Multi-Core Cable (EPD) Search 139

Multi-Core Cable (EPD)

Search
This option is accessed via a command button in the braid and tube
selection form and the cable details form or the HarnWare™
Tools>Multi-core cable>Search menu.

When accessed from the braid and tube form, the quantity and part
numbers of the wires routed through the selected leg are automatically
extracted from the wire list and entered into the multi-core cable
search form. Colours are removed from the wire part numbers, so you
should check the wire colours in any selected multi-core cable are
suitable. The number of layers of braid will also be automatically
transferred from the braid and tube form, but you will need to select
an appropriate jacket material. If you find a suitable multi-core cable,
140 User Guide HarnWare™ Version 6.3
the ‘OK’ command transfers the selected part number from the
treeview into the braid and tube selection form.

When accessed from the Tools menu, you will need to enter part
numbers of some or all of the wires required. Jacket and overall
shielding requirements can also be specified.

The database is searched for multi-core cables that match exactly, or

match with spare wires, or have similar diameter wires or have
different wire types. All cables found to match any of these search
conditions are listed and by clicking on their part numbers full details
and cross-section drawings can be displayed.

Wire part numbers are entered in the text box. As you start to enter a
wire part number the list box will be filled with TE wire part numbers
that match the characters you've typed. For example, once you've
entered '44A1' the list box is filled with all the wire part numbers from
the HarnWare™ database that start with '44A1'. Alternatively if you
enter '44A?1' the list box will be filled with all the part numbers
starting with '44A01', '44A11' and '44A31'.

The wire part number advice command button can help with
entering wire part numbers.

As wire part numbers are selected in the listbox, details and a cross-
section drawing are displayed.

Enter the minimum quantity of the wire that is required in the

multi-core cable. Use the add wire command button to transfer
the wire part number and quantity into the treeview. By default when
HarnWare™ searches for similar sizes, the limit is set to plus or minus
one gauge around the size entered. The limit can be adjusted for each
wire entered.

When a wire is selected in the treeview, a description of the

wire and a cross-section drawing are displayed. A selected
wire can be removed from the treeview using the delete wire
command button.
© TE Connectivity Multi-Core Cable (EPD) Search 141
The type of jacket material can be selected from the combo-box which
normally lists those that are preferred for the currently selected
harness material system. The ‘All’ option can be selected to fill the
combo-box with all the available jacket material options. Alternatively
the blank option can be selected in the combo-box if you do not wish
to include jacket material as a constraint when searching the database.

The required number of layers of braid or overall shielding can be

selected in the braid layers combo-box. Alternatively the blank option
can be selected if you do not wish to include layers of braid as a
constraint when searching the database.

Click the search command button to have HarnWare™ search

for multi-core cables (EPDs) that may suit your requirements.
Part numbers are listed for those cables that match your requirements:

 Exactly.
 With spare wires.
 Using different wire sizes within the limits defined.
 Using different wire sizes with spare wires.
 Using other wire types.
 Using other wire types with spare wires.
 Using other wire types with spare wires and different wire sizes.
Details on the alternative multi-core cables found in the database can
be viewed by expanding the treeview. Click on a multi-core cable part
number for further details and a cable cross-section drawing. Click on
a wire part number used within a multi-core cable for details on the
wire and drawings of the cross-section and wire colour(s).

Cable Database Set-Up

A separate utility program is used to enter the cable layout data into
the database. This utility uses cable layout drawings created in Visio
by the HarnWare™ Cable Lay Design and Filler Selection option.
These drawings can be modified prior to using the utility program to
save the layout details in the database. For example, when pilot and
142 User Guide HarnWare™ Version 6.3
direction colour coded wires need to be allocated to particular
positions in each cable layer.

Provided the number of wires and fillers and their sizes are correct,
the wire and filler part numbers used to generate the cable cross-
section drawing do not have to match those in the actual multi-core
cable. The actual wire and filler part numbers are listed in the cable
database. Fillers are ordered by diameter and then matched. Wires are
matched by the list numbers held in the database.

Database Selection
Use the HarnWare™ Tools>Multi-Core Cable>Set Cable Database
menu option to select the cable database. By default this is the
Cable.accdb file which is held in the HarnWare™ folder. Other
alternative cable databases installed by HarnWare™ include
'StandardCableRange.accdb' and 'VG95218 Part 28.accdb'.

Using this option enables you to switch between databases which can
be useful when different sets of multi-core cables are used on different
design projects.

These alternative cable databases can be saved on a shared network

disc drive to help distribute changes and ensure all users have access
to the same consistent data. HarnWare™ searches for the specified
cable database file in the installation folder and the specified folder
and then compares the file with any database file of the same name
that is stored in the user's application data folder. If the file isn't found
in the user's application data folder or if this file is an earlier version,
the database file is copied from the installation or the specified folder.
© TE Connectivity Braid &Tube 143

Braid &Tube
Opening Braid & Tube Form
Obtain the braid and tube form using one of the methods described in
the Open Shapes section for example:

 Click a harness leg line in the Design Wizard list,

double-click or use the HarnWare™ option from the
right-click menu for a harness leg in Visio. HarnWare™ will pop-
up in front of Visio and the form will be loaded with details such
as leg length, braid, tube and multi-core cable (EPD) part numbers
and cable bundle diameter, if you have used the wire routing
option.

 Alternatively if you will not wish to save data to a Visio drawing,

select 'Braid and Tube' from the HarnWare™ Window>Parts
menu. If the menu option is checked the form will contain
previously entered data, otherwise a new blank form will be
displayed.
144 User Guide HarnWare™ Version 6.3

Cable Lay Design

Click the cable lay design command button in the Braid and
Tube form if you would like to:

 Analyse the lay of wires that have been routed through

the leg

 Calculate the bundle diameter more accurately than the estimate

made by the wire routing option.

 Specify fillers

 Generate a cable cross-section drawing in Visio

This option is described more fully in the section entitled 'Cable Lay
Design'.
© TE Connectivity Braid &Tube 145

Braid & Tube Selection

Use the options in this form to build up the required layers of braid
and tube. One or two layers of braid and tube for the outer jacket can
be added. If necessary a layer of tube, or inner jacket, can be added to
pack up the wire bundle diameter to give a larger base diameter for
the first layer of braid.

The desired type of braid or tube is selected from the list in the
combo-box. Normally the combo-box displays only material types
that are preferred choices for the material system currently selected in
the HarnWare™ Options menu and displayed in the status bar.
However, by selecting the 'all' option you can access other material
types if your harness design requires you to use a non-preferred type.
Details on the harness design aspects of selecting the best type of
braid and tube are contained in the harness design section of the
online help system. When the braid or tube type combo-box is
selected, pressing <Shift>+F1 causes brief details of the type braid or
tube to be output.

You must build up the layers of inner jacket or packing, braid and
then tube, layer by layer in the correct order using the following
procedure:

 If braid is required, click the braid option button. A list box

containing the different types of TE braid will appear in the form.

 If you used the wire routing or cable lay design options,

HarnWare™ will have added the cable bundle diameter in the
diameters frame, but you can adjust this diameter if necessary.

 Click the database search toolbar icon

to obtain details of braid of the selected
type that is suitable for the cable diameter.

 HarnWare™ shows the number of suitable sizes of braid starting

with the largest diameter. Use the next database record toolbar
icons to view the other available options. For each option
HarnWare™ calculates the outside diameter that would be
146 User Guide HarnWare™ Version 6.3
obtained when using that braid on the cable bundle diameter; (the
database contains the wall thickness for each braid). HarnWare™
also outputs the minimum and maximum cable diameters the braid
can fit.

 When you are satisfied with the choice of braid, click the 2nd
braid layer or the tube option button to select the next layer. If you
require a 2nd layer of braid repeat the above process.

 If no suitable braid is found, click the inner jacket option. Select

an appropriate tube part number to increase the base diameter for
the braid. Click the braid option and use the braid selection
process again to see if a suitable braid part number can now be
identified.

 Tube selection is similar to braid. The list box is loaded with the
alternative tube types. The HarnWare™ database contains the wall
thickness at the fully recovered diameter. Wall thicknesses at other
diameters are calculated from the cross-sectional area based on a
formula that assumes the tube length shrinks by 5% over a
diameter range of 2:1 of the fully recovered diameter. If the
amount of unresolved recovery is less than 10% of the minimum
tube diameter the minimum diameter is highlighted in yellow; if
possible select an alternative tube. The default tube selection is
normally the largest that will fit. If you select a smaller alternative,
the maximum diameter text is highlighted in yellow as a warning
to check it will be possible to assemble the tube. For long leg
lengths it can be difficult to pull on tubes that only have a small
clearance.

 As each layer is selected, HarnWare™ outputs the braid and tube

part numbers. If necessary these part numbers can be changed
simply by typing in the text boxes.

 Click the save shape toolbar icon to save braid, tube and
filler data to the Visio harness leg shape. Alternatively use
the file menu save shape option or <Ctrl>+S. If you make a
mistake, this action can be undone using Visio's Undo command.
© TE Connectivity Braid &Tube 147

Braid Termination
The solder sleeves, protection sleeves and braid bandage used to
terminate braid are associated with the moulded parts at either end of
the harness leg. These parts are, therefore, selected using a form
which is accessed from the moulded part form.

Multi-Core Cables (EPD)

Where multi-core cables (EPD’s) are to be used in a harness design,
rather than a hand laid construction:

 Draw the harness.

 Define the wire list.

 Use the wire routing option.

 If required, the Multi-Core Cable (EPD) Analyser option can be

used to identify the configuration that would incur the minimum
assembly time.

 Select braid and tube for the harness legs as normal.

 The command button alongside the multi-core cable part

number text box provides access to the multi-core cable
details form which will help you enter or search for a suitable
cable.

 If, in a branched harness, a multi-core cable is to be stripped back

to the transition, only set the multi-core cable part number for the
leg that is completely formed from the multi-core cable. Leave the
multi-core cable part number blank in the other legs, where only a
few of the multi-core cable wires are routed.

 If, in a branched harness a multi-core cable is bundled with some

other wires for part of its length, only set the multi-core cable part
number for the leg that is completely formed from the cable. Leave
148 User Guide HarnWare™ Version 6.3
the multi-core cable part number blank in the other legs, where the
cable is bundled with other wires. In this case you should use the
cable lay design option to recalculate the diameter of legs that
contain the cable together with other wires.

 If a multi-core cable is bundled with other wires along its complete

length, enter the multi-core cable in the wire list as you would a
component wire.

When saving data to a harness leg and the multi-core cable part
number text box is not blank, HarnWare™ will compare the wire data
with any other harness legs in the drawing. If another leg specified as
a multi-core cable is found with some wires in common, an error
message is output and you are prevented from saving the data. You
can, however, specify the same multi-core cable part number for two
or more legs through which the same wires are routed. For example,
where a multi-core cable is used with a feed-through.

The parts listing option checks for wires that are routed through legs
that have been defined as a multi-core cable. Any such wires are not
included in the parts list and they are not ballooned in the legs through
which they are routed. The multi-core cable item number is entered in
the wire list table and the balloon on the harness leg. The multi-core
cable length is found by checking the routes of all the wires in the leg
and finding the longest of these. A 20mm (0.79”) per end allowance is
made when repair loops are specified, 100mm (3.94") is allowed for
bending wires through adaptors, etc. and an extra 10% lay loss
allowance is added when the multi-core cable is partly stripped back
or is partly routed in a leg with other wires.

The parts listing option ignores any braid and tube part numbers
included in legs specified as multi-core cables.

Details on the harness design aspects of using multi-core cables are

contained in the harness design section of the online help system.
© TE Connectivity Braid &Tube 149

Multi-Core Cable Details Form

This form is accessed via a command button in the braid and tube
selection form. It is intended to help you enter multi-core cable details
or to search for a suitable cable. Any bundle, braid or tube diameters
in the braid and tube selection form will be transferred to this form
when it is opened. Also any existing braid details will be entered.

The command button alongside the part number text box can be used
to search the cable database for multi-core cables.

The maximum adaptor diameter is the maximum diameter to which

the braid can be opened for fitting onto an adaptor. If this is not
known, a reasonable default is the next entry size above the outside
diameter of the cable. The command button alongside the maximum
adaptor diameter text box will enter this estimate. This diameter is
used when selecting adaptors.

If the braid outside diameter text box or the maximum adaptor

diameter text box is not blank or the number of braid layers is not "0"
the other two entries must be specified.

Lengths and Diameters

The lengths of braid, tube filler and EPDs are calculated by the parts
listing option. Braid and tube lengths are derived from the harness leg
length and adjustments for the styles of any moulded parts and
adaptors that are glued to the harness leg. For example, a greater
length is deducted from tube lengths when Uniboots rather than other
boots are used. In addition the length of braid is increased by 20% of
the leg length when the cable bundle diameter is larger than the
nominal diameter of the selected braid. The braid and tube
adjustments for each style of moulded part and adaptor are held in the
HarnWare™ database.

The parts listing option also checks for wires that are routed through
legs that have been defined as an EPD. Any such wires are not
included in the parts list and they are not ballooned in the legs through
150 User Guide HarnWare™ Version 6.3
which they are routed. The EPD item number is entered in the wire
list table and the balloon on the harness leg. The EPD length is found
by checking the routes of all the wires in the leg and finding the
longest of these. A 20mm (0.79”) per end allowance is made when
repair loops are specified, 100mm (3.94”) is allowed for bending
wires through adaptors, etc. and an extra 10% lay loss allowance is
added when the EPD is partly striped back or is partly routed in a leg
with other wires.

Unbraided Tinel and band strap adaptors are checked during the
adaptor selection process to ensure the braid can fit onto the adaptor.

Conduit
Conduit is selected using the conduit form. This form also allows
braid and jacket material to be selected for use over conduit. Different
shapes are used for conduit harness legs.
© TE Connectivity Cable Lay Design 151

Cable Lay Design

Overview
The cable lay design command button in the Braid and Tube
form allows you to:

 Analyse the lay of wires that have been routed through the leg.

 Calculate the bundle diameter more accurately than the estimate

made by the wire routing option.

 Specify fillers.

 Generate a cable cross-section drawing in Visio

The command calls up the cable lay design form. The wire list
number, quantity of wires and diameters are added into the list
box for each wire routed through the harness leg. These details
are obtained from the wire list in the harness drawing and can
be edited using the add and delete wire commands along with
the associated text boxes.
152 User Guide HarnWare™ Version 6.3

The style command button allows you to change the shape used to
draw the wire currently selected in the wire list box. The same
shapes are used for the drawing in the HarnWare™ form and
when the draw command is used to add a cross-section to the
Visio drawing.

If the wires in the harness leg are all of the same diameter,
HarnWare™ first attempts to apply the standard lay design for that
number of wires. If this is not possible, usually because an appropriate
size of filler is not available, a message is output and HarnWare™
then undertakes the more general lay design analysis. If a standard lay
design is possible this is displayed and you then have the option of
studying alternative designs.

The overall diameter calculated by HarnWare™ may differ from that

estimated using standard diameter factor tables. The difference may
be due to the size of fillers available or to the adjustments made to the
diameter of twisted pair wires.
© TE Connectivity Cable Lay Design 153
If the wires are not all the same diameter, a generalised cable lay
design analysis is undertaken. This compares a large number of
different arrangements of the wires routed through the harness leg.
HarnWare™ does not consider all arrangements, as this would take
far too long, but it does consider the arrangements that are most likely
to give the best solution. On a few occasions an experienced user may
observe that a better solution is possible, but the program will assist in
finding this optimum by displaying alternatives that are close to it.

The arrangement with the smallest overall diameter is displayed first

and it's number, along with the total number of alternative
arrangements, is flashed in green. You may look at other
arrangements by clicking the Next and Previous buttons. You may
return to the minimum diameter arrangement by clicking the minimum
diameter button. Each arrangement is labelled
with the wire numbers, trial number and the
calculated overall diameter.

Filler quantities and part numbers

selected by HarnWare™ are added to
the list box. These can be edited
using the add and delete commands
and the associated edit boxes.

Clicking the OK button causes the

calculated diameter to be added to the braid and tube form and any
filler data to be saved. This data is saved to the shape in the drawing if
the save shape option is used to save the harness leg data. Using the
cancel command allows you to exit back to the braid and tube form
without updating the cable bundle diameter or filler data.

Filler Type
The type of filler is selected using the combo-box. When the preferred
option is checked, the combo-box will only include the types of filler
preferred for use with the currently selected material system.
154 User Guide HarnWare™ Version 6.3
Details on the harness design aspects of selecting the best type of
filler are contained in the harness design section of the online help
system. When the filler type combo-box is selected, pressing the F1
key with the shift key held down (<Shift>+F1) causes brief details of
the particular type of filler to be output.

Twisted Pairs
Diameters of twisted pair wires are automatically reduced to account
for the fact that these wires can pack together in a smaller space than
other more rounded constructions. Any wire with a style including a
'2' in the name is taken to be a twisted pair and if the name also
includes 'Primary' it is assumed that there is no overall shield or
jacket. For these wires, the diameter is reduced by 15% if there are
more than 9 in the harness leg or 9% if there are more than 2. The
outside diameters of other styles of twisted pair wires are reduced by
10% if there are more than 9 in the harness leg or 5% if there are more
than 2.

Sub-Assemblies
In certain circumstances it can be useful to group some wires in a
cable together into sub-assemblies . For example, with cables
containing large numbers of wires or in branched harnesses where
certain wires need to be kept together in the centre of the cable.

To create a wire sub-assembly, select the wire or wires in the list-box.

Use the normal Windows shift or control plus mouse click methods of
selecting several wires in the list-box. Then click the sub-assembly
command which will generate a new form, similar to the cable lay
form containing the selected wires. Design the sub-assembly
in the same way as for a cable and click OK. In the main
cable form the wires selected into the sub-assembly will be
replaced in the list-box by a single line for the sub-
assembly.

To edit a sub-assembly, select it in the wire list and click the sub-
assembly command button. To explode a sub-assembly so that the
© TE Connectivity Cable Lay Design 155
wires are no longer grouped together, select the sub-assembly in the
wire list and click the delete wire command which is normally used to
copy wire data from the list into the edit boxes.

Cable Cross-Section Drawings

A cross-section drawing of the current arrangement may be added to
the harness drawing using the draw command. Except for any outer
braid or jacket you choose to add, the cross-section is drawn to-scale
and the shapes are grouped so that they can be easily moved
and sized to suit the wire number texts.

The labelling of cable cross-section drawings is controlled by

a HarnWare™ option menu setting. Unless the 'none' option is
selected, cable cross-section drawings are initially labelled with
numbers from the wire list as used in the HarnWare™ form. If the
'Item number' option is selected the parts lister will change these to
item numbers. If you change this HarnWare™ option simply re-parts
list the drawing to update the labelling of any existing cable cross-
sections, you do not have to re-generate the cable cross-section
drawings from the cable lay design form.

The cable cross-section shapes include a right-click menu option to

query and set the scale of the shape. This is useful when a drawing
contains a number of cable cross-sections and they all need to be set
to the same scale. If you size one shape to the required scale using the
normal Visio dragging method to move one of the shape handles.
With the right-click scale menu query the scale of the shape and then
right-click the other shapes to set their scales to the same value. The
default is 3:1 or 3 times scale.

Component Spacing
The minimum and maximum component spacings provide some
control over the cable lay design. These are normally set to 0. These
settings are used in the general lay analysis but not in the construction
of standard lays of common wire sizes.
156 User Guide HarnWare™ Version 6.3

Minimum Component Spacing

This is applied to all layers except the centre. It is assumed that the
centre layer will be closely packed at all times to provide a firm
foundation for outer layers.

If you enter a positive value, the components in outer layers will be

separated by at least this amount. This sometimes has the effect of
forcing components out of a layer into the next layer out and may
eliminate the need for filler. If you see an arrangement with one or
two filler wires in the outer layer you could try increasing the
minimum component spacing to see whether the fillers disappear.
Increasing the minimum spacing much beyond half the diameter of
the smallest wire may result in invalid arrangements.

Negative values of minimum wire spacing mean that the wires will be
squeezed together in the lay. Since wires may be oval rather than
round and may vary in size by a manufacturing tolerance, this may be
a valid design option. HarnWare™ does not reject solutions when the
outer layer is mostly filler wire, because these indicate that you could
try reducing the spacing to see whether the remaining wires can be
forced into the inner layers. However, large amounts of squeeze may
cause invalid arrangements.

The minimum spacing is applied to all wires equally. However, some

wires may be more oval than others and it may be better to change
individual wire diameters in order to obtain the best lay.

Maximum Component Spacing

The maximum spacing is generally less effective in optimising

arrangements than the minimum spacing. Nevertheless, it is useful if
you want to eliminate fillers in the outer layer.

The maximum spacing is only applied to the outermost layer. The

inner layers are packed as closely as possible without violating the
minimum spacing. If the outermost layer is not completely full of wire
then fillers are added. The number of fillers depends upon the
maximum spacing and the size of the fillers selected. HarnWare™
© TE Connectivity Cable Lay Design 157
will add as many fillers of the selected type without violating the
maximum spacing, then rearrange the components evenly around the
periphery.

The maximum spacing should be chosen with care and large values
may cause invalid arrangements. Initially it is best given the same
value as the minimum component spacing. After you are satisfied with
an arrangement, and it has filler wires in the outermost layer, you can
try increasing the maximum component spacing to see if you can
reduce the number of fillers while retaining an acceptable lay.

Rules and Limitations

If a multi-core cable (EPD) is routed in the leg along with other wires,
you will need to use the sub-assembly feature and, if necessary, adjust
the outside diameter to that of the multi-core cable.

The program accepts data for up to 40 different wires, and up to 100

wires in total. In addition, up to 100 fillers may be added by
HarnWare™. These limitations can be worked around if some wires
are grouped together into wire sub-assemblies. Theoretically a cable
could contain up to 100 sub-assemblies each containing 100 wires, i.e.
a total of 10,000 wires.

The arrangements for 1 to 8 wires in the centre are analysed, if

possible, and the following solutions are rejected:

 More than 6 layers.

 More than 30 components in a layer.
 More fillers than wires in the cable, or more fillers than wires in
the outer layer, except when there is just one wire in the outer
layer.
 When all reserved small wires cannot be put in interstices.
 Fillers are added into cable interstices when the diameter of the
interstice is 2.5mm (0.1”) or larger. A filler is also added in the
middle of a five-component centre arrangement, provided that it is
larger than the smallest available filler.
158 User Guide HarnWare™ Version 6.3
© TE Connectivity Connectors 159

Connectors
Opening Connector Form
Obtain the connector form using one of the methods described in the
Open Shapes section, for example:

 Click a connector line in the Design Wizard list, double-

click or right-click a connector shape in Visio to select
the connector, switch to HarnWare™ and load the data
into the form. The system will obtain what details it can
from the shape. For example, the connector code and shell size.

 Alternatively if you will not wish to save data to a Visio drawing,

select 'Connector' from the HarnWare™ Window>Parts menu. If
the menu option is checked the form will contain previously
entered data, otherwise a new blank form will be displayed.
160 User Guide HarnWare™ Version 6.3

Connector Selection
Connector requirements can be set in any or all of the fields in the
requirement frame. For example, if you know the connector part
number begins with 'D38' and the shell size is '19':

 Select 'PartNo' in one of the two Field combo-boxes.

 Enter 'D38' in the associated Value combo-box.

 Select '19' in the shell drop down list.

When Spec is selected in one of the two Field combo-boxes, anything

you type in the associated value combo-box is matched with the first
matching entry. If no match is found the value combo-box is blanked
before the database is searched.

If the form is linked to a Visio shape the required details and style of
part may have been already entered by the system. Details on the
© TE Connectivity Connectors 161
various design aspects of specifying connectors are contained in the
harness design section of the online help system. When the connector
style combo-box is selected <Shift>+F1 causes brief details of the
particular style to be output.

If you are unsure of the shell sizes available for a particular connector
code, click the command button next to the shell size combo-
box. This allows you to choose a shell size from a list that
includes only those applicable to the selected connector code.

When a connector code combo-box is selected, <Shift>+F1 causes

brief connector details associated with the particular code to be
output.

When extra details are available on a selected connector manufacturer,

a '?' command button will appear alongside the manufacturer combo-
box. In the case of a manufacturer that has been taken-over by
another company, the current alternative name(s) will be shown
and selected.

Click the database search icon in the

toolbar or use the Tools menu or
<Ctrl>+D. The HarnWare™ parts database will be searched for any
connectors that match the given details. The number of parts found to
meet these criteria is displayed along with the part number, series,
class and other information for the first part.

Other suitable parts maybe viewed using the database next record
icons in the toolbar. The four buttons can be used to move the first,
previous, next or last part found to meet the specified criteria.
162 User Guide HarnWare™ Version 6.3
If no suitable parts are found the system outputs '0 Found' in the form.
Try removing some of the requirements to see if they are too
restrictive. Alternatively it may be that the particular connector is not
in the database. In this case you can type in the details and save them
to the shape so that they will appear in the parts list. Contact
HarnWare™ system support if you feel the connector should be added
to the database.

When the correct base connector part number has been identified, use
the command button in the proposed frame, to specify the full
connector part number, check the connector planform and verify the
compatibility of the wires and contacts. Refer to the section
Connector Planforms and Part Number Construction for further
details on this option.

If solder sleeves or wire markers are required for wires associated

with the connector, click the devices command button to
select these parts. This facility is described in the Devices
section. This option can also be used to add filler plugs if
any connector contacts are unused.

You can edit or add information to the text boxes in the

proposed frame. For example, you may need to add extra characters to
the connector part number before saving the data to the shape in the
drawing.

NOTE

HarnWare™ makes extensive use of curly brackets {} to separate

items of information in shape data1 fields and elsewhere. Do not use
{} in any part number, description or any other text you enter in
HarnWare™.

When you have the required connector shown in the form you
can use the 'Save shape' option in the file menu, toolbar or
<Ctrl>+S. This saves the connector, solder sleeve and wire marker
other information to the shape in the Visio drawing. If you make a
mistake, this action can be undone using Visio's Undo command.
© TE Connectivity Connectors 163

Connector Planforms & Part

Number Construction
The part number and planform command button in the
connector form calls up the form used to help construct
connector part numbers and identify planform details. This form also
helps check that wires and connector contacts are compatible.
Connector planforms are shown and can be added to the Visio
drawing.

The connector form helps identify base connector part numbers using
such criteria as manufacturer, class, specification. The connector
planform and part number construction form then helps supplement
that with all the other part number details. The planform drawing and
details help ensure the correct part number is specified and that it is
compatible with the wires.
164 User Guide HarnWare™ Version 6.3
On loading this form, HarnWare™ searches the wire list page(s) in
the current Visio document for wires that run to the connector. Any
connector part number details that have been retrieved from the
drawing or the database are used to select the part number options. In
the case of connector codes 30, 40 and 61 shell sizes might be
automatically converted between their numeric and alpha equivalents.

As each connector part number option is selected in the combo-boxes,

a description of the option is normally output and the generated part
number text box is updated. Changing an option with a title shown in
bold text, will cause a new planform to be drawn. The hierarchical list
of wires and contacts will also be refreshed.

Option buttons allow contacts to be shown in the planform either as

filled circles or as contact references. The picture box is normally
scaled to hold planforms up to 40mm diameter. Larger planforms are
scaled to fit the box. This form can be resized or maximised to
increase the size of the planform drawing and hierarchical treeview of
wire and contact details. The numbers and sizes of contacts in the
planform layout are also displayed. Planforms are drawn showing the
mating face of connectors fitted with pin contacts and the termination
side for connectors fitted with socket contacts.

The draw command causes the current planform to be drawn in Visio

at a 1:1 scale. If a planform drawing has already been drawn for the
connector that is associated with the connector form, it is replaced
with the new drawing. Alternatively the new drawing is added on top
of the connector and it will need to be repositioned in the drawing. A
right-click 'Scale' menu is added to connector planform drawings to
allow all planforms to be set to a common scale. Planforms with
densely packed contacts may need to be drawn at a larger scale than
1:1 to avoid the contact references overlapping.

The hierarchical treeview lists wire conductors and contacts in the

planform. HarnWare™ allocates wire conductors to suitably sized
contacts. If there are any remaining conductors, a red background is
added to the number of 'Unassigned Conductors' legend. If some
wires are shielded, a yellow background is added to the 'Shields'
legend. HarnWare™ does not allocate contacts for shields, so you will
need to manually check that sufficient contacts remain for any shield
© TE Connectivity Connectors 165
terminations that may be required. If some contacts remain unassigned
a yellow background is added to the 'Unassigned Contacts' legend as a
reminder that you may need to add some filler plugs using the Devices
command button in the connector form. Clicking the + signs in the
treeview allows the allocation of wires and contacts to be studied in
more detail.

If the solder contact option is selected in the Connector form, any wire
size less than or equal to the maximum specified in the database for
the contact will be accepted. If the crimp contact option is selected in
the Connector form only wires between the minimum and maximum
specified for the contact will be accepted. For example, a 22 AWG
crimp contact will only accept 22 and 24 AWG wires but a 22 AWG
solder contact will accept any wire size of 22 AWG or less.

If the wire list contains wires of unknown conductor diameters, a red

background is added to the 'Unknown Diameters' legend. You will
need to manually check the contacts are suitable for such wires.

Where a databus harness leg is routed to a connector, the cable is

assigned to a single size 8 contact which is normally used for MIL-C-
38999 triaxial contacts. However, if a databus cable is included in a
wire list and is routed to the connector via a normal harness leg, the
cable is treated as a 24 AWG shielded twisted pair.

The ‘?’ command outputs details of the connector, specification,

etc.

The connector planform search option provides a more direct

means of identifying the part number combinations for
which planforms exist.

Some connectors including GPR rectangular connectors and ProBeam

fibre optic connectors are made up of more than one part. For
example, GPR connectors comprise a shell and one or more inserts
requiring two or more part numbers to be specified. When ancillary
parts are required a command button is displayed alongside the part
number combo-box. This command button opens the ancillary
connector parts form which enables ancillary parts to be added,
deleted or changed. If standard ancillary parts are available for the
166 User Guide HarnWare™ Version 6.3
selected connector, the categories and parts are listed in the 'Standard
parts' frame. NB Changes made in the connector ancillary parts form
are discarded if another part number is subsequently selected in the
connector planform form.

Clicking the OK command button causes the generated connector part

number to be transferred into the proposed part number text box in the
connector form. Use the cancel button to dismiss the form and the
generated connector part number.

Connector Planform Search

The connector planforms and part number construction form contains
all the options for each part number parameter. However, not all
combinations of the parameters are valid. When a specific connector
part number is known, all the options are defined, but when this is not
the case, scrolling through all the part number options to search for
planforms can be tedious.

