Requirements and Acceptance for Cable and Wire Harness Assemblies

Transcription

1 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 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 Tel Fax Wiring Harness Manufacturers Assoc Flying Cloud Drive, Suite 900 Eden Prairie, Minnesota Tel Fax

2 Table of Contents 1 Requirements and Acceptance for Cable and Wire Harness Assemblies Scope Purpose Approach to This Document Shall or Should Uncommon or Specialized Designs Terms and Definitions Classes of Products Document Hierarchy Tool and Equipment Control Observable Criteria Defects and Process Indicators Inspection Conditions Target Acceptable Process Indicator Defect Disposition Product Classification Implied Relationships Conditions Not Specified Electrical Clearance Measurement Units and Applications Verification of Dimensions Visual Inspection Lighting Magnification Aids and Lighting Electrostatic Discharge (ESD) Protection Contamination Materials and Processes Applicable Documents IPC Joint Industry Standards Society of Automotive Engineers (SAE) American National Standards Institute (ANSI) International Organization for Standardization (ISO) ESD Association (ESDA) Preparation Stripping Strand Damage and End Cuts Conductor Deformation/Birdcaging Twisting of Wires Wire Insulation Damage Soldered Terminations Material, Components and Equipment Materials Solder Flux Adhesives Solderability Tools and Equipment Gold Removal Cleanliness Presoldering Postsoldering Particulate Matter Flux Residue Cleanable Flux No-Clean Process Solder Connection General Requirements Soldering Anomalies Exposed Basis Metal Exposed Surface Finishes Partially Visible or Hidden Solder Connections IPC/WHMA-A-620A July 2006 v

3 4.4 Wire/Lead Preparation, Tinning Wire Insulation Clearance Postsolder Damage Insulation Sleeving Birdcaged Wire (Soldered) Connection Requirements 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 Solder Connection Turret Terminals Bifurcated Terminals Slotted Terminals Pierced/Perforated Terminals Hook Terminals Cup Terminals Crimp Terminations (Contacts and Lugs) Stamped and Formed - Open Barrel Insulation Support Crimp Insulation Inspection Window Conductor Crimp Crimp Bellmouth Conductor Brush Stamped and Formed Carrier Cutoff Tab Stamped and Formed - Closed Barrel Insulation Support Crimp Conductor Crimp and Bellmouth Machined Contacts Insulation Clearance Insulation Support Style Conductor Location Crimping CMA Buildup Termination Ferrule Crimp Insulation Displacement Connection (IDC) Mass Termination, Flat Cable End Cutting Notching Planar Ground Plane Removal Connector Position Connector Skew & Lateral Position Retention Discrete Wire Termination 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) 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 Ultrasonic Weld Splices Connectorization Hardware Mounting Jackpost - Height Jackscrews - Protrusion vi July 2006 IPC/WHMA-A-620A

4 9.2 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 Molding/Potting Molding Mold Fill - Initial Mold Fill - Final Mismatch Blow Through Terminal/Contact Position Fit Flashing Cracks, Flow Lines, Chill Marks (Knit Lines) or Weld Lines Color Wire Insulation, Jacket or Sleeving Damage Curing Rework Potting Filling Fit to Wire or Cable Curing Cable Assemblies and Wires Cable Measuring Reference Surfaces Straight/Axial Connectors Right-Angle Connectors Length Breakout Wire Measuring Electrical Terminal Reference Location Length Marking/Labeling Content Legibility Permanency Location and Orientation Functionality Marker Sleeve Wrap Around Tubular Flag Markers Adhesive Tie Wrap Coaxial and Twinaxial 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 IPC/WHMA-A-620A July 2006 vii

5 13.9 Center Pin Position Semirigid Coax Bending and Deformation Surface Condition Dielectric Cutoff Dielectric Cleanliness Solder Swage-Type Connector Soldering and Stripping of Biaxial 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 Ties over Splices and Ferrules Harness/Cable Electrical Shielding Braided Direct Applied Prewoven Shield Termination Shield Jumper Wire Attached Lead Solder/Heat Shrinkable Solder Device Crimp Shield Braid Woven Combed and Twisted Daisy Chain No Shield Wire Shield Termination - Connector Shrink and Crimp Shield Jumper Wire Attachment Shield Termination - Splicing Solder 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 Spiral Plastic Wrap (Spiral Wrap Sleeving) Conduit (Containment Loom) Tapes, Adhesive and Nonadhesive Finished Assembly Installation General Hardware Installation Threaded Fasteners Minimum Torque for Electrical Connections Wires High Voltage Applications Wire/Harness Installation Stress Relief Wire Dress Service Loops Solderless Wrap Number of Turns Turn Spacing End Tails, Insulation Wrap viii July 2006 IPC/WHMA-A-620A

6 18.4 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 Mechanical Tests Selection Mechanical Test Methods 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 Appendix A Terms and Definitions... A-1 Appendix B Metric Conversion Table... B-1 Appendix C Reproducible Test Tables... C-1 Standard Improvement Form 19.5 Electrical Test Methods Continuity Shorts Dielectric Withstanding Voltage (DWV) Insulation Resistance (IR) Voltage Standing Wave Ratio (VSWR) Insertion Loss Reflection Coefficient User Defined IPC/WHMA-A-620A July 2006 ix