IPC/WHMA-A-620E

2022–October

Requirements and
Acceptance for Cable and
Wire Harness Assemblies
Supersedes IPC/WHMA-A-620D
January 2020
An international standard developed by IPC

23
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 Association Connecting Electronics Industries

IPC/WHMA-A-620E
®

Requirements and
Acceptance for Cable
and Wire Harness
If a conflict occurs
between the English Assemblies
language and translated
versions of this document,
the English version will
take precedence.

Developed by the IPC Task Group (7-31f) of the Product Assurance

Subcommittee (7-30) and WHMA

Supersedes: Users of this publication are encouraged to participate in the development

IPC/WHMA-A-620D – January 2020 of future revisions.
IPC/WHMA-A-620C – January 2017
IPC/WHMA-A-620B with
Contact:
Amendment 1 – August 2013
IPC/WHMA-A-620B – October 2012 IPC Wiring Harness Manufacturers
IPC/WHMA-A-620A – July 2006 3000 Lakeside Drive, Suite 105 N Assoc.
IPC/WHMA-A-620 – January 2002 Bannockburn, Illinois (An affiliate of IPC)
60015-1219 3000 Lakeside Drive, Suite 105 N
Tel 847 615.7100 Bannockburn, Illinois
Fax 847 615.7105 60015-1219
Tel 847 615.7100
email: contact.us@whma.org
This Page Intentionally Left Blank
 Acknowledgment
Any document involving a complex technology draws material from a vast number of sources across many continents. While the
principal members of the IPC/WHMA-A-620 joint working group comprised of IPC Task Group (7-31f) of the Product Assurance
Subcommittee (7-30) and WHMA are shown below, it is not possible to include all of those who assisted in the evolution of this
standard. To each of them, the members of the IPC and WHMA extend their gratitude.

Product Assurance Committee IPC/WHMA-A-620 Joint Working Group

Chair Co-Chairs Vice Chairs
Robert Cooke Catherine Hanlin Bud Bowen
NASA Johnson Space Center Precision Manufacturing Tyler Siebert
Vice Chair Company, Inc. Lockheed Martin Missiles &
Debbie Wade George Millman Fire Control
Advanced Rework Technology Raytheon Missile Systems
Technical Liaisons of the Richard Rumas
IPC Board of Directors
Honeywell Canada
Bob Neves
Microtek (Changzhou) Laboratories

IPC recognizes this A-Team for their exceptional leadership and effort in the development of this standard. IPC A-Teams
are dedicated groups of volunteers who undertake a significant amount of work in standards development on behalf of
their group.
A special thank you to 7-31F-AT Wire Nutz for their dedication and commitment to this effort. Their support and time
during the development of this document is greatly appreciated.
Bud Bowen Garry McGuire Tyler Siebert
Thomas Carle NASA Marshall Space Flight Center Lockheed Martin Missiles
Ball Aerospace & Technologies Corp. Scott Meyer & Fire Control

Robert Cooke Collins Aerospace Christina Trussell

NASA Johnson Space Center George Millman Blue Origin, LLC

Symon Franklin Raytheon Missile Systems Debbie Wade

Custom Interconnect Ltd Richard Rumas Advanced Rework Technology

Catherine Hanlin* Honeywell Canada Lucas Walsh Cochran

Precision Manufacturing Company, Christina Rutherford Lockheed Martin Missiles
Inc. Honeywell Aerospace & Fire Control

Thank you to 7-31F-TEAMBONES for their dedication in working the x-ray criteria for this document.
Robert Bowden John Mastorides Timothy Pearson
Impact Centre for Training & Staffing Honeywell Aerospace Collins Aerospace
Milea Kammer Garry McGuire Christina Rutherford*
Honeywell International NASA Marshall Space Flight Center Honeywell Aerospace
Joseph Kane Scott Meyer George Tristan
BAE Systems Collins Aerospace Ball Aerospace & Technologies Corp.
Rebekah Kovarik George Millman
Lockheed Martin Raytheon Missile Systems

Thank you to 7-31F-SUGARKANE for their dedication in working the terms and definitions in Appendix A of this
document.
Catherine Hanlin Scott Meyer Christina Rutherford
Precision Manufacturing Company, Collins Aerospace Honeywell Aerospace
Inc.
Joseph Kane*
BAE Systems

IPC/WHMA-A-620E October 2022 iii

&*+
 Acknowledgment (cont.)