The binocular, planform search command button in the

connector planforms and part number construction form is
useful for quickly identifying the part number options for
which there are planforms. Clicking this command causes a form to be
displayed which contains a tree-view of the valid combinations of the
part number parameters for which planforms are defined in the
database. When an option at the bottom of one of the branches is
selected, the planform is drawn.
© TE Connectivity Connectors 167

Option buttons allow contacts to be shown in the planform either as

filled circles or as contact references. The picture box is normally
scaled to hold planforms up to 40mm diameter. Larger planforms are
scaled to fit the box. This form can be resized or maximised to
increase the size of the planform drawing and hierarchical treeview of
wire and contact details. The numbers and sizes of contacts in the
planform layout are also displayed. Planforms are drawn showing the
mating face of connectors fitted with pin contacts and the termination
side for connectors fitted with socket contacts.

When a planform is selected, clicking the OK command causes the

relevant part number options to be selected in the connector planform
and part number construction form. The cancel command simply
dismisses the planform search form.
168 User Guide HarnWare™ Version 6.3

Connector References
If the connector reference is found to contain a carriage return, a
warning is issued. If you save data to the shape HarnWare™ will
replace the carriage return with a space. This can lead to some
confusion so you should use single line connector references.

If you change the connector reference in the HarnWare™ form, save

the data to the connector shape and reopen it before using the devices
command button. This will ensure the devices form is loaded with
wire data relating to the correct connector reference.

Connector Part Number Texts

The connector part number text command button, near the
proposed part number textbox in the connector selection
form, adds or updates the connector part number text shape in the
Visio drawing..

The connector part number text shape is one of those in the

HarnWare™ Miscellaneous stencil.

HarnWare™ adds new connector part number shape onto the related
connector shape in the drawing. The leader line is glued to the centre
or pin of the connector shape. Therefore, when you drag the part
number text into the required position the end of the leader line will
remain anchored to the centre of the connector shape.

If a connector part number text shape is included in the drawing, the

part number is updated whenever connector data is saved from the
connector selection form.

A separate Visio drawing layer is used for connector part number text
shapes. This allows all the shapes to be easily selected should, for
example, you wish to delete them all.
© TE Connectivity Connectors 169
Connector part number text shapes are separate from the related
connector shapes. Therefore, if you delete a connector shape you
should be careful to also delete the related part number text.

This command can only be used if related to the connector selection

form there is a connector shape in the current active Visio page.

Keyway Angles
If the connector has anti-rotation teeth and a particular angle of
orientation relative to the master keyway is required for angled
adaptors, click the keyway command button in the proposed frame.
This option automatically calculates the achievable angles.
Use this option after a connector code has been retrieved
from the database and the shell size has been specified.

The keyway command button allows you to add a keyway shape to

the drawing. Normally the angles available for the currently selected
connector code and shell size are listed in a combo-box. However, if
the connector does not have anti-rotation teeth, or if the number is
unknown, a text box allows you to enter any angle.

Most connector designs feature anti-rotation teeth to facilitate the

tightening of accessories such as adaptors and prevent rotation after
assembly. These teeth govern the position of the connector's master
keyway. If a particular angle of orientation relative to the master
keyway is required for angled adaptors, the number of teeth and the
consequent angular increment govern the positions available. This is
especially important with short harness legs.

When a keyway shape has been added using this command, the right-
click 'Set Angle' menu for the keyway shape, automatically rounds
angles to the nearest available for the connector's code and shell size.
170 User Guide HarnWare™ Version 6.3

Go To Adaptor/KTKK
By clicking the command button with the adaptor icon the system will
search for an adaptor or KTKK shape that is glued to the
connector shape in Visio. If one is found the shape is
selected and the form displaying the adaptor or KTKK and
any associated information is displayed.

Combined Connector/Adaptors
Connectors that include an adaptor are treated slightly differently. To
search for these connectors you must first select a style in the combo-
box that ends in ‘A’. The form will display the boot and entry
diameters for any connectors that are found in the HarnWare™
database. If the entry size is smaller than the harness leg that is glued
to the connector, it is highlighted in red.

Flying Leads
If ‘FlyLeads’ is selected in the style combo-box,
use the solder sleeve command button to specify
any solder sleeves or wire markers. The fields in
the main connector form for part numbers,
manufacturer, etc. are not relevant for flying
leads.

D Connectors
D Connectors are treated slightly differently. To search for these
connectors you must first select the D-Conn style in the combo-box.
The form will display the length and width for any D connectors that
are found in the HarnWare™ database.

When the D-Conn style is selected, the shell size combo-box is loaded
with the available D subminiature connector shell sizes 1 to 5. When
the database is searched, the number of contacts available for each
shell size in the Amplimite product range will be shown in the part
© TE Connectivity Connectors 171
number text-box. Use the 'generate part number' command button to
select the actual Amplimite part number and, if required, to draw the
planform.

GPR Rectangular Connectors

GPR rectangular connectors are also treated slightly differently. To
search for these connectors you must first select the 'Rect' style in the
combo-box. GPRA connectors contain a single insert and are treated
as a single connector whereas GPRB2 connectors have two inserts
which are effectively two connectors represented by two shapes glued
together in the drawing:

GPRB2-A shell and insert. The parts selected for this shape will
include the shell, the 'A' insert and the required contacts. The ancillary
insert and contact part numbers and quantities can be edited via the
'ancillary parts' command button in the 'connector part numbers and
planforms' form.
172 User Guide HarnWare™ Version 6.3
GPRB2-B insert. The parts selected for this shape will include the 'B'
insert and the required contacts. The ancillary contact part numbers
and quantities can be edited via the 'ancillary parts' command button
in the 'connector part numbers and planforms' form.

ProBeam Fibre Optic

Connectors
ProBeam fibre optic connectors are also treated slightly differently.
To search for these connectors you must first select the 'FibreSt',
'Fibre90' or 'FibreRec' style in the combo-box. The ancillary insert,
ferrule and cable adaptor kit part numbers and quantities can be edited
via the 'ancillary parts' command button in the 'connector part
numbers and planforms' form.
© TE Connectivity Connectors 173

RF Coax Connectors
To search for RF MIL-C-39012 coax connectors select the
'RFPlugA', 'RFJackA', 'RFPlugRA' or 'RFWallA' style in the combo-
box and search the database and then use the 'connector part numbers
and planforms' form to find the connector part number required for
the particular RG cable.
174 User Guide HarnWare™ Version 6.3

Splices
When a splice is required in a harness use the splice shape from the
connector stencil. This must be glued to a part of the harness, usually
to a transition. This shape is a special form of connector, so opening
the shape causes the connector form to open with the ‘Splice’ style
selected in the combo-box. Splice shapes are given a reference just
like connectors. This reference appears in the wire form when a line in
the wire list is opened.

When 'Splice' is selected in the connector form style combo-

box, use the splice command button to call up the form used
to select splices and wire markers. This form is similar to
that used for selecting devices which is described in the
Devices section..
© TE Connectivity Connectors 175

HarnWare™ searches the wire list page(s) in the current Visio

document for wires that run to the splice. These wire part numbers are
loaded into the list box. Wire part numbers that include ‘SZF’ or
‘Filler’ are excluded from the list. The circular mil. areas (CMA) of
these wires are loaded into the CMA list box.

When CMAs are added or removed from the list HarnWare™:

 Sums the total area. You can change this total if required.

 Sets the part quantity text box to the number of wires times the
number of conductors for the currently selected wire. You can
change the part quantity if required.

Different types of splice and wire marker are selected from the
combo-box. The frame caption indicates whether the current selection
is a splice or a wire marker. A brief description of the type of part is
176 User Guide HarnWare™ Version 6.3
also output. Normally only the types suitable for the current harness
material system are shown. Click the ‘All’, rather than the ‘Preferred’
option button to access other types. Details on the harness design
aspects of selecting the most appropriate type of splice and wire
marker are contained in the harness design section of the online help
system. When the splice type combo-box is selected, <Shift>+F1
causes brief details of the particular type of splice to be output.

When the total area, working diameter or the selected type of part
changes, HarnWare™ searches the database for any parts of the
selected type that will fit the working dimension. If any parts are
found, the part number text box is set.

When an in-line, rather than a butt, type of splice is selected,

HarnWare™ sub-divides the list of wires into two groups. The
grouping chosen is that in which the two total CMAs are as near equal
as possible. For in-line crimp splices, it is the list of CMAs rather than
the total CMA which is used to determine the part required. The
database is searched for parts that are suitable for both calculated
areas.

Click the ‘copy to list’ command button to add the contents

of the part number and quantity text boxes to the list of
selected parts. To remove a part from the list, select it and
click the ‘copy from list’ command button. This copies the
part number and quantity into the text boxes and removes the data
from the list.

To select wire markers for all wires, select the required

type of wire marker and then click the ‘wire marker’
command button.

Click ‘OK’ to accept the list of splices and wire markers. If you
subsequently save the connector data to the shape in the harness
drawing, the splice and wire marker data will also be saved. Wire
marker quantities saved to the drawing are divided by 4, the number
of markers per part number so that the correct number is output in
parts lists and labour estimates. Wire marker quantities are not added
to parts list balloons.
© TE Connectivity Connectors 177
Click ‘Cancel’ to exit from the splice form without saving any of the
changes you made to the list of selected parts.
© TE Connectivity Devices 179

Devices
The devices command button in the connector form calls
up the form used to select solder sleeves, wire markers,
contacts, insulation caps and tubes. You can also use the
form to enter filler plug part numbers and connector
accessories.

HarnWare™ searches the wire list page in the current Visio document
for wires and databus cables that run to the connector. These wire part
numbers are loaded into the list box. Wire part numbers that include
‘SZF’ or ‘Filler’ are excluded from the list.
180 User Guide HarnWare™ Version 6.3
To select wire markers for all wires, first select the required
type of wire marker and the required number of scores. By
default the number of scores is three. Then click the 'wire
marker' command button. Details on the harness design aspects of
selecting the most appropriate type of wire marker are contained in
the harness design section of the online help system. When the wire
marker or solder sleeve type combo-box is selected, <Shift>+F1
causes brief details of the particular type to be output.

To select solder sleeves for terminating all shielded wires,

choose the required solder device and click the ‘terminate
shields’ command. Details on the harness design aspects of
selecting the most appropriate type of solder sleeve are contained in
the harness design section of the online help system.

If the shields are terminated to the connector shell rather than a pin,
you may wish to replace one solder sleeve with a pre-installed lead
with one with a pre-installed braid. To do this:

 Select the pre-installed lead solder sleeve in the list of part

numbers.

 Click the ‘copy from list’ command button to copy the

part number and quantity into the text boxes.

 Reduce the quantity in the text box by one.

 Use the ‘copy to list’ command button to add the part number and
quantity into the list.

 Use the procedure described below to select the solder sleeve with
a pre-installed braid.

When you select a wire in the list box, the number of conductors and
the number of wires are displayed. Also the diameter list box is loaded
with the outside diameter, shield diameter, wire diameter and
conductor diameter, where these are known. Where these are not
known, HarnWare™ uses 0.2mm (0.008”) wall thickness to estimate
the shield diameter from the outside diameter and 0.375mm (0.015”)
© TE Connectivity Devices 181
to estimate the wire diameter from the conductor AWG. You can
change the value in the diameter combo-box if the outside, shield,
wire or conductor diameter is not correct.

Click the ‘+’ command button to add a diameter to the

list of working diameters. To remove a diameter from
the list, select it and click the ‘-‘ command button.

When diameters are added or removed from the list of diameters

HarnWare™:

 Estimates the total working diameter by summing the diameters in

the list, or when there are three or more diameters, by using a
cable bundle diameter formula. You can change the estimated
working diameter if required.

 Sets the part quantity text box. If the diameter selected in the
diameter list is a conductor diameter, the quantity is set to the
number of wires times the number of conductors. Otherwise the
quantity is set to the number of wires. You can change the part
quantity if required.

Different types of solder sleeve, wire marker, insulation cap and tube
are selected from the combo-box. The frame caption indicates the part
type relevant to the current selection and a brief description is also
output. If you are unsure which part numbers refer to a particular type
of part, click on the combo-box and scroll through the list using the
keyboard up and down arrows while watching the frame caption as
each part number option is selected.

Normally only the types suitable for the current harness material
system are shown. Click the ‘All’, rather than the ‘Preferred’ option
button to access other types.

When the working diameter or the selected type of part changes,

HarnWare™ searches the database for any parts of the selected type
that will fit the working diameter. If any parts are found, the part
number text box is set. When selecting solder sleeves, the required
working diameter is that of the wire shield(s), whereas markers and
insulation caps are selected using the outside diameter of the wire(s).
182 User Guide HarnWare™ Version 6.3
If a databus cable is glued to the connector shape, databus pin and
socket contacts will appear as options in the list of part types. The
appropriate pin or socket part number is determined by the type of
databus cable rather than the diameter. With the part type combo-box
selected use <Shift>+F1 to obtain further information on these parts.
NB You should ensure that the contacts are compatible with the
connector - normally a MIL-C-38999 Series 1, 3 or 4 and a size 8
contact cavity. Databus contacts can also be included as separate
harness drawing shapes when they are selected using the databus
form.

Click the contact selection command to access the form used for
selecting coax and other connector contacts. This form contains lists
of contact styles, connector specifications and cable part numbers for
which contacts are available. HarnWare™ attempts to identify and
select the connector specification and series for the connector
currently selected in the connector form. If a contact is available for
any of the wire part numbers that are routed to the selected connector,
the wire/cable part number is selected.

As the contact style, connector specification or cable part number

selections are changed, the list of suitable contacts is updated. A
description of the selected contact is output to help ensure the correct
contact is selected.

When a contact part number is selected, clicking the 'OK' command

will copy the part number into the device selection form where the
required quantity can be entered.

Click the ‘copy to list’ command button to add the contents

of the part number and quantity text boxes to the list of
selected parts. To remove a part from the list, select it and
click the ‘copy from list’ command button. This copies the
part number and quantity into the text boxes and removes the data
from the list.

If you are unsure of the number of filler plugs that may be needed,
type an 'A' in the quantity text box and HarnWare™ will insert 'A/R'
(as required) for the quantity. This option is only allowed when 'Filler
© TE Connectivity Devices 183
Plug' is the selected type of part. The planform option in the connector
form may help you determine the required number of filler plugs.

Click ‘OK’ to accept the list of solder sleeves and wire markers. If
you subsequently save the connector data to the shape in the harness
drawing, the solder sleeve, wire marker, filler plug, insulation cap and
tube data will also be saved. Wire marker quantities saved to the
drawing are adjusted to account for the number of scores. For
example, if three scores is selected the quantity is divided by 4, the
number of markers per part number so that the correct number is
output in parts lists and labour estimates. Wire marker quantities are
not added to parts list balloons.

Click ‘Cancel’ to exit from the device form without saving any of the
changes you made to the list of selected parts.

A different form is provided for selecting solder sleeves used to

terminate braid or gross shields. This is accessed using a command
button in the moulded part selection form.
© TE Connectivity Adaptors 185

Adaptors
Opening Adaptor Form
Obtain the adaptor form using one of the methods described in the
Open Shapes section, for example:

 Click an adaptor in the Design Wizard list, double-click

or right-click an adaptor shape in Visio to select the shape
and switch to HarnWare™. The system will obtain what
details it can from the shape and any shapes that are glued to it.
For example, if a connector is glued to the adaptor, the connector
code and shell size will be obtained and the adaptor style will be
obtained from the adaptor shape. HarnWare™ searches for a
harness leg either glued directly to the adaptor or to a moulded
part that is glued to the adaptor. If a leg is found, the cable
diameter and braid part numbers are retrieved.

 If you do not wish to save data to a Visio drawing, select 'Adaptor'

from the HarnWare™ Window>Parts menu. If the menu option is
checked the form will contain previously entered data, otherwise a
new blank form will be displayed.
186 User Guide HarnWare™ Version 6.3

Adaptor Selection
Click the required style in the drop down list box. An image
representing the selected adaptor style is displayed as different styles
are selected in the combo-box. Details on the harness design aspects
of selecting the most appropriate type of adaptor, material and finish
are contained in the harness design section of the online help system.
When the adaptor style, finish or material combo-boxes are selected,
<Shift>+F1 causes brief details of the particular item to be output.

Choose the material and finish for the adaptor that will be compatible
with the connector. The two combo-boxes are filled with the material
and finish that are appropriate for the selected style of adaptor and
either one or two character material codes will be displayed. The
adaptor finishes listed in the combo-box are determined by the
selected style of adaptor and material. For example, the ‘Q’ zinc
cobalt finish is only displayed for Tinel adaptors and the ‘W’ shot
blast option is only displayed when the selected material is stainless
© TE Connectivity Adaptors 187
steel or nickel-aluminium bronze. When you click one of the two
combo-boxes a description of the adaptor material or finish is
displayed.

Enter the required connector code, shell size and cable diameter. If the
form is linked to a Visio shape the required details may have been
already entered by the system. If the adaptor is glued to a harness leg
or to a moulded part that is glued to a harness leg, the leg diameter
will be added to the form.

The shell sizes available for the each connector code are loaded into
the combo-box whenever a new connector code is selected.

Click the database search button in the

toolbar or use the tools menu option or
<Ctrl>+D. The HarnWare™ parts database will be searched for any
adaptors of the given style that are available for the given connector
code and shell size. If a cable diameter is specified, a further
constraint is that the adaptor entry size must be larger (an alternative
selection method is available for adaptors that are used with
Uniboots). The number of parts found to meet these criteria is
displayed along with the part numbers and diameters for the first part.

Other suitable parts maybe viewed using the database next record
icons in the toolbar. The four buttons can be used to move the first,
previous, next or last part found to meet the specified criteria.

If no suitable parts are found the system outputs '0 Found' in the form.

When you have your preferred choice of adaptor shown in the

form you can use the 'Save shape' option in the file menu,
toolbar or <Ctrl>+S. This saves the part number and diameters with
the shape in the Visio drawing. If you make a mistake, this action can
be undone using Visio's Undo command.

When you save adaptor data to the drawing, HarnWare™ checks the
selected style of adaptor against the currently selected material
system. A warning is displayed if the adaptor style is one that is not
normally used with the material system. HarnWare™ also checks if
the harness leg includes braid and compares this with the adaptor
188 User Guide HarnWare™ Version 6.3
style. A warning is issued if, for example, no braided leg can be found
glued to a Tinel adaptor.

Go To Connected Parts
By clicking the boot command button the
system will search for a moulded part shape
that is glued to the adaptor shape in Visio. If
one is found the shape is selected and the form displaying the
moulded part style and diameters is displayed.

By clicking the connector command button the system will search for
a connector that is glued to the adaptor. If one is found the shape is
selected and the form displaying the leg data is displayed.

By clicking the leg command button the system will search for a
harness leg that is either glued directly to the adaptor or to a moulded
part that is glued to the adaptor. If one is found the shape is selected
and the form displaying the leg data is displayed.

Non-Preferred Adaptors
Some adaptors, for example, Type 2 adaptors and STXR adaptors are
more expensive and should not be used if there is a more cost
effective alternative. Part numbers of these non-preferred parts are
shown in the adaptor form on a yellow, rather than a white
background.

Code 18 Adaptors
Some adaptors for code 18 connectors vary according to the connector
manufacturer. When connector code 18 is selected, the adaptor form
includes a list of the connector manufacturers and their codes. When
opening an adaptor shape, HarnWare™ checks for a connector that is
glued to the adaptor. If possible, the connector manufacturer and class
are obtained from the connector and used to select the required
manufacturer code.
© TE Connectivity Adaptors 189
There are three different cases that can be encountered for code 18
adaptors:
1) Where there is no difference between connector manufacturers.
HarnWare™ will search the database ignoring any manufacturer
you select.
1) Where there is a difference between connector manufacturers that
affects the Z or S diameters. Your choice of manufacturer will
affect the adaptor part numbers and diameters selected by
HarnWare™.
1) Where there is a difference between connector manufacturers that
does not affect the Z or S diameters. Your choice of manufacturer
will not affect the adaptor diameters, but you will notice that the
code in the part number changes when different manufacturers are
selected.

Code 54 Adaptors
Some adaptors for code 54 connectors vary according to the Mil Spec.
When opening a code 54, shell size 12 adaptor, HarnWare™ checks
for a connector glued to the adaptor and obtains the Mil Spec. In the
case of MIL-C-81703 connectors a shell size 14 rather than 12 is
used. HarnWare™ issues a warning for this special case.

Code 79 Adaptors
Some adaptors for code 79 connectors vary according to the connector
class. When opening a code 79 adaptor, HarnWare™ checks for a
connector glued to the adaptor and obtains the class. This data is then
used to ensure the correct adaptor is selected.

PATT 608, code 79 adaptors are a special case and are normally only
supplied in nickel aluminium bronze. HarnWare™ checks this is the
case when saving adaptor data to the drawing.
190 User Guide HarnWare™ Version 6.3

Code 88 Adaptors
Code 88 connectors vary according to the connector series. When
opening a code 88 adaptor, HarnWare™ checks for a connector glued
to the adaptor and obtains the connector series. If none is found, the
relevant connector series should be selected in the HarnWare™
adaptor form to ensure the correct part is selected.

Tinel Adaptors
If an unbraided Tinel adaptor style is chosen and a connected harness
leg with one or two layers of braid is found:

 The adaptor S diameter is checked against the allowable diameter

ranges for the braid.

 The entry size is checked to ensure adequate clearance is available

to roll-back the layer(s) of braid over the outside leg diameter.

To obtain the adaptor S diameter onto which the braid is fitted,

HarnWare™ adds a standard wall thickness of 1.65 mm (0.065”) to
the entry size stored in the database. This is compared with the
preferred and permissible diameter ranges for the braid part number(s)
stored in the database.

If the adaptor S diameter size falls outside the preferred range, the S
diameter is highlighted in yellow, or if it falls outside the permissible
diameter range, it is highlighted in red. If you then save the data to the
adaptor shape in Visio, HarnWare™ will warn you that the braid is
not suited to the adaptor. If possible you should choose an alternative
braid. After changing the braid and saving the data to the leg shape,
open the adaptor form again to refresh the associated braid details.

If the entry size is too small to allow the layer(s) of braid to be rolled
back over the leg, the entry size diameter is highlighted in yellow. If
you then save the data to the adaptor shape in Visio, HarnWare™ will
warn you that the entry diameter is too small. It may be advisable to
choose an adaptor with a larger entry size.
© TE Connectivity Adaptors 191
The above checks are not required with braided Tinel adaptors
because the braid does not have to fit over the adaptor S diameter and
the entry size does not have to be large enough to allow the braid to
be rolled back over the cable.

In the case of unbraided Tinel adaptors, the number of layers of braid

in the connected leg is checked to determine the correct lock ring. For
one layer of braid, an 'A' is inserted in the part number, for two layers
of braid a 'B' is inserted in the part number. In the case of braided
adaptors an 'A' is inserted in the part number. NB In cases where a
single layer of thicker 30 AWG braid is used, change the Tinel ring
reference in the adaptor part number from 'AI' to 'BI'.

Where a Tinel adaptor with an entry size of 07 or less is used with a

multi-core cable, an ‘A’ ring is always specified.

For Tinel and braided adaptors HarnWare™ will normally first output
the largest non-type 2 adaptor that will fit the braid and cable
diameters. However, when a Tinel or braided adaptor is used with a
Uniboot, 202C6 or 202G6, the smallest adaptor is output first.

Band Strap
When a Band Strap style of adaptor is selected, an ‘A’ or ‘B’ suffix is
automatically appended to the part number. This is determined by the
Band Strap Adaptor source which is currently selected in the Options
Menu. If UK is the selected source a ‘B’ suffix is used, if USA is the
selected source an ‘A’ suffix is used.

Conduit Adaptors
When a conduit style of adaptor is selected, the cable diameter text
box is changed to a combo-box containing a list of conduit part
numbers. When an adaptor shape is opened HarnWare™ searches for
a conduit harness leg either glued directly to the adaptor or to a
moulded part that is glued to the adaptor. If a conduit leg is found the
conduit part number and any braid part numbers are retrieved.
192 User Guide HarnWare™ Version 6.3
If no adaptor is found to suit the selected connector code, shell size
and conduit part number HarnWare™ will list any adaptors that are
available to fit other conduit part numbers.

Spin-Lock Adaptors
Cable-clamp spin-lock adaptors are selected in a similar manner to
other adaptors. However, please note that these are not used with
boots. Mono-boot spin-lock adaptors are supplied as an adaptor/boot
assembly and are selected in a similar manner to other KTKKs.

A range of Side Entry Bushing (SEB) parts are available to pack

cables out to a diameter suitable for the Spin-Lock adaptor clamp.
Please contact TE product management for further details.

Spin-Lock adaptors were at a preliminary design status at the time of

this HarnWare™ release. Therefore, you are advised to check all
Spin-Lock adaptor designs and component choices with TE product
management to confirm their suitability for your particular design
application and requirements.

Hexashield
When a Hexashield style of adaptor is selected,
an extra command button is displayed in the
adaptor selection form. Use this command
button only after you have specified the Hexashield style, connector
code, shell size and finish and have searched the database for the most
suitable Hexashield part number. The Hexashield command button
allows you to select the star and ferrules for use with the Hexashield
adaptor.
© TE Connectivity Adaptors 193

HarnWare™ searches the wire list page(s) in the current Visio

document for wires and databus cables that run to the connector.
These wire part numbers are loaded into the tree view. Wire part
numbers that include 'SZF' or 'Filler' are excluded.

By expanding the entry for an assigned or unassigned wire in the tree

view you can inspect the wire diameters and number of conductors.
With a wire selected in the tree view, you can use the delete wire
command button to transfer the wire details from the tree view into
the part number and diameter text boxes.

The part number and diameter text boxes can be used to add or edit
wire details. As you start to enter a wire part number in the text box
the list box will be filled with TE wire part numbers that match the
characters you've typed. For example, once you've entered '44A1' the
list box is filled with all the wire part numbers from the HarnWare™
database that start with '44A1'. Alternatively if you enter '44A?1' the
list box will be filled with all the part numbers starting with '44A01',
'44A11' and '44A31'.
194 User Guide HarnWare™ Version 6.3
If you select a standard TE wire part number in the listbox the outside,
shield and wire diameters and the number of conductors are
automatically entered. You then only need to specify the quantity of
that wire. A picture of the wire is also displayed for standard TE wire.
If you need to use a non-standard wire you will need to manually
enter the diameters and number of conductors. If the wire is not
shielded, leave the shield diameter text box blank.

Click the add wire command button to add the extra wire
details to the tree view.

In the case of larger shell sizes, 2 or 3 alternative star

configurations are available. These are displayed in the
HarnWare™ Hexashield form. Use the two command
buttons to view each alternative star. Stars with a drilled hole are
normally used when the cable includes unshielded wires that do not
need to be routed through a ferrule. The number of cavities and the
drilled hole diameter is displayed along with the pictorial
representation and in the tree view under the wire details.

Click the '?' allocate wires command button to have

HarnWare™ analyse alternative allocations of wires to
ferrules and drilled hole, if one is included in the star. Stars
can have up to 17 cavities and each one can be used for up to 4
shielded wires. There could, therefore, be many millions of alternative
ways of allocating wires to ferrules. HarnWare™ attempts to identify
a workable allocation of wires in a reasonable time as it would be
clearly impossible to analyse all the potential alternatives. Generally
this approach results in a good solution in only a few seconds, but if
you click the '?' allocate wires command button again, you may find
that other wire allocations are identified.

When searching for the best allocation of wires HarnWare™ tries to

allocate all wires (both sizes of ferrule are checked separately, with
the smallest ferrule being preferred). HarnWare™ also tries to allocate
wires so that all cavities are used and so that, in terms of bundle
diameter, shielded wires are evenly spread among the ferrules. If the
star includes a drilled hole any unshielded wires in the cable are
allocated to the drilled hole before using a ferrule.
© TE Connectivity Adaptors 195
When wires have been allocated, the star is shown with a pictorial
representation of the wire allocation. Shielded wires are represented
by green circles and unshielded wires by cyan circles. If more than 4
unshielded wires are allocated to a ferrule or drilled hole, 4 cyan
circles plus a magenta cross are drawn. The treeview is loaded with
details of the wire allocation. If it has not been possible to allocate all
wires, the number unassigned is flashed in red. If not all wires can be
allocated and other star configurations are available, try those with a
drilled hole or additional cavities. If the star includes a drilled hole
and no unshielded wires have been allocated to it, the drilled hole
entry in the tree view is flashed in yellow.

When wires are allocated, HarnWare™ determines the ferrule

and blanking plug part numbers and quantities. These are
loaded into the part number list box. The finish specified in
the adaptor form is automatically included in the ferrule part
numbers. Extra parts can be added or the part details can be
changed using the add and delete part command buttons to transfer the
details between the part number list box and the quantity and part
number text boxes. Details on the HET part numbers can be obtained
by selecting a part number in the listbox and using the <Shift>+F1
key combination.

Click 'OK' to accept the star and list of ferrules and blanking plugs.
The part number in the adaptor form will be updated to reflect the
selected star configuration. For example, if the star includes a drilled
hole, 'DS' is appended to the Hexashield part number. If you
subsequently save the adaptor data to the shape in the harness
drawing, these part details will also be saved.

Click 'Cancel' to exit from the Hexashield form without saving any of
the changes you made to the list of selected parts.
© TE Connectivity Moulded Parts 197

Moulded Parts
Opening Moulded Part Form
Obtain the moulded part form using one of the methods described in
the Open shapes section for example:

 Click a moulded part line in the Design Wizard list,

double-click or right-click a moulded part shape in Visio
to select it, switch to HarnWare™ and load the data into the form.
HarnWare™ will analyse the shape and load the diameters and
style into the form. If the part is a boot, HarnWare™ checks if an
adaptor shape is glued to it in Visio. If so, the mating diameter is
added to the H diameter text box in the form. NB If the adaptor
has been changed since the moulded part was last saved to the
Visio drawing, the diameter may be different; the database search
option will identify any parts suited to the newly selected adaptor.
Harness legs glued to the moulded part are also checked to obtain
leg diameters.

 If you do not wish to save data to a Visio drawing, select 'Moulded

Part' from the HarnWare™ Window>Parts menu. If the menu
option is checked the form will contain previously entered data,
otherwise a new blank form will be displayed. This form will not
be linked to any shape in the harness drawing.
198 User Guide HarnWare™ Version 6.3

Moulded Part Selection

Click the required style in the drop down combo-box. An image
representing the selected moulded part style is displayed as different
styles are selected in the combo-box. As styles with different numbers
of openings are selected, the number of diameter boxes contained in
the form is changed. Details on the harness design aspects of selecting
the best type of moulded part, material and adhesive are contained in
the harness design section of the online help system. When an item in
the style, material, adhesive or modification combo-boxes is selected
<Shift>+F1 causes brief details of the particular item to be output.

