IPC WHMA A 620A Table Of Contents
User Manual: 620A
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IPC/WHMA-A-620A ASSOCIATION CONNECTING ELECTRONICS INDUSTRIES ® Requirements and Acceptance for Cable and Wire Harness Assemblies Developed by the IPC Task Group (7-31f) of the Product Assurance Subcommittee (7-30) and the WHMA Industry Technical Guidelines Committee (ITGC) Supersedes: IPC/WHMA-A-620 January 2002 Users of this publication are encouraged to participate in the development of future revisions. Contact: IPC 3000 Lakeside Drive, Suite 309S Bannockburn, Illinois 60015-1219 Tel 847 615.7100 Fax 847 615.7105 Wiring Harness Manufacturers Assoc. 7500 Flying Cloud Drive, Suite 900 Eden Prairie, Minnesota 55344 Tel 952 835.4180 Fax 952 835.4774 Table of Contents 1 Requirements and Acceptance for Cable and Wire Harness Assemblies ................................... 1-1 2 Applicable Documents ................................................ 2-1 2.1 IPC ............................................................................... 2-1 1.1 Scope ........................................................................ 1-1 1.2 Purpose .................................................................... 1-1 2.3 Society of Automotive Engineers (SAE) ................ 2-1 1.3 Approach to This Document ................................. 1-1 2.4 American National Standards Institute (ANSI) ........................................................................... 2-2 1.4 Shall or Should ........................................................ 1-1 1.5 Uncommon or Specialized Designs ..................... 1-1 1.6 Terms and Definitions ........................................... 1-1 1.7 Classes of Products ............................................... 1-2 1.8 Document Hierarchy .............................................. 1-2 1.9 Tool and Equipment Control ................................ 1-2 3.3 Conductor Deformation/Birdcaging ...................... 3-5 1.10 Observable Criteria ................................................ 1-3 3.4 Twisting of Wires ...................................................... 3-7 1.11 Defects and Process Indicators .......................... 1-3 3.5 Wire Insulation Damage .......................................... 3-8 1.12 Inspection Conditions ............................................ 1-3 4 Soldered Terminations ................................................ 4-1 1.12.1 1.12.2 1.12.3 1.12.4 1.12.5 1.12.6 4.1 Material, Components and Equipment ................. 4-2 2.2 Joint Industry Standards ......................................... 2-1 2.5 International Organization for Standardization (ISO) ............................................................................. 2-2 2.6 ESD Association (ESDA) .......................................... 2-2 3 Preparation .................................................................... 3-1 Target ................................................................. Acceptable ......................................................... Process Indicator ............................................... Defect ................................................................. Disposition .......................................................... Product Classification Implied Relationships ...................................................... 1.12.7 Conditions Not Specified .................................... 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1.13 Electrical Clearance .............................................. 1-3 3.1 Stripping ..................................................................... 3-2 3.2 Strand Damage and End Cuts ................................ 3-2 4.1.1 4.1.1.1 4.1.1.2 4.1.1.3 4.1.1.4 4.1.1.5 4.1.2 Materials ........................................................ Solder ............................................................ Flux ................................................................ Adhesives ...................................................... Solderability ................................................... Tools and Equipment .................................... Gold Removal ................................................ 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4.2 Cleanliness ................................................................ 4-4 1.16 Visual Inspection .................................................... 1-4 4.2.1 4.2.2 4.2.2.1 4.2.2.2 4.2.2.2.1 4.2.2.2.2 1.16.1 Lighting .............................................................. 1-4 1.16.2 Magnification Aids and Lighting .......................... 1-4 4.3 Solder Connection .................................................... 4-6 1.14 Measurement Units and Applications ................ 1-4 1.15 Verification of Dimensions ................................... 1-4 1.17 Electrostatic Discharge (ESD) Protection .......... 1-5 1.18 Contamination ......................................................... 1-5 4.3.1 4.3.2 4.3.2.1 4.3.2.2 4.3.2.3 1.19 Materials and Processes ....................................... 