ELECTRONICS INDUSTRIES Requirements and Acceptance …

1 IPC/WHMA-A-620 ARequirements 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 publication are encouraged to participate in thedevelopment of future :IPC3000 Lakeside Drive, Suite 309 SBannockburn, Illinois60015-1219 Tel 847 847 Harness Manufacturers Flying Cloud Drive, Suite 900 Eden Prairie, Minnesota55344 Tel 952 952 :IPC/WHMA-A-620 -January 2002 ASSOCIATION CONNECTINGELECTRONICS INDUSTRIES 1 Requirements and Acceptance for Cableand Wire Harness Approach to This Shall or Uncommon or Specialized Terms and Classes of Document Tool and Equipment Observable Defects and Process Inspection Target .. Acceptable .. Process Indicator .. Defect .. Disposition .. Product Classification ImpliedRelationships.

2 Conditions Not Specified .. Electrical Measurement Units and Verification of Visual Lighting .. Magnification Aids and Lighting .. Electrostatic Discharge (ESD) Materials and 1-52 Applicable Joint Industry Society of Automotive Engineers (SAE).. American National Standards Institute(ANSI).. International Organization for Standardization(ISO).. ESD Association (ESDA).. 2-23 Strand Damage and End Conductor Twisting of Wire Insulation 3-84 Soldered Material, Components and .. and Equipment .. Removal .. Matter .. Residue .. Cleanable Flux .. No-Clean Process .. Solder Requirements .. Anomalies .. Basis Metal .. Surface Finishes .. Visible or HiddenSolder Connections .. 4-8 Table of ContentsvIPC/WHMA-A-620 AJuly Wire/Lead Preparation, Wire .. Damage .. Insulation Birdcaged Wire (Soldered).

3 Connection Terminals .. Terminals .. Side Route Attachments .. Bottom and Top Route Attachments .. Staked Wires .. Terminals .. Terminals .. Terminals .. Terminals .. Connected Terminals .. Placement - AWG 30 and SmallerDiameter Wires .. Solder Terminals .. Terminals .. Terminals .. Terminals .. Terminals .. Terminals .. 4-405 Crimp Terminations (Contacts and Lugs).. Stamped and Formed - Open Support Crimp .. Inspection Window .. Crimp .. Bellmouth .. Brush .. and Formed Carrier Cutoff Tab .. Stamped and Formed - Closed Support Crimp .. Crimp and Bellmouth .. Machined Clearance .. Support Style .. Location .. Buildup .. Termination Ferrule 5-296 Insulation Displacement Connection (IDC).. Mass Termination, Flat Cutting .. Ground Plane Removal .. Position .. Skew & Lateral Position .. Discrete Wire .. of Wire.

4 (Extension) .. Holder .. in Connection Area .. Connectors .. Connectors .. D-Connector (SeriesBus Connector) .. Connectors (RJ Type) .. 6-217 Ultrasonic Insulation Weld 7-38 Soldered .. Two or More Conductors .. Insulation Opening (Window) .. Shrinkable Solder Devices .. Crimped .. Sided .. Ultrasonic Weld 8-209 Hardware - Height .. - Protrusion .. 9-3 Table of Contents (cont.)viIPC/WHMA-A-620 AJuly Strain Fit .. Dress .. Approach .. Approach .. Sleeving and .. Connector .. - Hard Face - Mating Surface .. - Soft Face - Mating Surfaceor Rear Seal Area .. Installation of Contacts and Sealing Plugsinto of Contacts .. of Sealing Plugs .. 9-1810 Fill - Initial .. Fill - Final .. Through .. Position .. , Flow Lines, Chill Marks (Knit Lines)or Weld Lines .. Wire Insulation, Jacket or Sleeving Damage.

5 Curing .. Rework .. to Wire or cable .. 10-2411 cable Assemblies and cable Surfaces .. Straight/Axial Connectors .. Right-Angle Connectors .. Wire Terminal Reference Location .. 11-612 Location and Marker Around .. Flag .. Wrap .. 12-1013 Coaxial and Twinaxial cable Center Conductor .. Solder Ferrule .. Coaxial Connector - Printed WireBoard Coaxial Connector - Center ConductorLength - Right Angle Coaxial Connector - CenterConductor Coaxial Connector - Terminal .. Fit .. Shield Ground Rings .. Ferrule .. 13-19 Table of Contents (cont.)viiIPC/WHMA-A-620 AJuly Center Pin Semirigid and Deformation .. Condition .. Cutoff .. Cleanliness .. Swage-Type Soldering and Stripping of Biaxial and Tip Installation .. Installation .. 13-3514 Tie Wrap/Lacing .. Wires.