Members of 7-31F IPC/WHMA-A-620 Task Group

Bud Bowen Benoit Dagenais Adam Gowan

Mary Muller Innovative Vehicle Institute NASA Marshall Space Flight Center
Jan Saris Jose Delgado Stephen Graham
Jet Propulsion Laboratory Parsons – Missile Defense & C5ISR
Jonathan ALBRIEUX
IFTEC Ross Dillman William Graver
ACI Technologies, Inc. NTS - Baltimore
Tiberiu Baranyi
Flextronics Romania SRL Francesco Di Maio Andreas Gregor
GESTLABS S.r.l. Consultronica, S.L.
Robert Barnes
Northrop Grumman North Dakota Steven Dirkes-Gomez Ben Gumpert
U.S. Army Sustainment Command Lockheed Martin-Missiles & Fire
Geza Batiz
Toro Co. Rodney Doss Control
Samtec, Inc. Stefan Hanigk
Erik Bjerke
BAE Systems Ramon Essers Ariane Group GmbH
ETECH Training Catherine Hanlin
Kevin Boblits
K&M Manufacturing Solutions, LLC Dan Ezenekwe Precision Manufacturing Company,
Collins Aerospace Inc.
Wim Bodelier
PIEK International Education Centre Kathleen Fain Eric Harenburg
(I.E.C.) BV ESAM, Inc. Boeing Company
Gerald Bogert Tony Feldmeier Shelley Holt
Bechtel Plant Machinery, Inc. Honeywell Aerospace Minneapolis L3 Harris Technologies
Adam Fidura Communication Systems – West
Robert Bowden
Impact Centre for Training & Staffing Dyson Technology Limited Mark Hood
Dominic Field EEI Manufacturing Services
Randy Bremner
Northrop Grumman Moog Inc. Ife Hsu
Chris Fitzgerald Intel Corporation
Wendell Brockman
Collins Aerospace NASA Goddard Space Flight Center Frank Huijsmans
Ron Folkeringa PIEK International Education Centre
Lin Cao
Nortech Systems Inc. (I.E.C.) BV
Shenyang
Railway Signal Co., Ltd. Robert Fornefeld Henrik Jensen
STI Electronics, Inc. Gaasdal Bygningsindustri A/S
William Cardinal
Collins Aerospace Mathew Fortin Jodi Johnson
Belcan Engineering BEST Inc.
Thomas Carle
Ball Aerospace & Technologies Corp. Daniel Foster Kyle Johnson
Zhiman Chen Missile Defense Agency (MDA) Lockheed Martin Missiles & Fire
ZhuZhou CRRC Times Electric Co., Symon Franklin Control
Ltd. Custom Interconnect Ltd Richard Josselyn
Lucas Walsh Cochran Tim Gallagher Impact Centre for Training & Staffing
Lockheed Martin Missiles & Fire BAE Systems Milea Kammer
Control Mahendra Gandhi Honeywell International
Michael Cochran Northrop Grumman Space Systems Joseph Kane
Moog Inc. Mirko Giannecchini BAE Systems
Richard Cochrane Istituto Italiano della Saldatura - Sean Keating
MBDA UK Ltd. Legnano Amphenol Limited (UK)
Robert Cooke Stephen Golemme Russell Kido
NASA Johnson Space Center JITX Inc. Practical Components Inc.
Chengyan Cui Constantino Gonzalez Ramon Koch
Shenyang Railway Signal Co., Ltd. ACME Training & Consulting ETECH Training
iv October 2022 IPC/WHMA-A-620E
&*+
 Acknowledgment (cont.)
Maan Kokash Steven Neff Jose Servin Olivares
BAE Systems Textron Systems Vitesco Technologies
Rebekah Kovarik Torgrim Nordhus Tyler Siebert
Lockheed Martin Norautron AS Lockheed Martin Missiles & Fire
Sharath Kumar U Harald Olsen Control
Kaynes Technology India Pvt. Ltd FMC Technologies AS Thomas Silvers
Rick Hawthorne John O’Neill Lockheed Martin Missiles & Fire
Technical Training Center ETECH Training Control
Gaston Hidalgo Agnieszka Ozarowski Richard Smith
Toyota Motor North America BAE Systems Cobham Mission Equipment
Frank Honyotski Marie Parliman Samuel Sorto
STI Electronics, Inc. BAE Systems Blue Origin, LLC
Jeremy Lakoskey Gianluca Parodi Kim Souva
Sierra Space Cistelaier SpA Kearfott Corporation
Leo Lambert Helena Pasquito Jared Spencer
EPTAC Corporation EPTAC Corporation L3 Harris Technologies
Communication Systems – West
Gary Latta Antonio Perna
SAIC Leonardo Augustin Stan
L&G Advice Serv SRL
Marilyn Lawrence William Pfingston
Conformance Technologies, Inc. Miraco, Inc. Joseph Stanley
Amazon Project Kuiper
Andrew Leslie Sue Powers-Hartman
BAE Systems Killdeer Mountain Manufacturing, Ekaterina Stees
Inc. Lockheed Martin-Missiles & Fire
Lisa Maciolek
Control
Raytheon Company Jim Pryde
Ametek Aerospace Ltd Lorna Stoddart
John Mastorides
WL Gore & Associates (UK) Ltd
Honeywell Aerospace Owen Reid
Lockheed Martin Missiles & Fire Stephanie Stork
Garry McGuire
Control Northrop Grumman
NASA Marshall Space Flight Center
Edward Rios Toshiyasu Takei
Marcia McLaughlin
Motorola Solutions Japan Unix Co., Ltd.
EPTAC Corporation
Kris Roberson Nichole C. Thilges
Iain McMillan
BEST Inc. Raytheon Missile Systems
Exmel Solutions Ltd
Irene Romero Michael Timney
Scott Meyer
Delta Group Electronics Inc. Daniels Manufacturing Corporation
Collins Aerospace
Joel Rozga Ethan Tittle
Christopher Meyers
MJM Industries Inc East West Manufacturing : East West
Tobyhanna Army Depot
Raleigh
George Millman Richard Rumas
Honeywell Canada George Tristan
Raytheon Missile Systems
Ball Aerospace & Technologies Corp.
David Mitchell Christina Rutherford
Honeywell Aerospace Christina Trussell
Lockheed Martin Rotary & Mission
Blue Origin, LLC
Systems Paul Sargent
BAE Systems Monica Tucker
Claus Molgaard
Dynetics, Inc.
GN Hearing A/S Patricia Scott
STI Electronics, Inc. Ann Marie Tully
Rob Mullane
Lockheed Martin Missiles & Fire
Atek Training Services Ltd. Jonathan Senning
Control
Johnson Muriel Kongsberg Defense & Aerospace AS
Pietro Vergine
BTE Training & Electronics PLT Darrell Sensing
Advanced Rework Technology
BAE Systems

IPC/WHMA-A-620E October 2022 v

&*+
 Acknowledgment (cont.)

Jonathon Vermillion Mathew Williams Style Yuan

Ball Aerospace & Technologies Corp. Axis Electronics Ltd. Winchester Interconnect (Suzhou)
John Vickers Schuyler Williams Co., LTD
Advanced Rework Technology Lockheed Martin Missiles & Fire Ping Zhao
Debie Vorwald Control Shaanxi Fenghuo Electronics Co.,Ltd
Collins Aerospace Nicholas Wilson Jamie Zhou
Debbie Wade Northrop Grumman Corporation LCFC (HeFei) Electronics
Advanced Rework Technology Neil Wolford Technology Co., Ltd.
Rob Walls AbelConn, LLC Jack Zhu
PIEK International Education Centre Jie Yuan Veoneer China Co., Ltd
(I.E.C.) BV Shanghai Quickturn Electronics Co., Yaakov Zissman
Jarrod Webb Ltd. Elta Systems Ltd.
Lockheed Martin Missiles & Fire
Control

