IPC WHMA A 620A Table Of Contents

User Manual: 620A

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IPC/WHMA-A-620A

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)

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

Supersedes:

IPC/WHMA-A-620 -

January 2002

ASSOCIATION CONNECTING

ELECTRONICS INDUSTRIES

®

1 Requirements and Acceptance for Cable

and Wire Harness Assemblies ................................... 1-1

1.1 Scope ........................................................................ 1-1

1.2 Purpose .................................................................... 1-1

1.3 Approach to This Document ................................. 1-1

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

1.10 Observable Criteria ................................................ 1-3

1.11 Defects and Process Indicators .......................... 1-3

1.12 Inspection Conditions ............................................ 1-3

1.12.1 Target ................................................................. 1-3

1.12.2 Acceptable ......................................................... 1-3

1.12.3 Process Indicator ............................................... 1-3

1.12.4 Defect ................................................................. 1-3

1.12.5 Disposition .......................................................... 1-3

1.12.6 Product Classification Implied

Relationships ...................................................... 1-3

1.12.7 Conditions Not Specified .................................... 1-3

1.13 Electrical Clearance .............................................. 1-3

1.14 Measurement Units and Applications ................ 1-4

1.15 Verification of Dimensions ................................... 1-4

1.16 Visual Inspection .................................................... 1-4

1.16.1 Lighting .............................................................. 1-4

1.16.2 Magnification Aids and Lighting .......................... 1-4

1.17 Electrostatic Discharge (ESD) Protection .......... 1-5

1.18 Contamination ......................................................... 1-5

1.19 Materials and Processes ....................................... 1-5

2 Applicable Documents ................................................ 2-1

2.1 IPC ............................................................................... 2-1

2.2 Joint Industry Standards ......................................... 2-1

2.3 Society of Automotive Engineers (SAE) ................ 2-1

2.4 American National Standards Institute

(ANSI) ........................................................................... 2-2

2.5 International Organization for Standardization

(ISO) ............................................................................. 2-2

2.6 ESD Association (ESDA) .......................................... 2-2

3 Preparation .................................................................... 3-1

3.1 Stripping ..................................................................... 3-2

3.2 Strand Damage and End Cuts ................................ 3-2

3.3 Conductor Deformation/Birdcaging ...................... 3-5

3.4 Twisting of Wires ...................................................... 3-7

3.5 Wire Insulation Damage .......................................... 3-8

4 Soldered Terminations ................................................ 4-1

4.1 Material, Components and Equipment ................. 4-2

4.1.1 Materials ........................................................ 4-2

4.1.1.1 Solder ............................................................ 4-2

4.1.1.2 Flux ................................................................ 4-2

4.1.1.3 Adhesives ...................................................... 4-3

4.1.1.4 Solderability ................................................... 4-3

4.1.1.5 Tools and Equipment .................................... 4-3

4.1.2 Gold Removal ................................................ 4-3

4.2 Cleanliness ................................................................ 4-4

4.2.1 Presoldering .................................................. 4-4

4.2.2 Postsoldering ................................................. 4-4

4.2.2.1 Particulate Matter .......................................... 4-4

4.2.2.2 Flux Residue .................................................. 4-5

4.2.2.2.1 Cleanable Flux ............................................... 4-5

4.2.2.2.2 No-Clean Process ......................................... 4-5

4.3 Solder Connection .................................................... 4-6

4.3.1 General Requirements ................................... 4-7

4.3.2 Soldering Anomalies ...................................... 4-8

4.3.2.1 Exposed Basis Metal ..................................... 4-8

4.3.2.2 Exposed Surface Finishes ............................. 4-8

4.3.2.3 Partially Visible or Hidden

Solder Connections ....................................... 4-8

Table of Contents

vIPC/WHMA-A-620A July 2006

4.4 Wire/Lead Preparation, Tinning ............................. 4-9

4.5 Wire Insulation ........................................................ 4-11

4.5.1 Clearance ........................................................ 4-11

4.5.2 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 Turret Terminals .............................................. 4-19

