ELECTRONICS INDUSTRIES Requirements and Acceptance for ...

1 IPC/WHMA-A-620 Requirements andAcceptance for Cableand Wire HarnessAssembliesDeveloped by the IPC Task Group (7-31f) of the ProductAssurance Subcommittee (7-30) and the WHMA IndustryTechnical Guidelines Committee (ITGC)Users of this standard are encouraged to participate in thedevelopment of future :IPC2215 Sanders RoadNorthbrook, Illinois60062-6135 Tel 847 847 Harness Manufacturers N. Arlington Heights Road, Suite EArlington Heights, Illinois60004 Tel 847 847 CONNECTINGELECTRONICS INDUSTRIES 1 Requirements and Acceptance for Cableand Wire Harness Approach To This Specialized Terms and Classes of Document Tool and Equipment Observable Defects and Process Inspection Target .. Acceptable .. Process Indicator .. Defect .. Disposition .. Product Classification ImpliedRelationships .. Conditions Not Specified.

2 Electrical Measurement Units and Verification of Visual Lighting .. Magnification .. Electrostatic Discharge (ESD) 1-52 Applicable Joint Industry Standards (ANSI J-STD).. Department of Defense (Military).. American National Standards Institute(ANSI).. ESD Assocations (ESDA).. 2-23 Strand Conductor - Wire Separation (Birdcaging).. Damaged 3-54 Soldered Wire Preparation, Parts Preparation, Gold Prior to Soldering .. Solder Connections .. Particulate Matter .. Flux Residue .. Clearance .. Damage from Soldering .. Flexible Sleeve Birdcaged Wire (Soldered).. 4-11 Table of ContentsvIPC/WHMA-A-620 January Connection .. Terminals .. Terminals .. Side Route Attachments .. Bottom and Top Route Attachments .. Staked Wires .. Terminals .. Terminals .. Terminals.

3 Terminals .. Connected Terminals .. Solder General .. Fillet .. Turret Terminals .. Bifurcated Terminals .. Slotted Terminals .. Pierced/Perforated Terminals .. Hook Terminals .. Cup Terminals .. 4-325 Crimp Stamped and Formed Insulation Support Crimp .. Insulation Inspection Window .. Conductor Crimp .. Crimp Bellmouth .. Conductor Brush .. Carrier Cutoff Tab .. Machined Crimp Insulation Clearance .. Insulation Support (Insulation SupportStyle Contacts) .. Conductor Location .. Crimping .. Under Size Conductor - CMAB uildup Crimps .. 5-226 Insulation Displacement Connection (IDC).. Mass Termination, Flat End Cutting .. Notching .. Planar Ground Plane Removal .. Connector Position .. Connector Skew and Lateral Position .. Retention .. Discrete Wire General .. Position of Wire.

4 Overhang (Extension) .. Wire Holder .. Damage in Connection Area .. End Connectors .. Wiremount Connectors .. Subminiature D-Connector (SeriesBus Connector) .. Modular Connectors (RJ Type) .. 6-217 Ultrasonic Insulation Weld Geometry .. 7-38 Soldered Mesh .. Wrap .. Hook .. Lap .. Splices - Barrel .. Double Sided .. Splices - Ultrasonic 8-119 Hardware Jackscrews .. Strain Sleeving .. Sleeving and Position .. Bonding - Conductive Adhesive .. Connector Criteria .. Limits - Hard Face - Mating Surface .. Limits - Soft Face - Mating Surface orRear Seal Area .. Contacts .. 9-10 Table of Contents (cont.)viIPC/WHMA-A-620 January 200210 Insulation Damage .. Filling .. Terminal Positioning .. Fit to Wire or Cable .. Flashing .. Chill Marks (Knit Lines), Stress Linesor Cracks.

5 Compound Color .. Filling .. Fit to Wire or Cable .. Curing .. 10-1211 Cable Assemblies and Cable Surfaces .. Straight/Axial Connectors .. Right-Angle Connectors .. Measurement .. Wires (As an Assembly).. Electrical Terminal Reference Location .. Length Measurement .. 11-512 Marker Wrap Around .. Tubular .. 12-813 Coaxial and Twinaxial Cable Center Conductor Crimp .. Solder .. Solder Ferrule General .. Insulation .. Coaxial Connector - Printed WireBoard Coaxial Connector - Center ConductorLength - Right Angle Terminal Cover - Shield Clamped Ground Rings .. Crimped Ferrule .. Center Pin Semirigid Bending and Deformation .. Surface Condition .. Dielectric Cutoff .. Dielectric Cleanliness .. Solder .. Swage-Type Soldering and Stripping of Biaxial orTwinaxial Wire - Low Jacket and Tip Installation.