REGIONAL GROUPS

Members of 7-31F-EU IPC/WHMA-A-620 Task Group - Europe

Jonathan ALBRIEUX Henrik Jensen Gianluca Parodi
IFTEC Gaasdal Bygningsindustri A/S Cistelaier SpA
Piotr Armata Miloslav Kolcaba Antonio Perna
Murata Power Solutions Continental Teves Czech Republic, Leonardo
Tiberiu Baranyi** s.r.o. Jim Pryde
Flextronics Romania SRL Iain McMillan Ametek Aerospace Ltd
Alex Christensen Exmel Solutions Ltd Augustin Stan
HYTEK Claus Molgaard L&G Advice Serv SRL
Francesco Di Maio GN Hearing A/S John Vickers
GESTLABS S.r.l. Rob Mullane Advanced Rework Technology
Symon Franklin Atek Training Services Ltd. Pietro Vergine
Custom Interconnect Ltd Torgrim Nordhus Advanced Rework Technology
Mirko Giannecchini Norautron AS Debbie Wade**
Istituto Italiano della Saldatura - Harald Olsen Advanced Rework Technology
Legnano FMC Technologies AS Rob Walls
Andreas Gregor John O’Neill PIEK International Education Centre
Consultronica, S.L. ETECH Training (I.E.C.) BV
Stefan Hanigk
Ariane Group GmbH

7-31FCN: Acceptability of Electronic Wire Harnesses and Cables - China

Shang Lu Luke Chen Peter Chiang
Jing Bai Xiamen Macro-s Industrial Co., Ltd. MSI Computer (Shenzhen) Co., Ltd.
CRRC Datong CO., LTD. Yung Jui (Antoine) Chen Chengyan Cui***
Lin Cao Everbiz Industrial Co., Ltd. Shenyang Railway Signal Co., Ltd.
Shenyang Railway Signal Co., Ltd. Zhiman Chen** Junliang Dai
Tao Cao ZhuZhou CRRC Times Electric Co., ZhuZhou CRRC Times Electric Co.,
Changhong Machinery Factory Ltd. Ltd.
Leheng Chen Jie Chen Chengdu
CRRC Tangshan Co., LTD. Yaguang Electronics Co., Ltd.

vi October 2022 IPC/WHMA-A-620E

&*+
 Acknowledgment (cont.)

Wen Danqing Ting Li Style Yuan

CSIC Xi’an Dong Yi Science ZhuZhou CRRC Times Electric Co., Winchester Interconnect (Suzhou)
Technology & Industry Group Co., Ltd. Co., LTD
Ltd Lixiang Lin Jie Yuan Shanghai
Wei Deng BizLink Holding Inc., Xiang Yao Quickturn Electronics Co.,Ltd.
ZhuZhou CRRC Times Electric Co., Electronics (Shenzhen) Co., Ltd. Jianying Zeng
Ltd. Guangxiang Lu Jin Hong Electronic Co., Ltd
Chrise Ding Continental Holding China Zirui Zhang
AVIC Aeronautical Radio Electronics Dan Meng SAIC Motor
Research Institute CRCC YongJi Electric Co., Ltd. Yangchun Zhang
Feng Gao Yaoru Ren Dongguan Shin Tech Limited
ZhuZhou CRRC Times Electric Co., Shengyi Electronics Co. Ltd. Freeman Zhao
Ltd.
Wenyu Su AIWAYS Automobile Co., Ltd
Bin Huang CRRC Tangshan Co., LTD. Jacky Zhao
ZhuZhou CRRC Times Electric Co.,
Yongkun Sui Autoliv Shanghai
Ltd.
Changchun Railway Vehicles Co., Kangkang Zhang
Kun Jiang LTD Huaqin Technology Co., Ltd.
Hunan Zhongxian Harness Co., Ltd.
Min Tang Meichang Zhang
Ren Kang** Jabil Circuit (Shanghai) Ltd. CASC Beijing Institute of Space
AVIC Computing Technique
HaiJian Wang Mechanics and Electricity (BISME)
Research Institute
The Fifth Research Institute of MII Haifeng Zheng
Kiet Le
Tianxiang Wang Shenyang Railway Signal Co., Ltd.
Spitfire Controls (Vietnam) Co., Ltd.
Askey Technology (Jiangsu) Co. Ltd. Shuli Zheng
Daisy Li
Longhui Wei CRCC YongJi Electric Co., Ltd.
Federal-Mogul China
ZhuZhou CRRC Times Electric Co., Zhiyi Zhong
Fengshou Li Ltd. ZhuZhou CRRC Times Electric Co.,
CRRC Zhuzhou Institute Co. Ltd
Zhangyun Wu Ltd.
Iris Li Shenzhen Longsys Electronics Co., Fuliang Zhou
Fluke Networks Ltd. Dong Guan Mao Jia Plastic
Xin Lian Rich WuDongguan Electronics Co., Ltd.
CRCC YongJi Electric Co., Ltd. Molex Interconnect Co., Ltd. Jack Zhu
Jia Liang Yinhe Xiao Veoneer China Co., Ltd
AVIC TaiYuan Aero-Instruments Co., ZhuZhou CRRC Times Electric Co., Wenhui Zhu
Ltd. Ltd. JinHong Electronic Co., Ltd.
Jotty Liu Colin Xu***
Harting (Zhuhai) Sales LTD TT electronic integrated
Shaoqing Liu manufacturing services (Suzhou)
Amphenol (Changzhou) Electronics Limited
Co., Ltd.

* Leader of the A-Team at the time this document was published.

** Cochair of the regional group at the time this document was published.
*** Vice Chair of the regional group at the time this document was published.