4.8.2 Bifurcated Terminals ........................................ 4-21

4.8.2.1 Side Route Attachments ................................. 4-21

4.8.2.2 Bottom and Top Route Attachments .............. 4-23

4.8.2.3 Staked Wires ................................................... 4-24

4.8.3 Slotted Terminals ............................................ 4-25

4.8.4 Pierced/Perforated/Punched Terminals ........... 4-26

4.8.5 Hook Terminals ............................................... 4-27

4.8.6 Cup Terminals ................................................. 4-29

4.8.7 Series Connected Terminals ........................... 4-30

4.8.8 Lead/Wire Placement - AWG 30 and Smaller

Diameter Wires ................................................ 4-31

4.9 Solder Connection .................................................. 4-32

4.9.1 Turret Terminals .............................................. 4-34

4.9.2 Bifurcated Terminals ........................................ 4-35

4.9.3 Slotted Terminals ............................................ 4-37

4.9.4 Pierced/Perforated Terminals .......................... 4-38

4.9.5 Hook Terminals ............................................... 4-39

4.9.6 Cup Terminals ................................................. 4-40

5 Crimp Terminations (Contacts and Lugs) ................ 5-1

5.1 Stamped and Formed - Open Barrel ..................... 5-2

5.1.1 Insulation Support Crimp .................................. 5-3

5.1.2 Insulation Inspection Window ............................ 5-5

5.1.3 Conductor Crimp .............................................. 5-7

5.1.4 Crimp Bellmouth ............................................... 5-9

5.1.5 Conductor Brush ............................................. 5-11

5.1.6 Stamped and Formed Carrier Cutoff Tab ........ 5-13

5.2 Stamped and Formed - Closed Barrel ................ 5-14

5.2.1 Insulation Support Crimp ................................ 5-15

5.2.2 Conductor Crimp and Bellmouth .................... 5-17

5.3 Machined Contacts ................................................ 5-19

5.3.1 Insulation Clearance ........................................ 5-19

5.3.2 Insulation Support Style .................................. 5-22

5.3.3 Conductor Location ........................................ 5-23

5.3.4 Crimping ......................................................... 5-25

5.3.5 CMA Buildup ................................................... 5-27

5.4 Termination Ferrule Crimp ................................... 5-29

6 Insulation Displacement Connection (IDC) ............. 6-1

6.1 Mass Termination, Flat Cable ................................ 6-2

6.1.1 End Cutting ........................................................ 6-2

6.1.2 Notching ............................................................. 6-3

6.1.3 Planar Ground Plane Removal ........................... 6-4

6.1.4 Connector Position ............................................. 6-5

6.1.5 Connector Skew & Lateral Position .................... 6-8

6.1.6 Retention ............................................................ 6-9

6.2 Discrete Wire Termination .................................... 6-10

6.2.1 General ............................................................. 6-10

6.2.2 Position of Wire ................................................ 6-11

6.2.3 Overhang (Extension) ........................................ 6-12

6.2.4 Wire Holder ...................................................... 6-13

6.2.5 Damage in Connection Area ............................ 6-15

6.2.6 End Connectors ............................................... 6-16

6.2.7 Wiremount Connectors .................................... 6-18

6.2.8 Subminiature D-Connector (Series

Bus Connector) ................................................ 6-19

6.2.9 Modular Connectors (RJ Type) ......................... 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 Mesh .................................................................. 8-2

8.1.2 Wrap .................................................................. 8-4

8.1.3 Hook .................................................................. 8-5

8.1.4 Lap ..................................................................... 8-6

8.1.4.1 Two or More Conductors ................................... 8-7

8.1.4.2 Insulation Opening (Window) .............................. 8-9

8.1.5 Heat Shrinkable Solder Devices ....................... 8-11

8.2 Crimped Splices ...................................................... 8-13

8.2.1 Barrel ................................................................ 8-13

8.2.2 Double Sided ................................................... 8-16

8.3 Ultrasonic Weld Splices ........................................ 8-20

9 Connectorization .......................................................... 9-1

9.1 Hardware Mounting .................................................. 9-2

9.1.1 Jackpost - Height ............................................... 9-2

9.1.2 Jackscrews - Protrusion ..................................... 9-3

Table of Contents (cont.)

