Requirements and Acceptance for Cable and Wire Harness Assemblies

Transcription

1 IPC/WHMA-A-620C If a conflict occurs between the English and translated versions of this document, the English version will take precedence. 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-620B with Amendment 1 - August 2013 IPC/WHMA-A-620B - October 2012 IPC/WHMA-A-620A - July 2006 IPC/WHMA-A January 2002 Users of this publication are encouraged to participate in the development of future revisions. Contact: IPC Wiring Harness Manufacturers Assoc.

2 Table of Contents 1 General Scope Purpose Classification Measurement Units and Applications Verification of Dimensions Definition of Requirements Inspection Conditions Target Acceptable Defect Disposition Process Indicator Combined Contitions Conditions Not Specified Uncommon or Specialized Designs Material and Process Nonconformance Process Control Statistical Process Control Order of Precedence Clause References Appendices Terms and Definitions FOD (Foreign Object Debris) Inspection Manufacturer (Assembler) Objective Evidence Process Control Supplier User Wire Diameter (D) Requirements Flowdown Personnel Proficiency Acceptance Requirements Inspection Methodology Process Verification Inspection Visual Inspection Lighting Magnification Aids Sampling Facilities Field Assembly Operations Health and Safety Electrostatic Discharge (ESD) Protection Tools and Equipment Control Calibration Materials and Processes Electrical Clearance Contamination Rework/Repair Rework Repair Post Rework/Repair Cleaning Applicable Documents IPC Joint Industry Standards Society of Automotive Engineers (SAE) American National Standards Institute (ANSI) International Organization for Standardization (ISO) ESD Association (ESDA) United States Department of Defense (DoD) International Electrotechnical Commission (IEC) Aerospace Industries Association (AIA/NAS) Electronics Industries Alliance ASTM International Institute of Electrical and Electronics Engineers Preparation Stripping Strand Damage and End Cuts Conductor Deformation/Birdcaging IPC/WHMA-A-620C January 2017 vii

3 3.4 Twisting of Wires Insulation Damage Stripping Soldered Terminations Material, Components and Equipment Materials Solder Solder Purity Maintenance Flux Adhesives Solderability Tools and Equipment Gold Removal Cleanliness Presoldering Postsoldering Foreign Object Debris (FOD) Flux Residue Cleaning Required No-Clean Process Solder Connection General Requirements Soldering Anomalies Exposed Basis Metal Partially Visible or Hidden Solder Connections Wire/Lead Preparation, Tinning Wire Insulation Clearance Postsolder Damage Insulation Sleeving Birdcaged Wire (Soldered) Terminals Turrets and Straight Pins Lead/Wire Placement Solder Bifurcated Lead/Wire Placement Side Route Lead/Wire Placement Bottom and Top Route Lead/Wire Placement Staked/ Constrained Wires Solder Slotted 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 and Smaller Diameter Wires Crimp Terminations (Contacts and Lugs) Stamped and Formed Open Barrel Insulation Support Inspection Window Crimp Insulation Clearance if No Support Crimp Conductor Crimp Crimp Bellmouth Conductor Brush Carrier Cutoff Tab Individual Wire Seal Stamped and Formed Closed Barrel Insulation Clearance Insulation Support Crimp Conductor Crimp and Bellmouth Machined Contacts Insulation Clearance Insulation Support Style Conductor Crimping CMA Buildup Termination Ferrule Crimp Shrink Sleeving Wire Support Crimped Terminals Insulation Displacement Connection (IDC) Mass Termination, Flat Cable End Cutting Notching Planar Ground Plane Removal Connector Position Connector Skew & Lateral Position Retention viii January 2017 IPC/WHMA-A-620C

4 6.2 Discrete Wire Termination General Position of Wire Overhang (Extension) Insulation Crimp Damage in Connection Area End Connectors Pass Through Connectors Wiremount Connectors Subminiature D-Connector (Series Bus Connector) Modular Connectors (RJ Type) Ultrasonic Welding Insulation Clearance Weld Nugget Splices Soldered Splices Mesh Wrap Hook Lap Two or More Conductors Insulation Opening (Window) Heat Shrinkable Solder Devices Crimped Splices Barrel Double Sided Contact Wire In-Line Junction Devices (Jiffy Junctions) Ultrasonic Weld Splices Connectorization Hardware Mounting Jackpost Height Jackscrews Protrusion Retaining Clips Connector Alignment Strain Relief Clamp Fit Wire Dress Straight Approach Side Approach Sleeving and Boots Position Bonding Connector Damage Criteria Limits Hard Face Mating Surface Limits Soft Face Mating Surface or Rear Seal Area Contacts Installation of Contacts and Sealing Plugs into Connectors Installation of Contacts Installation of Sealing Plugs Over-Molding/Potting Over-Molding Mold Fill Inner Outer Mismatch Fit Cracks, Flow Lines, Chill Marks (Knit Lines) or Weld Lines Color Blow Through Position Flashing Wire Insulation, Jacket or Sleeving Damage Curing Potting (Thermoset Molding) Filling Fit to Wire or Cable Curing Measuring Cable Assemblies and Wires Measuring Cable and Wire Length Tolerance Measuring Cable Reference Surfaces Straight/Axial Connectors Reference Surfaces Right-Angle Connectors Length Breakout Breakout Measurement Points Breakout Length Measuring Wire Electrical Terminal Reference Location Length IPC/WHMA-A-620C January 2017 ix