6 Crossover .. Radius .. cable .. Wire Termination .. over Splices and Ferrules .. 14-1715 Harness/ cable Electrical Applied .. Shield Jumper Wire .. Lead .. Solder/Heat Shrinkable Solder Device .. Crimp .. Braid .. Woven .. Combed and Twisted .. Chain .. Shield Wire .. Shield Termination - Shrink and Crimp .. Shield Jumper Wire Attachment .. Shield Termination - Solder .. Tie/Tape On .. Tapes - Barrier and Conductive,Adhesive or Conduit (Shielding).. Shrink Tubing - Conductive 15-2516 cable /Wire Harness Protective Direct Applied .. Prewoven .. Sleeving/Shrink Spiral Plastic Wrap (Spiral Wrap Sleeving).. Conduit (Containment Loom).. Tapes, Adhesive and 16-917 Finished Assembly Hardware Threaded Fasteners .. Minimum Torque for Electrical Connections .. Wires .. High Voltage Applications.

7 Wire/Harness Stress Relief .. Wire Dress .. Service Loops .. 17-1318 Solderless Number of Turn End Tails, Insulation 18-4 Table of Contents (cont.)viiiIPC/WHMA-A-620 AJuly Raised Turns Connection Wire Wire Insulation .. Wires and Terminals .. 18-1319 Nondestructive Testing After Rework or Intended Table Electrical .. Electrical Test Continuity .. Shorts .. Dielectric Withstanding Voltage (DWV) .. Insulation Resistance (IR) .. Voltage Standing Wave Ratio (VSWR) .. Insertion Loss .. Reflection Coefficient .. User Defined .. Mechanical .. Mechanical Test Height (Dimensional Analysis) .. Terminal Positioning .. Force (Tensile) .. Without Documented Process Control .. Force Monitoring .. Tool Qualification .. Retention Verification .. Shield Pull Force (Tensile) .. Connector Shield Ferrule Torsion.

8 Defined .. 19-18 Appendix A Terms and A-1 Appendix B Metric Conversion B-1 Appendix C Reproducible Test C-1 Standard Improvement FormTable of Contents (cont.)ixIPC/WHMA-A-620 AJuly 2006If a conflict occurs between the Englishand translated versions of this document,the English version will take ScopeThis standard is a collection of visual, electricaland mechanical quality acceptability Requirements for cable ,Wire and Harness Assemblies. It was prepared by the Indus-try Technical Guidelines Committee of the Wire HarnessManufacturers Association and the Product Assurance Com-mittee of IPC - Association Connecting electronic can be used as a stand-alone documentfor purchasing products; however it does not specify fre-quency of in-process inspection or frequency of end productinspection. No limit is placed on the number of process indi-cators or the number of allowable repair/rework of information should be developed with a statistical pro-cess control plan (see IPC-9191).

9 PurposeThis publication describes tests and accept-ability criteria for producing crimped, mechanically secured, orsoldered interconnections and the associated lacing/restraining criteria associated with cable and harness assem-blies. Any method that produces an assembly conforming tothe acceptability Requirements described in this standard maybe Approach to This DocumentThe illustrations in thisdocument portray specific points noted in the title of eachsection. A brief description follows each illustration. The devel-opment committee recognizes that different parts of theindustry have different definitions for some terms used the purposes of this document, the terms cable and wireharness are used 3shall1develop and implement a documented processcontrol system. A documented process control system, ifestablished,shall2define process control and correctiveaction limits. This may or may not be a statistical processcontrol system.

10 The use of statistical process control (SPC) is optional and should be based on factors suchas design stability, lot size, production quantities, and theneeds of the control methodologiesshall2be used in the planning, implementationand evaluation of the manufacturingprocesses used to produce cables andwire harness assemblies. The philoso-phy, implementation strategies, toolsand techniques may be applied in differ-ent sequences depending on the specific company, opera-tion, or variable under consideration to relate process controland capability to end product Shall or ShouldThe word shall is used in the textof this document wherever a requirement is the word shall leads to a hardware defect for atleast one class, the Requirements for each class are annotatedin text boxes located adjacent to that occurrence in the this standard doesn t provide Acceptance criteria for aspecific class, the text box will note Not Est for that class(see ).