IPC/WHMA-A-620E October 2022 vii

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 This Page Intentionally Left Blank

viii October 2022 IPC/WHMA-A-620E

 Table of Contents

1.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.13 Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.13.1 Field Assembly Operations . . . . . . . . . . . . . . 1-6

1.13.2 Health and Safety . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.14 Electrostatic Discharge (ESD) Protection . . . . . 1-6
1.3 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.15 Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 Measurement Units and Applications . . . . . . . . 1-1
1.15.1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.1 Verification of Dimensions . . . . . . . . . . . . . . 1-1
1.15.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 Definition of Requirements . . . . . . . . . . . . . . . . . 1-1
1.16 Materials and Processes . . . . . . . . . . . . . . . . . . . 1-7
1.5.1 Inspection Conditions . . . . . . . . . . . . . . . . . . . 1-2
1.5.1.1 Acceptable . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.17 Electrical Clearance . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.5.1.2 Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.18 Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.5.1.2.1 Disposition . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.19 Rework/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5.1.3 Process Indicator . . . . . . . . . . . . . . . . . . . . . . 1-2 1.19.1 Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5.1.4 Conditions Not Specified . . . . . . . . . . . . . . . . 1-2 1.19.2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5.1.5 Uncommon or Specialized Designs . . . . . . . . 1-2 1.19.3 Post Rework/Repair Cleaning . . . . . . . . . . . . 1-8
1.5.2 Material and Process Nonconformance . . . . . 1-3
2.0 Applicable Documents . . . . . . . . . . . . . . . . . . . . . 2-1
1.6 Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.1 IPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.6.1 Statistical Process Control . . . . . . . . . . . . . . . 1-3
2.2 Joint Industry Standards . . . . . . . . . . . . . . . . . . . 2-1
1.7 Order of Precedence . . . . . . . . . . . . . . . . . . . . . . 1-3
2.3 Society of Automotive Engineers (SAE) . . . . . . . 2-1
1.7.1 Clause References . . . . . . . . . . . . . . . . . . . . . 1-4
1.7.2 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.4 American National Standards Institute
(ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1.8 Terms and Definitions . . . . . . . . . . . . . . . . . . . . . 1-4
2.5 International Organization for Standardization
1.8.1 FOD (Foreign Object Debris) . . . . . . . . . . . . . 1-4 (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
1.8.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.6 ESD Association (ESDA) . . . . . . . . . . . . . . . . . . . 2-2
1.8.3 Manufacturer (Assembler) . . . . . . . . . . . . . . . 1-4
2.7 United States Department of Defense (DoD) . . . 2-2
1.8.4 Objective Evidence . . . . . . . . . . . . . . . . . . . . . 1-4
1.8.5 Process Control . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.8 International Electrotechnical Commission
(IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
1.8.6 Supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8.7 User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.9 Aerospace Industries Association (AIA/NAS) . . 2-2

1.8.8 Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.10 Electronics Industries Alliance . . . . . . . . . . . . . . 2-2

1.8.8.1 Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.11 ASTM International . . . . . . . . . . . . . . . . . . . . . . . 2-2
1.8.8.2 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2.12 Institute of Electrical and Electronics
1.8.8.3 Strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Engineers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
1.8.9 Engineering Documentation . . . . . . . . . . . . . . 1-4 3.0 Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.9 Requirements Flowdown . . . . . . . . . . . . . . . . . . . 1-4
3.1 Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.10 Personnel Proficiency . . . . . . . . . . . . . . . . . . . . . 1-5 3.2 Strand Damage and End Cuts . . . . . . . . . . . . . . . . 3-1
1.11 Acceptance Requirements . . . . . . . . . . . . . . . . . 1-5 3.3 Conductor Deformation/Birdcaging . . . . . . . . . . . 3-4
1.12 Inspection Methodology . . . . . . . . . . . . . . . . . . . 1-5 3.4 Twisting of Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
1.12.1 Process Verification Inspection . . . . . . . . . . . 1-5 3.5 Insulation Damage – Stripping . . . . . . . . . . . . . . 3-7
1.12.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 1-5
4.0 Soldered Terminations . . . . . . . . . . . . . . . . . . . . 4-1
1.12.2.1 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
4.1 Materials and Components . . . . . . . . . . . . . . . . . 4-1
1.12.2.2 Magnification Aids . . . . . . . . . . . . . . . . . . . . . 1-5

IPC/WHMA-A-620E October 2022 ix

 Table of Contents (cont.)

4.1.1 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.8.5 Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

4.1.1.1 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.8.5.1 Lead/Wire Placement . . . . . . . . . . . . . . . . . . 4-37
4.1.1.1.1 Solder Purity Maintenance . . . . . . . . . . . . . . . 4-2 4.8.5.2 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.1.1.2 Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.8.6 Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.1.1.3 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.8.6.1 Lead/Wire Placement . . . . . . . . . . . . . . . . . . 4-40
4.1.1.4 Solderability . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.8.6.2 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.1.2 Gold Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.8.7 Series Connected . . . . . . . . . . . . . . . . . . . . . 4-43
4.2 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.8.8 Connection Requirements –
Lead/Wire Placement –
4.2.1 Presoldering . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
AWG 30 and Smaller Diameter Wires . . . . . 4-44
4.2.2 Postsoldering . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5.0 Crimp Terminations (Contacts and Lugs) . . . . . 5-1
4.2.2.1 Foreign Object Debris (FOD) . . . . . . . . . . . . . 4-5
4.2.2.2 Flux Residue . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 5.1 Stamped and Formed – Open Barrel . . . . . . . . . 5-3

4.2.2.2.1 Cleaning Required . . . . . . . . . . . . . . . . . . . . . 4-6 5.1.1 Insulation Support . . . . . . . . . . . . . . . . . . . . . 5-4

