Requirements and Acceptance for Cable If a conflict occurs ...

1 IPC/WHMA-A-620 BRequirements 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-620A -July 2006 IPC/WHMA-A-620 -January 2002If a conflict occursbetween the English andtranslated versions of thisdocument, the Englishversion will takeprecedence.

2 1 Approach to This Measurement Units and Verification of Dimensions .. Uncommon or Specialized Terms and Inspection .. Manufacturer (Assembler) .. Objective Evidence .. Process Control .. Supplier .. User .. wire Diameter (D) .. Classes of Order of Requirements Personnel Field Assembly Operations .. Tools and Control .. Calibration .. Materials and Processes .. Figures and Inspection Target .. Acceptable .. Process Indicator.

3 Defect .. Disposition .. Product Classification Implied Relationships .. Conditions Not Specified .. Electrical Sampling .. Lighting .. Magnification Aids .. Discharge (ESD) Protection .. Rework .. Repair .. Statistical Process 1-72 Applicable Joint Industry Society of Automotive Engineers (SAE).. American National StandardsInstitute (ANSI).. International Organization forStandardization (ISO).. ESD Association (ESDA).. United States Department of Defense (DoD).

4 ASTM 2-23 Strand Damage and End Conductor Twisting of Insulation Damage - 3-8 Table of ContentsviiIPC/WHMA-A-620 BOctober 20124 Soldered Material, Components and .. Solder .. Flux .. Adhesives .. Solderability .. Tools and Equipment .. Removal .. Particulate Matter .. Flux Residue .. Cleanable Flux .. No-Clean Process .. Solder Requirements .. Anomalies .. Exposed Basis Metal .. Partially Visible or Hidden SolderConnections .. wire /Lead Preparation, wire .

5 Damage .. Insulation Birdcaged wire (Soldered).. and Straight Pins .. Lead/ wire Placement .. Solder .. Lead/ wire Placement - Side Route .. Lead/ wire Placement - Bottom andTop Route .. Lead/ wire Placement - Staked/Constrained Wires .. Solder .. Lead/ wire Placement .. Solder .. Pierced/Perforated/Punched .. Lead/ wire Placement .. Solder .. Hook .. Lead/ wire Placement .. Solder .. Cup .. Lead/ wire Placement .. Solder .. Series Connected .. Lead/ wire Placement - AWG 30 andSmaller Diameter Wires.

6 4-445 Crimp Terminations (Contacts and Lug).. Stamped and Formed - Open Insulation Support .. Inspection Window .. Crimp .. Insulation Clearance if No Support Crimp .. Conductor Crimp .. Crimp Bellmouth .. Conductor Brush .. Carrier Cutoff Tab .. Stamped and Formed - Closed Insulation Clearance .. Insulation Support Crimp .. Conductor Crimp and Bellmouth .. Machined Insulation Clearance .. Insulation Support Style .. Conductor .. Crimping .. CMA Buildup .. Termination Ferrule 5-316 Insulation Displacement Connection (IDC).

7 Mass Termination, Flat End Cutting .. Notching .. Planar Ground Plane Removal .. Connector Position .. Connector Skew & Lateral Position .. Retention .. 6-9 Table of Contents (cont.)viiiIPC/WHMA-A-620 BOctober Discrete wire General .. Position of wire .. Overhang (Extension) .. Insulation Crimp .. Damage in Connection Area .. End Connectors .. Pass Through Connectors .. Wiremount Connectors .. Subminiature D-Connector (SeriesBus Connector) .. Modular Connectors (RJ Type).

8 6-217 Ultrasonic Insulation Weld 7-38 Soldered Mesh .. Wrap .. Hook .. Lap .. Two or More Conductors .. Insulation Opening (Window) .. Heat Shrinkable Solder Devices .. Crimped Barrel .. Double Sided .. Contact .. wire In-Line Junction Devices(Jiffy Junctions) .. Ultrasonic Weld 8-259 Hardware Jackpost - Height .. Jackscrews - Protrusion .. Retaining Clips .. Connector Alignment .. Strain Clamp Fit .. wire Dress .. Straight Approach.

9 Side Approach .. Sleeving and .. Connector .. - Hard Face - Mating Surface .. - Soft Face - Mating Surface orRear Seal Area .. Installation of Contacts and Sealing Plugsinto of Contacts .. of Sealing Plugs .. 9-2110 Over- Fill .. Inner .. Outer .. Mismatch .. Fit .. Cracks, Flow Lines, Chill Marks(Knit Lines), or Weld Lines .. Color .. Through .. Insulation, Jacket or SleevingDamage .. Potting (Thermoset Molding).. to wire or Cable .. 10-3111 Measuring Cable Assemblies and Measuring - Cable and WireLength Measuring - Surfaces - Straight/Axial Connectors.

10 Surfaces - Right-AngleConnectors .. Breakout Measurement Points .. Breakout Length .. 11-5 Table of Contents (cont.)ixIPC/WHMA-A-620 BOctober Measuring - Electrical Terminal Reference Location .. Length .. 11-712 Location and Marker Wrap Around .. Tubular .. Flag Adhesive .. Tie Wrap 12-1013 Coaxial and Biaxial Cable Center Conductor Crimp .. Solder .. Solder Ferrule General .. Insulation .. Coaxial Connector- Printed WireBoard Coaxial Connector - Center ConductorLength - Right Angle Coaxial Connector - Center Coaxial Connector - Terminal Soldering.