6 Ring Installation .. 13-3314 Wire Bundle Tie Wrap/Lacing Tightness .. Damage .. Spacing .. Individual Wires .. Spacing .. 14-10 Table of Contents (cont.)viiIPC/WHMA-A-620 January Wire Wire Crossover .. Coaxial Cable Routing .. Unused Wire Termination .. Ties over Splices and Ferrules .. 14-1615 Direct Applied .. Pre-Woven .. Shield Pick Off .. No Pick Off .. Low Temperature Insulated Wire -With Pick Off .. Shield Termination - Shrink and Shield Termination - Tapes - Barrier and Conductive,Adhesive or Conduit (Shielding).. Conductive Shrink Tubing - Conductive 15-2416 Cable/Wire Harness Protective Direct Applied .. Pre-Woven .. Shrink Tubing .. Spiral Plastic Wrap(Spiral Wrap Sleeving).. Conduit (Containment).. 16-817 Hardware Sequence.

7 Type and Missing .. Minimum Torque for ElectricalConnections .. Wires .. High Voltage Applications .. Wire/Harness Stress Relief .. Wire Dress .. Service Loops .. 17-1418 Solderless Number of Turn End Tails, Insulation Raised Turns Connection Wire Wire Insulation .. Wires and Terminals .. 18-13 Appendix A-1 Appendix B-1 Standard Improvement FormTable of Contents (cont.)viiiIPC/WHMA-A-620 January ScopeThis standard is a collection of visual Quality AcceptabilityRequirements for Cable, Wire and Harness Assemblies. It wasprepared by the ITGC Industry Technical Guidelines Commit-tee of the Wire Harness Manufacturers Association and theProduct Assurance Committee of IPC - Association Connect-ing electronic INDUSTRIES . IPC/WHMA-A-620 can be used as astand-alone document for purchasing products, however itdoes not specify frequency of in-process inspection or fre-quency of end product inspection.

8 No limit is placed on thenumber of process indicators or the number of allowablerepair/rework of defects. Such information should be devel-oped with a statistical process control plan (see IPC-9191). PurposeThis publication describes acceptability criteria for producingcrimped, mechanically secured, or soldered interconnectionsand the associated lacing/restraining criteria associated withcable and harness assemblies. It is not the intent of this docu-ment to exclude any acceptable procedure used to make theelectrical connection; however, the methods used must pro-duce completed assemblies that conform to the acceptabilityrequirements described in this Approach To This DocumentThe illustrations in this document portray specific points notedin the title of each section. A brief description follows eachillustration. The development committee recognizes that differ-ent parts of the industry have different definitions for someterms used herein.

9 For the purposes of this document, theterms cable and wire harness are used Specialized DesignsIPC/WHMA-A-620, as an industry consensus document, can-not address all of the possible product design , the standard does provide criteria for commonlyused technologies. Where uncommon or specialized tech-nologies are used, it may be necessary to develop uniqueacceptance criteria. The development of unique criteria shouldinclude customer involvement or consent and the criteriadeveloped should include an agreed upon definition foracceptance of each possible, new criteria, or criteria on specializedproducts should be submitted, using the Standard Improve-ment Form included in this standard, to the IPC TechnicalCommittee to be considered for inclusion in upcoming revi-sions of this Terms and DefinitionsTerms are consistent with the definitions provided by IPC-T-50.

10 For the understanding of this document, selected defini-tions are listed below and in Appendix or Must Mean that the requirement or attribute dis-cussed is mandatory for all Product Reflects recommendations and is used to reflectgeneral industry practices and procedures for guidance Diameter In this document, wire diameter (D) is theoverall diameter of conductor plus Classes of ProductsThe customer has the ultimate responsibility for identifying theclass to which the assembly is evaluated. Thus, accept and/orreject decisions must be based on applicable documentationsuch as contracts, drawings, specifications, standards andreference documents. Criteria defined in this standard reflectthree Product Classes, which are as follows:Class 1 General electronic ProductsIncludes products suitable for applications where the majorrequirement is the function of the completed 2 Dedicated Service electronic ProductsIncludes products where continued performance andextended life is required, and for which uninterrupted serviceis desired but not critical.