4.2.2.2.2 No-Clean Process . . . . . . . . . . . . . . . . . . . . . . 4-6 5.1.1.1 Inspection Window . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.1.2 Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
4.3 Solder Connection . . . . . . . . . . . . . . . . . . . . . . . . 4-7
5.1.2 Insulation Clearance if No Support Crimp . . . 5-8
4.3.1 General Requirements . . . . . . . . . . . . . . . . . . 4-9
5.1.3 Conductor Crimp . . . . . . . . . . . . . . . . . . . . . . 5-9
4.3.2 Soldering Anomalies . . . . . . . . . . . . . . . . . . 4-10
5.1.4 Crimp Bellmouth . . . . . . . . . . . . . . . . . . . . . 5-11
4.3.2.1 Exposed Basis Metal . . . . . . . . . . . . . . . . . . 4-10
5.1.5 Conductor Brush . . . . . . . . . . . . . . . . . . . . . . 5-13
4.3.2.2 Partially Visible or Hidden Solder
Connections . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.1.6 Carrier Cutoff Tab . . . . . . . . . . . . . . . . . . . . 5-15
5.1.7 Individual Wire Seal . . . . . . . . . . . . . . . . . . . 5-16
4.4 Wire/Lead Preparation, Tinning . . . . . . . . . . . . 4-11
5.2 Stamped and Formed – Closed Barrel . . . . . . . 5-18
4.5 Wire Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
5.2.1 Insulation Clearance . . . . . . . . . . . . . . . . . . . 5-19
4.5.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
5.2.2 Insulation Support Crimp . . . . . . . . . . . . . . . 5-20
4.5.2 Postsolder Damage . . . . . . . . . . . . . . . . . . . . 4-15
5.2.3 Conductor Crimp and Bellmouth . . . . . . . . . 5-21
4.6 Insulation Sleeving . . . . . . . . . . . . . . . . . . . . . . . 4-16
5.2.4 Cutoff Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
4.7 Soldered Strand Separation (Birdcaging) . . . . 4-18
5.3 Machined Contacts . . . . . . . . . . . . . . . . . . . . . . 5-24
4.8 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.3.1 Insulation Clearance . . . . . . . . . . . . . . . . . . . 5-24
4.8.1 Turrets and Straight Pins . . . . . . . . . . . . . . . 4-22 5.3.2 Insulation Support Style . . . . . . . . . . . . . . . . 5-26
4.8.1.1 Lead/Wire Placement . . . . . . . . . . . . . . . . . . 4-22 5.3.3 Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
4.8.1.2 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 5.3.4 Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
4.8.2 Bifurcated . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 5.3.5 CMA Buildup . . . . . . . . . . . . . . . . . . . . . . . . 5-31
4.8.2.1 Lead/Wire Placement – Side Route . . . . . . . 4-25
5.4 Termination Ferrule Crimp . . . . . . . . . . . . . . . . 5-33
4.8.2.2 Lead/Wire Placement –
Bottom and Top Route . . . . . . . . . . . . . . . . . 4-27 5.5 Shrink Sleeving – Wire Support –
Crimped Terminals . . . . . . . . . . . . . . . . . . . . . . . 5-35
4.8.2.3 Lead/Wire Placement –
Staked/Constrained Wires . . . . . . . . . . . . . . 4-29 6.0 Insulation Displacement Connection (IDC) . . . . 6-1
4.8.2.4 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 6.1 Mass Termination, Flat Cable . . . . . . . . . . . . . . . 6-2
4.8.3 Slotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 6.1.1 End Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
4.8.3.1 Lead/Wire Placement . . . . . . . . . . . . . . . . . . 4-32 6.1.2 Notching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
4.8.3.2 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 6.1.3 Planar Ground Plane Removal . . . . . . . . . . . . 6-4
4.8.4 Pierced/Perforated/Punched . . . . . . . . . . . . . 4-34 6.1.4 Connector Position . . . . . . . . . . . . . . . . . . . . . 6-5
4.8.4.1 Lead/Wire Placement . . . . . . . . . . . . . . . . . . 4-34 6.1.5 Connector Skew and Lateral Position . . . . . . 6-8
4.8.4.2 Pierced/Perforated/Punched – Solder . . . . . . 4-36 6.1.6 Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
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6.2 Discrete Wire Termination . . . . . . . . . . . . . . . . . 6-10 9.2.2 Wire Dress . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

6.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 9.2.2.1 Straight Approach . . . . . . . . . . . . . . . . . . . . . . 9-7
6.2.2 Position of Wire . . . . . . . . . . . . . . . . . . . . . . 6-11 9.2.2.2 Side Approach . . . . . . . . . . . . . . . . . . . . . . . . 9-8
6.2.3 Overhang (Extension) . . . . . . . . . . . . . . . . . . 6-12 9.3 Sleeving and Boots . . . . . . . . . . . . . . . . . . . . . . . 9-9
6.2.4 Insulation Crimp . . . . . . . . . . . . . . . . . . . . . . 6-13 9.3.1 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
6.2.5 Damage in Connection Area . . . . . . . . . . . . 6-15 9.3.2 Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
6.2.6 End Connectors . . . . . . . . . . . . . . . . . . . . . . 6-16 9.4 Connector Damage . . . . . . . . . . . . . . . . . . . . . . 9-13
6.2.7 Pass Through Connectors . . . . . . . . . . . . . . . 6-17 9.4.1 Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
6.2.8 Wiremount Connectors . . . . . . . . . . . . . . . . . 6-18 9.4.2 Limits – Hard Face – Mating Surface . . . . . 9-14
6.2.9 Subminiature D-Connector 9.4.3 Limits – Soft Face –
(Series Bus Connector) . . . . . . . . . . . . . . . . 6-19 Mating Surface or Rear Seal Area . . . . . . . . 9-15
6.2.10 Modular Connectors (RJ Type) . . . . . . . . . . 6-21 9.4.4 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
7.0 Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . . . . . 7-1 9.5 Installation of Contacts and Sealing Plugs
7.1 Insulation Clearance . . . . . . . . . . . . . . . . . . . . . . 7-1 into Connectors . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.5.1 Installation of Contacts . . . . . . . . . . . . . . . . . 9-17
7.2 Weld Nugget . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
9.5.2 Installation of Sealing Plugs . . . . . . . . . . . . . 9-19
8.0 Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
10.0 Over-Molding/Potting . . . . . . . . . . . . . . . . . . . . 10-1
8.1 Soldered Splices . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
10.1 Over-Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
8.1.1 Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
10.1.1 Mold Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
8.1.2 Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
10.1.1.1 Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
8.1.3 Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
10.1.1.2 Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
8.1.4 Lap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
10.1.1.2.1 Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
8.1.4.1 Two or More Conductors . . . . . . . . . . . . . . . . 8-5
10.1.1.2.2 Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
8.1.4.2 Insulation Opening (Window) . . . . . . . . . . . . 8-7
10.1.1.2.3 Cracks, Flow Lines, Chill Marks
8.1.5 Heat Shrinkable Solder Devices . . . . . . . . . . . 8-8
(Knit Lines) or Weld Lines . . . . . . . . . . . . . 10-12
8.2 Crimped Splices . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 10.1.1.2.4 Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
8.2.1 Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 10.1.2 Blow Through . . . . . . . . . . . . . . . . . . . . . . . 10-15
8.2.1.1 Insulation Opening (Window) . . . . . . . . . . . 8-13 10.1.3 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
8.2.2 Double Sided . . . . . . . . . . . . . . . . . . . . . . . . 8-14 10.1.4 Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
8.2.3 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 10.1.5 Wire Insulation, Jacket or
8.2.4 Wire In-Line Junction Devices Sleeving Damage . . . . . . . . . . . . . . . . . . . . 10-21
(Jiffy Junctions) . . . . . . . . . . . . . . . . . . . . . . 8-18 10.1.6 Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
8.3 Ultrasonic Weld Splices . . . . . . . . . . . . . . . . . . . 8-19 10.2 Potting (Thermoset Molding) . . . . . . . . . . . . . 10-23
8.4 Sleeving Over Splices . . . . . . . . . . . . . . . . . . . . 8-20 10.2.1 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
9.0 Connectorization . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 10.2.2 Fit to Wire or Cable . . . . . . . . . . . . . . . . . . 10-26
10.2.3 Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
9.1 Hardware Mounting . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Jackpost – Height . . . . . . . . . . . . . . . . . . . . . . 9-1 10.3 Over-Molding of Flexible Flat Ribbon . . . . . . . 10-29