Enter the required diameters. If the form is linked to a Visio shape the
required diameters may have been already been entered from the
shape or adaptor and harness leg shapes that are glued to the moulded
part.
© TE Connectivity Moulded Parts 199
HarnWare™ knows how the outlets on each boot or transition relate
to each diameter. In the case of transitions you may find you have
connected the legs to the wrong outlets so that, for example, a small
cable is matched with the H diameter and a large cable with the K
diameter. You can either re-orientate the shape or change the numbers
around in the diameter text boxes to enable HarnWare™ to search the
database correctly.

Click the database search icon in the

toolbar, or use the Tools menu or
<Ctrl>+D. The HarnWare™ parts database will be searched for any
moulded parts of the given style that can recover onto the specified
diameters. The number of parts that are found to meet these criteria is
displayed along with the part number and diameters for the first part.
The amount of unresolved recovery is calculated for each diameter
and if it is less than 10% of the diameter it is highlighted in yellow.
Diameters that might fit with packing or shimming are highlighted in
red.

If all the required diameters have been specified, the

‘degree of fit’ for each part is calculated as a percentage.
The part with the best degree of fit is displayed first.
Green is used to highlight the part(s) with the best degree of fit. ‘No
fit’ is displayed for parts that will not fit directly onto the specified
diameters or with packing, but may fit with shim boots. Use the
packing command button to check.
200 User Guide HarnWare™ Version 6.3

100%

Degree of Fit
50%

0%
0 10 20 30
J Diameter (mm)

The degree of fit is calculated using relationships similar to that

shown in this graph. An outlet mated with a diameter between 1.1 and
1.5 times the fully recovered diameter is generally considered to be an
ideal, 100% fit. Diameters either side of this are considered less good.
Slightly different rules are used to calculate the degree of fit for H
diameter on boots, the diameter that mates with the adaptor. A
dynamic drawing explaining the moulded part degree of fit calculation
is installed in the HarnWare™ Sample drawing folder.

Other suitable parts maybe viewed using

the database next record icons in the
toolbar. The four buttons can be used to move the first, previous, next
or last part found to meet the specified criteria. The first part being the
largest suitable moulded part and the last being the smallest.

The required material, adhesive coating and any modification may be

selected from the combo-boxes. The boxes are filled with the options
that are appropriate to the style of moulded part and the harness
material system selected in the HarnWare™ Options menu. You can,
however, click the ‘All Types’, rather than the preferred, option
button to select other materials.
© TE Connectivity Moulded Parts 201
As you select these combo-boxes a brief description of the material,
adhesive or modification is displayed. When data is saved to the
drawing, the moulded part number is constructed by adding a '-'
before the material and modification and a '/' before the adhesive
code. These are omitted if no modification is entered or if the
adhesive is supplied as a sachet or tape, rather than a coating. (-
CS1972 adhesive for transitions is an exception to these rules). If you
enter a non-preferred adhesive you are prompted to select whether it is
supplied in the form of a coating, tape or sachet.

When you have your preferred choice of part shown in the

form you can use the 'Save shape' option in the file menu,
toolbar or <Ctrl>+S. This saves the moulded part, packing and braid
termination part numbers and other information to the shape in the
Visio drawing. This action can be undone using the Visio Undo
command.

D Connector Boots
Boots for D connectors (214A, 214A3, 234A0 and
234A1 moulded part styles) do not work in the same
way as other boots. HarnWare™ obtains the length
and width of the D connector glued to the boot. These
are used as the H and J dimensions. The degree of fit
calculation ignores these so that only the K cable diameter is used. D
boots can only be packed on the K diameter.

Boots Used as Transitions

Special shapes for 202A and 202K boots are included in
the "Moulded Part - Boot transitions" and "Moulded
Part - System All" stencils. These boots are sometimes
used as a transition. In these situations a HarnWare™
multi-cable shape should be glued between the H end of the boot and
the two or more cables to be joined into the single cable emerging
from the J end.
202 User Guide HarnWare™ Version 6.3

Bent Boots
Special shapes for certain boots are included in the
"HarnVis" stencil. These shapes include a right-
click menu which allows the boot to be bent to a
specified angle.

Go To Adaptor
By clicking this command button the system will search for
an adaptor shape that is glued to the moulded part shape in
Visio. If one is found the shape is selected and the form
displaying the adaptor style and diameters is displayed.

Alternative Styles
The 'Alternative Styles' command button in the moulded part
selection form lists other styles that are suitable for use with
the current harness material system and which may fit without
packing.

When the list box has focus, <Shift>+F1 causes brief details of the
particular moulded part style to be output.
© TE Connectivity Moulded Parts 203
If you click 'OK' the style will be selected in the moulded part form.
Click 'Cancel' if you wish to retain the style currently selected in the
moulded part form.

Packing or Shimming
If one or more diameters are highlighted in yellow or red,
you can use the packing command option to specify the
packing/shimming part number(s). However, you may
wish to use the 'Alternative Styles' command button to check for other
moulded parts that may fit without packing.

The packing command button allows you to search for suitable

packing/shimming parts for each oversize diameter. If no suitable
parts are found a warning is issued.
204 User Guide HarnWare™ Version 6.3
When choosing tube packing, select the desired type of tube from the
list in the combo-box. Normally the combo-box displays only material
types that are preferred choices for the currently selected material
system. However, by selecting the ‘all’ option you can access other
material types if your harness design requires you to use a non-
preferred type. When you click a type in the combo-box a description
of the tube material is displayed, <Shift>+F1causes further details of
the particular material to be output.

HarnWare™ tries to use packing under the harness jacket where

possible. Multi-core cables (EPDs) and harness legs where the jacket
tube material is unknown are two examples of situations where
HarnWare™ is not able to use under jacket packing. The maximum
jacket diameter used to determine whether under jacket packing will
fit is taken as the maximum tube inside diameter, obtained from the
HarnWare™ database, less 15% to allow clearance for assembly. If
sufficient packing cannot be accommodated under the jacket
HarnWare™ will specify a mixture of under and over jacket packing.

The draw command button can be used to add illustrations of

the various different packing and shim boot options into the
harness drawing. The HarnWare™ illustrations stencil
includes shapes for shim boots, under, over and under-over packing.
Illustrations of over packing with one, two and three layers of packing
are included.

HarnWare™ selects packing pieces in order to build the mating part

diameter up to the minimum diameter of the moulded part. The 10%
minimum grip allowance is not employed as it assumed the adhesive
will add some thickness to the packing.

When a packing material other than AT099 is selected, a list of any

suitable adhesives is displayed. Suitable adhesives are determined by
the moulded part material selected in the moulded part form. The
required quantity of adhesive is calculated as packing is selected.
Adhesive is only added for over jacket packing.

You can select the tube, shim boot or no packing options by clicking
the appropriate option button. Part numbers and diameters are shown
© TE Connectivity Moulded Parts 205
in the packing form. The currently selected tube packing material or
shim boot is noted alongside each diameter that needs packing.

The shim boot option is only offered when the material system is 10,
20, 30, 770, 790 or 300 and the moulded part style is 301A5, 381A3
382C or 462A4.

Clicking the OK button confirms the selected packing options. The

packed diameter(s) are added into the moulded part form. If you then
save the moulded part data to the Visio shape, the packing part
numbers, type of packing and packed diameters are also saved.

Braid Termination
The solder sleeves, protection sleeves and braid bandage
used to terminate braid are selected with a form accessed
using the braid termination command button in the
moulded part form. This command button is visible except when the
selected style of moulded part is a D connector boot. Braid
termination part numbers and other details are saved to the moulded
part shape when you use the save shape option.

Details on the harness design aspects of terminating braid are

contained in the harness design section of the online help system.
206 User Guide HarnWare™ Version 6.3

When the form is loaded, details from the harness legs glued
to the moulded part are added to the diameter list box.
Normally the outside, braid and wire bundle diameters will be
included for each harness leg. However, if a leg does not
include a bundle diameter calculated by the wire router or braid has
not been selected, these diameters will be missing. In these cases use
the edit diameter text box and add diameter command to insert the
missing information.

If any braid termination parts have already been selected, these are
loaded into the part data list box.

The types of solder sleeve and protection sleeve that are normally
used with the currently selected harness material system are loaded
into the two combo-boxes. If your design requires another type to be
used, click the All option button to have HarnWare™ load the combo-
boxes with all types of solder sleeve and protection sleeve. If you do
not require protection sleeves between the wire bundle and solder
sleeves, select ‘None’ from the list of types of protection sleeves.
© TE Connectivity Moulded Parts 207
When either the solder sleeve or protection sleeve combo-box is
selected, <Shift>+F1 causes brief details of the particular type to be
output.

If the form is associated with a transition, rather than a boot,

command buttons will be available for two alternative braid
termination methods:

 Braid bandage and one solder sleeve per harness leg.

Clicking this command button causes HarnWare™ to
select all the necessary solder sleeves, protection sleeves
and braid bandage. The selected part details are added to the
quantity and part number list box. In selecting the solder sleeves, a
standard thickness of 0.4mm (0.016”) is assumed for the braid
bandage. A standard braid bandage length of 1000mm or 36
inches is added to the list of parts. Also 50mm (2") lengths of
RAY-101-3.0 braid are added for use as straps joining the braids
of each harness leg as detailed in TE' Code of Practice number
365.

 Braid overlap on the largest harness leg. HarnWare™

identifies the leg with the largest outside diameter. For
this configuration to be feasible, all wires must pass
through the largest harness leg. Protection sleeves are selected for
the other legs and a single solder sleeve is selected that will fit
over all the other legs and the braid of the largest leg.

If the form is associated with a boot only the second command button
is available. This selects a solder sleeve and protection sleeve suitable
for the leg diameter plus the thickness of the braid on the braided
adaptor.

The H,J,K … opening names are added to the end of each line of the
list of selected parts. If a selected type of solder sleeve does not cover
all the necessary diameters, these names help if you then select solder
sleeves of a different type to the list. You will need to remove any
duplicate solder sleeves, braid bandage or protection sleeves.
208 User Guide HarnWare™ Version 6.3
HarnWare™ calculates the wall thickness of the protection sleeve at
the actual wire bundle diameter. The smallest solder sleeve that will
fit onto the wire bundle, plus protection sleeve plus braid and that will
clear the outside diameter of the relevant harness leg, is
selected.

The quantity and part number text boxes can be used with
the add and delete part data command buttons to edit the list
of selected parts.

Once the required parts are contained in the list box, click the OK
button to return to the moulded part form. Use the save shape option
to save the braid termination data along with the moulded part data to
the shape in the harness drawing.

Click the cancel button to discard all the changes to the braid
termination parts.

These facilities are similar to those provided for selecting solder

sleeves to terminate shielded wires, refer to the Devices section or to
the online help system.
© TE Connectivity Feedthroughs 209

Feedthroughs
Feedthrough Shapes
Feedthrough shapes should be glued between two harness leg shapes.
They should not be glued on top of a single harness leg in the manner
used for cable marker shapes. The exceptions to this rule are round
and oval bobbins (202W3 and 210W3 styles). The master shapes for
bobbins include a dimension which should be glued to one end of the
harness leg onto which the bobbin is to be fitted.

Opening Feedthrough Form

Obtain the feedthrough form using one of the methods described in
the Open Shapes section for example:

 Click a feedthrough line in the Design Wizard list

or double-click a feedthrough shape in Visio. The
HarnWare™ window will pop-up in front of Visio
and the system will obtain what details it can from
the shape and any glued leg. For example, the
product, part number and cable diameter.

 If you do not wish to save data to a Visio drawing, select

Feedthrough from the HarnWare™ Window>Parts menu. If the
menu option is checked the form will contain previously entered
data, otherwise a new blank form will be displayed.

Feedthrough Selection
Select the required feedthrough product from the list of options in the
combo-box. Initially the list will only contain the products that are
preferred for the currently selected material system. Click the ‘All’,
rather than the ‘Preferred’, option button to obtain a list of all the
210 User Guide HarnWare™ Version 6.3
available feedthrough products. This will also add all the available
moulded part materials and adhesives to the relevant combo-boxes.
Details on the harness design aspects of selecting the most appropriate
type of feedthroughs are contained in the harness design section of the
online help system.

Depending on the type of feedthrough product that is selected,

different options and materials combo-boxes will be displayed. For
example, TCFT’s do not include a moulded part, therefore, the
moulded part material and coating combo-boxes are not displayed, but
an extra command to select the boot glued to the feedthrough is
displayed.

Select the required options from the materials and options combo-
boxes. As each option is selected a brief description is output to the
form. The product option combo-boxes include a blank at the top of
each list. Select the blank if you wish to search the database
independent of the option. For example, if you want to obtain details
on all feedthroughs that will fit a given cable diameter irrespective of
© TE Connectivity Feedthroughs 211
the size of feedthrough, select the blank in the list of sizes. When a
product, material or adhesive type combo-box is selected, <Shift>+F1
causes brief details of the particular item to be output. NB The
material options do not constrain the choice of parts from the
database, as each material option can be used with all parts in a given
product range.

If the form was opened from a drawing shape, the cable diameter text
box will contain the outside diameter of the cable to which the
feedthrough is glued. If the cable diameter is left blank, all the
feedthroughs that match the other specified options will be retrieved.

NOTE

If different size harness legs are used on either side of the

feedthrough, check that HarnWare™ has selected the correct leg and
diameter. Generally this will be the larger leg.

Use the database search option to obtain

details of feedthroughs that meet the
specified criteria. As each part is selected from the database a picture
representing the style of feedthrough is output along with its name. If
no suitable parts are found the system outputs '0 Found' and a red sign
in the style frame. The minimum and maximum cable diameters that
the feedthrough is suitable for use with are output. In the case of
TCFTs the maximum diameter the entry size will accommodate and
the braid diameter is output along with the Y diameter onto which the
boot is fitted.

Except for TCFTs, feedthroughs are retrieved starting with the largest
suitable alternative. In the case of TCFTs the smallest size and the
smallest entry size is retrieved first, followed by any larger entry sizes
and then any larger feedthrough sizes.

When you have the part number for your preferred choice of
feedthrough displayed in the form, use the Save Shape option
to save the part number and text to the shape in the drawing.
212 User Guide HarnWare™ Version 6.3

Go To Leg
By clicking this command button the system will search for a
harness leg shape that is glued to the feedthrough shape in
Visio. If one is found the shape is selected and the form
displaying the leg braid and tube data is displayed.

TCFT Feedthroughs
If the chosen product is TCFT, and a connected harness leg with one
or two layers of braid is found:

 The feedthrough X or braid diameter is checked against the

allowable diameter ranges for the braid.

 The entry size is checked to ensure adequate clearance is available

to roll-back the layer(s) of braid over the outside leg diameter.

To obtain the feedthrough X diameter onto which the braid is fitted,

HarnWare™ adds a standard wall thickness of 1.65 mm (0.065”) to
the entry size stored in the database. This is compared with the
preferred and permissible diameter ranges for the braid part number(s)
stored in the database. If the feedthrough X diameter size falls outside
the preferred range, the braid diameter is highlighted in yellow, or if it
falls outside the permissible diameter range, it is highlighted in red. If
you then save the data to the feedthrough shape in Visio, HarnWare™
will warn you that the braid is not suited to the feedthrough. You
should choose an alternative braid. After changing the braid and
saving the data to the leg shape, open the feedthrough form again to
refresh the associated braid details.

If the entry size is too small to allow the layer(s) of braid to be rolled
back over the leg, the entry size diameter is highlighted in yellow. If
you then save the data to the feedthrough shape in Visio, HarnWare™
will warn you that the entry diameter is too small. It may be advisable
to choose a larger entry size.
© TE Connectivity Feedthroughs 213
In the case of TCFTs the number of layers of braid in the connected
leg is checked to determine the correct lock ring. For one layer of
braid, the ‘A’ option is selected, for two layers of braid a ‘B’ is
selected. This selection is normally correct, but you should check the
help system for further details.
© TE Connectivity KTKKs 215

KTKKs
Opening KTKK Form
Obtain the KTKK form using one of the methods described in the
Open Shapes section for example:

 Click a KTKK line in the Design Wizard list, double-

click or use the HarnWare™ option from the right-click
menu for a a KTKK shape in Visio. HarnWare™ will pop-up in
front of Visio and obtain what details it can from the shape and
any shapes that are glued to it. For example, if a connector is glued
to the KTKK shape the connector code and shell size will be
obtained and the KTKK style will be obtained from the KTKK
shape. If a harness leg is glued to the KTKK, the cable diameter is
retrieved.

 If you do not wish to save data to a Visio drawing, select KTKK

from the HarnWare™ Window>Parts menu. If the menu option is
checked the form will contain previously entered data, otherwise a
new blank form will be displayed.

KTKK Selection
Click the required style in the combo-box. An image representing the
selected KTKK style is displayed as different styles are selected in the
combo-box. Details on the harness design aspects of selecting the
most appropriate type of KTKK, material, finish and adhesive are
contained in the harness design section of the online help system.
When the style, material, finish or coating combo-boxes are selected,
<Shift>+F1 causes brief details of the particular item to be output.
216 User Guide HarnWare™ Version 6.3

Enter the required connector code, shell size and cable diameter. If the
form is linked to a Visio shape the required details may have been
already entered by the system. If the KTKK is glued to a harness leg,
the leg diameter will be added to the form.

The shell sizes available for the each connector code are loaded into
the combo-box whenever a new connector code is selected.

Select the required adaptor material and finish and the moulded part
material and adhesive coating from the four combo-boxes. The
adaptor finishes listed in the combo-box are determined by the
selected material. For example, the ‘W’ shot blast option is only
displayed when the selected material is nickel-aluminium bronze.
When you click one of the four combo-boxes a description of the
material, finish or coating is displayed. When one of the four combo-
boxes has focus <Shift>+F1 pops-up brief details of the particular
material, finish or adhesive and which may include links to further
product information on the Internet or in the TE Product Catalogue.
© TE Connectivity KTKKs 217
If you are unsure of the material, finish or adhesive coating
requirements, select the blank option that appears at the top of each
list of options. HarnWare™ will then retrieve all the KTKKs from the
database that match the criteria which you have specified.

When you save KTKK data to the drawing, HarnWare™ checks if the
harness leg includes braid. A warning is issued if, for example, the
moulded part is not shielded and the leg includes one or two layers of
braid.

Click the database search button in the

toolbar or use <Ctrl>+D. The HarnWare™
parts database will be searched for any KTKKs of the given style that
are available for the given connector code, shell size and any specified
material, finish and coating. If a numeric cable diameter is specified, a
further constraint is that it falls between the minimum and maximum
KTKK diameters. The number of parts found to meet these criteria is
displayed along with the part number, material, finish, coating and
diameters for the first part. A comment may also be output regarding
the particular KTKK.

If the minimum KTKK diameter is within 10% of the cable

diameter, the unresolved recovery is highlighted in yellow to
warn that the amount of grip is less than is normally preferred and
may need packing. Parts with a diameter greater than the cable
diameter that might fit with packing or shimming are shown with the
unresolved recovery highlighted in red. If the part requires packing on
the cable diameter, use the packing command button to specify the
packing/shimming part number(s).

Other suitable parts maybe viewed using

the database next record buttons in the
toolbar. The four buttons can be used to move the first, previous, next
or last part found to meet the specified criteria.

If no suitable parts are found the system outputs '0 Found' in the form.

When you have your preferred choice of part shown in the

form you can use the Save shape option in the file menu,
toolbar or <Ctrl>+S. This saves the part number, material, finish,
218 User Guide HarnWare™ Version 6.3
coating and diameter with the shape in the Visio drawing. This action
can be undone using Visio's Undo command.

Go To Connected Parts
By clicking the connector or leg command buttons,
the system will search for a connector or leg that is
glued to the KTKK shape in Visio. If one is found the
shape is selected and the connector or leg form is
displayed.

Code 18 KTKKs
Some KTKKs for code 18 connectors vary according to the connector
manufacturer. When connector code 18 is selected the KTKK form
includes a list of the connector manufacturer's and their codes. There
are three different cases that can be encountered for code 18 KTKKs:

 Where there is no difference between connector manufacturers,

HarnWare™ will search the database ignoring any manufacturer
you select. Any part numbers found to match the specified style
and shell size will be output.

 Where there is a difference between connector manufacturers that

affects the KTKK diameters, your choice of manufacturer will
affect the KTKKs selected by HarnWare™. Any part numbers
found to match the specified style and shell size will be output.

 Where there is a difference between connector manufacturers that

does not affect the KTKK diameters, your choice of manufacturer
will not affect the KTKK diameters output by HarnWare™.

Code 54 KTKKs
Some KTKKs for code 54 connectors vary according to the Mil Spec.
When connector code 54 is selected HarnWare™ obtains the Mil
Spec from the connector shape glued to the KTKK. In the case of
© TE Connectivity KTKKs 219
MIL-C-81703 connectors a shell size 14 rather than 12 is used.
HarnWare™ issues a warning for these special cases.

Code 79 KTKKs
Some KTKKs for code 79 connectors vary according to the connector
class. When opening a code 79 KTKK, HarnWare™ checks for a
connector glued to the KTKK and obtains the class. This data is then
used to ensure the correct KTKK is selected.

PATT 608, code 79 KTKKs are a special case and are normally only
supplied in nickel aluminium bronze. HarnWare™ checks this is the
case when saving KTKK data to the drawing.

Code 88 Adaptors
Code 88 connectors vary according to the connector series. When
opening a code 88 adaptor, HarnWare™ checks for a connector glued
to the adaptor and obtains the connector series. If none is found, the
relevant connector series should be selected in the HarnWare™
adaptor form to ensure the correct part is selected.

Spin-Lock Adaptors and Boots

Spin-lock adaptors and boots are selected in a similar manner to other
KTKKs. Also available are a range of cable clamp spin lock adaptors
which are selected in a similar manner to other adaptors.

Spin-Lock adaptors were at a preliminary design status at the time of

this HarnWare™ release. Therefore, you are advised to check all
Spin-Lock adaptor designs and component choices with TE product
management to confirm their suitability for your particular design
application and requirements.
220 User Guide HarnWare™ Version 6.3

Packing or Shimming
If the unresolved recovery is highlighted in yellow or red,
you can use the packing command option to specify
packing/shimming part number(s).

The packing command button allows you to search for suitable

packing/shimming parts for the KTKK cable or J diameter. If no
suitable parts are found a warning is issued.

Select the desired type of tube from the list in the combo-box.
Normally the combo-box displays only material types that are
preferred choices for the currently selected material system. However,
by selecting the ‘all’ option you can access other material types if
your harness design requires you to use a non-preferred type. When
© TE Connectivity KTKKs 221
you click a type in the combo-box a description of the tube material is
displayed, <Shift>+F1causes further details of the particular material
to be output.

HarnWare™ tries to use packing under the harness jacket where

possible. Multi-core cables (EPDs) and harness legs where the jacket
tube material is unknown are two examples of situations where
HarnWare™ is not able to use under jacket packing. The maximum
jacket diameter used to determine whether under jacket packing will
fit is taken as the maximum tube inside diameter, obtained from the
HarnWare™ database, less 15% to allow clearance for assembly. If
sufficient packing cannot be accommodated under the jacket
HarnWare™ will specify a mixture of under and over jacket packing.

The draw command button can be used to add illustrations of

the various different packing and shim boot options into the
harness drawing. The HarnWare™ illustrations stencil
includes shapes for shim boots, under, over and under-over packing.
Illustrations of over packing with one, two and three layers of packing
are included.

HarnWare™ selects packing pieces in order to build the mating part

diameter up to the minimum diameter of the KTKK. The 10%
minimum grip allowance is not employed as it assumed the adhesive
will add some thickness to the packing.

Shielded KTKKs, except for those including the two smallest boots
(121 and 132), include a packing piece. In these cases HarnWare™
indicates that packing is required and checks that it provides sufficient
build up on the cable diameter. No additional packing pieces are
added in these cases.

When a packing material other than AT099 is selected, a list of any

suitable adhesives is displayed. Suitable adhesives are determined by
the moulded part material selected in the KTKK form. The required
quantity of adhesive is calculated as packing is selected. Adhesive is
only added for over jacket packing.
222 User Guide HarnWare™ Version 6.3
You can select the tube or no packing options by clicking the
appropriate option button. Part numbers and diameters are shown in
the packing form.

Clicking the OK button confirms the selected packing options. The

packed diameter is added into the KTKK form. If you then save the
KTKK part data to the Visio shape, the packing part numbers, type of
packing and packed diameters are also saved.
© TE Connectivity Marker Sleeves 223

Marker Sleeves
Opening Marker Sleeve Form
Obtain the marker sleeve form using one of the methods described in
the Open Shapes section for example:

 Click a marker line in the Design Wizard list, double-

click a marker sleeve shape in Visio. The HarnWare™
window will pop-up in front of Visio and the system will obtain
what details it can from the shape. For example, the types of
marker and protection sleeve and the cable diameter.

 If you do not wish to save data to a Visio drawing, select Marker

Sleeve from the HarnWare™ Window>Parts menu. If the menu
option is checked the form will contain previously entered data,
otherwise a new blank form will be displayed.

Marker Sleeve Selection

Select the required type of marker sleeve from the list of options in
the combo-box. Initially the list will only contain the type that is the
preferred choice for the currently selected material system. Click the
‘All’, rather than the ‘Preferred’, option button to obtain a list of all
the available types of marker sleeve. Details on the harness design
aspects of selecting the most appropriate type of cable markers are
contained in the harness design section of the online help system.
When the marker or protection sleeve type combo-box is selected,
<Shift>+F1 causes brief details of the particular type to be output.
224 User Guide HarnWare™ Version 6.3

Depending on the type of shape in your harness drawing, the

protection sleeve combo-box will show ‘None’ or a type suited to the
currently selected material system. If the ‘All’, rather than the
‘Preferred’, option button is selected the list will contain of all the
available types of protection sleeve.

If a wrap around, rather than a sleeve, type of marker sleeve is

selected the number of score options will be disabled. For sleeve
markers selecting 1,2 or 3 scores relates to 2,3 and 4 markers per 48
or 50mm standard marker width.

The colours available for the selected type of marker sleeve are
contained in the colour combo-box. If a non-standard colour is
required, the standard colour part number suffix can be overtyped
before saving data to the drawing shape.

If the form is linked to a drawing shape, the diameter text box will
contain the outside diameter of the cable to which the marker sleeve is
glued.
© TE Connectivity Marker Sleeves 225
Use the database search icon or <Ctrl>+D
to obtain details of marker sleeves of the
required type that will fit the specified diameter. Where appropriate '-
S1', '-S2', etc are appended to the marker part number to indicate the
number of scores and '-4', '-0', etc is appended to indicate the chosen
colour.

The cable diameter is highlighted in yellow if it is within 10% of the

minimum marker sleeve diameter. It may be advisable to select a
smaller marker sleeve.

The textbox in the marker selection form reflects the selected font,
size and bold settings but not the colour or layout of text within the
marker. The Edit Text and Select Font command is used to edit the
marker sleeve text, select the font, size and to preview the layout of
text within the marker. Please refer to the section Cable Marker Text
and Font.

When you have the part number for your preferred choice of
marker sleeve displayed in the form, use the Save Shape
option to save the part number and text to the shape in the drawing. If
a type of protection sleeve is specified HarnWare™ will retrieve an
appropriate part number from the database and also save it the shape.
If a wrap-around type of marker sleeve is selected without a
protection sleeve, HarnWare™ will add two cable ties to the drawing
shape.

When you generate a parts list for the harness design, the number of
markers will be adjusted according to the number of scores. For
example, if one score is selected the number of markers will be
divided by two and then rounded up to the next whole number.
Therefore, if two such markers with identical part numbers are
included in the design, the parts list will show a quantity of one. This
approximation should be checked if accurate numbers are required.

Protection sleeve part numbers stored in the HarnWare™ database

generally have a -65MM length suffix. If a scored marker and a
protection sleeve are selected, the protection sleeves may require
trimming to length or an alternative should be selected.
226 User Guide HarnWare™ Version 6.3

Cable Marker Text and Font

When the "Edit Text and Select Font" command in the marker
selection form is clicked, HarnWare™ checks to ensure a numeric
cable diameter and a recognised cable marker part number has been
selected. This information is required to determine the size of marker
which is available for printing.

Text that is entered in the text box but not shown in the "printed size"
colour box preview may not fit on the marker sleeve given the
currently selected font, size and bold options. However, the printers
used to print marker sleeves vary widely and may offer different fonts
and line pitches so that more or less text might fit. HarnWare™
simply gives a guide to the text that can be fitted on a marker sleeve
under normal circumstances.

The preview of the marker as it would appear when installed on the

harness cable diameter is only intended to serve as a general guide.
Especially with lower resolution computer screens, some pixels
maybe lost in the process of scaling the printed size down to the
installed size.
© TE Connectivity Marker Sleeves 227
The text preview shows the area available for text on the marker
sleeve. This depends upon the part number and the number of scores
specified in the marker selection form. The text is shown centre-
justified in the available marker sleeve width and middle justified in
the available marker height. Centre and middle justification are the
most commonly used for markers, but left and right, top and bottom
justifications can be used on some cable marker printers.

The 'Side 2' option allows you to preview text on the second side of
the marker sleeve. If a wrap around, rather than a sleeve, type of
marker sleeve is selected the 'Side 2' option is disabled.

Font sizes between 8 and 120 can be specified, either integer or

floating point numbers.

Printers used to print marker sleeves vary widely and may offer
different fonts and line pitches so that more or less text might fit.
HarnWare™ simply gives a guide to the text that can be fitted on a
marker sleeve under normal circumstances.

Marker Page and Data Export

This option, accessed from the tools menu, can generate:

 A marker sleeve drawing page. This contains the manufacturing

information required for each cable marker used in the harness
design.

 Cable marker text and formatting details in an '.xmt' or COMMS

file that is suitable for import into the TE TMS Total and
WinTotal labelling software.

 Cable marker text in a comma delimited format output to a file or

to the Windows clipboard. This data can be imported into other
labelling software systems.

Using the Marker Page and Data form you can select the output
options required. If the data output to file is selected the controls in
path and file name frame are enabled.
228 User Guide HarnWare™ Version 6.3
If you select the TMS COMMS option you have the option of adding
a description in the file. As a wide variety of different printers can be
used with the TE TMS Total and WinTotal systems the exact text
formatting may be different to that suggested in HarnWare™. For
example, you may find that certain fonts are not available on a
particular printer or that the text takes up more or less space.