5 12 Marking/Labeling Content Legibility Permanency Location and Orientation Functionality Marker Sleeve Wrap Around Tubular Flag Markers Adhesive Tie Wrap Markers Coaxial and Biaxial Cable Assemblies Stripping Center Conductor Termination Crimp Solder Solder Ferrule Pins General Insulation Coaxial Connector Printed Wire Board Mount Coaxial Connector Center Conductor Length Right Angle Connector Coaxial Connector Center Conductor Solder Coaxial Connector Terminal Cover Soldering Press Fit Shield Termination Clamped Ground Rings Crimped Ferrule Center Pin Position Damage Semirigid Coax Bending and Deformation Surface Condition Solid Conformable Cable Dielectric Cutoff Dielectric Cleanliness Center Conductor Pin Point Damage Solder Swage-Type Connector Soldering and Stripping of Biaxial/ Multi-Axial Shielded Wire Jacket and Tip Installation Ring Installation Securing Tie Wrap/Lacing Application Tightness Damage Spacing Breakouts Individual Wires Spacing Routing Wire Crossover Bend Radius Coaxial Cable Unused Wire Termination Shrink Sleeving Flexible Sleeving Ties over Splices and Ferrules Broom Stitching Harness/Cable Electrical Shielding Braided Direct Applied Prewoven Shield Termination Shield Jumper Wire Attached Lead Solder Crimp Shield Braid Woven Combed and Twisted Daisy Chain Common Ground Point x January 2017 IPC/WHMA-A-620C

6 No Shield Jumper Wire Shield Not Folded Back Shield Folded Back Shield Termination Connector Shrink Crimp Shield Jumper Wire Attachment Soldered Shield Termination Splicing Prewoven Soldered Tie/Tape On Tapes Barrier and Conductive, Adhesive or Nonadhesive Conduit (Shielding) Shrink Tubing Conductive Lined Cable/Wire Harness Protective Coverings Braid Direct Applied Prewoven Sleeving/Shrink Tubing Sealant Spiral Plastic Wrap (Spiral Wrap Sleeving) Wire Loom Tubing Split and Unsplit Tapes, Adhesive and Nonadhesive Finished Assembly Installation General Hardware Installation Threaded Fasteners Minimum Torque Wires Safety Wiring Safety Cable Wire/Harness Installation Stress Relief Wire Dress Service Loops Clamping Tie Wrap Lacing Raceways Grommets Wire/Cable Bundle Sealing Not Required Wire/Cable Sealing Required Solderless Wrap Number of Turns Turn Spacing End Tails, Insulation Wrap Raised Turns Overlap Connection Position Wire Dress Wire Slack Plating Damage Insulation Wires and Terminals Testing Nondestructive Tests Testing After Rework or Repair Intended Table Usage Electrical Test Selection Electrical Test Methods Continuity Shorts Dielectric Withstanding Voltage (DWV) Insulation Resistance (IR) Voltage Standing Wave Ratio (VSWR) Insertion Loss Reflection Coefficient User Defined Mechanical Test Selection Mechanical Test Methods Crimp Height (Dimensional Analysis) Terminal Positioning Pull Force (Tensile) Without Documented Process Control Crimp Force Monitoring Crimp Tool Qualification IPC/WHMA-A-620C January 2017 xi

7 Contact Retention Verification RF Connector Shield Pull Force (Tensile) RF Connector Shield Ferrule Torsion User Defined High Voltage Applications Appendix A Terms and Definitions... A-1 Appendix B Reproducible Test Tables... B-1 Appendix C Guidelines for Soldering Tools and Equipment... C-1 Table A-1 Electrical Clearance... A-5 Table 1-1 Magnification Aids Table 1-2 Magnification Aid Applications Other Table 3-1 Allowable Strand Damage Table 13-1 Coaxial and Biaxial Shield and Center Conductor Damage Table 13-2 Semirigid Coax Deformation Table 13-3 Dielectric Cutoff Table 14-1 Table 17-1 Minimum Bend Radius Requirements Minimum Swaged Ferrule Pull-Off Load Table 18-1 Minimum Turns of Bare Wire Table 19-1 Electrical Test Requirements Table 19-2 Table 19-3 Continuity Test Minimum Requirements Shorts Test (low voltage isolation) Minimum Requirements Table 4-1 Maximum Limits of Solder Bath Contaminant Table 19-4 Dielectric Withstanding Voltage Test (DWV) Minimum Requirements Table 4-2 Solder Connection Anomalies Table 4-3 Table 4-4 Turret and Straight Pin Terminal Lead/Wire Placement Bifurcated Terminal Lead/Wire Placement Side Route Table 19-5 Table 19-6 Insulation Resistance (IR) Test Minimum Requirements Voltage Standing Wave Ratio (VSWR) Test Parameters Table 19-7 Insertion Loss Test Parameters Table 4-5 Bifurcated Terminal Lead/Wire Placement Bottom Route Table 19-8 Reflection Coefficient Test Parameters Table 4-6 Staking Requirements of Side Route Straight Through Connections Bifurcated Terminals Table 19-9 Mechanical Test Requirements Table Crimp Height Testing Table 4-7 Pierced or Perforated Terminal Lead/Wire Placement Table Pull Force Testing Minimum Requirements Table 4-8 Hook Terminal Lead/Wire Placement Table Pull Test Force Values Table 4-9 AWG 30 and Smaller Wire Wrap Requirements Table Pull Test Force Values (Classes 1 & 2) For UL, SAE, GM and Volvo Table 10-1 Definitions of Molding/Potting Visual Anomalies Table Pull Test Force Values (Classes 1 & 2) For IEC Table 11-1 Cable/Wire Length Measurement Tolerance Table RF Connector Shield Pull Force Testing xii January 2017 IPC/WHMA-A-620C