9.1.2 Jackscrews – Protrusion . . . . . . . . . . . . . . . . . 9-2 10.3.1 Mounting and Alignment Feature

Adhesion . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
9.1.3 Retaining Clips . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10.3.2 Adhesion Between Ribbon and
9.1.4 Connector Alignment . . . . . . . . . . . . . . . . . . . 9-4
Connector Potting . . . . . . . . . . . . . . . . . . . . 10-31
9.2 Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 10.3.3 Mounting Hardware . . . . . . . . . . . . . . . . . . 10-32
9.2.1 Clamp Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
11.0 Measuring Cable Assemblies and Wires . . . . . 11-1

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11.1 Measuring – Cable and Wire Length 13.7.1 Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 13.7.2 Press Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
11.2 Measuring – Cable . . . . . . . . . . . . . . . . . . . . . . . 11-1 13.8 Shield Termination . . . . . . . . . . . . . . . . . . . . . . 13-17
11.2.1 Reference Surfaces – 13.8.1 Clamped Ground Rings . . . . . . . . . . . . . . . 13-17
Straight/Axial Connectors . . . . . . . . . . . . . . 11-1 13.8.2 Crimped Ferrule . . . . . . . . . . . . . . . . . . . . . 13-18
11.2.2 Reference Surfaces –
13.9 Center Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
Right-Angle Connectors . . . . . . . . . . . . . . . . 11-2
11.2.3 Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 13.9.1 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
11.2.4 Breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 13.9.2 Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21
11.2.4.1 Breakout Measurement Points . . . . . . . . . . . 11-3 13.10 Semirigid Coax . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
11.2.4.2 Breakout Length . . . . . . . . . . . . . . . . . . . . . . 11-4 13.10.1 Bending and Deformation . . . . . . . . . . . . . 13-23
11.3 Measuring – Wire . . . . . . . . . . . . . . . . . . . . . . . . 11-5
13.10.2 Surface Condition . . . . . . . . . . . . . . . . . . . . 13-25
11.3.1 Electrical Terminal Reference Location . . . . 11-5 13.10.2.1 Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
11.3.2 Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 13.10.2.2 Conformable Cable . . . . . . . . . . . . . . . . . . . 13-27
13.10.3 Dielectric Cutoff . . . . . . . . . . . . . . . . . . . . . 13-28
12.0 Marking/Labeling . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13.10.4 Dielectric Cleanliness . . . . . . . . . . . . . . . . . 13-30
12.1 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 13.10.5 Center Conductor Pin . . . . . . . . . . . . . . . . . 13-31
12.2 Legibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 13.10.5.1 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
12.3 Permanency . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 13.10.5.2 Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34
12.4 Location and Orientation . . . . . . . . . . . . . . . . . . 12-4
13.10.6 Semirigid Coax – Solder . . . . . . . . . . . . . . 13-34
13.11 Swage-Type Connector . . . . . . . . . . . . . . . . . . 13-36
12.5 Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
13.12 Soldering and Stripping of Biaxial/Multi-Axial
12.6 Marker Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Shielded Wire . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
12.6.1 Wrap Around . . . . . . . . . . . . . . . . . . . . . . . . 12-6
13.12.1 Jacket and Tip Installation . . . . . . . . . . . . . 13-37
12.6.2 Tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
13.12.2 Ring Installation . . . . . . . . . . . . . . . . . . . . . 13-39
12.7 Flag Markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
14.0 Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
12.7.1 Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
14.1 Tie Wrap/Lacing Application . . . . . . . . . . . . . . . 14-1
12.8 Tie Wrap Markers . . . . . . . . . . . . . . . . . . . . . . . 12-10
14.1.1 Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
13.0 Coaxial and Biaxial Cable Assemblies . . . . . . . 13-1 14.1.2 Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
13.1 Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 14.1.3 Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
13.2 Center Conductor Termination . . . . . . . . . . . . . 13-4 14.2 Breakouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
13.2.1 Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 14.2.1 Individual Wires . . . . . . . . . . . . . . . . . . . . . . 14-8
13.2.2 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 14.2.2 Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
13.3 Solder Ferrule Pins . . . . . . . . . . . . . . . . . . . . . . . 13-8 14.3 Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12
13.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 14.3.1 Wire Crossover . . . . . . . . . . . . . . . . . . . . . . 14-12
13.3.2 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10 14.3.2 Bend Radius . . . . . . . . . . . . . . . . . . . . . . . . 14-13
13.4 Coaxial Connector – 14.3.3 Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . 14-14
Printed Wire Board Mount . . . . . . . . . . . . . . . . 13-11 14.3.4 Unused Wire Termination . . . . . . . . . . . . . 14-15
13.5 Coaxial Connector – Center Conductor 14.3.4.1 Shrink Sleeving . . . . . . . . . . . . . . . . . . . . . 14-15
Length – Right Angle Connector . . . . . . . . . . 13-12 14.3.4.2 Flexible Sleeving . . . . . . . . . . . . . . . . . . . . 14-16
13.6 Coaxial Connector – 14.3.5 Ties over Splices and Ferrules . . . . . . . . . . 14-16
Center Conductor Solder . . . . . . . . . . . . . . . . 13-13
14.4 Broom Stitching . . . . . . . . . . . . . . . . . . . . . . . . 14-17
13.7 Coaxial Connector – Terminal Cover . . . . . . . 13-15
15.0 Harness/Cable Electrical Shielding . . . . . . . . . 15-1