1-5 IPC/WHMA-A-620A July 2006 Presoldering .................................................. Postsoldering ................................................. Particulate Matter .......................................... Flux Residue .................................................. Cleanable Flux ............................................... No-Clean Process ......................................... General Requirements ................................... Soldering Anomalies ...................................... Exposed Basis Metal ..................................... Exposed Surface Finishes ............................. Partially Visible or Hidden Solder Connections ....................................... 4-4 4-4 4-4 4-5 4-5 4-5 4-7 4-8 4-8 4-8 4-8 v Table of Contents (cont.) 4.4 Wire/Lead Preparation, Tinning ............................. 4-9 5.4 Termination Ferrule Crimp ................................... 5-29 4.5 Wire Insulation ........................................................ 4-11 6 Insulation Displacement Connection (IDC) ............. 6-1 4.5.1 4.5.2 6.1 Mass Termination, Flat Cable ................................ 6-2 Clearance ........................................................ 4-11 Postsolder Damage ......................................... 4-13 4.6 Insulation Sleeving ................................................. 4-14 4.7 Birdcaged Wire (Soldered) .................................... 4-16 4.8 Connection Requirements .................................... 4-17 4.8.1 4.8.2 4.8.2.1 4.8.2.2 4.8.2.3 4.8.3 4.8.4 4.8.5 4.8.6 4.8.7 4.8.8 Turret Terminals .............................................. Bifurcated Terminals ........................................ Side Route Attachments ................................. Bottom and Top Route Attachments .............. Staked Wires ................................................... Slotted Terminals ............................................ Pierced/Perforated/Punched Terminals ........... Hook Terminals ............................................... Cup Terminals ................................................. Series Connected Terminals ........................... Lead/Wire Placement - AWG 30 and Smaller Diameter Wires ................................................ 4-19 4-21 4-21 4-23 4-24 4-25 4-26 4-27 4-29 4-30 4-31 4.9 Solder Connection .................................................. 4-32 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6 Turret Terminals .............................................. Bifurcated Terminals ........................................ Slotted Terminals ............................................ Pierced/Perforated Terminals .......................... Hook Terminals ............................................... Cup Terminals ................................................. 4-34 4-35 4-37 4-38 4-39 4-40 5 Crimp Terminations (Contacts and Lugs) ................ 5-1 5.1 Stamped and Formed - Open Barrel ..................... 5-2 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 Insulation Support Crimp .................................. 5-3 Insulation Inspection Window ............................ 5-5 Conductor Crimp .............................................. 5-7 Crimp Bellmouth ............................................... 5-9 Conductor Brush ............................................. 5-11 Stamped and Formed Carrier Cutoff Tab ........ 5-13 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 End Cutting ........................................................ Notching ............................................................. Planar Ground Plane Removal ........................... Connector Position ............................................. Connector Skew & Lateral Position .................... Retention ............................................................ 6-2 6-3 6-4 6-5 6-8 6-9 6.2 Discrete Wire Termination .................................... 6-10 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 General ............................................................. Position of Wire ................................................ Overhang (Extension) ........................................ Wire Holder ...................................................... Damage in Connection Area ............................ End Connectors ............................................... Wiremount Connectors .................................... Subminiature D-Connector (Series Bus Connector) ................................................ Modular Connectors (RJ Type) ......................... 6-10 6-11 6-12 6-13 6-15 6-16 6-18 6-19 6-21 7 Ultrasonic Welding ....................................................... 7-1 7.1 Insulation Clearance ................................................ 7-2 7.2 Weld Nugget .............................................................. 7-3 8 Splices ............................................................................ 8-1 8.1 Soldered Splices ....................................................... 8-2 8.1.1 8.1.2 8.1.3 8.1.4 8.1.4.1 8.1.4.2 8.1.5 Mesh .................................................................. 8-2 Wrap .................................................................. 