Click the OK command button to have HarnWare™ generate the

marker page and/or the marker data. HarnWare™ searches the harness
drawing page for cable markers and their associated parts list
balloons. This information is used to construct the marker page and
data.

If no page named 'Markers' is found, HarnWare™ adds a new page to

the active Visio document. The page size and scale is set to the same
as a wire or parts list page. If no page with a name including the
words 'Parts List' or 'Wire List' is found in the active document,
HarnWare™ will not be able to set up a new marker page. The marker
border shape is selected from the Metric or Imperial HarnWare™
stencil depending on which template you used to start the drawing. In
the page generated by HarnWare™ you may need to adjust the size of
the marker shapes to fit the text and to move them to fit the page.
Also, especially with double-sided labels you may need to edit the
© TE Connectivity Marker Sleeves 229
marker text. HarnWare™ sets the marker shape to indicate the number
of scores selected for the marker.

If the drawing does not contain parts list balloons or if the parts list
was generated with an early version of HarnWare™, the marker page
will not contain item numbers.

Importing Data into WinTotal

“.xmt” files generated by the HarnWare™ Marker Page & Data
Export tools menu or design wizard options can be imported into the
TE WinTotal software. The general procedure for importing data into
WinTotal V5.2.00 is outlined below, however, for full details or the
procedure for other versions please refer to the WinTotal online help
system or the user manual.

Select the WinTotal File>Import menu, choose the "XMT" option and
click the browse icon to select the folder and name of the .xmt file
exported from HarnWare™.

Clicking the "Import" command will then initiate the import process.
If the .xmt file includes a true type font which is not recognised on the
computer running WinTotal the import will fail with the error
message "Bad product info". The safest fonts to select in HarnWare™
are "Arial" or "Courier New". WinTotal may also warn, if you have
attempted to fit more text than will fit the selected marker, with the
error message “Sleeve data has too many characters”. You might like
to change the font selection, size or marker text in HarnWare™ and
then generate a new .xmt file or alternatively make the changes
directly in WinTotal.
© TE Connectivity Databus 231

Databus
Databus design is a separate option within HarnWare™ for which
different Visio drawing templates are used. This option is only
available to those who have attended the 1 day specialist databus
harness design training course.

Opening Databus Form

Obtain the databus form using one of the methods described in the
Open Shapes section for example:

 Click a databus shape in the Design Wizard list, double-click a

databus shape in Visio to select the shape, switch to HarnWare™
and load the data into the HarnWare™ form.

 If you do not wish to save data to a Visio drawing, select 'databus'

from the HarnWare™ Window>Parts menu. If the menu item is
checked, the form will contain previous data, otherwise a new
blank form will be displayed.

Three tabs in the Databus form provide access to:

 couplers

 connectors

 miscellaneous items, including contacts and cable.

When a drawing shape is opened the appropriate tab is selected.

There is no need to use the wire list or wire router for Databus
harnesses. Also the Multi-Core Cable (EPD) Analyser and Wiring
Schematic options are not relevant to Databus harnesses.
232 User Guide HarnWare™ Version 6.3

Databus Coupler Selection

An image representing the style of coupler is displayed in the form.
As a Databus coupler shape is opened HarnWare™ obtains details of
the cables glued to the shape. Warning messages are output if cables
or connectors are glued to invalid or incorrect points on the shape.

Box Couplers

In the case of box couplers the number of stub cables is selected in the
combo-box. Bus cable connectors are expected to be glued to the two
outer points on the box coupler shape and stub cable connectors are
expected to be glued to any of the inner 8 points.

The bus connector can be selected from the threaded and bayonet A,
B or C coupling options. If the 'Threaded' option is selected, the stub
connectors will also be threaded. If one of the bayonet options is
selected the stub connectors will be 'Bayonet - D' couplings.
© TE Connectivity Databus 233
When opening a box coupler shape, HarnWare™ checks that, if
specified, all connectors glued to a coupler are of the same threaded or
bayonet coupling and that the contacts are correctly selected for the
bus and stub connections.

Micro and Flat-Pack Couplers

In the case of micro and flat-pack couplers HarnWare™ notes the stub
and bus cables that are glued to each of the shape's connection points.
Any point that is not glued to a cable is assumed to be a terminator.
HarnWare™ checks that each point can be used for a stub, bus or
terminator as suggested by the drawing layout. 'B', 'S' or 'T' are
selected in the 'Conn' combo-boxes depending on whether a bus, stub
or no cable is glued to each connection point on the shape. These
combo-boxes only list the available options for each connection point.
For example, if a point can only be configured for a bus cable the
combo-box is only loaded with 'B', if a number of options are
available the combo-box also includes a blank if you wish to search
the database for all configuration options.
234 User Guide HarnWare™ Version 6.3

Micro and flat-pack couplers are normally supplied with cable. In this
case couplers are connected using splices. However, in-house TE can
assemble databus harnesses without splices. In the former case the
check box for the cable frame should be selected so that cable type
and length is reflected in selected coupler part numbers and the
associated cables are not included in parts lists.

The length of each stub or bus cable is loaded into the 'Length' text
boxes. When the database is searched for suitable parts the next length
above that of the longest of these is selected in the cable length
combo-box. Lengths in the cable length combo-box are in inches and
are appended to part numbers retrieved from the database.

Three types of cable can be selected from the cable type combo-box.
These offer three levels of shielding. The last three digits of the
selected cable type are appended to part numbers retrieved from the
database.
© TE Connectivity Databus 235
When opening a micro or flat-pack coupler shape, HarnWare™
checks that, if specified, all cables glued to a coupler are of the same
type.

Space Application

A few Databus parts are available to meet the low outgassing

requirements of NASA specification SP-R-0022A for use in outer
space applications. Click to check the 'Space Application' check box
in order to restrict searches of the database to these items.

Database Search and Save Shape

Click the database search button in the

toolbar or use <Ctrl>+D. The HarnWare™
parts database will be searched for any Databus couplers that match
the selected style and other options. The number of parts found to
meet these criteria is displayed along with the part number and brief
description.

Other suitable parts maybe viewed using the database next record
buttons in the toolbar. The four buttons can be used to move the first,
previous, next or last part found to meet the specified criteria.

When you have your preferred choice of part shown in the

form you can use the 'Save shape' option in the file menu,
toolbar or <Ctrl>+S. This saves the part number and other details to
the shape in the Visio drawing. This action can be undone using
Visio's Undo command.

Databus Connector Selection

As a Databus connector shape is opened HarnWare™ obtains details
of the cables, connectors and couplers glued to the shape. Warning
messages are output if the connector is glued to an invalid point on a
coupler and for other similar errors.
236 User Guide HarnWare™ Version 6.3

The type of connector (plug, jack - standard or jack - long reach) is

obtained from the connector shape.

The coupling and contact style are also obtained from the connector
shape. However, these two options are overwritten if coupling and
contact data is available from a mating connector or coupler. For
example, if the mating connector is threaded and has a socket contact,
the 'Threaded' and 'Pin' contact options will be selected. If the
connector is glued to a box coupler, 'Pin' contact will be selected if it
is a bus connector and 'Socket' if it is a stub connector.

If a cable is not glued to the connector HarnWare™ will assume a

terminator is required. The mating connector or coupler is used to
determine whether to select a 78 ohm terminator for a bus or 3k ohm
terminator for a stub connection.
© TE Connectivity Databus 237

Space Application

A few Databus parts are available to meet the low outgassing

requirements of NASA specification SP-R-0022A for use in outer
space applications. Click to check the 'Space Application' check box
in order to restrict searches of the database to these items.

Database Search and Save Shape

Click the database search button in the

toolbar or use <Ctrl>+D. The HarnWare™
parts database will be searched for any Databus connectors that match
the selected options. The number of parts found to meet these criteria
is displayed.

Other suitable parts maybe viewed using the database next record
buttons in the toolbar. The four buttons can be used to move the first,
previous, next or last part found to meet the specified criteria.

When you have your preferred choice of part shown in the

form you can use the 'Save shape' option in the file menu,
toolbar or <Ctrl>+S. This saves the part number and other details to
the shape in the Visio drawing. This action can be undone using
Visio's Undo command.

Databus Miscellaneous Part

Selection
As a Databus cable, contact or other miscellaneous shape is opened
HarnWare™ obtains details from the shape and from other shapes
glued to it. For example, when opening a contact or splice
HarnWare™ searches for a cable glued to the shape so that the cable
type can be selected in the miscellaneous Databus form.
238 User Guide HarnWare™ Version 6.3

Lists of the appropriate options are displayed in the Databus form

depending upon the selected class of part. For example, when
'Connector Cap' is selected, the alternative threaded and bayonet
connector couplings are listed.

When the databus cable class is selected an extra command button is

displayed 'Set all Cables'. Once you have selected a databus cable
from the database, in a single step this command sets all the databus
cables in the current drawing to the same type and part number.

H06, 7724H0664 MIL-C-17/176D M17/176-00003 and EP3,

EPD30653Q and EPD31346-6L9 cables are normally only used with
lightweight micro couplers.

H06, 7724H0664 MIL-C-17/176D M17/176-00003 cable is only

supplied in white. When this option is selected, stub cables are
changed from the blue striped linestyle.
© TE Connectivity Databus 239
As an alternative to separate shapes for databus contacts, these items
can be included in a connector shape. The databus contacts are
normally used with MIL-C-38999 Series 1, 3 or 4 connectors with
size 8 contact cavities. When a connector shape is included in the
harness drawing use the devices selection option in the connector
form to select the databus contact.

Space Application

A few Databus splices and terminators with spliced in cables are

available to meet the low outgassing requirements of NASA
specification SP-R-0022A for use in outer space applications. Click to
check the 'Space Application' check box in order to restrict searches
of the database to these items.

Database Search and Save Shape

Click the database search button in the

toolbar or use <Ctrl>+D. The HarnWare™
parts database will be searched for any Databus parts that match the
selected options. The number of parts found to meet these criteria is
displayed.

Other suitable parts maybe viewed using the database next

record buttons in the toolbar. The four buttons can be used to
move the first, previous, next or last part found to meet the specified
criteria.

When you have your preferred choice of part shown in the form you
can use the 'Save shape' option in the file menu, toolbar or <Ctrl>+S.
This saves the part number and other details to the shape in the Visio
drawing. This action can be undone using Visio's Undo command.
© TE Connectivity Conduit 241

Conduit
Separate Visio templates are used for Conduit harness designs.

Opening Conduit Form

Obtain the conduit form using one of the methods described in the
Open Shapes section for example:

 Click a conduit leg or transition line in the Design

Wizard list, double-click or right-click a conduit shape
in Visio to select the shape, switch to HarnWare™ and
load the data into the form. The system will obtain what
details it can from the shape.

 Alternatively, if you will not wish to save data to a Visio drawing,

select 'Conduit' from the HarnWare™ Window>Parts menu. If the
menu option is checked the form will contain previously entered
data, otherwise a new blank form will be displayed.

Two tabs in the Conduit form provide access to:

 Conduit selection
 Conduit transition
When a drawing shape is opened the appropriate tab is selected.
Conduit adaptors are selected using the adaptor selection form.

Conduit Selection
When a conduit leg shape is opened HarnWare™ will load any
available details such as leg length, conduit, braid and tube part
numbers and wire bundle diameter, if you have used the wire routing
option.
242 User Guide HarnWare™ Version 6.3
This form is similar to that used for selecting braid and tube for non-
conduit harness leg shapes.

Conduit Selection

Use the options in this form to select the required conduit part
number. Although not normally used, one or two layers of braid and
one layer of tube can also be added over the conduit.

Click the database search toolbar to obtain

conduit suited to the wire bundle diameter.
The first conduit part number selected is that which gives 20% or
more clearance over the wire bundle diameter. Use the next database
record toolbar icons to view other options. For each option
HarnWare™ calculates fill factors and outputs the outside diameter of
the conduit. A simple to-scale sketch is also drawn of the wire bundle
and the conduit inside and outside diameter to illustrate the clearance
available for drawing wires up the conduit. The fill factors are wire
© TE Connectivity Conduit 243
bundle diameter / conduit inside diameter * 100% or area of wire
bundle / area inside conduit * 100% The fill factors are flashed in
yellow when the available clearance is less than 20%.

Braid and Tube Selection

The desired type of braid or tube is selected from the list in the
combo-box. Normally the combo-box displays only material types
that are preferred choices for the currently selected material system.
However, by selecting the 'all' option you can access other material
types if your harness design requires you to use a non-preferred type.
Details on the harness design aspects of selecting the best type of
braid and tube are contained in the harness design section of the
online help system. When the braid or tube type combo-box is
selected, pressing the F1 key with the shift key held down causes brief
details of the type braid or tube to be output.

You must build up the layers of braid and tube layer by layer in the
correct order using the following procedure:

 If braid is required, click the braid

option button. A list box containing the
different types of TE braid will appear in the form. If you used the
wire routing or cable lay design HarnWare™ will have added the
cable bundle diameter in the leg diameters frame, but you can
adjust this diameter if necessary. Click the database search toolbar
icon to obtain details of braid of the selected type that is suitable
for the cable diameter.
 HarnWare™ shows the number of suitable sizes of braid, starting
with the largest diameter. Use the next database record toolbar
icons to view the other available options. For each option
HarnWare™ calculates the outside diameter that would be
obtained when using that braid on the cable bundle diameter; (the
database contains the wall thickness for each braid). HarnWare™
also outputs the minimum and maximum cable diameters the braid
can fit.
 When you are satisfied with the choice of braid, click the 2nd
braid layer or the tube option button to select the next layer. If you
require a 2nd layer of braid repeat the above process.
244 User Guide HarnWare™ Version 6.3

 Tube selection is similar to braid. The list box is loaded with the
alternative tube types. The HarnWare™ database contains the wall
thickness at the fully recovered diameter. Wall thicknesses at other
diameters are calculated from the cross-sectional area based on a
formula that assumes the tube length shrinks by 5% over a
diameter range of 2:1 of the fully recovered diameter. If the
amount of unresolved recovery is less than 10% of the minimum
tube diameter the minimum diameter is highlighted in yellow; if
possible select an alternative tube. The default tube selection is
normally the largest that will fit. If you select a smaller alternative,
the maximum diameter text is highlighted in yellow as a warning
to check it will be possible to assemble the tube. For long leg
lengths it can be difficult to pull on tubes that only have a small
clearance.
 As each layer is selected, HarnWare™ outputs the braid and tube
part numbers. If necessary, these part numbers can be changed
simply by typing in the text boxes.
 Click the save shape tool to save conduit, braid and tube
data to the Visio conduit leg shape. Alternatively use the
'Save shape' option in the file menu or <Ctrl>+S. If you make a
mistake, this action can be undone using Visio's Undo command.

Lengths and Diameters

The lengths of conduit, braid and tube are calculated by the parts
listing option. These lengths are derived from the conduit harness leg
length and adjustments for the styles of any moulded parts and
adaptors that are glued to the conduit harness leg. In addition the
length of braid is increased by 20% of the leg length when the
installed diameter is larger than the nominal diameter of the selected
braid. The braid and tube adjustments for each style of moulded part
and adaptor are held in the HarnWare™ database.

Unbraided Tinel and band strap adaptors are checked during the
adaptor selection process to ensure the braid can fit onto the adaptor.
© TE Connectivity Conduit 245

Conduit Transition Selection

When a conduit transition shape is opened HarnWare™ will load
what details it can from the shape and any conduit leg shapes that are
glued to it. For example, if conduit leg(s) are glued to a transition, the
conduit part number(s) and any braid details will be obtained.

Click the required style in the drop down list box. An image
representing the selected conduit transition style and a brief
description is displayed as different styles are selected in the combo-
box. As styles with different numbers of openings are selected, the
number of conduit combo-boxes contained in the form is changed.
When an item in the style, material or finish combo-boxes is selected
<Shift>+F1 causes brief details of the particular item to be output.

Select the conduit part numbers for each of the conduit legs. If the
form is linked to a Visio shape the required conduit part numbers may
246 User Guide HarnWare™ Version 6.3
have been already entered from the shape and conduit harness leg
shapes that are glued to the transition.

Choose the material and finish for the conduit transition that will be
compatible with the intended service conditions. The two combo-
boxes are filled with the material and finish that are appropriate for
the selected style of conduit transition. The finishes listed in the
combo-box are determined by the selected style of conduit transition
and material. When you click one of the two combo-boxes a
description of the adaptor material or finish is displayed.

The number of layers of braid in the connected leg determines the

correct Tinel lock ring. For one layer of braid, select 'AI' for insertion
into the transition or adaptor part number, for two layers of braid, or a
single layer of 30 AWG braid ensure 'BI' is selected.

Click the database search button in the

toolbar or use <Ctrl>+D. The HarnWare™
parts database will be searched for any conduit transitions of the given
style that fit the specified conduit part numbers. The number of parts
that are found to meet these criteria is displayed along with the part
numbers and diameters for the first part.

Some styles of conduit transition use adaptors on one or more ports.

HarnWare™ automatically selects the appropriate conduit transition
adaptor part numbers.

Other suitable parts maybe viewed using the database next record
buttons in the toolbar. The four buttons can be used to move the first,
previous, next or last part found to meet the specified criteria. The
first part being the smallest suitable conduit transition.

When you have your preferred choice of part shown in the

form you can use the 'Save shape' option in the file menu,
toolbar or using the <Ctrl>+S short-cut key combination. This saves
the conduit transition and any adaptor part numbers and other
information to the shape in the Visio drawing. This action can be
undone using the Visio Undo command.
© TE Connectivity Design Checker 247

Design Checker
The design checker analyses the drawing and wire list to produce a
list of warning messages. For warnings that relate to specific drawing
items the checker can add warning shapes and texts into the drawing.
A table of the messages can also be added in a separate page in the
drawing.

This option is initiated via the tools menu or the Design

Wizard. You are given the option of adding yellow warning
shapes and messages to the drawing.

The design checker compares certain harness design features against a

set of predefined rules. When the conditions specified in a rule are
satisfied, the appropriate warning is output. In addition some general
warnings are always output, e.g., to check whether connector
248 User Guide HarnWare™ Version 6.3
accessories are required. In itself the checker cannot ensure your
design is adequate or suitable for the intended application. The
objective of the design checker is simply to warn you of some of the
more common mistakes.

General warnings, such as to check the

adaptor material and finish are
compatible with the connectors, are listed
in the form. Warnings that are specific to
a particular shape, for example, that a
low-profile boot has been selected when
repair loops are specified, are listed in the
form and a yellow warning shape is
added on the moulded part in the drawing
if you selected that option. The warning shape contains the same text
as appears in the form.

Each warning message output in the design checker form is linked to

an appropriate help topic. Click the message in the list and, with the
shift key held down, press the F1 key (<Shift>+F1) to access the pop
help topic. Most of these small help topics have hypertext links to
appropriate topics in the main HarnWare™ help system. Each shape
used to construct the table of warning messages and each warning
shape added to the Visio drawing is also linked to these same pop help
topics. Right click the line or warning shape and select the shape help
menu item.

The design checker form can be maximised in order to view more

information thus reducing the need to scroll through the list of
messages.

Use the 'Add Notes to Drawing' command button to add the complete
list of warning messages to the Visio drawing. If this option is
selected, HarnWare™ first checks if the current document contains a
page named 'Design Checks'. If not, a new page is added. A Design
Checks drawing border is added to the page from the metric or
imperial sheets stencil. HarnWare™ then adds the information to the
drawing border shape.
© TE Connectivity Design Checker 249
While the design checker is analysing the drawing or adding a
warning list to the drawing, you can press the escape key to stop the
process.
© TE Connectivity Parts Listing 251

Parts Listing
Overview
The parts listing option analyses the drawing and wire list to produce
a sorted and totalized list of parts. The resulting list is displayed in
HarnWare™ and saved to a table in the drawing. Item number
balloons are automatically added to the drawing shapes to cross-
reference them to the parts list table. The parts listing option is
initiated via the HarnWare™ tools menu or the <Ctrl>+L
short-cut key or the parts list line in the Design Wizard.

Once a parts list has been added to a drawing, it can be

exported to the clipboard, or a file using the HarnWare™ File, Export
Parts List menu. This allows the data to be used in a spread sheet,
database or the TE UK CBOM system.

With the 'Retain Existing Item Numbers' option you can ensure new
parts added to a design are given item numbers that have not
previously been used. This is useful when production drawings are
modified and need to remain compatible with existing production
documentation and systems.

The parts lists from two or more HarnWare™ drawings can be

totalized using the composite parts list option in the HarnWare™
Tools menu.

To save time only pages named 'Harness Drawing' and those with
names containing the words 'Parts List' and 'Wire List' are analysed
when HarnWare™ is collecting information for parts listing.
Examples of page names that will be included in the analysis are 'Parts
List', Parts List 1', 'Parts List 2', 'Wire List', 'Wire List 1' and 'Wire
List 2'. You should use the standard pages in the HarnWare™
template for the specified purposes to avoid problems. Parts lists
generated by HarnWare™ are automatically generated on pages
named 'Parts List 1', 'Parts List 2', etc.
252 User Guide HarnWare™ Version 6.3
Until the time when HarnWare™ starts to add information to the
harness drawing you can press the escape key to stop the parts listing
process.

Balloons
Parts listing balloons have a control handle used to
draw a leader line. Select the shape and position the
mouse pointer over the control handle just below the
centre of the balloon to obtain the tip showing the
purpose of the control handle.

Balloons are added on a separate drawing layer. Using the Visio

Edit>Drawing Layer or View>Layer Properties menu and clicking the
'#' column heading you can obtain a count on the number of balloons
in the drawing page, hide all the balloons, etc. You can delete all the
parts list balloons by using the Visio Edit, Select Special or Select by
Type menu option to select all shapes on the 'Parts List Balloon' layer
and then clicking the delete key. Note that this will delete both user
balloons and those added automatically by the parts lister.
© TE Connectivity Parts Listing 253
HarnWare™ adds balloons at the pin of the shape to which they
relate. The pin is at the centre of most shapes. Kinked harness legs are
an exception where the pin is at the end which is glued to the
transition. Balloons can be moved to the required drawing position.
When you next use the parts listing option, balloons for a given shape
are re-used so you do not have to re-position them.

Parts are sorted into sequence and HarnWare™ applies the resulting
item numbers to balloons in the drawing. Balloons added by
HarnWare™ include the name of the associated part shape in the
data1 field (use the Visio, ‘Format Special’ menu to inspect the data1
field). If you add a part number to one of these balloons, when you
next use the HarnWare™ parts listing option it will be treated just as a
balloon you added from the stencil.

If the HarnWare™ parts lister finds more balloons associated with a

shape than are required, the last one added is automatically deleted.
This situation can arise for example when a layer of braid is removed
from a harness leg or a piece of packing is removed from a moulded
part.

User Balloons
For parts that do not have database selection options, add a balloon
from the miscellaneous stencil.

As with other HarnWare™ parts a user balloon form is available for

entering part data by clicking a balloon line in the Design Wizard, or
by using the right-click HarnWare™ shape menu for a balloon in
Visio. The HarnWare™ user balloon form also gives access to the
User Parts Library.
254 User Guide HarnWare™ Version 6.3

This form can also be accessed via the HarnWare™ Window>Parts

menu. Only part descriptions that are relevant to the selected part code
are included in the form. If you are unsure of the quantity that may be
needed, type an 'A' in the quantity text box and HarnWare™ will
insert 'A/R' (as required).

You may wish to add non-standard parts that you use on a regular
basis to the User Parts Library which is accessed using the command
button in this User Parts List Balloon form.

Balloon data is saved into the Visio drawing using the normal save
shape option. If the HarnWare™ form is associated with a balloon in
the drawing, the balloon is updated. If not, HarnWare™ offers you the
option of adding a new balloon to the drawing.

As an alternative to this HarnWare™ form, the Visio Custom

Properties or Shape Data option can be used to enter the data by right
clicking the balloon or by using the Visio Shape menu. You can enter
© TE Connectivity Parts Listing 255
the part number, description, specification, quantity and units. You
may also add one of the three character codes listed in the section
entitled Parts List Class Codes so the part appears in the correct place
in the parts list. If you do not enter a quantity a default of 1 is
assumed, if you do enter a quantity it appears in the custom property
and as a small text alongside the balloon. From Visio you can access
the parts listing help topic by right clicking a balloon and selecting the
shape help topic.

Non-Parts Listing Layer & Sub-

Assemblies
Shapes that are included on the drawing layer named 'Non-Parts
Listing' are ignored by the parts lister.

This is useful when part of a harness is to be made as a sub-assembly:

After completing the design and parts listing it in the normal manner,
a copy of the document file can be made. Select the parts to be
included in the sub-assembly and use the Visio View>Shape Layer
menu option to add the parts to the 'Non-Parts Listing' layer. The
shapes will change to light grey. Any parts list balloons added to the
layer will also be ignored by the parts lister which may be useful if
you would like to retain a reference to their original item numbers in
the original full assembly parts list. Add a 99 balloon, using the ‘Asy’
sub-assembly code and enter the sub-assembly part number. Re-parts
list the drawing to obtain a list with the sub-assembly part number and
none of the constituent parts. For a parts list of the sub-assembly
simply copy the parts into a new drawing, check that they are not on
the Non-Parts Listing layer and use the parts lister in the normal
manner.

The Visio>Edit>Select Special menu option (or in Visio 2010 the

Select>Select by Type option in the Home tab) provides a quick way
of selecting all shapes on a given drawing layer.
256 User Guide HarnWare™ Version 6.3

Gap Shapes & Item Number

Sequences
These shapes enable you to include gaps in the item number sequence.
For example, you may wish to allow a gap after the moulded parts so
extra parts can be added without changing the item numbers of
subsequent items in the parts list. These are mainly used with the
'Retain Existing Item Numbers' option.

Retain Existing Item Numbers

The default 'Assign Item Numbers' option automatically applies
sequential item numbers to the parts included in the harness design.
With drawings that have already been parts listed, the 'Retain Existing
Item Numbers' option ensures newly added parts are given previously
unused item numbers. This is useful when production design drawings
are modified and need to remain compatible with existing production
documentation and systems. Use the Options menu if you wish to
disable the dialog box that allows you to choose this option.

Gap shapes from the HarnWare™ miscellaneous stencil enable you to

include gaps in the item number sequence. If no gap shapes with the
required part class code are available, new parts are added at the end
of the parts list.

When a part is deleted from a design, the Retain Existing Item

Numbers option adds a gap shape to the drawing with an 'xxx' class
code. This ensures the item number is not re-used. If you wish the
item number to be re-used, use the Visio Custom Properties (right
click the gap shape or use the Visio Shape menu) to set the class code.
The class code and item number custom properties automatically
appear on the shape. Do not try to type the class code into the shape.
Gap shapes are not normally printed.

If a part number, description or specification is changed the 'Retain

Existing Item Numbers' option will assign the part a new item number
© TE Connectivity Parts Listing 257
and add a gap shape to prevent the previous item number from being
re-used.

When the 'Retain Existing Item Numbers' option is used HarnWare™

must be able to construct a consecutive sequence of item numbers
from the parts list table and the gap shapes.

Wire List
Wire item numbers are entered into the wire list table. Wires that form
part of a multi-core cable (EPD) are assigned the cable item number.

Balloons for Wires in Legs

If the HarnWare™ option balloon wires menu is set, the parts lister
adds balloons for each different wire part number in each harness leg.
If you find you do not need balloons for wires, un-check the balloons
option and run the parts listing option again.

If, when this option is set, a wire is found in a leg for which no details
exist in the wire list table an error message is output and the parts
lister stops. This situation could occur if, for example, you deleted a
line from the wire list table after using the wire route option.

If a leg is found with no wire route data, a message is output and you
have the option to continue parts listing or stop. This situation could
occur if you haven’t used the wire routing option prior to parts listing,
or if you added a new harness leg after wire routing.

If a harness leg has been specified as a multi-core cable (EPD), the

cable item number will be added to the leg rather than item numbers
for the constituent wires.

In the case of link wires, parts list balloons are added to the relevant
connector shape when this option is set.
258 User Guide HarnWare™ Version 6.3

Cable Cross-Section Drawings

Wire and fillers included in cable cross-section drawings generated by
the draw command in the cable lay design form, are numbered by the
parts lister. The HarnWare™ Options Menu or the Set Properties form
is used to select whether item numbers, wire list numbers or no
references are applied.

If the item numbers option is selected, both wire and fillers are
numbered with their item numbers, or if they are a part of a multi-core
cable (EPD), the cable item number. If the wire list numbers option is
selected, only the wires will be numbered - these are the numbers first
applied when HarnWare™ draws the cable cross-section.

If you change this HarnWare™ option simply re-parts list the drawing
to update the labelling of any cable cross-sections, you do not have to
re-generate the cable cross-section drawings from the cable lay design
form.

Parts List Tables

Parts list data is displayed in the HarnWare™ parts list form. The
parts list form can be maximised in order to view more information
thus reducing the need to scroll through the rows of parts. Some data
maybe too long to fit in the standard columns. You can adjust the
column widths by moving the mouse over the titles until the pointer
changes to a line and two arrows. You can then drag the column
dividing line. To reset the column widths back to the default layout,
close the form and re-run the parts list option.

HarnWare™ creates parts lists in the Visio drawing using the parts list
line shape from one of the two miscellaneous stencils.

If one or more parts list lines are found in the pages of the active Visio
document, the line at the lowest y co-ordinate is used to position
further lines when required. If fewer lines are required, HarnWare™
uses the lines in the order they were added to the drawing and then
deletes those that are not required. If no part lines are found in the
© TE Connectivity Parts Listing 259
drawing, HarnWare™ adds a new page named 'Parts List 1'. If the
parts list border from the HarnWare™ Metric or Imperial stencils or
the standard HarnWare™ templates is used, HarnWare™ will
automatically start a new page when the first page is full. The start
and end positions for parts lists are indicated by named connection
points in the parts list border shapes. Using the Visio 'Edit Special'
menu option you can select all the part lines as they are drawn on a
separate layer.

Parts lists are normally sorted using the parts list class codes into the
TE standard itemising sequence order. The following section
describes how this sequence can be altered. Within each class of part,
parts are sorted by part number. Parts with identical part number and
descriptions are totalized. If the units of measure are:

 ‘mm’, quantities are converted to metres and rounded as

necessary.

 'in' quantities are converted to feet and rounded as necessary.

260 User Guide HarnWare™ Version 6.3

 ‘Pc’ or ‘KT’ quantities are rounded up to the next whole number.