8 1 Requirements and Acceptance for Cable and Wire Harness Assemblies General The following topics are addressed in this section: 1 General 1.1 Scope 1.2 Purpose 1.3 Classification 1.4 Measurement Units and Applications Verification of Dimensions 1.5 Definition of Requirements Inspection Conditions Target Acceptable Defect Disposition Process Indicator Combined Condition Conditions Not Specified Uncommon or Specialized Designs Material and Process Nonconformance 1.6 Process Control Statistical Process Control 1.7 Order of Precedence Clause References Appendices 1.8 Terms and Definitions FOD (Foreign Object Debris) Inspection Manufacturer (Assembler) Objective Evidence Process Control Supplier User Wire Diameter (D) 1.9 Requirements Flowdown 1.10 Personnel Proficiency 1.11 Acceptance Requirements 1.12 Inspection Methodology Process Verification Inspection Visual Inspection Lighting Magnification Aids Sampling 1.13 Facilities Field Assembly Operations Health and Safety 1.14 Electrostatic Discharge (ESD) Protection 1.15 Tools and Equipment Control Calibration 1.16 Materials and Processes 1.17 Electrical Clearance 1.18 Contamination 1.19 Rework/Repair Rework Repair Post Rework/Repair Cleaning IPC/WHMA-A-620C January

9 1 Requirements and Acceptance for Cable and Wire Harness Assemblies General (cont.) 1.1 Scope This standard prescribes practices and requirements for the manufacture of cable, wire and harness assemblies. This standard does not provide criteria for cross-section or X-ray evaluation. If a conflict occurs between the English and translated versions of this document, the English version will take precedence. 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). 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. 1.2 Purpose This standard describes materials, methods, tests and acceptability criteria for producing crimped, mechanically secured, or soldered interconnections and the related assembly activities associated with cable and harness assemblies. The intent of this document is to rely on process control methodology to ensure consistent quality levels during the manufacture of products. Any method that produces an assembly conforming to the acceptability requirements described in this standard may be used. Standards may be updated at any time, including with the use of amendments. The use of an amendment or newer revision is not automatically required. The revision in effect shall [D1D2D3] be as specified by the User. 1.3 Classification Use of this standard requires agreement on the Class to which the product belongs. The User has the ultimate responsibility for identifying the Class to which the assembly is evaluated. If the User does not establish and document the acceptance Class, the Manufacturer may do so. Accept and/or reject decisions shall [D1D2D3] be based on applicable documentation such as contracts, drawings, specifications, standards and reference documents. Criteria defined in this standard reflect three Product Classes, which are as follows: Class 1 General Electronic Products Includes products suitable for applications where the major requirement is the function of the completed assembly. Class 2 Dedicated Service Electronic Products Includes products where continued performance and extended life is required, and for which uninterrupted service is desired but not critical. Typically, the end-use environment would not cause failures. Class 3 High Performance/Harsh Environment Electronic Products Includes products where continued performance or performance-on-demand is critical, equipment downtime cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must function when required, such as life support systems and other critical systems. 1.4 Measurement Units and Applications This document uses the International System of Units (SI) in accordance with ASTM SI10-10, IEEE/ASTM SI 10, American National Standard for Metric Practice (Section 3). Imperial English equivalent units follow in brackets. The derived SI units used in this document are millimeters (mm) [in] for dimensions and dimensional tolerances, Celsius ( C) [ F] for temperature and temperature tolerances, grams (g) [oz] for weight, and lux (lx) [footcandles] for illuminance Verification of Dimensions Where not specifically invoked by this standard, actual measurements (e.g. of specific solder fillet dimensions, determination of damage and wrap percentages) are not required except for referee purposes. 1.5 Definition of Requirements The word shall is used in the text of this document wherever there is a requirement for materials, process or acceptance of cable, wire and harness assemblies. 1-2 January 2017 IPC/WHMA-A-620C