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15.1 Braided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 17.2.1.1 Minimum Torque . . . . . . . . . . . . . . . . . . . . . 17-5
15.1.1 Direct Applied . . . . . . . . . . . . . . . . . . . . . . . 15-2 17.2.2 Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
15.1.2 Prewoven . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 17.2.2.1 Solid Wires . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
15.2 Shield Termination . . . . . . . . . . . . . . . . . . . . . . . 15-5
17.2.2.2 Stranded Wires . . . . . . . . . . . . . . . . . . . . . . 17-10
15.2.1 Shield Jumper Wire . . . . . . . . . . . . . . . . . . . 15-5 17.2.3 Safety Wiring . . . . . . . . . . . . . . . . . . . . . . . 17-11
15.2.1.1 Attached Lead . . . . . . . . . . . . . . . . . . . . . . . . 15-5 17.2.4 Safety Cable . . . . . . . . . . . . . . . . . . . . . . . . 17-13
15.2.1.1.1 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 17.3 Wire/Harness Installation . . . . . . . . . . . . . . . . 17-14
15.2.1.1.2 Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10 17.3.1 Stress Relief . . . . . . . . . . . . . . . . . . . . . . . . 17-14
15.2.1.2 Shield Braid . . . . . . . . . . . . . . . . . . . . . . . . 15-11 17.3.2 Wire Dress . . . . . . . . . . . . . . . . . . . . . . . . . 17-15
15.2.1.2.1 Woven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11 17.3.3 Service Loops . . . . . . . . . . . . . . . . . . . . . . . 17-16
15.2.1.2 Combed and Twisted . . . . . . . . . . . . . . . . . 15-11 17.3.4 Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . 17-17
15.2.1.3 Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . 15-12 17.3.5 Tie Wrap/Lacing . . . . . . . . . . . . . . . . . . . . . 17-17
15.2.1.4 Common Ground Point . . . . . . . . . . . . . . . . 15-12 17.3.6 Raceways . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
15.2.2 Unterminated Shield . . . . . . . . . . . . . . . . . . 15-13 17.3.7 Grommets . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19
15.2.2.1 Shield Not Folded Back . . . . . . . . . . . . . . . 15-13 17.3.7.1 Sealing Not Required . . . . . . . . . . . . . . . . . 17-19
15.2.2.2 Shield Folded Back . . . . . . . . . . . . . . . . . . . 15-14 17.3.7.2 Sealing Required . . . . . . . . . . . . . . . . . . . . 17-20
15.3 Shield Termination – Connector . . . . . . . . . . . 15-15 18.0 Solderless Wrap . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
15.3.1 Shrink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 19.0 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
15.3.2 Crimp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17 19.1 Nondestructive Tests . . . . . . . . . . . . . . . . . . . . . 19-1
15.3.3 Shield Jumper Wire Attachment . . . . . . . . 15-19
19.2 Testing After Rework or Repair . . . . . . . . . . . . 19-1
15.3.4 Soldered . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
19.3 Intended Table Usage . . . . . . . . . . . . . . . . . . . . 19-1
15.4 Shield Termination – Splicing Prewoven . . . . 15-20
19.4 Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
15.4.1 Soldered . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21
19.4.1 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
15.4.2 Tie/Tape On . . . . . . . . . . . . . . . . . . . . . . . . 15-23
19.5 Electrical Test Methods . . . . . . . . . . . . . . . . . . . 19-3
15.5 Tapes – Barrier and Conductive, Adhesive
or Non-Adhesive . . . . . . . . . . . . . . . . . . . . . . . . 15-24 19.5.1 Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3
15.6 Conduit (Shielding) . . . . . . . . . . . . . . . . . . . . . . 15-25
19.5.2 Shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4
19.5.3 Dielectric Withstanding Voltage (DWV) . . . 19-5
15.7 Shrink Tubing – Conductive Lined . . . . . . . . . 15-26
19.5.4 Insulation Resistance (IR) . . . . . . . . . . . . . . 19-6
16.0 Cable/Wire Harness Protective Coverings . . . 16-1 19.5.5 Voltage Standing Wave Ratio (VSWR) . . . . 19-7
16.1 Braid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 19.5.6 Insertion Loss . . . . . . . . . . . . . . . . . . . . . . . . 19-7
16.1.1 Direct Applied . . . . . . . . . . . . . . . . . . . . . . . 16-1 19.5.7 Reflection Coefficient . . . . . . . . . . . . . . . . . 19-8
16.1.2 Prewoven . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3 19.5.8 User Defined . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
16.2 Sleeving/Shrink Tubing . . . . . . . . . . . . . . . . . . . 16-5 19.6 Mechanical Test . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
16.2.1 Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6 19.6.1 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
16.3 Spiral Plastic Wrap (Spiral Wrap Sleeving) . . . 16-7 19.7 Mechanical Test Methods . . . . . . . . . . . . . . . . 19-10
16.4 Wire Loom Tubing – Split and Unsplit . . . . . . . 16-8 19.7.1 Crimp Height (Dimensional Analysis) . . . . 19-10
16.5 Tapes, Adhesive and Non-Adhesive . . . . . . . . . 16-8
19.7.1.1 Terminal Positioning . . . . . . . . . . . . . . . . . 19-11
19.7.2 Pull Force (Tensile) . . . . . . . . . . . . . . . . . . 19-12
17.0 Finished Assembly Installation . . . . . . . . . . . . . 17-1
19.7.2.1 Without Documented Process Control . . . . 19-13
17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 19.7.3 Crimp Force Monitoring . . . . . . . . . . . . . . . 19-17
17.2 Hardware Installation . . . . . . . . . . . . . . . . . . . . . 17-2 19.7.4 Crimp Tool Qualification . . . . . . . . . . . . . . 19-17
17.2.1 Threaded Fasteners . . . . . . . . . . . . . . . . . . . . 17-3 19.7.5 Contact Retention Verification . . . . . . . . . . 19-17