NOTE

A separate Part Number Translator program is available to convert the

part numbers in HarnWare™ parts lists into standard reference
numbers or into customer in-house part numbers. Refer to the system
support contacts listed in Appendix A if you are interested in
discussing this option.

Edit Parts List Format

The following describes a procedure for changing the format of the
Parts List table that HarnWare™ constructs in Visio. This procedure
might seem rather long-winded when written out but in practice it is
quite straightforward and it’s something you will only need do once:

1) Make a backup copy of the standard HarnWare™ stencils and

templates. For imperial this will be “HarnWare™ – Imperial.vst”
“Miscellaneous – Imperial.vss” and “Sheets - Imperial.vss”.
Simply substitute "Metric" for "Imperial" in all the template and
stencil references in this topic if required.

2) In Visio use File>Open to open the original copy of “HarnWare™

– Imperial.vst” Conveniently this also opens copies of the
“Miscellaneous – Imperial.vss” and “Sheets - Imperial.vss”
stencils which is what we need to edit.

3) Right-click the title bar of the “Miscellaneous – Imperial.vss”

stencil and select the “Edit stencil” menu option.

4) Right-click the “Part Line” icon and select the Edit Master>Edit
Master Shape menu option.

5) Use normal Visio drawing and text editing techniques to change

the column widths, text size and tab positions as required. NB
The text in part line shapes must be formatted with the same
number of tabs to retain the text structure as:
© TE Connectivity Parts Listing 261
6) <TAB>Item Number<TAB>Description<TAB>Part
Number<TAB>Specification<TAB>Quantity<TAB>Units

7) Hence the Format>Text>Tabs option shows the position of 6 tabs.

8) Select the part line shape and use <Ctrl>+C to copy it to the
windows clipboard.

9) Close the editing window and click “Yes” to update the “Part
Line” master shape.

10) Right-click the title bar of the “Miscellaneous – Imperial.vss”

stencil and select the “Save” menu option to save your “Part
Line” shape edits to disc.

11) Right-click the title bar of the “Sheets - Imperial.vss” stencil and
select the “Edit stencil” menu option.

12) Right-click the “Parts List” icon and select the Edit Master>Edit
Master Shape menu option.

13) Use normal Visio drawing and text editing techniques to change
the column widths, text size and tab positions as required. You
may wish to use <Ctrl>+V to paste the copy of the “Part Line”
shape made in step (6) into the editing window so that the parts
list titles can be easily lined up with the changes made to the “Part
Line” shape. Be sure to delete the temporary copy of the “Part
Line” shape before saving the “Parts List” shape.

14) Close the editing window and click “Yes” to update the “Parts
List” master shape.

15) Right-click the title bar of the “Sheets - Imperial.vss” stencil and
select the “Save” menu option to save your “Parts List” shape
edits to disc.

16) In the original copy of “HarnWare™ – Imperial.vst” which you

opened in step (2) go to the “Parts List 1” page.
262 User Guide HarnWare™ Version 6.3
17) Delete the “Parts List” border shape and the “Part Line” shape.
Replace these by dragging and dropping your newly edited copies
of the “Parts List” border and “Part Line” shapes from the “Sheets
- Imperial.vss” and “Miscellaneous – Imperial.vss” stencils.Use
File>Save to save your changes to the “HarnWare™ –
Imperial.vst” template.

Parts List Class Codes

The class codes used in parts list balloons to ensure items appear in
the correct place in lists generated by the parts listing option are listed
below.

If you would like to alter the standard parts listing order use Notepad
or your preferred text editor to edit the HARNWARE™.INI file. If
you have used the parts lister, you will find a line: 'Parts List Codes='
Simply add a list of the codes, separated by commas, which you want
to appear first in parts lists. For example, if you want moulded parts
and then adaptors to appear first in parts list you would need to
include a line 'Parts List Codes=MPt,ADA' in the
HARNWARE™.INI file. HarnWare™ will then list moulded parts,
adaptors and then all other items in the standard order.

ADA Adaptor
Adh Adhesive
Asy Sub-Assembly
Bra Braid
Cad Conduit Adaptor
Cap Insulation Cap
Cnd Conduit
CON Connector
COX Coax Cable
Cri Crimp Splice
CTr Conduit Transition
DBC Databus Coupler
© TE Connectivity Parts Listing 263

DBM Databus
Miscellaneous
EPD Multi-Core cable
Fed Feedthrough
FIL Filler
KTK KTKK
Mar Marker Sleeve
MIS Misc (the default)
MPt Moulded Part
Pro Protection Sleeve
PWR Power Cable
Sol Solder Device
Tap Shielding Tape
TER Wire Terminal
Tub Tube
WIR Wire

Braid, Tube, Wire & EPD Lengths

Braid and tube lengths are derived from the harness leg length and
adjustments for the styles of any moulded parts, adaptors and KTKKs
that are glued to the harness leg. For example, a greater deduction is
made from tube lengths for uniboots than for other styles of boot. The
braid and tube adjustments for each style of moulded part and adaptor
are held in the HarnWare™ database. The minimum tube length is
200mm (approximately 8").

Where the cable bundle diameter is greater than the nominal diameter
of the selected braid, an extra 20% of the leg length is added to the
braid length (NB the wall thickness of the first layer of braid is
ignored when comparing the nominal diameter of a second layer of
braid with the cable bundle diameter).
264 User Guide HarnWare™ Version 6.3
Tube lengths are increased to allow for shrinkage from the as-supplied
length. The increase is between 0% and 5% depending upon the cable
bundle diameter relative to the fully recovered tube diameter. The
calculated increase is based on the assumption that a 5% length
reduction occurs across a 2:1 ratio of as-supplied to fully recovered
tube diameters.

If you have specified that repair loops are to be included, the parts
lister will increase braid lengths by 20mm (0.79”) for each adaptor or
KTKK that is glued to the harness leg. By default HarnWare™
includes an allowance for repair loops. Use the set properties option in
the Design Wizard to can change the repair loop setting.
Alternatively:

 Call up the harness drawing in Visio.

 Click on a blank part of the drawing page to ensure no shapes are

selected.

 Use the Visio Shape, Custom Properties or Shape Data menu or

the right click , Custom Properties or Shape Data menu (in Visio
2010 check the 'Show/Hide Shape Data Window' checkbox in the
Data tab).

 Select either yes or No in the repair loops custom property.

After using the wire routing or parts listing options HarnWare™

outputs a prompt indicating whether allowances have been made for
repair loops.

The length of fillers included in cable cross-section designs are

calculated from the harness leg length plus 200mm (4") end allowance
plus 10% lay loss allowance.

Adjustments to wire lengths for adaptors, moulded parts, repair loops,

etc. are made by the wire routing option and the adjusted wire lengths
are output to wire list table in the Visio drawing. These lengths are
used by the parts listing option, so if you change a length in the wire
list table it will be used by the parts lister, but any such changes in the
wire list table will be lost if you re-use the wire routing option.
© TE Connectivity Parts Listing 265
Braid and tube in harness legs that are specified as multi-core cable
(EPD) are not included in the parts list. Multi-core cable lengths are
set to the sum of the leg lengths plus 100mm (3.94"). If the multi-core
cable is used in a branched harness where part of its length is stripped
back or is bundled with some other wires, a 10% lay loss allowance is
added to the maximum wire route length.

Warnings
When HarnWare™ generates warnings during
the parts listing process a warning shape is placed
in the drawing on the shape where the problem
was encountered. You do not need to delete these
warning shapes as they will be cleared when you
next use an option such as wire routing, parts
listing or labour estimating. However, if you wish
you can delete all the warnings using the Visio Edit, Select Special
menu option to select all shapes on the 'Warning' layer.

A brief description of the problem is added to the yellow warning

shapes. Further details can be obtained by right-clicking the warning
shape in Visio, and selecting the help menu option.

When HarnWare™ warns of such errors as harness legs with no

dimension, you can choose to continue with the analysis or to finish at
that point. If you check the 'Continue without further warnings' check
box, HarnWare™ will complete the parts list process without showing
any further warning dialogs that ask whether you want to continue.
However, all the yellow warning shapes will be added to the drawing.

Export Parts List

The HarnWare™ File>Export Parts List menu option allows parts
lists contained in the current Visio document or a selected set of
documents to be exported to the clipboard or a text file. This data can
then be used in a spread sheet, database, or the TE UK CBOM,
System.
266 User Guide HarnWare™ Version 6.3
Before using this option, a parts list should have been added to the
drawing(s) with the Tools, Parts List or Composite Parts List menu
option.

To Export Parts List from Selected Documents, select the document

file names from the file list box using the normal control and shift key
combinations to select all the required files.

Standard Headers Option

The Export Parts List form allows you to select the columns to export
and their order. For example, if you only want to use part numbers
and quantities in a spread sheet, just check these two options. A note
of the columns you select and their order is saved on disc so that when
you next use the export parts list option, the same column options and
ordering are shown as the initial defaults.
© TE Connectivity Parts Listing 267
The up and down commands move the selected column up and down
the order list. The 'Reset' command changes the column order to the
standard ordering which is 'Blank field', 'File name', 'Item number',
'Description', 'Part number', 'Spec/remarks', 'Quantity' and 'Units'. The
'Reset' command also sets all columns to be included in the output.

Prior to HarnWare™ V6, parts lists were exported to files named with
a ".dat" filename extension. This has now been changed to a ".txt" file
extension and a new ".csv" option allows comma, rather than tab
delimited files to be output.

You have the option of entering five headers for output as the first
line in the export file. If any of the header text boxes contain some
text the first line of the output file will contain <TAB> File Name
<TAB> Part Number <TAB> Project Number <TAB> Customer
Drawing Number <TAB> Issue <TAB> Labour time. (NB In the case
of ".csv" comma delimited files <TAB> will be replaced by ", ".) The
length of the file name has no limit and the other headers can be up to
25, 8, 25, 6 and 10 characters respectively. The TE CBOM system
uses this information when importing data. HarnWare™ can
automatically extract this information from the Visio document. The
labour time is the total labour hours in the Labour Estimate page and
the other items of data can be obtained from a drawing border
contained in the Harness Drawing page.

If you check the Clipboard option, the file name frame will be
disabled. Uncheck the box to reactivate the frame.

The folder or directory and file name will normally default to that of
the current drawing, except the file extension is changed from ".vsd"
to ".txt" or ".csv"

If you check Set Default Directory, the folder or directory path name
will be saved in the HarnWare™ INI file. When you next use the
export parts list option, this same folder or directory path will be
selected as the default and the check box will be set. If you uncheck
the box and click OK to export a parts list, the system will offer the
drawing folder or directory path as the default when you next use the
export parts list option.
268 User Guide HarnWare™ Version 6.3
When exporting parts list data, HarnWare™ searches the Visio
document(s) for pages with the words "Parts List" in their names. For
example, page names 'Parts List', 'Parts List 1' and 'Parts List 2' will be
included in the analysis. HarnWare™ extracts the data contained in
the parts list lines which form the parts list table.

A separate Part Number Translator program is available to convert the

part numbers in HarnWare™ parts lists into standard reference
numbers or into customer in-house part numbers. Please contact
system support if you are interested in discussing this option.

TE CBOM Headers Option

This option should only be used for exporting parts list data from a
single document. As the file required by the TE CBOM system
requires tab delimiters and certain columns, the options to change
these settings are disabled when the TE CBOM headers option is
selected. Also the CBOM system requires different headers to be
added to the file, so a different set of text-boxes are displayed.

Composite Parts Lists

With this option in the HarnWare™ Tools menu a composite parts list
can be generated for a number of HarnWare™ drawings that have
been parts listed. The procedure required to generate a composite
parts list is:

 Generate the individual drawings and parts list them in the normal
manner. The composite parts listing option uses the parts list table
data not the data stored with the shapes in the harness drawing.
Therefore, any shapes added after the parts list was generated for a
drawing will not appear in the composite parts list.

 Close and save the individual harness drawings to disc. Make sure
all drawings open in Visio are closed

 Open a new HarnWare™ drawing blank which has a page name

containing the words "Parts List".
© TE Connectivity Parts Listing 269

 Use the Composite Parts List option in the Tools menu. Select the
drawing file names from the file list box using the normal control
and shift key combinations to select all the required files. DO
NOT select the current drawing as adding any parts from the
current drawing to those contained in other drawings will produce
meaningless results.

 If required, quantities for each drawing and the total number of

kits can be adjusted. By default all these quantities are set to 1.
270 User Guide HarnWare™ Version 6.3

In generating a composite parts list, HarnWare™ searches each

selected drawing for pages with the words "Parts List" in their names.
For example, page names 'Parts List', 'Parts List 1' and 'Parts List 2'
will be included in the analysis. HarnWare™ extracts the data
contained in the parts list lines which form the parts list table. Once all
the drawings have been processed, HarnWare™ sorts and totals the
data using the standard parts listing sequence or your own sequence if
you have modified it using the method described in the section Parts
List Class Codes.

The resulting composite parts list is output to the HarnWare™ parts

listing form and to parts list page(s) in the current drawing.

Until the time when HarnWare™ starts to add information to the

harness drawing you can press the escape key to stop the composite
parts listing process.

Harness drawings generated with versions of HarnWare™ earlier than

V4 will not have parts list codes stored in the parts list tables and so
the composite parts list table will not be in the correct order. Simply
re-parts list the drawing to correct this problem.
© TE Connectivity User Parts Library 271

User Parts Library

Part Numbering Schemes
Non-standard parts that you use regularly can be held in the User
Parts Library. A copy of Microsoft Access 97 or later is all that is
required if you wish to add part numbers and part numbering schemes
into the User Parts Library.

The User Parts Library contains examples of each of these styles of

part numbering schemes:

 Coded part numbering schemes as are used for most TE products

and military connectors. In such schemes different characters in
the part number are used to describe various aspects of the part,
such as dimensions, materials and finishes. The number of
individual part numbers that can be generated by such schemes is
often very large. The User Parts Library provides a means of
handling such part numbering schemes in a way that avoids the
need to add all the individual part numbers into the database.
 Sequential or non-coded part numbering schemes. The User Parts
Library also allows individual part numbers to be stored in the
database along with design parameters that describe each part.
This allows the user to search for a part number by entering all or
a selection of the required design parameters. For example, part
style, size, material and finish.
 Limited coded part numbering schemes. The sequential part-
numbering approach can also be used for coded part numbering
schemes where only certain combinations of options are available
and when it is feasible to enter the valid part numbers into the
database.
272 User Guide HarnWare™ Version 6.3

Using the Parts Library

The HarnWare™ User Parts Library form is accessed via a command
button in the User Balloon form. To construct a part number or to
search for a part, select the part category and the master from those
listed in the two combo-boxes. As each master is selected,
descriptions, images and hyperlinks to documents containing further
information will appear in the form if these have been defined in the
User Parts Library database. The form can be enlarged to provide
more space for viewing this extra information.

As each master is selected in the combo-box the parameters used to

describe the part are loaded into combo-boxes. As each combo-box or
individual parameter is selected a description, image and hyperlink
information maybe displayed in the form. The master, parameter or
part number to which the information relates is indicated by the label
© TE Connectivity User Parts Library 273
shown in bold. The hyperlink may reference a file on your local hard
disc, a network drive or an internet web site.

If individual part numbers for the master are contained in the

database, the number matching the selected parameters will be
displayed and they will be listed in the part number combo-box. Each
of the parameter combo-boxes include a blank at the top of the list so
that a parameter can be ignored when searching. When an entry is
selected in the part number combo-box the settings for all the
parameters are selected in the parameter combo-boxes. A description,
image and hyperlink may also be displayed for the individual part
number if the database contains such references.

The Clear All command button selects blanks for all the parameters.
This can provide a more useful starting point for a search than the
defaults that are initially selected.

Where individual part numbers are not contained in the database, the
parameter combo-boxes are used to construct a part number. As each
option is selected the part number is updated to reflect the chosen
options. In addition to the listed values you may also enter other
values or edit the constructed part number. Obviously you need to
ensure the options selected and any non-standard text entered form a
valid combination and, therefore, a meaningful part number.

Clicking the OK command button causes the part number to be copied

into the HarnWare™ Balloon form. Any description, specification and
remarks associated with the selected part master are also copied into
the Balloon form. If data is subsequently saved to the balloon shape in
the drawing, the part number parameter settings are also saved. These
maybe viewed in the Design Wizard and they are also used to select
the default part number parameters if the User Parts Library form is
opened again for that Balloon shape.

Clicking the Cancel command button simply unloads the User Part
Library form without saving any data.
274 User Guide HarnWare™ Version 6.3

User Parts Library Database

A copy of Microsoft Access 97 or later is all that is required if you
wish to add part numbers and part numbering schemes into the User
Parts Library.

The database is held in the User Parts Library folder under the
HarnWare™ folder which, by default is in the Program Files folder.
This folder can also be used for any image files and documents you
wish to reference or hyperlink to, although the files can be on any
other disc or internet web site. Using the HarnWare™ Options menu a
shared master database folder can be specified to allow users to share
a common user parts library database and associated files that have
been saved to a shared network disc drive.

The User Parts Library contains examples of the various different

styles of part numbering schemes.

On opening the database in Microsoft Access you will see that it

comprises four tables:

 Masters contains records for each different part numbering

scheme, or master. The master name is used to relate the records in
all four tables and should, therefore, be carefully chosen to be
meaningful and unique. As you click on each field in this and the
© TE Connectivity User Parts Library 275
other tables, a brief description of the field is output in the
Microsoft Access status bar. Refer to the Parts List Class Codes
section or to the online help system for details on parts list codes.
The parts list description and Spec/Remarks are the texts copied
into the HarnWare™ Balloon form for saving into the balloon
shape and that are extracted by the Parts Lister.
 Part Number Fields contains records for each parameter used to
construct the part number or to search for part numbers. The Prefix
and Suffix fields are only used for constructing part numbers and
are not required for masters that have part numbers stored in the
Specific Part Numbers table. The Units and Tolerance fields are
only relevant to numeric parameters for masters with records in
the Specific Part Numbers table.
 Part Number Field Options contains records for each value of each
parameter or the default value for a parameter with a ValueList in
the Part Number Fields table.
 Specific Part Numbers contains a record for each part number
along with values for each parameter used to describe the part. The
parameters are held in the Field 1 to 15 which relates to the Field
Index values in the Part Number Fields table.
When adding data to the User Parts Library database it is important to
ensure data is entered consistently and accurately. For example,
master names must match in the four tables and FieldNames must
match in the Part Number Fields and Part Number Field Options table.

Although non-standard parts are normally represented by a balloon

shape in the drawing, any shape can be used provided the basic
structure matches that of a standard HarnWare™ balloon shape. In
particular the data1 field, custom properties and sub-shape with the
data1 field setting for the item number.

For those wishing to add data into the User Parts Library, we strongly
recommend the 1 day system administrator's training course. This also
covers setting up company drawing borders, special connector shapes,
etc.
© TE Connectivity Weight Estimator 277

Weight Estimator
Overview
The HarnWare™ Tools>Weight menu option provides a means of
estimating the weight of a harness. The accuracy of the estimate is
constrained by a number of factors including the availability of
component weight data. Where component weight data is not
available, especially in the case of connectors you will need to enter
the relevant data. However, a user weight database is provided for you
to store weights of frequently used part numbers.

The accuracy of harness weight estimates is also affected by a number

of factors such as manufacturing tolerances and conversions between
units of measure and the allowances HarnWare™ makes when
adjusting wire, braid and tube lengths, etc.
278 User Guide HarnWare™ Version 6.3

Estimating the Weight of a

Harness

The Tools>Weight menu option analyses the current HarnWare™

Visio document in a similar manner to that used for the parts listing
process. Quantities of identical parts are totalised, lengths of wire,
braid and tube are adjusted for repair loops and length adjustments are
made for right-angled adaptors, boots, etc. Shapes on the 'Non-Parts
Listing' layer are not included in the weight estimation so that a
weight can be supplied for a sub-assembly. Part numbers are sorted
into the same component class order that is used by the parts lister.
Parts lists are normally sorted into the TE standard itemising sequence
(for details on how to change this sequence refer to the Parts List
Class Codes section or to the online help system).

Part numbers are first checked against the user's weight database. If a
match for the part number is found in the database, the relevant
© TE Connectivity Weight Estimator 279
weight is used. Part numbers in the user database can include wild
cards so that ranges of part numbers can be matched by a single
database record and weight.

If no match is found in the user weight database, the HarnWare™

database is checked for a weight for the part number. Where no
weight can be found for an item, the 0.0 weight is shown in red to
attract your attention to those items for which you may like to supply
your own weight estimates.

The harness weight estimator form shows the weights per part or per
unit length and the total for the number of parts or total length of the
part included in the harness design. Where there are no items of a
particular class of part, a line is included as a reminder in case you
would like to add an extra allowance.

The weights displayed in the form can be edited using the text
boxes and the update button. The values that can be edited are
determined by the type of line that is selected in the grid. For
example, the weight in a line containing the sub-total for a class of
parts can only be edited if there are no parts of that class in the
drawing. When a weight or part quantity is changed, the relevant sub-
total and the overall total for the harness is updated. All these values
are shown in blue as an indicator of the values that you have changed.

The weights form can be maximised in order to view more

information thus reducing the need to scroll through the list of
weights.

If the units of measure selected in the HarnWare™ Options menu is

millimetres, weights are shown in kilograms whereas pounds are used
when inches is selected.

The database command allows you to add and edit weights in

the user weight database.

The draw command adds a page named 'Weight Estimate' to

the Visio document and a table is generated containing
weights for each class of part that is used in the design and the
total for the harness.
280 User Guide HarnWare™ Version 6.3
The HarnWare™ Tools>Composite Weight menu option provides a
means of estimating the weight of a number of harnesses.

User Weight Database

This option is accessed using the database command button in
the HarnWare™ Weight form. It provides a means of entering
and editing weights for specific part numbers, such as connector part
numbers.

When the weight database in a master database folder is used, the

options to delete or update records in the database are disabled.

Wild cards can be included in part numbers, so that ranges of part

numbers that have the same weight can be specified by a single record
in the database. For example, a connector that is available in a range
of different finishes as indicated by different characters in a particular
position in the part number. The wild cards are '_' for any single
character and '%' for any number of characters. For example, the
weight for a part number of '123456%' entered in the database would
be used for '123456', '123456-123', '1234567', etc. Care should be
© TE Connectivity Weight Estimator 281
exercised when using, especially the '%' wild card to avoid matching
more than the intended number of part numbers are matched.

Weights can be entered in grams or ounces. Weights are supplied

either for individual components or per unit length; per metre when
grams is selected or per foot when ounces is the selected units of
measure.

If you wish you can save a comment with each part number to help
you manage your weight database.

The Update command enters the current values in the database, or

amends an existing database record. The Delete command removes
the data for the current part number from the database. The Done
command unloads the User Weight Database form.

Using the Options menu a shared master database folder can be

specified to allow users to share a common weights database saved to
a shared network disc drive.

Composite Weight
The HarnWare™ Tools>Composite Weight menu option provides a
means of estimating the weight of a number of harnesses. The
procedure required to generate a composite weight estimate is:

 Generate the individual drawings and use the HarnWare™

Tools>Weight menu option to estimate the weight of each harness.
The composite weight option uses the weight estimate table data,
not the data stored with the shapes in the harness drawing.
Therefore, any shapes added after the weight estimate was
generated for a drawing will not appear in the composite weight
estimate.
 Close and save the individual harness drawings to disc. Make sure
all drawings open in Visio are closed.
 Open a new HarnWare™ drawing blank.
 Use the Composite Weight option in the Tools menu. Select the
drawing file names from the file list box using the normal control
282 User Guide HarnWare™ Version 6.3
and shift key combinations to select all the required files. DO
NOT select the current drawing as adding any parts from the
current drawing to those contained in other drawings will produce
meaningless results.
In generating a composite weight estimate, HarnWare™ searches each
selected drawing for a page named "Weight Estimates". HarnWare™
extracts the weight for each class of part in the table of weight
estimates. HarnWare™ sorts and totals the data using the standard
parts listing sequence or your own sequence if you have saved a
modified sequence (refer to the Parts List Class Codes section or to
the online help system for details on how to change this sequence).

The total weight estimates for the selected drawings are displayed in
the weight estimates form. The estimates can be edited and can be
saved into the current Visio document using the same procedures as
are used for estimating the weight of an individual harness.

The accuracy of weight estimates is constrained by a number of

factors including the availability of component weight data. Where
component weight data is not available, you will need to enter the
relevant data. However, a user weight database is provided for you to
store weights of frequently used part numbers.
© TE Connectivity Labour Estimating 283

Labour Estimating
Overview
The labour estimate option analyses the drawing and wire list.
Summary information is presented in HarnWare™ and data is added
to the Labour Estimate page in Visio. This page acts as a spread sheet
so you can easily adjust times and quantities in the estimate.

To initiate the labour estimating option use one of the following

alternatives:

 Click the Design Wizard Labour Estimate line.

 With no shapes selected right click a page in Visio.

Select labour estimate from the menu. HarnWare™ will pop-up in
front of Visio and the analysis process will start.

 Use the HarnWare™ tools, labour estimate menu.

 Use the <Ctrl>+E HarnWare™ short-cut key combination.

As the labour estimating process may take a minute or so on a large

harness, HarnWare™ takes the opportunity to show tips that may help
you make more effective use of TE products, Visio and HarnWare™.

Until the time when HarnWare™ starts to add information to the

harness drawing you can press the escape key to stop the labour
estimating process.
284 User Guide HarnWare™ Version 6.3

Labour Estimate Page

During the labour estimating operation HarnWare™ displays counts
of parts and lengths of tube, braid and multi-core cables (EPD’s). This
and other information is entered in the Visio labour estimate page.
Separate texts are used in the page for each item of data. HarnWare™
identifies the texts by name. If one of the required texts is deleted
HarnWare™ will detect this and generate an error message. To
correct this error you should delete the contents of the page and copy
all the text and shapes from the labour estimating page of a newly
created document using one of the two HarnWare™ templates.

In the labour estimate page most calculations involve 3 numbers:

 The time per part or per unit length. The name of these texts
normally ends in a ‘T’. If you need to use a different time simply
select the text and enter the required value. Ensure the value is a
number. The calculated total times will be updated as you change
© TE Connectivity Labour Estimating 285
the text. If the time is a standard, you may wish to change the
value in the HarnWare™ template so that it is applied to all new
drawings.

 The quantity of parts or length. The name of these texts normally

ends in an ‘N’. These texts are either updated by HarnWare™ or
they are highlighted in red for setting by the user.

 The calculated time. The calculation is either set in the actual text
or in the text’s shape sheet. Select the text, and use the Visio,
insert field menu to inspect the calculation. Or use the Visio,
window shape sheet menu to inspect calculations in the user
defined cells section. If you need to change these calculations,
contact HarnWare™ system support for assistance.

Warnings
As HarnWare™ collects data from the harness drawing and wire list
pages, various checks are made. You will be warned of such errors as
harness legs with no dimension or a non-numeric dimension. In these
cases you can choose to continue with the analysis or to finish at that
point. If you check the 'Continue without further warnings' check box,
HarnWare™ will complete the labour estimating process without
showing any further warning dialogs that ask whether you want to
continue. However, all the yellow warning shapes will be added to the
drawing.

Yellow warning flags are added to the drawing to indicate shapes with
which any problems were detected. You do not need to delete these
warning flags as they will be cleared when you next use an option
such as wire routing, labour estimating or parts listing. However, if
you wish you can delete all the warnings using the Visio Edit, Select
Special menu option to select all shapes on the 'Warning' layer.

A brief description of the problem is added to the yellow warning

shapes. Further details can be obtained by right-clicking the warning
shape in Visio, and selecting the help menu option.
286 User Guide HarnWare™ Version 6.3

Lengths
Unlike the parts listing option, labour estimating uses the harness leg
lengths included in the drawing when calculating braid and tube
lengths. No adjustments are made for repair loops or for the different
styles adaptors, boots and KTKKs.

Multi-core cable (EPD) lengths are calculated from the harness leg
lengths using the same method as is used for parts listing. If, in a
branched harness, part of a multi-core cable jacket is stripped, the
stripped length is estimated by subtracting the leg length from the
cable length.

HarnWare™ includes a time allowance for adding repair loops when

this option is specified and when the wire is smaller than 18AWG.
Click Set Properties in the Design Wizard to change the repair loop
setting. Alternatively:

 Call up the harness drawing page in Visio. Use the Visio Edit
GoTo menu if you have the parts list, wire list, drawing notes or
labour estimate, rather than the harness drawing, page on the
screen.

 Click on a blank part of the drawing page to ensure no shapes are

selected.

 Use the Visio Shape, Custom Properties menu or the right click ,
Custom Properties menu.

 Select either Yes or No in the Repair Loops custom property.

Solder and Crimp

The type of contact is determined by the setting in the connector
selection form. The default is crimp. With solder contacts,
HarnWare™ uses the wire size to determine which time element to
apply.
© TE Connectivity Labour Estimating 287

Potential Problems
The labour estimating option updates most of the part counts and
lengths of braid and tube in the labour estimating page. Time values
and counts in red texts are not changed. Therefore, any changes you
make to these values will be retained if you use the labour estimating
option again.

To save time only the pages named ‘Harness Drawing’ and those with
names including the words ‘Wire List’, e.g. 'Wire List', 'Wire List 1',
'Wire List 2', etc. are analysed when HarnWare™ is collecting
information for labour estimating. You should use the standard pages
in the HarnWare™ template for the specified purposes to avoid
confusion.

The Labour Estimating option needs to know which wires are routed
through each harness leg. The line numbers in the wire list table must
match the numbers added to each harness leg by the Wire Routing
option. Hence you should not add or delete harness legs or wires from
the wire table between routing and labour estimating.

The number of jacket ends that are to be prepared is set to the number
of connectors. Where multi-core cables (EPDs) are used this may
need adjusting. For example, if three multi-core cables are routed into
a boot on the back of a connector and the harness drawing contains
four connectors HarnWare™ would include an allowance to prepare
four ends but you may wish to increase this to six as there would be
six cable ends to prepare.

The number of conductors and wire gauge is determined from data

saved to the wire list table after selecting wire. Inconsistencies may
arise if you edit the part number such that the wire construction differs
from that indicated in the specification list boxes in the HarnWare™
wire selection form.