8-4 Hook .................................................................. 8-5 Lap ..................................................................... 8-6 Two or More Conductors ................................... 8-7 Insulation Opening (Window) .............................. 8-9 Heat Shrinkable Solder Devices ....................... 8-11 8.2 Crimped Splices ...................................................... 8-13 5.2 Stamped and Formed - Closed Barrel ................ 5-14 5.2.1 5.2.2 Insulation Support Crimp ................................ 5-15 Conductor Crimp and Bellmouth .................... 5-17 8.2.1 8.2.2 Barrel ................................................................ 8-13 Double Sided ................................................... 8-16 8.3 Ultrasonic Weld Splices ........................................ 8-20 5.3 Machined Contacts ................................................ 5-19 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 vi Insulation Clearance ........................................ Insulation Support Style .................................. Conductor Location ........................................ Crimping ......................................................... CMA Buildup ................................................... 5-19 5-22 5-23 5-25 5-27 9 Connectorization .......................................................... 9-1 9.1 Hardware Mounting .................................................. 9-2 9.1.1 9.1.2 July 2006 Jackpost - Height ............................................... 9-2 Jackscrews - Protrusion ..................................... 9-3 IPC/WHMA-A-620A Table of Contents (cont.) 9.2 Strain Relief ............................................................... 9-4 11.2 Wire Measuring ..................................................... 11-5 9.2.1 9.2.2 9.2.2.1 9.2.2.2 11.2.1 11.2.2 Clamp Fit ......................................................... Wire Dress ....................................................... Straight Approach ............................................ Side Approach ................................................. 9-4 9-5 9-6 9-7 Electrical Terminal Reference Location ........... 11-5 Length ........................................................... 11-6 12 Marking/Labeling ..................................................... 12-1 9.3 Sleeving and Boots ................................................... 9-8 12.1 Content ................................................................... 12-2 9.3.1 9.3.2 12.2 Legibility ................................................................. 12-2 Position ............................................................ 9-8 Bonding ........................................................... 9-9 12.3 Permanency ........................................................... 12-4 9.4 Connector Damage ................................................. 9-12 9.4.1 9.4.2 9.4.3 9.4.4 Criteria ........................................................... Limits - Hard Face - Mating Surface .............. Limits - Soft Face - Mating Surface or Rear Seal Area .......................................... Contacts ........................................................ 9-12 9-13 12.5 Functionality .......................................................... 12-6 9-14 9-15 9.5 Installation of Contacts and Sealing Plugs into Connectors ...................................................... 9-16 9.5.1 9.5.2 12.4 Location and Orientation .................................... 12-4 Installation of Contacts ................................... 9-16 Installation of Sealing Plugs ............................ 9-18 12.6 Marker Sleeve ....................................................... 12-7 12.6.1 12.6.2 Wrap Around ................................................. 12-7 Tubular ........................................................... 12-9 12.7 Flag Markers ...................................................... 12-10 12.7.1 12.7.2 Adhesive ...................................................... 12-10 Tie Wrap ...................................................... 12-10 10 Molding/Potting ........................................................ 10-1 10.1 Molding ................................................................... 10-2 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8 Mold Fill - Initial .............................................. 10-2 Mold Fill - Final ............................................... 10-4 Mismatch ....................................................... 10-8 Blow Through ................................................ 10-9 Terminal/Contact Position ............................ 10-10 Fit ................................................................. 10-12 Flashing ....................................................... 10-14 Cracks, Flow Lines, Chill Marks (Knit Lines) or Weld Lines ............................................... 10-16 10.1.9 Color ............................................................ 10-18 10.1.10 Wire Insulation, Jacket or Sleeving Damage . 10-18 10.1.11 Curing .......................................................... 