vi IPC/WHMA-A-620AJuly 2006

9.2 Strain Relief ............................................................... 9-4

9.2.1 Clamp Fit ......................................................... 9-4

9.2.2 Wire Dress ....................................................... 9-5

9.2.2.1 Straight Approach ............................................ 9-6

9.2.2.2 Side Approach ................................................. 9-7

9.3 Sleeving and Boots ................................................... 9-8

9.3.1 Position ............................................................ 9-8

9.3.2 Bonding ........................................................... 9-9

9.4 Connector Damage ................................................. 9-12

9.4.1 Criteria ........................................................... 9-12

9.4.2 Limits - Hard Face - Mating Surface .............. 9-13

9.4.3 Limits - Soft Face - Mating Surface

or Rear Seal Area .......................................... 9-14

9.4.4 Contacts ........................................................ 9-15

9.5 Installation of Contacts and Sealing Plugs

into Connectors ...................................................... 9-16

9.5.1 Installation of Contacts ................................... 9-16

9.5.2 Installation of Sealing Plugs ............................ 9-18

10 Molding/Potting ........................................................ 10-1

10.1 Molding ................................................................... 10-2

10.1.1 Mold Fill - Initial .............................................. 10-2

10.1.2 Mold Fill - Final ............................................... 10-4

10.1.3 Mismatch ....................................................... 10-8

10.1.4 Blow Through ................................................ 10-9

10.1.5 Terminal/Contact Position ............................ 10-10

10.1.6 Fit ................................................................. 10-12

10.1.7 Flashing ....................................................... 10-14

10.1.8 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 Filling ............................................................. 10-22

10.2.2 Fit to Wire or Cable ....................................... 10-23

10.2.3 Curing ........................................................... 10-24

11 Cable Assemblies and Wires ................................. 11-1

11.1 Cable Measuring ................................................... 11-2

11.1.1 Reference Surfaces ........................................ 11-2

11.1.1.1 Straight/Axial Connectors ............................... 11-2

11.1.1.2 Right-Angle Connectors ................................. 11-2

11.1.2 Length ........................................................... 11-3

11.1.3 Breakout ........................................................ 11-4

11.2 Wire Measuring ..................................................... 11-5

11.2.1 Electrical Terminal Reference Location ........... 11-5

11.2.2 Length ........................................................... 11-6

12 Marking/Labeling ..................................................... 12-1

12.1 Content ................................................................... 12-2

12.2 Legibility ................................................................. 12-2

12.3 Permanency ........................................................... 12-4

12.4 Location and Orientation .................................... 12-4

12.5 Functionality .......................................................... 12-6

12.6 Marker Sleeve ....................................................... 12-7

12.6.1 Wrap Around ................................................. 12-7

12.6.2 Tubular ........................................................... 12-9

12.7 Flag Markers ...................................................... 12-10

12.7.1 Adhesive ...................................................... 12-10

12.7.2 Tie Wrap ...................................................... 12-10

13 Coaxial and Twinaxial Cable Assemblies ............ 13-1

13.1 Stripping ................................................................. 13-2

13.2 Center Conductor Termination .......................... 13-4

13.2.1 Crimp .............................................................. 13-4

13.2.2 Solder ............................................................. 13-6

13.3 Solder Ferrule Pins .............................................. 13-8

13.3.1 General ........................................................... 13-8

13.3.2 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

13.7 Coaxial Connector - Terminal Cover .............. 13-16

13.7.1 Soldering ....................................................... 13-16

13.7.2 Press Fit ........................................................ 13-17

13.8 Shield Termination ............................................. 13-18

13.8.1 Clamped Ground Rings ................................ 13-18

13.8.2 Crimped Ferrule ............................................ 13-19

Table of Contents (cont.)