When a multi-cable shape is used to link two or more harness legs to

one opening in a moulded part, adaptor, KTKK or feed-through, you
may wish to add some special time allowances. For example, 5
minutes per cable and 15 minutes to terminate the braid.
288 User Guide HarnWare™ Version 6.3

NOTE

Labour estimating is not an exact science. Always fully check labour

estimates to ensure all the necessary factors have been taken into
account. Some further details are contained it the harness design
section of the online help system.
© TE Connectivity CoP, Tooling & Materials 289

CoP, Tooling & Materials

Overview
The codes of practice (CoP) , tooling equipment and assembly
materials option analyses the drawing and wire list. Codes of practice
(CoP), materials and equipment that are relevant to the parts contained
in the harness design are listed. You can add and delete from the lists
and then output the information to the drawing. (NB Prior to
HarnWare™ V6 this option also listed fax-on-demand references and
drawing notes. The fax-on-demand service has been replaced by the
comprehensive TE Connectivity web site and output from the
HarnWare™ Design Checker replaces drawing notes.)

Generating CoP, Tooling

Equipment & Assembly
Materials Lists
To initiate this option use one of the following alternatives:

 With no shapes selected right click a page in Visio. Select drawing

notes from the menu. HarnWare™ will pop-up in front of Visio
and the analysis process will start.

 Use the HarnWare™ tools menu.

 Use the <Ctrl>+T HarnWare™ short-cut key combination.

While HarnWare™ is searching the drawing you can press the escape
key to stop the process.
290 User Guide HarnWare™ Version 6.3

HarnWare™ checks each part in the drawing and wire list against a
set of rules to determine which CoP’s, tooling equipment and
assembly materials maybe relevant. Those selected are displayed in
two separate lists for codes of practice and for materials and
equipment. For each entry in the list a reference number and a
description is displayed. Use <Shift>+F1 to obtain further details on
the selected CoP, material or equipment.

You can delete items from each list using the normal Windows mouse
and keystroke options to select single or multiple items. For example,
while holding down the left mouse key you can drag over a number of
entries or you can build up a selection by clicking the left mouse
button with the control key held down. Use the delete or backspace
key to delete the selected items from the list.

The undo command button will restore the list to the set of
options initially offered by HarnWare™. The All command
button will list all options from the database.
© TE Connectivity CoP, Tooling & Materials 291
The CoP and materials and equipment command
buttons allow you to move between the two lists.

When adding the information to the drawing,

HarnWare™ first checks if the current document contains a page
named 'CoP' or 'Materials and Equipment'. If not, a new page is
added. A drawing border is added to the page from the metric or
imperial sheets stencil. HarnWare™ then adds the information to the
drawing page. Each line in the list may have a right-click help menu
option used to access further details on the CoP, materials or
equipment.

Alternatively visit www.te.com or www.HarnWare™.com for further

product information.
© TE Connectivity Drawing Translator 293

Drawing Translator
Overview
The translator searches through selected pages in Visio documents for
recognised TE harness design phrases. These phrases are replaced
with translations for the selected language. The translation process is
phrase, rather than word, based in order to achieve better grammatical
results.

The translator checks each text in the selected pages in the active
Visio document to see if it includes any of the standard phrases. The
standard phrases in the dictionary are searched starting with the
longest and working through to the shortest. For a phrase to be
translated it must be surrounded by word delimiters, for example,
beginning or end of line, tab, space or hyphen. These two techniques
ensure that translations of short words, for example ‘to’, are not
applied to parts of longer words such as ‘torque’ and that parts of a
phrase are not translated when a translation is available for the
complete phrase.

Options are provided for adding and editing the phrases and
translations stored in the HarnWare™ translator database. If required,
Microsoft Access can be used to print the contents of the dictionary
database. Unlike the HarnWare™ product database, the translation
database is not protected against changes.

Provided Visio has been set-up correctly for the local language, the
HarnWare™ translator will handle languages that include extended
character sets, for example, Taiwanese and Japanese. Extra languages
can be added simply by inserting a new field in the database and
loading it with translations for each of the stored English phrases.
294 User Guide HarnWare™ Version 6.3

Method of Use
With a HarnWare™ drawing open, use the HarnWare™ Tools,
drawing translator menu option:

 Select one or more drawing pages from the list box.

 Select the required language in the drop down list box.

 Click the ‘Translate’ command button. While the translator is

working the name of the drawing page and the English texts being
translated are shown in the form. During the translation process
the escape key can be used to halt the translation process at
anytime. The selected language is stored in the HarnWare™ INI
file on disc and is used as the default when the translator option is
next used.
© TE Connectivity Drawing Translator 295
Formatting options (e.g. bold, italic and font size) previously applied
to texts or selected characters within a text string should be
maintained correctly during the translation process. All texts, whether
or not they are in a shape within a group, will be translated.

Because the length of translated phrases can vary considerably from

the English original, drawing text formatting can be disturbed. The
labour estimate page causes particular problems in this respect.
Therefore, we recommend:

 Translate and format the HarnWare™ templates in the

HARNWARE™\TEMPLATE folder or directory. Thereafter all
new harness drawings you create based on these templates will be
formatted correctly.

 You may also wish to translate and format the drawing border
shapes contained in the metric and imperial sheets stencils. These
are also contained in the HARNWARE™\TEMPLATE folder or
directory.

Phrase Database Management

The options in the Phrase Database Management frame allow the
dictionary of English phrases and their translations to be inspected
and, if required, amended or supplemented.

When the translator database in a master database folder is used, the

options to delete or update records in the database are disabled.

Use the combo-box to select an English phrase or to enter a new

phrase. Enter the translation for the currently selected language in the
translation text box. Phrases and translations can each be up to 200
characters long. The translation text box and the English combo-box
use the Microsoft System font which should allow characters from
extended character sets to be entered correctly on localised versions of
Windows.

Click the ‘Update’ command button to insert the contents of the

English combo-box and the translation text box into the database.
296 User Guide HarnWare™ Version 6.3
Alternatively click the ‘Delete’ command button to remove the
English phrase and any associated translations from the database.
Appropriate warning messages are output asking you to confirm the
delete or update action before changes are committed to the database.

Using the HarnWare™ Options menu a shared master database folder

can be specified to allow users to share a common drawing translator
database saved to a shared network disc drive.

Extended Character Sets

If translated texts do not include the correct characters used in
extended sets used in such countries as Taiwan and Japan, check that
the correct default font is selected in Visio:

 Add a new text into the drawing using the standard Visio text tool.

 Select the Format Font option to check the name of the default
font.
© TE Connectivity RoHS 297

RoHS
Overview
The HarnWare™ Restriction on Hazardous Substances (RoHS)
option analyses the parts referenced in the drawing and wire list. A list
of RoHS compliance codes for each part is presented in the
HarnWare™ form and the list may also be added to a page in the
Visio document. This option is accessed via the HarnWare™ Tools
menu.

The RoHS form can be maximised in order to view more information

thus reducing the need to scroll through the list of codes.
298 User Guide HarnWare™ Version 6.3
Where parts are listed as non-RoHS compliant, alternatives are
usually available in the parts listed in the relevant HarnWare™ part
selection form. Alternatively please contact TE Product Management
for more information.

The results of a RoHS analysis maybe saved to page(s) in the

file Visio document using the 'Draw' command.

Background Information
The Restriction Of the use of certain Hazardous Substances in
electrical and electronic equipment, Directive 2002/95/EC becomes
law in July 2006. It restricts the use of mercury, cadmium, lead,
hexavalent chromium, polybrominated biphenyls (PBB) and
polyrominated diphenyl ethers (PBDE). The scope of applications is
defined in the Waste Electrical and Electronic Equipment directive
2002/96/EC (WEEE) Annex IA, applications and includes:

 Large household appliances

 Small household appliances

 IT and Telecommunications equipment

 Consumer equipment

 Lighting equipment

 Electrical and electronic tools (with the exception of large-scale

stationary industrial tools)

 Toys, leisure and sports equipment

 Automatic dispensers

Hence, it is our interpretation that products containing substances

banned in RoHS can be sold into applications not covered by WEEE.
For example:
© TE Connectivity RoHS 299

 Military Applications

 Civil Aerospace Applications

The EU Directive 2002/95/EC) and other legislation/initiatives require

disclosure of certain substances to aid in the recycling or disposal of
electrical and electronic equipment. However, There is currently no
legislation nor industry standard that requires or defines what a
material disclosure should include.

By definition, RoHS compliant products do not contain concentrations

in excess of 0.1% by weight of Lead, Mercury, Hexavalent
Chromium, PBB, PBDE and 0.01% for Cadmium per homogenous
material. An homogenous material is a substance or mixture of
substances with uniform composition (such as solders,resins, platings,
etc.) that cannot be mechanically separated.

Certain exemptions apply to some TE products, for example:

 Lead as an alloying element in steel (0.35%), aluminum (0.4%),

and copper (4.0%)

 Lead in solder for telecom infrastructure equipment and servers (5

of 6)

 Lead in compliant pin connector systems (pressfit connects)

 Cadmium in electrical contacts

RoHS Code Definitions

A Converted to Directive 2000/53/EC ELV compliant (running
change – same part number) See note 1

Y Converted to Directive 2002/95/EC RoHS compliant

(running change – same part number) . These parts are also
Directive 2000/53/EC ELV compliant.
300 User Guide HarnWare™ Version 6.3
E Always Directive 2000/53/EC ELV compliant (no change
required and new parts) See note 1

R Always Directive 2002/95/EC RoHS compliant (no change

required and new parts). These parts are also Directive
2000/53/EC ELV compliant.

V Always Directive 2002/95/EC RoHS compliant (no change

required and new parts). These parts are NOT Directive
2000/53/EC ELV compliant. Examples would be products
that utilize the exemption for lead in compliant pin connector
systems or cadmium in electrical contacts.

5 Always Directive 2000/53/EC ELV compliant (no change

required and new parts). In addition these parts are Directive
2002/95/EC RoHS compliant except that they contain lead in
the solderable interface only. (e.g. no hex chrome, no PBB or
PBDE)

L Contains lead or other hazardous materials (not RoHS or

ELV compliant)

S Not in scope of Directive 2000/53/EC ELV See note 3

T Not in scope of Directive 2002/95/EC RoHS See note 3

U Not in scope of ELV and RoHS See note 3

N Not yet reviewed

K Customer Controlled Part (TE does not control Bill of

Material) See note 2

M 44A1* wires manufactured in the USA contain Pb stabiliser

in the jacket insulation and are not, therefore, RoSH
compliant. Those manufactured in the UK are RoSH
compliant.
© TE Connectivity RoHS 301
Notes:

1) Addresses part changes after 1 January 2003, so parts converted

prior to 1 January 2003 are coded as “Always Compliant.”

2) Code K used for only those cases where a customer controls the
bill of material and TE is not responsible for determining
RoHS/ELV compliance of the product (certain cable assemblies
may fall into this category). Should the product status become
known, either by TE evaluation or customer notification (verified
by TE), the appropriate RoHS/ELV compliance code may be
designated at that time.

3) Codes S, T, and U are used ONLY for items clearly not covered
by applicable directives (e.g., hand tools – non-electrical).
Customers should verify prior to use that RoHS/ELV compliant
products are not required.

Further Information
For further information please visit
http://www.te.com/customersupport/productcompliance/
© TE Connectivity Compare Designs 303

Compare Designs
This option is initiated from the HarnWare™ Tools menu and is used
to analyse the changes between two HarnWare™ Visio design
documents, typically two different revisions of a harness design or
two similar designs.

Check boxes allow the parts lists, wire lists, cable marker text and
labour estimates to be included or excluded from the design
comparison.

Item numbers can be included or excluded in the wire and parts list
comparisons. When this item number option is checked, if a part has
been added or deleted and if, when the drawing was re-parts listed the
retain item numbers option was not selected, all parts with a higher
304 User Guide HarnWare™ Version 6.3
item number will be listed as changed (delete and add) simply because
their item number has changed.

Items added, deleted or unchanged are listed in the treeview. The total
numbers of parts list, wire list, cable marker texts and labour estimate
items that are added, deleted or unchanged are also included in the
treeview.

Wire list numbers, item numbers and positions for deleted parts list
balloons or cable markers relate to file 1. Those for added items relate
to file 2.

X-Y co-ordinate positions are relative to the default 0,0 datum which
is at the bottom left corner of the Visio drawing page. If the datum has
been changed, to avoid confusion it should be moved back to the
default position. Co-ordinates are output in the units selected in
HarnWare™ which maybe different to that selected in Visio.

Changes in wire list numbers are ignored by the comparison

operation.

A change to a parts list, wire list item or cable marker text is recorded
as a deleted item and an added item. Although in some cases it might
seem more logical to list changes to items in a single line as is done
for the labour estimate, this approach is taken because it is not always
possible to pair parts list, wire items or cable marker texts that have
been edited. If multiple markers have the same text and not all are
changed, the listed position may relate to one that has not changed.

The results of a design comparison maybe saved to page(s)

in the file 2 Visio document using the 'Draw' command or to
a file or the Windows clipboard. Results maybe saved to the clipboard
or file in tab or comma delimited format which are both
suitable for importing into programs such as Microsoft Excel
and Access. Unchanged items can be included or excluded
from the saved results.
© TE Connectivity Create Shape 305

Create Shape
You can set up your own shapes. If you wish HarnWare™ to
recognise your shape in the part selection, wire routing and parts
listing processes you will need to add the correct information to the
data1 field. Drag and drop a HarnWare™ shape and use the Visio
'Format Special' menu option (or in Visio 2010 the Shape Name
option in the Developer tab) to inspect the data1 field.

If the Format>Special menu option (or in Visio 2010 the Developer

tab) isn’t visible use the Tools>Options>Advanced dialog and check
the "Run in developer mode" option (or in Visio 2010 use Visio
Options>Advanced in the File tab).

If you copy and paste the data1 field into your shape, most of the
HarnWare™ options will recognise your shape. Moulded part
transitions are, however, more complicated to set up because opening
names have to be related to connections.

The Tools>Create shape menu option assists with certain aspects of

creating your own shapes for use with HarnWare™.
306 User Guide HarnWare™ Version 6.3
Before selecting this menu option a single shape or group should be
selected in Visio. As some of the changes made by this option cannot
be undone, it is advisable to make a copy of your shape before using
this option.

The more common part classes (connectors, adaptors, etc) are listed
and when selected provide a basic setting for the shape Data1 field
which is used to store most of the data used by HarnWare™.

The 'Twist shape' option is typically used for angled adaptors or boots
where the begin and end points of the OneD shape need to be adjusted
to the positions of the openings in the part. The opening positions in
the part are indicated by two connection points which must be added
to the shape before using the 'Create shape' option. As part of the twist
shape operation the shape height is set to zero so when the shape is
selected or dragged a line connects the begin and end points.

Clicking 'OK' causes:

 The shape to be converted into a OneD shape

 Protection to be added to the width, height and aspect ratio

 Right-click and double-click menu options to be added for

opening the shape in HarnWare™ and for accessing the rotate
option

 The shape data1 field to be set to the specified text

 The shape name to be set

 If the connector class is selected, a text is added to the shape along

with a control handle to control it's position. The text angle is also
fixed. This text is used for the connector reference.

After using the 'Create shape' option the processed shape should be
added to a stencil, so that a master can be dragged and dropped in a
harness drawing.
© TE Connectivity Create Shape 307

Drawing Hints
When drawing shapes for parts such as connectors or adaptors you
may need to omit the geometry which is normally hidden when
assembled with a boot.

If possible keep the drawing symmetrical about the part centre line. If
not, try adding two connection points and use the 'Twist shape' option
to realign the shape.

Generally shapes should be drawn with closed lines which can be

filled to help shape selection.

Extra information such as part numbers, dimensions and material

details can be stored in the data1 field. After selecting and saving a
standard part from HarnWare™, make a note of the relevant
information required for your particular part. Each data item in the
data1 field is enclosed with '{' '}' brackets. Please contact
HarnWare™ system support for advice.

There are various books and internet web sites that contain a wealth of
information on creating shapes in Visio, manipulating the ShapeSheet,
etc.

Errors
Unfortunately a number of errors can occur while making these type
of changes to Visio shapes. A dialog will outline the action causing
the problem along with some extra information. This information
should help identify the changes you will need to make to your shape.
Alternatively please contact HarnWare™ system support for advice.
© TE Connectivity Miscellaneous Options 309

Miscellaneous Options
Rotate and Group Shapes
This option can be initiated using:

 The toolbar icon

 The HarnWare™ Edit, Rotate menu option

 The <Ctrl>+R short-cut key combination.

 Right clicking a HarnWare™ shape in Visio and selecting the

rotate menu option.

The rotate form provides two options: rotate and group glued shapes.

Rotate Shapes

The selected shapes in Visio are rotated clockwise or anti-clockwise

by the angle you enter. Any angle between 0 and 360 in 7½°
increments can be entered (7½° is the largest common denominator of
the TE transition angles).

Clicking in the slider bar or using the keyboard page up and down
keys increments the angle by 45°, whereas clicking the arrows at the
end of the slider bar or using the keyboard arrow keys increments the
angle by 7½°.

Normally HarnWare™ rotates about the centre of the selected group

of shapes. However, if a suitable glued connection is found from one
of the selected shapes to another which isn’t selected, rotation is about
that glued point. This means that rotating does not break the glued
connection. However, because HarnWare™ has to search the whole
drawing for glued connections, you should uncheck the ‘Check Glues’
310 User Guide HarnWare™ Version 6.3
check box to save time when rotating shapes that are not glued to any
other shape.

If you use the kinked leg shape in the miscellaneous stencil, you may
not need to rotate any shapes. This is often a quicker and easier way
of producing harness drawings. The right-click menu for the kinked
leg shape allows any of the TE transition angles to be set. Further
shapes can then be added to the horizontal leg.

Another way of drawing an angled harness leg is to:

 Drag and glue the shapes in a horizontal line starting at the

transition outlet.

 Select all the shapes, except the transition, by dragging a selection

rectangle.

 Use the rotate option to rotate the leg to the desired angle. The
shapes will be rotated about the glued connection to the transition
outlet and the glue will not be broken as it would if you simply
used the Visio rotate tool.

After rotating the selected shapes, you should be able to use the Visio
Undo option to correct any mistakes you may make.
© TE Connectivity Miscellaneous Options 311
The HarnWare™ harness leg shapes have been designed so that the
dimension text and surrounding box is oriented to be readable from
the bottom or right edge of the drawing. To achieve this, the text and
box flip to the other side as the leg is rotated. Some boots with eyelets
have also been designed in a similar manner so that eyelets on all the
boots are oriented in the same direction.

You cannot rotate guidelines or shapes that are locked from being
rotated. If any such shape is included in your selection the
HarnWare™ rotate option will generate a suitable warning message.

A further alternative is provided by the Visio rotate page option. Refer

to the Visio online help for details on page rotation.

Group Glued Shapes

The group command, groups all shapes that are glued to the selected
shapes, including any associated balloons that were added by the parts
lister. This is useful when, for example, a harness leg formed by
several components needs to be moved.

Multi-Cable Shapes
Multi-cable shapes allow two or more harness
legs to be associated with one opening in a
moulded part, adaptor, KTKK or feed-through.
The HarnWare™ miscellaneous stencils contain
shapes catering for 2, 3 and 4 legs to be
associated with one opening. If more than 4 legs
are required, glue the multi-cable shapes end to end.

When a multi-cable shape is used, HarnWare™ searches for the

expected number of harness legs. For example, if a 3-way shape is
used HarnWare™ will search for 3 legs, or multi-cable shapes glued
to the shape. A warning is given if fewer legs are found.

The diameter over the bundle of cables is calculated and is used as the
harness leg diameter in the moulded part, adaptor, KTKK and feed-
through forms.
312 User Guide HarnWare™ Version 6.3
With shielded systems you may need to add a length of braid,
protection tubing and a solder sleeve to terminate the braid of the legs.
If the number of legs is greater than 4, difficulty may be experienced
with terminating braids and sealing the interstices with adhesive.
Particular care should be taken when selecting a piece of braid for use
with Tinel adaptors, Feedthroughs or KTKKs to ensure the braid size
range is suited to these parts and the diameter over the multi-leg
braids.

HarnWare™ attempts to select the appropriate braid when a Tinel

adaptor is used with a multi-cable. When saving the adaptor shape
you will be asked if you wish a 150mm (6") length of braid to be
included. The lengths are doubled if the harness legs have two layers
of braid.

A multi-cable outlet can only be used when the moulded part material
and adhesive is suitable. For example, HarnWare™ will warn that
multi-cable outlets are not recommended for use with shielded
Rayaten boots or with -55 moulded part material. In such
circumstances you should either convert your design to use a
transition or check if another material or adhesive can be used. If the
moulded part material and adhesive is suitable, HarnWare™ will add
one sachet of adhesive for sealing the interstice gaps. With large
numbers of cables or large diameters in a multi-cable you may need to
add more adhesive.

When using multi-cables you may wish to add some extra time to the
labour estimate. For example, 5 minutes per cable and 15 minutes to
terminate the braid.

Copy, Paste and View Part Data

The Edit menu contains options for copying, pasting and viewing data
from a HarnWare™ part form. These options are mainly used when a
number of wires are identical, except for colour, or when two harness
legs with identical braid and tube are required either side of a
feedthrough. In these cases copy and paste can save the time spent in
re-selecting part and material options. Alternatively the copy and view
© TE Connectivity Miscellaneous Options 313
options can provide a simple notepad or reminder of options selected
for a previously specified part.

With any HarnWare™ part form active you can use the copy option to
make a temporary copy of the part numbers, diameters, material
options, etc. contained in the form. This temporary data can be viewed
using the view part data option. Individual items of data can be copied
from the view part data form by dragging the mouse over the text to
highlight it and then using the normal <Ctrl>+C key combination to
copy the text to the windows clipboard. This text can then be pasted
into any HarnWare™ text box using the <Ctrl>+V key combination.

The product information command button also allows you to access

more information on the relevant TE products and materials.

The paste menu option copies all the temporary data into the part
form. This option should be used with care as it overwrites
diameters, part numbers, material options etc. Before using this option
it is advisable to use the view part data option and study the temporary
data alongside the current form to see if you really do want to change
all the data. HarnWare™ will prevent you from trying to paste data
into a form for a different class of part. For example, if you copied
314 User Guide HarnWare™ Version 6.3
data from a moulded part form, HarnWare™ will not allow you to
copy that data into an adaptor form.

Print Document(s)
The print document option is selected from the HarnWare™ File
Menu to print selected pages from the current document or from a
selected set of Visio document files.

The height and width of each page is checked. HarnWare™

automatically selects the most appropriate orientation for printing,
either portrait or landscape. Recent versions of Visio now include an
option for setting different print options for each page in a document
and so this HarnWare™ print option is not so often required.

Documents

Before using this option you should close any documents that are
open in Visio. You will be warned to save any open documents that
have unsaved changes.
© TE Connectivity Miscellaneous Options 315
If you want to print pages in the current Visio document select the
'Current Document' option. Alternatively click the 'Selected
Documents' option and then select one or more drawing files using the
drive, directory and file name list boxes. Use the normal Windows
control and shift key combinations to select more than one file.

Pages

If the 'Current Document' option is selected, HarnWare™ will load

the page name list box with the page names in the current document.
If the 'Selected Documents' option is selected, the page name list box
will be loaded with the standard HarnWare™ page names. Clicking
the 'Reset' command causes the page name list box to be cleared and
reloaded.

Select one or more page names from the list box in the pages frame or
add page names using the text box and the >> add command. You can
use '*' and '?' wild cards in page names. For example, entering ' Parts
List*' into the text box and selecting it in the list box would cause
both the pages 'Parts List 1' and 'Parts List 2' pages to be processed.

Printing

Click the 'Print' command button to access the Windows Print dialog
and to start the printing process. The selected pages in the current
document or the selected document files will be scaled to fit on one
page and are printed. Other settings are those previously set using the
Visio>Page Set-Up>Print Setup options (or in Visio 2010 the Page
Setup option in the Design tab).

By comparing the height and width of each page HarnWare™ selects

the most appropriate orientation for printing, either portrait or
landscape.

You can use the escape key at any time to cancel the print document
operation.

If you find page orientations have changed after using the print
option, use the Visio File>Page Setup>Page Size menu option (or in
316 User Guide HarnWare™ Version 6.3
Visio 2010 the Page Setup option in the Design tab) and ensure all
pages are set to a pre-defined page size.

Data Import
This option is used to import data from an Excel spread sheet to help
create parts of a harness design. Three example Excel spread sheets
named 'DataImportExample*.xls' are contained in the HarnWare™
Sample folder. These examples can be used as a basis to create your
own spread sheets.

The spread sheet should comprise three worksheets named

'Connectors', 'Splices' and 'Wire'. Headings for each column should be
named. For example, the 'Connectors' worksheet requires named cells
'Connector_Reference', 'Connector_Part_Number', etc. The columns
can appear in any order in each worksheet. The actual data should be
contained on rows below the row containing these headings.

Connectors

Reference is the only data that must be entered for connectors. By

default the 'Plug' master from the HarnWare™ 'Connectors' stencil is
used. If a different master from the 'Connectors' stencil is required, the
master name should be entered in the 'Master' column. If the master is
contained in another stencil the stencil name should be added in the
'Stencil' column.

If a connector is selected using the HarnWare™ connector selection

facilities and then saved to a Visio drawing, this shape's data1 field
contents could subsequently be used for the 'Data1' column of the
'Connectors' worksheet. The data import option will then be able to
create a connector shape with all the necessary data. If the data1
column is blank, connector code and shell size can be entered to
provide the HarnWare™ adaptor selection with the required data.

Splices

The 'Splices' worksheet contains fewer columns than the 'Connectors'

worksheet and is handled in a similar manner.
© TE Connectivity Miscellaneous Options 317

Wire

The 'Wire' worksheet requires 'From Connector' and 'To Connector'

references for each wire. The other columns are optional. To fully
specify a wire the part number, quantity, diameter and data1 fields
would be required. If a wiring schematic is required:

The 'Part Number/Description' column can be used for part numbers,

signal names or other information useful to the schematic or to guide
selection of the most appropriate wire.

The 'Number of Conductors', 'Shield' and 'Coax' columns should be

used so that the appropriate twist and shield symbols are included in
the schematic. For shield or coax wires add 'Y' in the appropriate
column otherwise an unshielded wire construction is assumed. If the
'Number of Conductors' column is blank a single primary wire is
assumed.

The quantity column can be used in cases where more than 1 wire of
the same type is required between the same pair of connectors and/or
shields.

Processing

The 'Read spreadsheet' command processes the worksheets. A wide

range of checks are performed on the data and appropriate warnings
and messages are added into the treeview. For example, connector and
splice references are cross-checked to the from and to connector
references listed in the 'Wire' worksheet. The 'Generate drawing'
command uses the data previously read from the spreadsheet to
construct a partial HarnWare™ drawing based on the selected
template. Connector and splice shapes are dropped into columns in the
'Harness Drawing' page and wire lines are added into the 'Wire List'
page(s). After re-positioning the connector and splice shapes, a wiring
schematic can be produced if required. Also adaptors, boots, moulded
part, etc can be added to complete the harness drawing.
318 User Guide HarnWare™ Version 6.3

Pre-Processing Documents for

Export
The drawing export processor is selected from the HarnWare™ File
Menu to process selected pages from the current document or from a
selected set of drawing files. Certain options in Visio are not
implemented in other CAD systems, such as AutoCAD, and therefore
HarnWare™ drawings transferred into other CAD systems via DXF,
or other file formats can require some editing. This option makes
various modifications to allow HarnWare™ drawings to transfer in a
more acceptable manner.

NOTE

After using the Drawing Export Processor do not save the Visio
document. When a document has been processed for export, it is no
longer suitable for use with HarnWare™.
© TE Connectivity Miscellaneous Options 319

Documents

Before using this option you should close any documents that are
open in Visio. You will be warned to save any open documents that
have unsaved changes.

If you want to process pages in the current Visio document select the
'Current Document' option. Alternatively click the 'Selected
Documents' option and then select one or more drawing files using the
drive, directory and file name list boxes. Use the normal Windows
control and shift key combinations to select more than one file.

Pages

If the 'Current Document' option is selected, HarnWare™ will load

the page name list box with the page names in the current document.
If the 'Selected Documents' option is selected, the page name list box
will be loaded with the standard HarnWare™ page names. Clicking
the 'Reset' command causes the page name list box to be cleared and
reloaded.

Select one or more page names from the list box in the pages frame or
add page names using the text box and the >> add command. You can
use '*' and '?' wild cards in page names. For example, entering ' Parts
List*' into the text box and selecting it in the list box would cause
both the pages 'Parts List 1' and 'Parts List 2' pages to be processed.

Processing

Click the 'Process' command button to start the process. The selected
pages in the current document or the selected document files will then
be converted into a format better suited to other CAD systems such as
AutoCAD. Among the modifications made are:

 Wire and parts list tables are reformatted with fixed pitch fonts
and spaces rather than tabs to ensure the data is arranged into
columns. You may find it necessary to select a fixed pitch font in
the receiving CAD system. For example, in AutoCAD use the
Format>Text Style menu option to select Courier New. If this font
320 User Guide HarnWare™ Version 6.3
is not available in the receiving CAD system, you may need to
adjust the number of spaces in the parts and wire lists to align the
text with the column lines. New parts and wire list border shapes
are included in the metric and imperial sheet stencils. If a drawing
contains a parts or wire list border shape from a version of
HarnWare™ prior to V4.5, replace the shapes with the new
versions before using this program.
 Harness leg lines passing under cable marker and cable break
shapes are hidden and the invisible parts of these shapes are
removed. Also the dimension texts are deleted from harness legs
and databus cables with invisible dimensions.
 WMF files used in cable cross-section drawings are ungrouped to
allow them to be included in DXF and other file formats. This
process can take sometime to complete.
 Spaces are removed from shape names as systems such as
AutoCAD error when a DXF file contains a block name that
includes a space.
 The texts in wiring schematic connectors that are flipped are
rotated.

 The custom line style used for databus cables is replaced with a
single line that will be included in DXF and other file formats.
You will need to substitute a parallel line in the receiving system.

A new parts list balloon shape was introduced in HarnWare™ V4.5

which avoids leader lines crossing into the centre of the balloon
circles. Drawings created with earlier versions of HarnWare™ should
be re-parts listed to update the balloon shapes to the latest standard.

When the process is complete each of the selected documents will be

open in Visio. Go to each of the required page and use the Visio
File>Save As menu option to save the page as an AutoCAD DXF file
or your preferred file format. When you have created the necessary
files, close the drawing.

The drawing export processor can take sometime to complete. You

can use the escape key at any time to cancel the process.
© TE Connectivity Miscellaneous Options 321
The special HarnWare™ linestyles used for conduit legs are not
available in other CAD systems. Therefore, after transfer a conduit leg
will usually be represented as a single line. It will be necessary to
change the line to a more suitable representation in the receiving CAD
system.