10-20 10.1.12 Rework ........................................................ 10-21 10.2 Potting .................................................................. 10-22 10.2.1 10.2.2 10.2.3 Filling ............................................................. 10-22 Fit to Wire or Cable ....................................... 10-23 Curing ........................................................... 10-24 13 Coaxial and Twinaxial Cable Assemblies ............ 13-1 13.1 Stripping ................................................................. 13-2 13.2 Center Conductor Termination .......................... 13-4 13.2.1 13.2.2 Crimp .............................................................. 13-4 Solder ............................................................. 13-6 13.3 Solder Ferrule Pins .............................................. 13-8 13.3.1 13.3.2 General ........................................................... 13-8 Insulation ....................................................... 13-10 13.4 Coaxial Connector - Printed Wire Board Mount ........................................................ 13-11 13.5 Coaxial Connector - Center Conductor Length - Right Angle Connector ...................... 13-12 13.6 Coaxial Connector - Center Conductor Solder ............................................... 13-14 11 Cable Assemblies and Wires ................................. 11-1 13.7 Coaxial Connector - Terminal Cover .............. 13-16 11.1 Cable Measuring ................................................... 11-2 11.1.1 11.1.1.1 11.1.1.2 11.1.2 11.1.3 Reference Surfaces ........................................ Straight/Axial Connectors ............................... Right-Angle Connectors ................................. Length ........................................................... Breakout ........................................................ IPC/WHMA-A-620A 11-2 11-2 11-2 11-3 11-4 13.7.1 13.7.2 Soldering ....................................................... 13-16 Press Fit ........................................................ 13-17 13.8 Shield Termination ............................................. 13-18 13.8.1 13.8.2 July 2006 Clamped Ground Rings ................................ 13-18 Crimped Ferrule ............................................ 13-19 vii Table of Contents (cont.) 13.9 Center Pin Position ............................................ 13-21 15.3 Shield Termination - Connector ...................... 15-15 13.10 Semirigid Coax .................................................. 13-22 15.3.1 Shrink and Crimp ........................................... 15-15 15.3.2 Shield Jumper Wire Attachment ..................... 15-19 13.10.1 13.10.2 13.10.3 13.10.4 13.10.5 Bending and Deformation .......................... Surface Condition ...................................... Dielectric Cutoff ......................................... Dielectric Cleanliness ................................. Solder ........................................................ 13-22 13-25 13-27 13-29 13-30 15.4 Shield Termination - Splicing ........................... 15-20 15.4.1 Solder ............................................................. 15-20 15.4.2 Tie/Tape On ................................................... 15-22 13.11 Swage-Type Connector ................................... 13-32 15.5 Tapes - Barrier and Conductive, Adhesive or Nonadhesive ................................. 15-23 13.12 Soldering and Stripping of Biaxial Wire ....... 13-33 15.6 Conduit (Shielding) ............................................. 15-24 13.12.1 13.12.2 Jacket and Tip Installation ......................... 13-33 Ring Installation ......................................... 13-35 15.7 Shrink Tubing - Conductive Lined .................. 15-25 14 Securing .................................................................... 14-1 16 Cable/Wire Harness Protective Coverings ......... 16-1 14.1 Tie Wrap/Lacing Application .............................. 14-2 14.1.1 14.1.2 14.1.3 Tightness ..................................................... 14-6 Damage ....................................................... 14-7 Spacing ....................................................... 14-8 16.1 Braid ........................................................................ 16-2 16.1.1 Direct Applied ................................................... 16-2 16.1.2 Prewoven ......................................................... 16-4 16.2 Sleeving/Shrink Tubing ....................................... 16-6 14.2 Breakouts ............................................................... 14-9 16.3 Spiral Plastic Wrap (Spiral Wrap Sleeving) ...... 16-7 14.2.1 14.2.2 Individual Wires ............................................ 14-9 Spacing ..................................................... 14-10 16.4 Conduit (Containment Loom) ............................. 16-8 14.3 Routing ................................................................. 14-13 16.5 Tapes, Adhesive and Nonadhesive ................... 