IPC/WHMA-A-620E October 2022 xiii

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 Table of Contents (cont.)
19.7.6 RF Connector Shield Pull Force (Tensile) . 19-18 Table 19-2 Continuity Test Minimum
19.7.7 RF Connector Shield Ferrule Torsion . . . . 19-19 Requirements . . . . . . . . . . . . . . . . . . . . . . . 19-4
19.7.8 User Defined . . . . . . . . . . . . . . . . . . . . . . . . 19-19 Table 19-3 Shorts Test (low voltage isolation)
Minimum Requirements . . . . . . . . . . . . . . 19-5
20.0 High Voltage Applications . . . . . . . . . . . . . . . . . 20-1
Table 19-4 Dielectric Withstanding Voltage Test
Appendix A Terms and Definitions . . . . . . . . . . . . . . . . A-1 (DWV) Minimum Requirements . . . . . . . . 19-6
Appendix B Reproducible Test Tables . . . . . . . . . . . . . . B-1 Table 19-5 Insulation Resistance (IR) Test Minimum
Appendix C Guidelines for Soldering Tools Requirements . . . . . . . . . . . . . . . . . . . . . . . 19-7
and Equipment . . . . . . . . . . . . . . . . . . . . . . C-1 Table 19-6 Voltage Standing Wave Ratio (VSWR)
Appendix D X-Ray Guidelines . . . . . . . . . . . . . . . . . . . . D-1 Test Parameters . . . . . . . . . . . . . . . . . . . . . 19-8
Table 19-7 Insertion Loss Test Parameters . . . . . . . . . 19-8
Tables Table 19-8 Reflection Coefficient Test Parameters . . . 19-9
Table 1-1 Magnification Aid Applications – Table 19-9 Mechanical Test Requirements . . . . . . . . 19-10
Wire and Wire Connections . . . . . . . . . . . . . 1-5
Table 19-10 Crimp Height Testing . . . . . . . . . . . . . . . . 19-11
Table 1-2 Magnification Aid Applications – Other . . . 1-6
Table 19-11 Pull Force Testing Minimum
Table 3-1 Allowable Strand Damage . . . . . . . . . . . . . . 3-3 Requirements . . . . . . . . . . . . . . . . . . . . . . 19-14
Table 4-1 Maximum Limits of Solder Bath Table 19-12 Pull Test Force Values . . . . . . . . . . . . . . . 19-15
Contaminant . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Table 19-13 Pull Test Force Values (Classes 1 & 2)
Table 4-2 Solder Connection Anomalies . . . . . . . . . . 4-10 For UL, SAE, GM and Volvo . . . . . . . . . 19-16
Table 4-3 Turret or Straight Pin Terminal Table 19-14 Pull Test Force Values (Classes 1 & 2)
Lead/Wire Placement . . . . . . . . . . . . . . . . . 4-22 For IEC . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17
Table 4-4 Bifurcated Terminal Lead/Wire Placement – Table 19-15 RF Connector Shield Pull Force
Side Route . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19
Table 4-5 Bifurcated Terminal Lead/Wire Placement – Table A-1 Electrical Clearance . . . . . . . . . . . . . . . . . . A-2
Bottom Route . . . . . . . . . . . . . . . . . . . . . . . 4-27
Table 19-1 Electrical Test Requirements . . . . . . . . . . . B-2
Table 4-6 Staking Requirements of Side Route Straight
Through Connections – Bifurcated Table 19-2 Continuity Test Minimum Requirements . B-3
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Table 19-3 Shorts Test (low voltage isolation)
Table 4-7 Pierced/Perforated/Punched Terminal Minimum Requirements . . . . . . . . . . . . . . B-4
Lead/Wire Placement . . . . . . . . . . . . . . . . . 4-34 Table 19-4 Dielectric Withstanding Voltage Test
Table 4-8 Hook Terminal Lead/Wire Placement . . . . 4-37 (DWV) Minimum Requirements . . . . . . . . B-5
Table 4-9 AWG 30 and Smaller Wire Wrap Table 19-5 Insulation Resistance (IR) Test Minimum
Requirements . . . . . . . . . . . . . . . . . . . . . . . 4-44 Requirements . . . . . . . . . . . . . . . . . . . . . . . B-6
Table 11-1 Cable/Wire Length Measurement Table 19-6 Voltage Standing Wave Ratio (VSWR)
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Test Parameters . . . . . . . . . . . . . . . . . . . . . B-7
Table 13-1 Coaxial and Biaxial Shield and Center Table 19-7 Insertion Loss Test Parameters . . . . . . . . . B-8
Conductor Damage . . . . . . . . . . . . . . . . . . 13-1 Table 19-8 Reflection Coefficient Test Parameters . . . B-9
Table 13-2 Semirigid Coax Deformation . . . . . . . . . . 13-24 Table 19-9 Mechanical Test Requirements . . . . . . . . B-10
Table 13-3 Dielectric Cutoff . . . . . . . . . . . . . . . . . . . 13-28 Table 19-10 Crimp Height Testing . . . . . . . . . . . . . . . . B-11
Table 14-1 Minimum Bend Radius Requirements . . . 14-13 Table 19-11 Pull Force Testing Minimum
Table 17-1 Minimum Swaged Ferrule Requirements . . . . . . . . . . . . . . . . . . . . . . B-12
Pull-Off Load . . . . . . . . . . . . . . . . . . . . . . 17-13 Table 19-15 RF Connector Shield Pull
Table 19-1 Electrical Test Requirements . . . . . . . . . . . 19-3 Force Testing . . . . . . . . . . . . . . . . . . . . . . B-13

xiv October 2022 IPC/WHMA-A-620E

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 1.0 General

1.0 General

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. For X-ray guidelines, see Appendix D X-Ray Guidelines.
If a conflict occurs between the English and translated versions of this document, the English version will take precedence.
The illustrations in this document portray specific points noted in the title of each section. 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. &*+

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).
1.2 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. 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
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) [foot-candles] for illuminance.
1.4.1 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 words ‘‘shall’’ or “shall not” are used in the text of this document wherever there is a
requirement for materials, process or acceptance of cable, wire and harness assemblies.
Where the words ‘‘shall’’ or “shall not” indicates a requirement for at least one Class, the requirements for each Class are in
brackets next to the ‘‘shall’’ or “shall not” requirement.
N = No requirement has been established for this Class
A = Acceptable
P = Process Indicator
D = Defect
Examples:
[A1P2D3] is Acceptable Class 1, Process Indicator Class 2 and Defect Class 3
[N1D2D3] is Requirement Not Established Class 1, Defect Classes 2 and 3

IPC/WHMA-A-620E October 2022 1-1

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