Arrange Dialog and Main Forms

When a dialog form is open the F8 function key can be used to move
all other dialog forms and the main HarnWare™ form to the same
position.

If the HarnWare™ forms are obscuring a part of the Visio drawing:

 Move the active dialog form.

 Press the F8 function key to rearrange all the other HarnWare™

forms under the active form.
© TE Connectivity Support Contacts 323

HarnVis

Overview
HarnVis is a 3D modelling system for visualising harness designs
generated by the TE HarnWare™ PC Harness Design System. This
option is available for a small annual charge.

HarnVis can be started from the:

 Windows Start Menu

324 User Guide HarnWare™ Version 6.3

 HarnWare™ Tools menu or by using the HarnWare™ <Ctrl>+H

short-cut key

 Visio View>Add-Ons

 HarnWare™ tab in Visio

HarnVis automatically generates to-scale 3D models which provide

“virtual prototypes” of harnesses designed using HarnWare™. The
user can see what a harness will look like with lengths, diameters and
parts shown to-scale. This should reduce the potential for errors.

HarnVis can also generate to-scale Visio harness drawings. These can
help with the design of harness lay-up boards, also known as nail
boards, peg boards, form boards and loom boards. The to-scale Visio
drawings can include the lay-up board pegs. Drill charts can be
generated so that peg x-y co-ordinates can be automatically
transferred to NC drilling or laser cutting machines.

Overall sizes can easily be checked. When one or more parts are
selected, HarnVis draws the minimum enclosing orthogonal volume
and the dimensions of the colour coded sides of the volume can be
obtained. This is especially useful for establishing the overall size of
connector and right-angled adaptor or boot assemblies.

HarnVis gives a good representation of most moulded parts when

fitted to any suitable size of adaptor and harness leg. The HarnWare™
degree of fit calculation indicates the preferred choice to the user, but
HarnVis makes the reason for the choice much clearer. For example, a
small boot may seem a reasonable choice until it is seen straining to fit
onto an adaptor in HarnVis.

When choosing between alternative TE products, users often require

more dimensional information than is contained in HarnWare™. By
clicking a part in HarnVis, the key part dimensions can be displayed.
Moreover, sizes output for moulded parts relate to the dimensions
achieved when the part is mated to the actual adaptors and harness
legs. The user can also access such data as TE part numbers,
materials, finishes, adhesives, etc. This information is the same as that
displayed in the HarnWare™ Design Wizard but as it is obtained by
© TE Connectivity Support Contacts 325
clicking a part rather than by scanning through a list, it is quicker to
access in a way that relates to the harness design. Relevant product
information can also be displayed.

An optional feature in HarnVis generates an estimate of the exposed

surface area of moulded parts, harness legs and adhesive which can be
useful for certain applications.

HarnVis 3D models can be viewed from any angle and centred on any
part. Views are rendered in colour with lighting effects which are very
realistic. The smoothness of the model can be adjusted, as can the
position of the light source. The perspective angle can also be
adjusted.

3D views are ideal for quotation drawings, presentations, exhibitions,

etc. They have a more immediate impact than 2D schematic drawings,
especially for those who are not trained in reading engineering
drawings. HarnVis 3D views can be saved to file on disc or copied
onto the Windows clipboard for pasting into Visio and other
Windows programs such as Microsoft Word.

Harness legs can be bent and twisted into the shapes required either in
the final equipment or the laying up board used to assemble the
harness.

The 3D modelling methods used in HarnVis are finely tuned for this
particular type of geometry. These methods are more restrictive than
those used in general purpose 3D CAD systems. But with HarnVis the
ease of use is dramatically better. The user works in the simple and
fast 2D Visio/HarnWare™ environment and 3D models can be
produced fully automatically in only a few seconds whenever the user
wishes. The 3D complexities do not get in the way or slow the user
down as it is an optional output, rather than a working environment
imposed upon him in the manner of most 3D CAD systems. 3D
geometry is inherently difficult to work with, especially in a
parametric form and, therefore, ease of use is still a serious constraint
on the use of other 3D CAD systems.

HarnVis will work on any desktop or laptop computer that is suitable

for the current version of Visio.
326 User Guide HarnWare™ Version 6.3

Demonstration
This section describes a brief sequence of operations that can be used
to demonstrate HarnVis or to gain an initial familiarity with the
system. The demonstration drawings are stored in the
HarnWare™\Sample folder. These drawings are standard
HarnWare™ drawings.

Open the 3DMix.vsd drawing in Visio. Use the Visio>Tools>Macro

menu to start HarnVis. An opening splash screen will be displayed. If
you accept the terms by clicking the OK command button, the main
HarnVis form will then be shown. Use the File>Model Assembly
menu or the <Ctrl>+A short-cut key to generate a 3D model for the
harness defined in the HarnWare™ drawing currently open in Visio.
While HarnVis is generating a 3D model you can hit the escape key to
interrupt the process.
© TE Connectivity Support Contacts 327
You will see that an unusual mix of adaptor finishes, marker sleeve
colours, protection sleeves and harness leg coverings have been
specified in this harness design. Refer to the Viewing section, page
327 or to the online help system for details on how to manipulate the
3D view and to change the lighting position and perspective angle.

In Visio open the 3DBend.vsd drawing. This is similar to the 3DMix

drawing except that three bend shapes have been added from the
HarnVis stencil. The control points on these bend shapes are glued to
the end of the harness leg. Double-click the bend shapes to open the
custom properties dialog box. Note that the first shape has a sequence
number of 1, a distance of 100mm, a right angle of 90 and a bend
radius of 50mm. The second shape has a sequence number of 2, a
distance of 50mm, an up angle of 90 and a bend radius of 50mm and
the shape has a sequence number of 3, a distance of 50mm, a right
angle of -90 and a bend radius of 50mm. Use the HarnVis
File>Model Assembly menu to generate a new 3D model.

The 3DCoil.vsd drawing has a twist shape glued to the harness leg in
addition to some bend shapes. Use the HarnVis File>Model Assembly
menu to generate a 3D model for this drawing. Note that the twist
allows a coiled leg to be modelled. Refer to the Bend and Twist
Harness Legs section for further details.

The 3DLayUp.vsd drawing contains a harness with a long leg that has
been bent to fit into a lay-up board. Use the HarnVis File>Model
Assembly menu to generate a 3D model and then use the Tools>Lay-
Up Board menu option to add a harness lay-up board. After viewing
the model of the lay-up board, click the Draw command to generate a
to-scale drawing in the Visio document. Then click the Drill Chart
command to generate a list of peg x-y co-ordinates.

Viewing
Orbit, Centre View and Zoom

To move around the 3D model, hold down the left mouse key and
move the mouse. Imagine the surface of the screen to be like a
trackball.
328 User Guide HarnWare™ Version 6.3
Initially the focus of attention is the centre of the harness assembly
model. To re-centre the view use the right mouse button to click on
any part in the harness assembly and select the ‘Look At Part’ menu
option. The 3D model will be re-positioned so that this part is now in
the centre of the screen.

To zoom in or out, press the control key <Ctrl> on the keyboard. A

magnifying glass icon will be displayed. While pressing the control
key, drag up or down with the left mouse button. Moving the mouse
up will zoom in toward the 3D model to enlarge the view. Moving the
mouse down will zoom out from the model, making the view smaller.

Use the HarnVis View>Assembly menu option to restore the view to

the default of the complete harness assembly. A quick alternative is to
use the <Ctrl>+W short-cut key combination.

The HarnVis View>Part menu option can be used to centre and zoom
in on a named part in the harness. The option displays a list of the
Visio shape names that appear in the harness drawing.

Background Colours

The background of the main HarnVis window can have two colours
graduated in various ways or a single colour can be used. The
background colour(s) are changed with the View>Background
Colours menu option. The selected colour(s) and graduated option are
used until they are changed with this menu, as the setting is saved on
disc.
© TE Connectivity Support Contacts 329

Usually a graduated background is formed with two shades of the

same colour. For example, two shades of blue such as 196, 196, 255
for colour 1 and 240, 240, 255 for colour 2. These settings are entered
in the standard Windows colour dialog box which is accessed via the
View>Background Colours>Colour 1 and Colour 2 menu options.

Lighting

As you move around the 3D model the light source moves with you.
Use the HarnVis View>Light Position menu option to move the light
source relative to the viewing position. You can either drag the light
icon or click in the lighting form to reposition the light source.

The chosen lighting position is used until the File>Model Assembly

menu option is used to generate another 3D model.
330 User Guide HarnWare™ Version 6.3

Perspective Angle

Views generated by HarnVis use a perspective projection. Parts that

are further away appear smaller.

The default perspective angle is 20. Use the View>Perspective Angle

menu option to select an alternative perspective angle. Smaller angles
reduce the perspective effect. Larger perspective angles introduce
distortions similar to those produced by wide angle camera lenses. For
example, when viewed end on, harness legs seem much longer.
© TE Connectivity Support Contacts 331

The selected perspective angle is retained until HarnVis is restarted.

Smoothness

Circles are approximated by a large number of facets. If more facets

are used, circles will appear smoother, but the model may take a little
longer to generate on slower computers.

Use the View>Speed/Quality menu to adjust this parameter and then

use the File>Model Assembly menu to observe the effect of the
change when a new model is generated. Note that the number of
facets reported in the HarnVis status bar will also reflect the change.
332 User Guide HarnWare™ Version 6.3

When HarnVis saves a view to disc or the Windows clipboard, an

antialiasing technique is applied to smooth the image. This
significantly improves the quality of diagonal lines and details such as
the knurls on adaptors and connectors.

This dialog also enables you to turn textures on or off. This setting
affects all textures including those used on tubing, knurls on
connectors and adaptors and lay-up board finishes.

Pixel Formats

Pixel Formats determine how colours are displayed and how memory
available to the graphics card is allocated.

Normally HarnVis will automatically select the best Pixel Format to

use for your particular hardware and software configuration. You can,
however, use the HarnVis View>Pixel Formats menu to ascertain if
there are alternative settings that can be used and, if so, to test these
alternatives. Depending upon the current screen resolution and
graphics card, two or more alternatives may be available. HarnVis
lists certain parameters for each alternative. The selected Pixel Format
is saved to disc and is used until you select an alternative using this
menu option.
© TE Connectivity Support Contacts 333

The ‘default format’ is the number of the pixel format that HarnVis
would normally choose. The currently selected pixel format is the one
selected in the listbox.

For each of the available pixel formats HarnVis lists:

 The colour depth, for example, 32 bit. This should match the
colour depth you have selected in the Windows Control Panel
Display settings. This is shown in the HarnVis Pixel Formats
dialog box along with the currently selected horizontal and vertical
resolutions.
 The number of bits allocated to each of the red, green and blue
colours.
 The number of bits allocated to the alpha plane. The alpha bit
plane can help improve the display of semi-transparent materials
such as cable marker protection sleeves.
 The number of bits allocated for the depth buffer. The depth buffer
is used when comparing relative distances in order to determine
the visibility of each part. Some faces which are very close,
relative to the overall size of a wiring harness, may be incorrectly
rendered if too few bits are allocated to the depth buffer.
334 User Guide HarnWare™ Version 6.3

 The number of bits allocated for the accumulation buffer. This

buffer is used when smoothing images ready for saving to file or
the clipboard.
 Whether hardware is acceleration (Accl) is enabled for the Pixel
Format. When hardware acceleration is enabled the performance
of your graphics card will be employed to make zooming and
rotating models faster and smoother. Unfortunately graphics card
drivers often have problems and selecting a Pixel Format without
hardware acceleration may eliminate visual artefacts in harness
models.
Refer to the Miscellaneous section or to the online help system for
details and solutions to a number of common problems.

Bend and Twist Harness Legs

Harness legs can be bent and twisted into the shapes required for
installation in the equipment or for the laying up board used to
manufacture the harness. Shapes are added to the HarnWare™
drawing to specify the bend positions, dimensions, etc.

The HarnVis Visio stencil contains 2 shapes that are used

to define harness leg bends and twists. These shapes have a
control handle which should be glued to one end of the
harness leg that you wish to bend or twist. Double-clicking
the bend and twist shapes opens the dialog box which is
used to specify the custom properties which are used to
specify bend positions and dimensions.

One or more bend shapes can be added to a leg. The custom

properties are:

 The sequence number controls the order in which the bends are
applied starting from the end of the leg to which they are glued.
 The distance is the measurement from the end of the previous
bend, or the start of the leg dimension, to the beginning of the
current bend. The start of the leg dimension is normally the centre
of a transition or the end face of the connector, or the connector
centre line when a right-angled boot or adaptor is used. If the bend
© TE Connectivity Support Contacts 335
is the first from the end of the leg, remember the dimension must
be sufficient to span the length of any connector, adaptor and
moulded part. If the bend shape is not the first in the sequence
from the end of a leg, a zero dimension indicates that the bend
starts immediately after the previous bend.
 The up angle specifies a bend that is normally up or down from
the plane of the 2D drawing. However, previous bends may have
already altered the orientation of the harness assembly. For bends
coming up from the plane of the paper enter a value between 0
and +90. For bends going down enter a value between 0 and
-90.
 The right angle specifies a bend that is normally left or right when
viewed from the end of the leg to which the bend shape is glued. A
bend to the right is specified by entering a value between 0 and
+90. A bend to the left is specified by entering a value between
0 and -90. If both up and right angles are specified the bend will
be a compound angle.
 The bend radius is the radius to the centre of the leg in either
millimetres or inches, depending upon the units of the drawing.
Only one twist shape should be glued to a harness leg. The twist angle
entered is applied along the length of the harness leg.

Note that harnesses must lie flat on a lay-up board. Therefore, you
should not twist harness legs or bend them up or down when
designing a lay-up board. Only use +/- right bends to fit long harness
legs into a lay-up board.

Measuring Parts
One or more parts can be selected and the measurements of the
minimum enclosing volume can be obtained. This is especially useful
for establishing the overall size of connector and right-angled adaptor
or boot assemblies.
336 User Guide HarnWare™ Version 6.3

Use the mouse button to click a part and choose the 'Select in
HarnVis' menu option. As each part is selected, HarnVis draws the
minimum enclosing orthogonal volume. The sides of the volume are
coloured red, green and blue. The dimensions of the colour coded
sides of the volume can be obtained using the Selection>Query
Dimensions menu.
© TE Connectivity Support Contacts 337

The first part that is selected, determines the axis system for the
minimum enclosing volume. This allows parts on angled harness legs
to be measured with respect to the axis of the leg rather than to the
harness assembly.

Use the Selection>Clear menu to deselect all parts. Alternatively use

the right-click ‘Select in HarnVis’ menu to deselect a single selected
part.

The Selection>Look At menu, centres and zooms in on the selected

part(s).

Part Details and Dimensions

The right-click HarnVis menu includes two options for obtaining
details on the part that is clicked.

The Query Part option lists part numbers, materials, finishes,

adhesives, etc. This information is the same as that listed in the
HarnWare™ Design Wizard. Further information on TE products and
338 User Guide HarnWare™ Version 6.3
materials can be accessed using the product information command
button, see below for further details.

The Dimensions right click menu option lists dimensional information

for the part and the position of the mating points within the assembly.
The key TE Sales Control Drawing (SCD) dimensions are included in
the listed part dimensions.
© TE Connectivity Support Contacts 339

Product Information

TE harnessing product and material information that is relevant to the

clicked shape can be obtained by using the product information
command button in the Query Part form.

This option lists all the products and materials that are relevant to the
clicked shape and to the parts in the current harness design. Finally a
full list of products and materials contained in the database can be
displayed - those that are used in the clicked shape and harness design
are highlighted in a cyan colour.

Clicking any product or material description displays a pop-help.

Most of the pop-help topics contain hyper-links to further information
on the www.HarnWare™.com internet web site and the online
product catalogue.

In the case of some products, a small image is displayed when an item

is clicked in the treeview listing of product descriptions.

If the Visio document name has changed since the current model was
generated a warning note will be included in the Product Information
form.
340 User Guide HarnWare™ Version 6.3
© TE Connectivity Support Contacts 341

Exposed Surface Area

This optional HarnVis feature generates an estimate of the exposed
surface area of moulded parts, harness legs and adhesive which can be
useful for certain applications. This option is accessed using the Tools
menu. The estimates for each class of part and the total for the harness
can be saved to a text file or to the Windows Clipboard, from where
they can be pasted into the Visio document.

Please contact HarnWare™ System Support for details on how to gain

access to this optional feature.

Where no surface area can be calculated for an item, the 0.0 is shown
in red to attract your attention to those items for which you may like
to supply your own estimates.

Depending upon the units of measure used when the harness was
designed using HarnWare™ surface area estimates are shown in
square millimetres or square inches. Where there are no items of a
342 User Guide HarnWare™ Version 6.3
particular class of part, a line is included as a reminder in case you
would like to add an extra allowance.

The surface areas displayed in the form can be edited using the text
box and the update button. The values that can be edited are
determined by the type of line that is selected in the grid. For
example, the surface area in a line containing the sub-total for a class
of parts can only be edited if there are no parts of that class in the
drawing. When a surface area is changed, the relevant sub-total and
the overall total for the harness is updated. All these values are shown
in blue as an indicator of the values that you have changed.

The calculated areas will vary from the actual values in certain cases.
For example, Y shaped transitions such as the 382 range are modelled
as a more bulbous shape than the actual shapes. The accuracy of the
estimates is also affected by such factors as manufacturing tolerances
and conversions between units of measure.

NOTE

Exposed surface areas estimated by HarnVis should always be

carefully checked. These estimates are only intended to serve as a
general guide.

Select in Visio or HarnWare™

By right-clicking any part in HarnVis you can use the menu to select
that part in Visio or to open it in HarnWare™.

The first option is useful if you wish to establish which Visio drawing
shape is related to a part in HarnVis.

The second option is useful when you wish to change a part selection
in HarnWare™. For example if, having viewed a harness assembly in
HarnVis, you decide a larger boot would be more suitable:

 Use the HarnVis ‘Open in HarnWare™’ right-click menu to select

the part in Visio and open it HarnWare™.
© TE Connectivity Support Contacts 343

 Search the HarnWare™ database to identify a suitable larger boot.

 Save the larger boot data from HarnWare™ into the Visio drawing
shape.

 Use the <Ctrl>+H short-cut key to switch directly from

HarnWare™ to HarnVis.

 Use the <Ctrl>+A short-cut key in HarnVis to remodel the harness

assembly with the newly selected boot.

Lay-Up Board Design

The Tools>Lay Up Board HarnVis menu option provides facilities for
designing lay-up boards and for generating to-scale harness drawings
in Visio. Pegs can be automatically positioned and a drill chart of the
peg centre positions can be generated ready for importing into an NC
drill or laser cutter.
344 User Guide HarnWare™ Version 6.3
Before using this option use the HarnVis File>Model Assembly menu
to generate a 3D model of a harness. Refer to the Demonstration
section for an introduction to how to model and view a harness.

To fit long harness legs into a lay-up board, use the methods described
in the Bend and Twist Harness Legs section. Note that harnesses must
lie flat on a board and, therefore, you should not twist harness legs or
bend them up or down. Only use +/- right bends to fit long harness
legs into a lay-up board.

The check box at the right of the Lay-Up Board frame should be
checked to activate the options in the frame. When this is checked,
clicking the Model command button will add a board to the harness.
When you wish to remove the lay-up board from a model, uncheck
the box and click the Model command. The current setting of this
check box is remembered until you exit from HarnVis.

Click the Done command to close the Lay-Up board dialog box
whenever you want to manipulate the view of the harness assembly
and lay-up board.

The overall size of the harness assembly is shown in the dialog box.
Using this information you can enter appropriate values for the board
width and height. These values, along with the peg dimensions, are
stored on disc and are entered as the default values when you next use
the lay-up board option. After changing the board size, click the
Model command to update the model. The harness is positioned
centrally on the board.

Two wood grains, a checker board and one white board option is
available. Alternatively you can replace the Wood1, 2 and 3.bmp files
in the Textures folder with alternative Windows bitmap files. The
width and height of the bitmap images must each be a power of 2, for
example, 64, 128, 256, etc.

If you wish to add pegs to the lay-up board, ensure the check box at
the top right-hand corner of the Pegs frame is checked. You can set
the maximum pitch that HarnVis uses to position pegs along harness
legs. Pegs are also positioned at both ends of each harness leg and of
each bend. However, pegs that would be less than two diameters from
© TE Connectivity Support Contacts 345
another peg are omitted. You can also specify the peg diameter and
length.

The Sketch and Draw commands add a to-scale outline of the harness
into the Visio document. Peg positions are also included in the
drawing. The Sketch command represents each component with a
rectangle sized to the maximum orthogonal dimensions. The Draw
command produces an accurate to-scale outline of each component,
which takes a little longer to generate. If the Visio Window is
obscured, click Visio on the Windows taskbar to bring the Visio
Window to the front so that you can watch HarnVis actually
generating the drawing.

Once having used the Sketch or Draw commands to produce a to-

scale drawing in the Visio document, you can move and add or delete
pegs. When you have the desired peg layout, the Drill Chart command
enables you to generate a list of the x-y co-ordinates of all the pegs in
the lay-up board drawing from the Visio document. The co-ordinates
can be saved to the Windows clipboard or to a text file. Each pair of
co-ordinates is held on a separate line with a tab character placed
between the x and y co-ordinate. This is a format that is suitable for
transferring into NC drills or laser cutting machine controllers.

While HarnVis is generating a to-scale sketch or drawing of the

harness you can hit the escape key to interrupt the process.

Copying and Saving Views

HarnVis views can be saved to disc or to the Windows clipboard
ready for pasting into Visio or other Windows applications such as
Microsoft Word. Use the File>Save or Copy menu options.
Alternatively the <Ctrl>+S and <Ctrl>+C short-cut key combinations
are a quick alternative. The size of the HarnVis windows controls the
size of the view that is saved to file or to the clipboard.

Diagonal lines appear jagged due to the relatively low resolution of

computer screens. When HarnVis saves a file to disc or the Windows
clipboard an antialiasing technique is applied to smooth the image.
346 User Guide HarnWare™ Version 6.3
This significantly improves the quality of diagonal lines and details
such as the knurls on adaptors and connectors.

An antialiased view takes longer to generate than the views normally

generated when moving around a model in HarnVis. The File>Save
dialog box contains a slide control which allows you to set
antialiasing to a value between none and smooth. This setting is saved
on disc and, therefore, remains in effect until you change to another
setting.

Another slide control in the File>Save dialog allows you to set the
antialiasing effect between fine, soft focus and blur. This setting
remains in effect until you restart HarnVis.

The files saved to disc by HarnVis are 'Device Independent Bitmaps'

or '.dib' files. This file format has a number of advantages over the
more common Windows Bitmap '.bmp' files. Most Windows
applications can open or import DIB files. Applications like Windows
Paint and PaintShop Pro are specifically intended for raster file
formats and tend to display DIB and BMP files better than other
applications such as Visio and Microsoft Word.
© TE Connectivity Support Contacts 347

Save As IGES
HarnVis 3D harness assembly models can be saved to disc ready for
use in CAD systems or any other application that supports the IGES
standard. Use the File>Save As IGES HarnVis menu option to create
an IGS file.

Check boxes in the Save As IGES form allow you to choose whether
associativity, surfaces or harness legs and markers is included in the
file.

Depending upon the receiving system, the initial viewpoint,

background window colour and lighting may differ from those used in
HarnVis. These are purely aesthetic details which have no effect on
the harness assembly geometry.

Each component in the harness assembly is inserted in a separate

segment in the IGES file. The ability to select, move, delete each
component will depend upon the receiving system.

Please refer to the “Saving Views and Models>Save As IGES” topic

in HarnVis online help system for further details.
348 User Guide HarnWare™ Version 6.3

Save As HSF
HarnVis 3D harness assembly models can be saved to disc ready for
use in CAD systems or any other application that supports the
OpenHSF standard. Use the File>Save As HSF HarnVis menu option
to create an HSF file. In addition an HTML file can also be generated
to allow the HSF to be viewed in Microsoft Internet Explorer.

Check boxes in the Save As HSF form allow you to choose whether
colour, normals, texture, connector references and leg length data is
included in the file. Selecting more options will increase the file size
but, depending upon the receiving system, selecting more options may
improve the appearance of the resulting model.

If a lay-up board is included in the current HarnVis view, the board

and pegs will be included in the HSF file. NB Pegs are modelled as a
cylinder without the sphere that is shown in HarnVis.

Depending upon the receiving system, the initial viewpoint,

background window colour and lighting may differ from those used in
HarnVis. These are purely aesthetic details which have no effect on
the harness assembly geometry.
© TE Connectivity Support Contacts 349
Each component in the harness assembly is inserted in a separate
segment in the HSF file. This should enable each component to be
selected, moved, deleted, etc. within the receiving system.

A check box allows you to generate an HTML file with a’.html’ suffix
appended to the HSF filename. The first time that one of these HTML
files is opened, the HOOPS 3D Stream Control will be downloaded
from the Hoops3D Internet Web site. The download file is
approximately 1.4 Mbytes and, depending upon the speed of your
Internet connection may take a few minutes. However, once the
HOOPS 3D Stream Control has been downloaded and installed, files
can be opened and viewed quickly. Using the mouse to click and drag,
along with the right-click menu you can orbit, pan and zoom around
the 3D model.

Full details on OpenHSF may be found at: www.openhsf.org The

OpenHSF Initiative is an industry-wide effort to establish a common,
open format for sharing visualization data between disparate
engineering applications. The engineering industry is in urgent need
of a widely adopted visualization format robust enough to meet the
demands of the MCAD and A/E/C marketplaces, yet compact enough
to be utilized over the web. A widely-used MCAD industry
assessment is that for every part designed, there are upwards of 10
people who need to visualize the part as it makes its way through the
supply chain. These include: engineers from various functional
domains, managers, partners, suppliers, purchasing agents, sub-
contractors, governmental organizations, technical publications
writers, sales forces and ultimately customers. These process
participants may be using applications in the areas of CAD, Digital
Mock-up, PDM, Simulation, CAM, CAE, View & Mark-up, etc. The
OpenHSF Initiative delivers an open format, freely available to
anyone, so all content creators can export the HSF format and any
downstream applications can import this data. Through this effort,
intelligent digital models in the HSF format will be able to move
smoothly through concept, design, analysis, manufacturing,
marketing, e-commerce, maintenance and end-of-life segments that
make up the product life-cycle. Participants in the OpenHSF Initiative
believe the most direct and viable route to an industry-wide solution is
to open a 2D/3D visualization format focused specifically on the
needs of engineering, developed by a vendor not tied to a specific
350 User Guide HarnWare™ Version 6.3
CAD company, which can garner support from a range of end users,
software vendors and industry analysts.

The HOOPS Stream File (HSF) format is a robust, customizable and

highly compressed 2D/3D visualization format specifically tailored to
the needs of displaying engineering data. Through the OpenHSF
Initiative, the HSF Specification has been openly published and the
OpenHSF Advisory Council has been formed to advise on extensions
to the format specification. Using HSF, application developers can
create highly customized, stream-capable visualization files
containing tessellated geometry as well as application-specific
information (such as assembly structure, analysis data, topological
data, object behaviors, etc.) and have that data intelligently associated
with the tessellated model. Through its rapid widespread adoption and
open, published nature, HSF is fast becoming a ubiquitous medium
for engineering applications to share visual data and for end users to
publish and store their visual data. A wide range of CAD/CAM/CAE
and A/E/C application developers as well as end users have aligned in
support of the OpenHSF Initiative to unify the engineering software
industry on a common, shared visualization format that is lightweight
enough for the Web but powerful enough to fully represent complex
engineering models.

A number of HSF reference applications can be downloaded from

www.hoops3d.com These include 3D part viewers for Hoops,
ParaSolids, ACIS and PTC Granite One format files.

When creating HSF files, HarnVis uses the 'zlib' general purpose
compression library version 1.1.4, March 11th, 2002 which is
Copyright (C) 1995-2002 Jean-loup Gailly and Mark Adler. Visit
www.zlib.org for the official zlib web page.

Model Part
This File menu option is mainly intended to help adding 3D part
models into the HarnVis database. However, it can also be useful for
individual parts or checking part dimensions.
© TE Connectivity Support Contacts 351

Having selected a part style from the combo-box, HarnVis will

display text boxes and combo-boxes for the independent parameters
that need to be specified. For example, in the case of a 222K right-
angled boot a part number should be selected from the list of options
along with values for the H, adaptor diameter, and the J, leg diameter.
Depending upon how the part model has been defined, one or two
colours can also be selected from a list of options.

When all the independent parameters have been specified, click the
draw command to model and view the part. While the Model Part
form is loaded you can orbit around and zoom in on the view of the
part using the normal HarnVis viewing methods. Also part views can
be saved to the clipboard or to file using the normal copy and save
menu options or <Ctrl>+C and <Ctrl>+S short-cut keys.
352 User Guide HarnWare™ Version 6.3

The large text box in the Model Part form contains full details of the
formulae and calculations used to generate the parameterised part
model. These details can be selected and copied to the Windows
clipboard if you wish to analyse them in more detail. The Model Part
form can be maximised to increase the size of this textbox.

Notes

Some parts, for example protected marker sleeves, may not be shown
in the same colour as used in harness assembly models.

All dimensions in the Model Part form are in millimetres.

Miscellaneous
Multi-Cables

Multi-cables are shapes used in HarnWare™ drawings where two or

more harness legs are joined directly to a moulded part. Typically
multi-cables are used as a lower cost alternative to transitions.
HarnWare™ allows two or more multi-cable shapes to be glued
together. For example, rather than using a four-way multi-cable shape,
it is possible to glue 3 two-way multi-cable shapes together in a
HarnWare™ drawing.

HarnVis represents multi-cable grouping of cables best when a single

multi-cable shape, with the required number of harness legs, is used.
© TE Connectivity Support Contacts 353

Viewing Quality and Speed

The speed of your computer processor determines how quickly

HarnVis generates 3D models. The speed of your graphics card and
the amount of memory contained on the graphics card determines how
smoothly you can move around and zoom into the model. If you find
moving around the model is not very smooth, try reducing the size of
the HarnVis window.

HarnVis lighting and colour shading effects are best when the display
is set to true or 32 bit colour. Use the Windows Start
Menu>Settings>Control Panel>Display>Settings dialog to set this
option.

HarnVis uses the OpenGL graphics interface which has been included
in Microsoft Windows since Windows 98. Graphics cards
manufacturers often replace the generic Microsoft graphics software
with their own software that is tailored to the particular features of
their graphics card. This can result in considerable gains in speed and
image quality. However, sometimes the graphics card manufacturer's
software contains errors which may affect some system settings. For
example, one popular graphics card works well in all resolutions
except for 1024 x 768 which causes the system to crash. There are
four ways to solve this type of probem:

 Check whether a newer driver is available for your graphics card.