16-9 14.3.1 14.3.2 14.3.3 14.3.4 14.3.5 Wire Crossover .......................................... Bend Radius .............................................. Coaxial Cable ............................................ Unused Wire Termination .......................... Ties over Splices and Ferrules ................... 14-13 14-14 14-15 14-16 14-17 15 Harness/Cable Electrical Shielding ...................... 15-1 15.1 Braided ................................................................... 15-2 15.1.1 15.1.2 Direct Applied .............................................. 15-3 Prewoven .................................................... 15-5 15.2 Shield Termination ............................................... 15-6 15.2.1 15.2.1.1 15.2.1.1.1 15.2.1.1.2 15.2.1.2 15.2.1.2.1 15.2.1.2.2 15.2.1.3 15.2.2 viii Shield Jumper Wire ..................................... 15-6 Attached Lead ............................................. 15-6 Solder/Heat Shrinkable Solder Device ......... 15-7 Crimp ........................................................ 15-11 Shield Braid ............................................... 15-11 Woven ....................................................... 15-11 Combed and Twisted ................................ 15-12 Daisy Chain ............................................... 15-12 No Shield Wire .......................................... 15-13 17 Finished Assembly Installation ............................. 17-1 17.1 General ................................................................... 17-2 17.2 Hardware Installation .......................................... 17-3 17.2.1 17.2.2 17.2.3 17.2.4 Threaded Fasteners ......................................... 17-3 Minimum Torque for Electrical Connections ..... 17-6 Wires ................................................................ 17-7 High Voltage Applications ............................... 17-10 17.3 Wire/Harness Installation ................................. 17-11 17.3.1 Stress Relief ................................................... 17-11 17.3.2 Wire Dress ...................................................... 17-12 17.3.3 Service Loops ................................................ 17-13 18 Solderless Wrap ....................................................... 18-1 18.1 Number of Turns ................................................... 18-2 18.2 Turn Spacing ......................................................... 18-3 18.3 End Tails, Insulation Wrap .................................. 18-4 July 2006 IPC/WHMA-A-620A Table of Contents (cont.) 18.4 Raised Turns Overlap .......................................... 18-6 19.6 Mechanical Tests ............................................... 19-10 19.6.1 Selection ....................................................... 19-10 18.5 Connection Position ............................................. 18-7 19.7 Mechanical Test Methods ................................ 19-11 18.6 Wire Dress ............................................................. 18-9 18.7 Wire Slack ............................................................ 18-10 18.8 Plating ................................................................... 18-11 18.9 Damage ................................................................ 18-12 18.9.1 Insulation ........................................................ 18-12 18.9.2 Wires and Terminals ....................................... 18-13 19.7.1 19.7.1.1 19.7.2 19.7.2.1 19.7.3 19.7.4 19.7.5 19.7.6 19.7.7 19.7.8 Crimp Height (Dimensional Analysis) ............. Terminal Positioning ...................................... Pull Force (Tensile) ........................................ Without Documented Process Control .......... Crimp Force Monitoring ................................ Crimp Tool Qualification ................................ Contact Retention Verification ....................... Coaxial Shield Pull Force (Tensile) ................. RF Connector Shield Ferrule Torsion ............ User Defined ................................................. 19-11 19-12 19-13 19-14 19-16 19-16 19-16 19-17 19-18 19-18 19 Testing ....................................................................... 19-1 Appendix A Terms and Definitions .............................. A-1 19.1 Nondestructive Tests ........................................... 19-2 Appendix B Metric Conversion Table .......................... B-1 19.2 Testing After Rework or Repair ......................... 19-2 Appendix C Reproducible Test Tables ....................... C-1 19.3 Intended Table Usage .......................................... 19-2 Standard Improvement Form 19.4 Electrical Test ....................................................... 19-3 19.4.1 Selection ......................................................... 19-3 19.5 Electrical Test Methods ...................................... 19-4 19.5.1 19.5.2 19.5.3 19.5.4 19.5.5 19.5.6 19.5.7 19.5.8 Continuity ......................................................... Shorts .............................................................. Dielectric Withstanding Voltage (DWV) ............. Insulation Resistance (IR) .................................. Voltage Standing Wave Ratio (VSWR) .............. Insertion Loss ................................................... Reflection Coefficient ........................................ User Defined .................................................... IPC/WHMA-A-620A 19-4 19-5 19-6 19-7 19-8 19-8 19-9 19-9 July 2006 ix 1 Requirements and Acceptance for Cable and Wire Harness Assemblies Foreword If a conflict occurs between the English and translated versions of this document, the English version will take precedence. This standard is a collection of visual, electrical and mechanical quality acceptability requirements for Cable, Wire and Harness Assemblies. It was prepared by the Industry Technical Guidelines Committee of the Wire Harness Manufacturers Association and the Product Assurance Committee of IPC - Association Connecting Electronic Industries. IPC/WHMA-A-620 can be used as a stand-alone document for purchasing products; however it does not specify frequency of in-process inspection or frequency of end product inspection. No limit is placed on the number of process indicators or the number of allowable repair/rework of defects. Such information should be developed with a statistical process control plan (see IPC-9191). 1.1 Scope This publication describes tests and acceptability criteria for producing crimped, mechanically secured, or soldered interconnections and the associated lacing/ restraining criteria associated with cable and harness assemblies. Any method that produces an assembly conforming to the acceptability requirements described in this standard may be used. 1.2 Purpose The illustrations in this document portray specific points noted in the title of each section. A brief description follows each illustration. The development committee recognizes that different parts of the industry have different definitions for some terms used herein. For the purposes of this document, the terms cable and wire harness are used interchangeably. 1.3 Approach to This Document Class 3 shall1 develop and implement a documented process control system. A documented process control system, if established, shall2 define process control and corrective action limits. This may or may not be a ‘‘statistical process control’’ system. The use of ‘‘statistical process control’’ (SPC) is optional and should be based on factors such as design stability, lot size, production quantities, and the needs of the company. 2 Process control methodologies shall be used in the planning, implementation and evaluation of the manufacturing processes used to produce cables and wire harness assemblies. The philosophy, implementation strategies, tools and techniques may be applied in differ- IPC/WHMA-A-620A (1) Class 1-Not Est Class 2-Not Est Class 3-Defect (2) Class 1-Not Est Class 2-Defect Class 3-Defect ent sequences depending on the specific company, operation, or variable under consideration to relate process control and capability to end product requirements. The word ‘‘shall’’ is used in the text of this document wherever a requirement is mandatory. 1.4 Shall or Should Where the word ‘‘shall’’ leads to a hardware defect for at least one class, the requirements for each class are annotated in text boxes located adjacent to that occurrence in the text. When this standard doesn’t provide acceptance criteria for a specific class, the text box will note ‘‘Not Est’’ for that class (see 1.5). The word ‘‘should’’ reflects recommendations and is used to reflect general industry practices and procedures for guidance only. IPC/WHMA-A620, as an industry consensus document, cannot address all of the possible product design combinations. However, the standard does provide criteria for commonly used technologies. Where uncommon or specialized technologies are used, it may be necessary to develop unique acceptance criteria. The development of unique criteria should include user involvement or consent and the criteria developed should include an agreed upon definition for acceptance of each characteristic. 1.5 Uncommon or Specialized Designs Whenever possible, new criteria or criteria on specialized products should be submitted, using the Standard Improvement Form included in this standard, to the IPC Technical Committee to be considered for inclusion in upcoming revisions of this standard. Terms are consistent with the definitions provided by IPC-T-50. For the understanding of this document, selected definitions pertaining specifically to cable and wire harness manufacturing are listed below and in Appendix A. 1.6 Terms and Definitions Manufacturer (Assembler) – The individual, organization, or company responsible for the assembly process and verification operations necessary to ensure full compliance of assemblies to this standard. Objective Evidence – Documentation in the form of hard copy, computer data, video, or other media. Process Control – A system or method to continually steer an operation in reducing variation in the processes or products to meet or exceed the goal in quality and performance. Supplier – The individual, organization or company which provides to the manufacturer (assembler) components (cables, July 2006 1-1
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