viiIPC/WHMA-A-620A July 2006

13.9 Center Pin Position ............................................ 13-21

13.10 Semirigid Coax .................................................. 13-22

13.10.1 Bending and Deformation .......................... 13-22

13.10.2 Surface Condition ...................................... 13-25

13.10.3 Dielectric Cutoff ......................................... 13-27

13.10.4 Dielectric Cleanliness ................................. 13-29

13.10.5 Solder ........................................................ 13-30

13.11 Swage-Type Connector ................................... 13-32

13.12 Soldering and Stripping of Biaxial Wire ....... 13-33

13.12.1 Jacket and Tip Installation ......................... 13-33

13.12.2 Ring Installation ......................................... 13-35

14 Securing .................................................................... 14-1

14.1 Tie Wrap/Lacing Application .............................. 14-2

14.1.1 Tightness ..................................................... 14-6

14.1.2 Damage ....................................................... 14-7

14.1.3 Spacing ....................................................... 14-8

14.2 Breakouts ............................................................... 14-9

14.2.1 Individual Wires ............................................ 14-9

14.2.2 Spacing ..................................................... 14-10

14.3 Routing ................................................................. 14-13

14.3.1 Wire Crossover .......................................... 14-13

14.3.2 Bend Radius .............................................. 14-14

14.3.3 Coaxial Cable ............................................ 14-15

14.3.4 Unused Wire Termination .......................... 14-16

14.3.5 Ties over Splices and Ferrules ................... 14-17

15 Harness/Cable Electrical Shielding ...................... 15-1

15.1 Braided ................................................................... 15-2

15.1.1 Direct Applied .............................................. 15-3

15.1.2 Prewoven .................................................... 15-5

15.2 Shield Termination ............................................... 15-6

15.2.1 Shield Jumper Wire ..................................... 15-6

15.2.1.1 Attached Lead ............................................. 15-6

15.2.1.1.1 Solder/Heat Shrinkable Solder Device ......... 15-7

15.2.1.1.2 Crimp ........................................................ 15-11

15.2.1.2 Shield Braid ............................................... 15-11

15.2.1.2.1 Woven ....................................................... 15-11

15.2.1.2.2 Combed and Twisted ................................ 15-12

15.2.1.3 Daisy Chain ............................................... 15-12

15.2.2 No Shield Wire .......................................... 15-13

15.3 Shield Termination - Connector ...................... 15-15

15.3.1 Shrink and Crimp ........................................... 15-15

15.3.2 Shield Jumper Wire Attachment ..................... 15-19

15.4 Shield Termination - Splicing ........................... 15-20

15.4.1 Solder ............................................................. 15-20

15.4.2 Tie/Tape On ................................................... 15-22

15.5 Tapes - Barrier and Conductive,

Adhesive or Nonadhesive ................................. 15-23

15.6 Conduit (Shielding) ............................................. 15-24

15.7 Shrink Tubing - Conductive Lined .................. 15-25

16 Cable/Wire Harness Protective Coverings ......... 16-1

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

16.3 Spiral Plastic Wrap (Spiral Wrap Sleeving) ...... 16-7

16.4 Conduit (Containment Loom) ............................. 16-8

16.5 Tapes, Adhesive and Nonadhesive ................... 16-9

17 Finished Assembly Installation ............................. 17-1

17.1 General ................................................................... 17-2

17.2 Hardware Installation .......................................... 17-3

17.2.1 Threaded Fasteners ......................................... 17-3

17.2.2 Minimum Torque for Electrical Connections ..... 17-6

17.2.3 Wires ................................................................ 17-7

17.2.4 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

Table of Contents (cont.)

viii IPC/WHMA-A-620AJuly 2006

18.4 Raised Turns Overlap .......................................... 18-6

18.5 Connection Position ............................................. 18-7

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 Testing ....................................................................... 19-1