Driver software upgrades are issued very frequently, sometimes as
often as once a month and new computers are often delivered with
very old drivers for graphics cards and other hardware devices.
Newer drivers often fix problems and enhance performance.
 Normally HarnVis will automatically select the best pixel format
to use for the particular hardware and software configuration. You
can, however, use the HarnVis View>Pixel Formats menu to
ascertain if there are alternative settings that can be used and, if so,
to test these alternatives. Depending upon the current screen
resolution and graphics card two or more alternatives may be
available. HarnVis lists certain parameters for each alternative.
The selected Pixel Format is saved to disc and is used until you
select an alternative using this menu option.
354 User Guide HarnWare™ Version 6.3

 Use the Windows Start Menu>Settings>Control

Panel>Display>Settings dialog to try alternative screen areas or
resolutions.
 Right-click the Windows desktop and select the properties menu
or use the Windows Control Panel to select the
properties>settings>advanced>troubleshoot menu. Move the
hardware acceleration slider to "none".
These actions may also resolve problems encountered with the display
of marker sleeves and textures that HarnVis uses for harness legs and
for the knurls on connectors and adaptors.

The Internet is a valuable source for information on resolving

OpenGL problems with the latest graphics hardware.

Alternatively, please contact [email protected] HarnVis and

HarnWare™ system support.
© TE Connectivity Support Contacts 355

APPENDIX A
Support Contacts
For HarnWare™ system support please email [email protected] or:
HarnWare™ Support Team
Faraday Road
Dorcan
Swindon
SN3 5HH
United Kingdom
eMail: [email protected]

HarnWare™ and HarnVis were designed and developed by:

Roger Billsdon
ADE Analysis & Design Engineering Ltd..
eMail [email protected]
Web site: www.ade4cae.co.uk

HarnWare™ uses the Microsoft Visio drag and drop drawing system.
The www.microsoft.com/office/visio web site includes links to
excellent support forums, background papers and discussion groups.
Many other useful web sites, blogs, background papers and forums on
a wide variety of Visio issues can be found by searching the internet.
A few examples which were available at the time of writing include:

http://blogs.msdn.com/b/visio/

http://www.facebook.com/MicrosoftVisio

http://blogs.msdn.com/b/chhopkin/

http://visualsignals.typepad.co.uk/vislog/

http://visiotoolbox.com/2010/
356 User Guide HarnWare™ Version 6.3
http://www.visguy.com/

http://www.shapesource.com/scripts/default.asp

Please refer to the Visio online help system for other Visio support
contacts.

There are not many good Visio books and unfortunately for each new
version of Visio the number of books seems to decline. The best
books we know are:

“Microsoft Visio 2010 Step by Step” by Scott A Helmers ISBN 978-

0735648876 This covers the basics for beginners.

“Microsoft Office Visio 2007 Inside Out” by Mark H Walker ISBN

978-0735623293 This 976 page book covers most aspects that users
would need.

“Visio 2003 Developer’s Survival Pack” by Graham Wideman ISBN

1-4120-1112-4 For those wishing to develop programs for use with
Visio, this is probably the best alternative and, even though it hasn’t
been updated since Visio 2003, most of the content remains valid.

“Developing Visio Solutions” by Microsoft Press ISBN 978-

0735613539 Again this is for those wishing to develop programs for
use with Visio and, although it hasn’t been updated since Visio 2002,
most of the content remains valid.

For further information on TE products please visit: www.te.com

© TE Connectivity Installation Guidelines 357

APPENDIX B
Installation Guidelines
Visio Requirements

HarnWare™ requires Visio Version 2007 as a minimum.

HarnWare™ will work with either the Standard or Professional
editions of Visio. HarnWare™ has been tested and is supported for
use with Visio 2007 or 2010.

The extra stencils and other features of the more expensive Visio
Professional products are not essential for HarnWare™. However,
Visio Professional is useful for converting HarnWare™ drawings for
use on other CAD systems.

Visio must be properly installed on your PC before installing

HarnWare™. You should install Visio on your local hard disc,
normally named C:

HarnWare™ will run satisfactorily if Visio is installed on a network

drive. However, we recommend proving Visio and HarnWare™ on a
local hard disc before tackling the more varied network installation
issues. Refer to the Microsoft web site www.microsoft.com for further
information.

HarnWare™ Installation

Visio must be properly installed on your PC before installing

HarnWare™.

As normal when installing software, ensure all other programs are

shut down first. This includes anti-virus software and the Windows
Control Panel. You must have Administrator Privileges to install
HarnWare™.
358 User Guide HarnWare™ Version 6.3
If HarnWare™ has previously been installed on your PC, you may
wish to keep that copy and use a different folder to install the new
version. Alternatively, if you do not wish to keep the previous
version:

 Make a copy of any HarnWare™ files you have modified. For

example, drawings, stencils, templates, drawing translator
database, weight and cable databases. Please refer to the folders
topic for details on the locations of the various files.

 Uninstall the previous version of HarnWare™ using the method

described in the 'Uninstalling' section.

Insert the HarnWare™ CD-ROM. If autoplay is enabled for your CD

or DVD drive the set-up program will automatically start. If not, use
Windows Start Menu>Run option and enter d:\setup.exe (change 'd:'
if your CD or DVD drive is assigned a different letter).

The HarnWare™ set-up program uses a standard Microsoft set-up

toolkit and works in a similar manner to many other installation
systems. The program checks that there is sufficient disc space
available on your PC - depending on the options already installed on
your PC, HarnWare™ requires about 100 Mbytes of disc space.

The set-up program prompts for the folder into which you want
HarnWare™ installed. By default HarnWare™ is installed in the
Program Files\HarnWare™ folder. You should use this default if
possible. We do not recommend installing HarnWare™ on a network
drive.

Uninstalling

To uninstall HarnWare™ use the Windows>Control

Panel>Add/Remove Programs option and select HarnWare™.

If HarnWare™ has been installed more than once, without removing

the previous copy, you may find more than one entry in the list of
programs to uninstall. Selecting each entry to uninstall it will tidy up
© TE Connectivity Installation Guidelines 359
the system, although during the uninstall process you will find that a
lot of the files will have already been removed by a previous uninstall.

Both HarnWare™ V5.4 and V6 can be installed on the same

computer.

Start Up

The HarnWare™ set-up program adds a new program group with

options for HarnWare™ and the Help system into the Windows Start
Menu.

In the Windows Start menu, click HarnWare™. The

HarnWare™ copyright notice should appear with your
name. A HarnWare™ key file is issued to a named
individual and company for each computer on which
HarnWare™ is installed. If you accept the terms stated in the
HarnWare™ copyright notice, click the OK button. HarnWare™ will
then start Visio.

In Visio select the File>New menu option and choose the

HarnWare™ metric or imperial template. Visio will then load a new
blank document.

Select the Visio Tools>Snap and Glue menu option. To make

HarnWare™ shapes easier to position and glue we recommend
checking only the following options:

 Currently Active: Snap, Glue and Drawing aids

 Snap to: Ruler subdivisions, Grid, Guides and Connection Points

 Glue to: Guides and Connection Points

The best Snap and Glue strength settings will vary depending on the
resolution of your screen and personal preference. As a starting point
try the following settings:
360 User Guide HarnWare™ Version 6.3
Rulers 4 Grid 5
Guides 10 Points 10
Geometry 8 Extensions 13

HarnWare™ stencils and templates are supplied in Visio 2007/2010

format so they can be used with all the supported versions of Visio. If
you need to share a drawing with someone who has an earlier version
of Visio you can use the Visio File>Save As menu to create a file of
the Visio 2002 version which can also be read by Visio 2000.

Setup Problems

Please contact [email protected] for the latest details on all known

installation and set-up issues.

If the set-up program fails to start use <Ctrl>+<Alt>+<Del> to check

if a copy of setup.exe is already running. If so, use the End Task
command and then try running the set-up program again.

Problems that occur just after installing software are often resolved by
rebooting your computer.

NOTE

You cannot simply copy the HarnWare™ folder onto another

computer. The set-up program does more than simply copy files into
the HarnWare™ folder.

During the installation process, extra file path names are added to
Visio. If Visio is re-installed after HarnWare™, you may need to re-
apply these.

HarnWare™ checks the Visio file paths during the start up process
and warns if a Visio file path setting does not contain the normal
HarnWare™ file path. If in response to this warning you choose not
to update the file paths, this check will be skipped in future.
© TE Connectivity Installation Guidelines 361
The extra file paths can also be added to Visio using the HarnWare™
"Options>Visio File Paths" command. Alternatively in Visio 2007 use
"Tools>Options>Advanced>File Paths" or, in Visio 2010,
"File>Options>Advanced>File Locations" to add the HarnWare™
path names to the beginning of four settings. For example:

Templates: C:\Program Files\Tyco Electronics\HarnWare™

V6\Template;Solutions
Stencils: C:\Program Files\Tyco Electronics\HarnWare™
V6\Template;Solutions
Help: C:\Program Files\ Tyco Electronics\HarnWare™
V6;Solutions
Add-ons: C:\Program Files\ Tyco Electronics\HarnWare™
V6;Solutions

The above settings assume HarnWare™ is installed in 'C:\Program

Files\ Tyco Electronics\HarnWare™ V6’ Other folder names, such as
My Documents and Solutions will have been added by Visio. Folder
or file path names are separated by a ';' or the list separator specified
on your version of Windows.

If the HarnWare™ path setting is not included in the Stencils and

Templates settings, the HarnWare™ files won't appear in the Visio
File Open list. If the HarnWare™ file path is not included in the Add-
ons setting, double-clicking or right-clicking a shape in Visio will not
'open' the shape in HarnWare™.

File path settings are stored in the Windows Registry database under
the HKEY_CURRENT_USER\Software\Microsoft\Office\[12.0 or
14.0]\Visio key. After altering a file path setting, Visio should be
restarted to activate the changes.

Installed in the HarnWare™ 'System Utilities' folder is a diagnostics

program which generates a file of system information which can help
us diagnose most system installation problems. When the
“Diagnostics.exe” program is run, click the “Generate diagnostics”
command. The program will generate a long list of diagnostic
information which will be saved in a file named “C:\Users\<User
Name>\Documents\Diagnostics.zip”. If you could email this zip file
to [email protected] it should help us analyse the problem and advise on
362 User Guide HarnWare™ Version 6.3
the most appropriate solution. Also when you email the file it would
help if you could let us know any further details on the problem, for
example, whether HarnWare™ has previously been used successfully
on the computer and, if so, what changes have been subsequently
made.

HarnWare™ Key File

Access to the various HarnWare™ and HarnVis program options is
controlled by the HarnWare™ software security mechanism. New
users are issued with a licence to use HarnWare™, HarnVis, etc. on
completion of their training course. Software licences need to be
periodically updated. When the licence is within 60 days of the expiry
date, an invitation to renew the licence will be issued each time
HarnWare™ or HarnVis is started. Alternatively existing users can
apply to update or renew their software licence using the HarnWare™
or HarnVis Help>Update Licence menus.

Please enter your name, company, email address, etc into the User
System Registration form. The required fields are those marked with a
red ‘*’, other fields maybe left blank. Only standard ASCII English
characters can be entered into this form, i.e. A-Z, 0-9 and symbols
such as @ < > & ' and ". Unfortunately the system is not able to
handle the special characters that are used in such languages as French
and Japanese.

In the "Your Computer Name" field, you should enter a name which
you can easily relate to your particular computer.

When you have completed the form, click ‘OK’. A file named
"HarnWare™ User System Data.txt"" will be saved into your
HarnWare™ local settings folder, which on Windows XP is normally:
C:\Documents and Settings\<User Name>\Local Settings\Application
Data\Tyco Electronics\HarnWare™ and on Windows Vista or 7 is
"C:\Users\<User Name>\AppData\Local\Tyco
Electronics\HarnWare™"

On most computers you can simply click the "mail to" link to
compose an email with this file as an attachment. On some computers
© TE Connectivity Installation Guidelines 363
it maybe necessary to prepare an email manually. If so, please address
your email to [email protected] and attach the HarnWare™ User System
Data.txt file to your email.

HarnWare™ System Support will email back a file named

"HarnWare™ Key File.txt". These files are generated specifically for
a single computer and should be placed in the same folder as your
HarnWare™ User System Data.txt file. The key file should not be
modified as this could prevent HarnWare™ from starting. Your
licence will then be automatically updated when HarnWare™ is next
started.

The "HarnWare™ User System Data.txt" file is a standard text file

which can be opened in any text editor or word processor should you
wish to check the file contents before emailing it to HarnWare™
System Support. The file simply contains the information which you
entered in the User System Registration form together with some
information such as your disc serial ID and version numbers of
various files on your computer. This computer system information is
used to relate the key file to your particular computer and to help us
provide you with support and advice should you encounter problems
running HarnWare™ on your computer.

Prior to HarnWare™ V5.2 a hardware lock or dongle was used to

activate the software on each computer. After eight years of
successfully using these devices, the number of installation and
hardware compatibility issues started to grow and we decided to
change to the current software security mechanism. This mechanism
is intended to ensure HarnWare™ is used only by users who have
been properly trained and who have the necessary harness design
skills and experience.

A new key file will usually be required for HarnWare™ V6. These
key files will also work with V5.4. Both HarnWare™ V5.4 and V6
can be installed on the same computer.
364 User Guide HarnWare Version 6.0

APPENDIX C
What’s New
HarnWare™ Version 1.0 was released in December 1995. For details
of the changes made between this and the versions up to and including
V5.2 refer to previous issues of this User Guide. The key changes and
new features introduced since Version 5.2, which was originally
released in 2006, include:

Version 5.3
The key change added in HarnWare™ V5.3 was a new Tools>RoHS
menu option, the other changes were more minor fixes and
enhancements including:

1) Grommet pictures and details added to user parts library.

2) HarnVis additions for 2 or 3 over packing pieces.

3) Changed Viton and Viton-E to RW-200 and RW-200-E

4) Improved selection of search criteria in user parts library

form when a specific part number is clicked.

5) Added 301A028 eyelets and 203, 204 and 224W parts.

6) Added HFT5000.

7) Added motor sport shell size 06.

© TE Connectivity Index 365

Version 5.4.2
The following is a list of the key changes introduced in this version
which was released in August 2007.

1) IGES export options for HarnVis.

2) Support for Visio 2007

3) Support for Windows Vista including new file and folder

structures required by the new Windows Vista security
system.

4) New HarnWare™ and HarnVis help systems providing a

more attractive user interface, integrated table of contents,
etc.

5) New TE product catalogues.

6) Altitude de-rating option in wire gauge advice form.

7) Add scaled packing, braid and jacket to sub-assemblies

drawn in cable cross-sections. Improved method of obtaining
sub-assembly diameters from user.

8) Quantities for each harness and an overall kit quantity can

now be specified for composite parts lists.

9) Drawing border properties can now be set in the “Set

Properties” form and on saving the properties are copied to
borders in all pages of the current document.

10) Added check in HarnVis for very long harnesses which may
not be visible when fully zoomed out.

11) New masters to allow 202F2, 202D2, 202D9 and 202G2

boots to be bent in HarnVis.
366 User Guide HarnWare Version 6.0
12) Add new 99M wire colour stock data into database and
removed 55M?1* obsolete part numbers.

13) Added ZHPCG-36 power cable into database and removed

ZHI as preferred choice for System 100.

14) Currently selected units of measure is now displayed in

HarnWare™ status bar alongside the current harness material
system.

15) Added rotate option to keyway masters.

16) Added 200mm for end allowance plus 10% lay loss
allowance to filler lengths.

17) Added options for pull up and push down for grouping
associated wires in schematic and schedule AZ sort/group
command.

18) 55D wire added.

HarnWare™ V5.4.5 and HarnVis

1.2.6
This version was released in May 2009 and included the following
key changes:

1) New cable marker text editing, print preview and font

selection for proportional spaced Windows True Type fonts.

2) Added TXS adaptors into HarnWare™ and HarnVis.

3) Added Cabletec bonding leads into User Parts Library.

4) BACC63CB, 63CC and BACC68D connectors added into

database.
© TE Connectivity Index 367
5) Added connector part number text command into connector
selection form.

6) 180 adhesive excluded from list of options available for use

with 45 degree boots.

7) Deutsch autosport connectors added.

8) Added 202K transition.

9) Connector form now initialises with the nearest equivalent

standard part number to match a partial connector part
number.

10) Added HexaShield adaptors into HarnVis.

11) Added separate utility program to restore customised Visio

toolbars and menus.

HarnWare™ V6
This version was released in November 2011 and included the
following key changes:

1. Upgrade to latest Microsoft .NET programming technology

which required substantial changes to all parts of
HarnWare™. This new version is compatible with 64 bit
versions of Windows 7 and 32 bit versions of Windows XP,
Vista and 7. Only the 32 bit standard and professional
versions of Visio 2007 are supported.

2. Various user interface enhancements including hyperlinked

product details in design wizard, improved product images,
enhanced file open dialogs, resizable design wizard, parts
list, router, design checker, RoHS and weight forms, a new
options form and improved connector planform forms.

3. New setup system using latest Microsoft installation

technology. NB A new HarnWare™ key file is required for
368 User Guide HarnWare Version 6.0
V6 which will also work with V5. By default HarnWare™
V6 is installed in a folder named “C:\Program Files\Tyco
Electronics\HarnWare™ V6” and both HarnWare™ V5 and
V6 can be used on the same computer.

4. Databases which are available for the user to edit (e.g. cable
and user parts library) can now be stored in a shared network
folder to allow easier distribution and control of updates.

5. TE Amplimite D connector part numbers can be selected and

their planforms drawn. These program and database changes
will now allow other out-of-round connectors and other
connectors with unstructured part numbers to be added in
future releases.

6. Adaptor and KTKK product updates to the database and help

system to align with changes to the TE product portfolio.

7. Added 4,554 STXR adaptors which are a more cost effective

and space efficient alternative than Type II adaptors.

8. Added 700 TXR88 and TXS88 adaptors to suit Glenair

Series 800, 801, 802, 803, 804 and 805 Mighty Mouse
connectors.

9. Changed GTC* and GTS* connectors from code 18 to 64.

10. Updated codes of practice to align with the latest TE

manufacturing procedures.

11. Added a parts list export option formatted to suit the TE

CBOM system.

12. Micro moulded part ranges added.

13. Braid straps added for terminating braid in transitions.

14. D-SCE markers added.

15. RT-780 orange tube added.

© TE Connectivity Index 369
16. Standard cable marker colours can now be overwritten with
non-standard colours.

17. Wire router can now analyse much more complicated harness
designs (tested on a sample containing 1.7 million alternative
routes).

18. Added a design compare option into the HarnWare™ Tools

menu. This allows two versions or a design or two similar-to
harness designs to be compared for differences in their wire
lists, parts lists, labour estimates and cable marker texts. The
comparison results can be saved to the Visio drawing, text
file or Windows clipboard ready for importing into Microsoft
Excel, etc.

19. Added facilities for non-circular connectors, unstructured

connector part numbers and part numbers for ancillary items
in a connector assembly.

20. Added TE GPR rectangular connectors.

21. Changed black anodised to black zinc cobalt in connector

database.

22. Added materials and equipment listing option to replace the

obsolete fax-on-demand and drawing notes options. Added
CoP outline descriptions into help system along with
hyperlinks to the relevant material and equipment details.

23. Option to label only selected contacts in connector planforms

in order to reduce complexity.

24. A new print dialog allows selection of printer and properties

in the HarnWare™ print option.

25. A new Tools menu option provides facilities for creating

custom shapes for use with HarnWare™. The obsolete Visio
SmartShape wizard is no longer required for configuring
connector shape texts and the twist shape function is now
included in the main HarnWare™ program.
370 User Guide HarnWare Version 6.0
26. Added fibre optic cable and TE ProBeam connectors.

27. During start-up the Visio file paths are now checked and a
new Visio file path command has been added in the
HarnWare™ options.

28. Added RG coax cable and RF connectors.

HarnWare™ V6.1
This version was released in November 2012 and included the
following key changes:

1. HarnVis, Cable Database Utility and the Part Number

Translator upgraded to latest programming technologies to
achieve compatibility and more trouble-free installation with
HarnWare™ V6 and with 64 bit versions of Windows 7 and
32 bit versions of Windows XP, Vista and 7.

2. New diagnostic program.

3. New product and adhesive catalogues hyper-linked to

specific pages from HarnWare™ and the HarnWare™ Help
system which has also been extended to include information
on the newly added TE products, shielding and coiled cable
calculations.

4. Data import option to import data from an Excel spread sheet

to help create parts of a harness design

5. New disconnected/automotive schematic style and coax and

triax contact options
© TE Connectivity Index 371

HarnWare™ V6.2.3
This version was released in June 2015 and included the following
key changes:

1. Created a 64 bit Version of HarnWare™ to run with MS

Visio 64 bit.

2. Updated minor errors within the HarnWare™ database

HarnWare™ V6.3
This version was released in July 2020 and included the following key
changes:

1. Inclusion of TE Polamco Series 60 and BTH Range of

Backshells.

2. Addition of the Harness Reliability Analysis, which will give

an estimated Mean Time Between Failures (MTBF)

3. New BOM Export directly into EXCEL, which also allows

you to pull in a specific template or create a new Excel
Template.

4. Inclusion of the TE Highly Flexible Power Cables into the

Harnware database i.e. FDR25 and FDR25 SJ

5. Inclusion of ZH150 tubing, high temperature Zero Halogen

tubing.

6. Updated the operating system to run with MS Visio 2019.

7. Updated the product links to TE.com within the Harnware™

Help System.

8. Updates minor errors within HarnWare™.

372 User Guide HarnWare Version 6.0

Index
KTKK, 219
A
Materials, 43, 295
Accuracy, 337 Time Estimating, 42, 64,
Adaptor, 189, 201 289
Band Strap, 195 AT099, 208, 225

Conduit, 196
B
Finish, 48
Background colours, 334
HexaShield, 196
Balloons, 46, 79, 256, 261, 278
Side Entry Bushing (SEB),
196 Band strap, 154

Spin-Lock, 196 Band Strap Adaptor, 195

Tinel, 194 Bandage, 209

Bend and twist harness legs, 340
Adaptors
Bent Boots, 206
Spin-Lock Adaptors and
Boots, 223 Bill of materials, 40, 255
ADE Analysis & Design Boot, 201
Engineering Ltd., 1, 363
Used as transition, 205
Adhesive, 48, 204
Brackets, 166
Adobe Acrobat, 87
Braid, 147, 247
Alternative styles, 206
Length, 268
Always on top, 47
Termination, 209
Analyse drawing, 78
Bundle diameters, 127, 130, 148,
Arrange forms, 327 155, 318
Assembly
Feedthrough, 213
© TE Connectivity Index 373

C Connector, 91, 163

18,54,79&88 codes, 192,
Cable 222
Assemblies, 135 Code, 165, 191
Cross-section drawings, 46, Manufacturer, 193
79, 159, 262
Part number texts, 172
Lay design, 155
Planform, 167, 187
Marker, 41, 72, 227
References, 67, 92, 131,
Calculator, 45 172
Caps, 183 Contacts, 183
CBOM, 255, 271 CoP, Tooling & Materials, 43,
Centre view, 334 295

Check design, 41, 251 Copy and save, 352

Child form, 18 Copy, paste and view, 33, 319

Circular Mil Area, 179 Copyright, 1

Clipboard, 272 Coupler, 236

Close all forms, 53 Create Shape, 311

CMA, 179 Crimp, 292

Coating, 205 Custom properties, 259

Codes of Practice, 43, 295

D
Colour depth, 339
Combined connector/adaptors, D Connectors, 174, 205
174 Data import, 322
Combo-box, 18 Data1, 22, 29, 70, 257, 311
Command button, 18 Database, 9, 37, 59
Compare Designs, 309 Databus, 63, 170, 235
Composite parts list, 40, 273
Cable, 186
Composite Weight, 287
Contacts, 183
Conduit, 63, 154, 196, 245
Degree of fit, 203
374 User Guide HarnWare Version 6.0
Demonstration, 332 Exit, 33
Design Export
Checker, 41, 251 3D models, 353, 354
Compare, 309 DXF, 324
Sequence, 18 Parts list, 271
Wizard, 14, 28, 37, 57, 75
F
Devices, 166, 183
Diagnostics program, 372 F8 function key, 327
Dictionary, 299 Fax-on-Demand, 295
Dimension, 66, 317, 343 Feedthrough, 152, 213
Disc space, 64, 72 Fibre Optic
Dongle, 373 Cable, 102
Double-clicking, 28 Connectors, 176
Drawing, 63, 68 File Size, 31
Layer, 71, 256 Filler, 157
Notes, 295 Plug, 183
Translation, 44, 299 Filler plug, 169
Drill chart, 330, 349 Find shape, 34, 58
DXF, 31, 324 Flying leads, 174
Foreign language, 44, 299
E Form boards, 12
Edit menu, 33 Format Special, 311
Entry size, 194 Forms, 18, 52, 327
EPD, 151, 161, 261, 292, 293 Fully recovered diameter, 204

Analyser, 39, 135

G
Equipment, 295
Error, 23, 132 Gap shapes, 260

Escape key, 19 Gauge, 97

© TE Connectivity Index 375
Glossary, 54 J
Glue, 64, 315
Jacket, 147
Graphics card, 338, 360
Group shapes, 35, 315 K
H Key combinations, 61
Key File, 372
Hardware Lock, 373
Keyway, 73, 173
Harness design process, 14
Kinked leg, 66, 257, 316
Harness leg, 66, 79, 340
KTKK, 219
Harness material systems, 83
HarnVis, 11, 44, 329 L
HarnWare™ Support Team, 6
Label, 227
Help, 8, 20, 41, 53, 60, 133, 252
Labour estimate, 42, 64, 289
HET, 199
Landscape format, 320
HexaShield, 63, 196
Lay loss, 129
HOOPS, 354
Lay-up board, 12, 330, 349
HSF, 12, 354
Lengths, 129, 153, 292
Hypertext, 252
Licence, 1, 372
I Lighting, 335

IGES files, 12, 353 M

Import data, 322
Marker
Inches, 47, 79
Page, 41, 231
Inner jacket, 147, 149
Insulation caps and tube, 183 Sleeve, 72, 227

Interstice, 161 Master Database Folder, 49

Item numbers, 46, 79 Materials, 295

Sequences, 260 Systems, 13, 48, 79, 83

376 User Guide HarnWare Version 6.0
Measuring, 341 P
Menu, 19, 27
Packing, 149, 203, 207, 224
Microsoft Access, 9
Pages, 63
MIL-C-39012 Coax Connectors,
177 Setup, 64
Millimetres, 47, 79 Pan, 334
Model Part
Part, 357 Details, 343
Quality, 337 Dimensions, 343, 357
Moulded part, 201 Number translator, 265
Stencils, 67 Selection, 13
Multi-cable, 67, 293, 317, 359 Parts listing, 40, 255
Multi-core cable, 39, 135, 143, Codes, 259
151, 158, 292, 293
Edit table format, 265
N Export data, 29

Nail board, 12, 349 Non-parts listing layer, 259

Network Folder, 49 Paste, 33, 319

Next / previous shape, 34, 58 PATT 608, 194, 223

Next database record, 38 PDF files, 87

Non-standard parts, 277 Peg board, 12, 349

Perspective angle, 336
O Phrase translation, 299

Open in HarnWare™, 348 Pin-out data export, 124

Open shape, 22, 27, 58 Pixel formats, 338

OpenHSF files, 12, 354 Planform, 167, 187

Options menu, 45 Pop help, 20, 41

Orbit, 334 Portrait format, 320

Overview, 329 Print document, 30, 64, 320

© TE Connectivity Index 377
Product information, 20, 53, 87, Schematic, 105
93, 319, 345
Data export, 124
Protection sleeves, 209, 229
Screen, 184, 209
Purge unused Visio masters, 31
Select

Q In HarnVis, 341
In Visio, 348
Query part, 343
Selection menu, 341
Quick start guide, 332
Set properties, 15, 79
R Shapes, 70
Shared Network Folder, 49
Read me file, 11
Shell size, 165, 191
Registered user, 1
Shield, 184, 209
Release history, 375
Shielding tape, 209
Repair loops, 79, 129, 269
Shift F1 help, 20
Retain existing item numbers, 46,
255, 260 Shimming, 207
RF Coax Connectors, 176 Short-cut key, 20, 61
Right-click menu, 28, 334, 342, Side Entry Bushing (SEB), 196
343, 348
Size check, 330
RoHS, 43, 303
Smoothness, 337
Roll-back, 194
Snap and glue, 65, 369
Rotate shapes, 35, 315
Solder, 292
Routing wires, 39, 64, 93, 127
Sleeves, 166, 183, 209

S Spin-Lock Adaptors, 196, 223

Splice, 178
Sample drawings, 47
Stencils, 67, 72
Save shape, 28, 52, 58
STXR adaptors, 192
Schedule, 117
Sub-assemblies, 158, 259
Data export, 124 Support contacts, 53, 363
378 User Guide HarnWare Version 6.0
Surface Area, 347 Units, 47, 79
System Data File, 372 User
SZF Filler, 183 Balloons, 258
Parts library, 258
T
Parts Library, 277
TCFT, 214 System data file, 372
TE product catalogue, 345
Temperature rise, 97 V
Three-dimensional, 11, 44 View data, 33, 319
Time synthetics, 136
Viewing, 334
Tinel, 154, 194
Quality, 338
Tips, 289
Visio, 9, 21
TMS WinTotal, 231
Custom properties, 259
Tool tips, 20, 47
File paths, 370
Toolbar, 57
Shape data, 259
Tooling equipment, 43, 295
Support, 364
Tools menu, 35
Voltage drop, 97
Transitions, 70, 203
Angle, 66, 315 W
Translator, 44, 299
Wall thickness, 150
Tube, 147, 247
Warnings, 132, 252, 270, 291
Length, 268
Web site, 345
Twisted pair, 158
Forum, 11
Type 2 adaptors, 192
Weight, 43, 283
U What’s new, 375
Window menu, 28, 50
Undo, 22
WinTotal, 233
Uninstall, 368
Wire, 46, 91
© TE Connectivity Index 379
Colour, 100 Sub-assemblies, 158
Diameters, 184 Wiring

Gauge, 97 Schedule, 38, 117

Lengths, 93, 127, 129, 269 Schematic, 38, 105
List, 63, 70, 103, 261
X
List numbers, 46
XMT file, 231
Markers, 166, 183
Routing, 39, 64, 93, 127 Z
Source, 49, 100
Zoom, 334
Specification, 95