19.1 Nondestructive Tests ........................................... 19-2

19.2 Testing After Rework or Repair ......................... 19-2

19.3 Intended Table Usage .......................................... 19-2

19.4 Electrical Test ....................................................... 19-3

19.4.1 Selection ......................................................... 19-3

19.5 Electrical Test Methods ...................................... 19-4

19.5.1 Continuity ......................................................... 19-4

19.5.2 Shorts .............................................................. 19-5

19.5.3 Dielectric Withstanding Voltage (DWV) ............. 19-6

19.5.4 Insulation Resistance (IR) .................................. 19-7

19.5.5 Voltage Standing Wave Ratio (VSWR) .............. 19-8

19.5.6 Insertion Loss ................................................... 19-8

19.5.7 Reflection Coefficient ........................................ 19-9

19.5.8 User Defined .................................................... 19-9

19.6 Mechanical Tests ............................................... 19-10

19.6.1 Selection ....................................................... 19-10

19.7 Mechanical Test Methods ................................ 19-11

19.7.1 Crimp Height (Dimensional Analysis) ............. 19-11

19.7.1.1 Terminal Positioning ...................................... 19-12

19.7.2 Pull Force (Tensile) ........................................ 19-13

19.7.2.1 Without Documented Process Control .......... 19-14

19.7.3 Crimp Force Monitoring ................................ 19-16

19.7.4 Crimp Tool Qualification ................................ 19-16

19.7.5 Contact Retention Verification ....................... 19-16

19.7.6 Coaxial Shield Pull Force (Tensile) ................. 19-17

19.7.7 RF Connector Shield Ferrule Torsion ............ 19-18

19.7.8 User Defined ................................................. 19-18

Appendix A Terms and Definitions .............................. A-1

Appendix B Metric Conversion Table .......................... B-1

Appendix C Reproducible Test Tables ....................... C-1

Standard Improvement Form

Table of Contents (cont.)

ixIPC/WHMA-A-620A July 2006

If a conflict occurs between the English

and translated versions of this document,

the English version will take precedence.

1.1 Scope This standard is a collection of visual, electrical

and mechanical quality acceptability requirements for Cable,

Wire and Harness Assemblies. It was prepared by the Indus-

try Technical Guidelines Committee of the Wire Harness

Manufacturers Association and the Product Assurance Com-

mittee 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 fre-

quency of in-process inspection or frequency of end product

inspection. No limit is placed on the number of process indi-

cators or the number of allowable repair/rework of defects.

Such information should be developed with a statistical pro-

cess control plan (see IPC-9191).

1.2 Purpose This publication describes tests and accept-

ability criteria for producing crimped, mechanically secured, or

soldered interconnections and the associated lacing/

restraining criteria associated with cable and harness assem-

blies. Any method that produces an assembly conforming to

the acceptability requirements described in this standard may

be used.

1.3 Approach to This Document The illustrations in this

document portray specific points noted in the title of each

section. A brief description follows each illustration. The devel-

opment 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.

Class 3 shall

1

develop and implement a documented process

control system. A documented process control system, if

established, shall

2

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.

Process control methodologies shall

2

be used in the planning, implementation

and evaluation of the manufacturing

processes used to produce cables and

wire harness assemblies. The philoso-

phy, implementation strategies, tools

and techniques may be applied in differ-

ent sequences depending on the specific company, opera-

tion, or variable under consideration to relate process control

and capability to end product requirements.

1.4 Shall or Should The word ‘‘shall’’ is used in the text

of this document wherever a requirement is mandatory.

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.

1.5 Uncommon or Specialized Designs IPC/WHMA-A-

620, as an industry consensus document, cannot address all

of the possible product design combinations. However, the

standard does provide criteria for commonly used technolo-

gies. 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.

Whenever possible, new criteria or criteria on specialized

products should be submitted, using the Standard Improve-

ment Form included in this standard, to the IPC Technical

Committee to be considered for inclusion in upcoming revi-

sions of this standard.

1.6 Terms and Definitions 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.

Manufacturer (Assembler) – The individual, organization, or

company responsible for the assembly process and verifica-

tion operations necessary to ensure full compliance of assem-

blies 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 pro-

vides to the manufacturer (assembler) components (cables,

(1) Class 1-Not Est

Class 2-Not Est

Class 3-Defect

(2) Class 1-Not Est

Class 2-Defect

Class 3-Defect

1 Requirements and Acceptance for Cable and Wire Harness Assemblies

Foreword

1-1IPC/WHMA-A-620A July 2006