IPC/WHMA-A-620D

2020–January

RequirementsandAcceptanceforCableandWire

HarnessAssemblies

SupersedesIPC/WHMA-A-620C

January2017

AninternationalstandarddevelopedbyIPC

15

?

IPC/WHMA-A-620D

IfaconflictoccursbetweentheEnglishandtranslatedversionsofthisdocument,theEnglishversionwilltakeprecedence.

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RequirementsandAcceptanceforCableandWireHarnessAssemblies

DevelopedbytheIPCTaskGroup(7-31f)oftheProductAssuranceSubcommittee(7-30)andtheWHMAIndustryTechnicalGuidelinesCommittee(ITGC)

Supersedes:

IPC/WHMA-A-620C-

January2017IPC/WHMA-A-620Bwith

Amendment1-

Usersofthispublicationareencouragedtoparticipateinthedevelopmentoffuturerevisions.

Contact:

August2013IPC/WHMA-A-620B-

October2012IPC/WHMA-A-620A-

July2006IPC/WHMA-A-620-

January2002

IPC

3000LakesideDrive,Suite105NBannockburn,Illinois

60015-1219

Tel847615.7100

Fax847615.7105

WiringHarnessManufacturersAssoc.(AnaffiliateofIPC)

3000LakesideDrive,Suite105NBannockburn,Illinois

60015-1219

Tel847615.7100

email:

contact.us@

TableofContents

TableofContents(cont.)

IPC/WHMA-A-620D

January2020

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General 1-1

Scope 1-1

Purpose 1-1

Classification 1-1

MeasurementUnitsandApplications 1-1

VerificationofDimensions 1-1

DefinitionofRequirements 1-1

InspectionConditions 1-2

Acceptable 1-2

Defect 1-2

Disposition 1-2

ProcessIndicator 1-2

CombinedContitions 1-3

ConditionsNotSpecified 1-3

UncommonorSpecializedDesigns 1-3

MaterialandProcessNonconformance 1-3

ProcessControl 1-3

StatisticalProcessControl 1-3

OrderofPrecedence 1-4

ClauseReferences 1-4

Appendices 1-4

TermsandDefinitions 1-4

FOD(ForeignObjectDebris) 1-4

Inspection 1-4

Manufacturer(Assembler) 1-4

ObjectiveEvidence 1-4

ProcessControl 1-4

Supplier 1-4

User 1-5

WireDiameter(D) 1-5

EngineeringDocumentation 1-5

RequirementsFlowdown 1-5

PersonnelProficiency 1-5

AcceptanceRequirements 1-5

InspectionMethodology 1-5

ProcessVerificationInspection 1-5

VisualInspection 1-5

Lighting 1-5

MagnificationAids 1-5

Facilities 1-6

FieldAssemblyOperations 1-6

HealthandSafety 1-6

ElectrostaticDischarge(ESD)Protection 1-6

ToolsandEquipment 1-7

Control 1-7

Calibration 1-7

MaterialsandProcesses 1-7

ElectricalClearance 1-8

Contamination 1-8

Rework/Repair 1-8

Rework 1-8

Repair 1-8

PostRework/RepairCleaning 1-8

ApplicableDocuments 2-1

IPC 2-1

JointIndustryStandards 2-1

SocietyofAutomotiveEngineers(SAE) 2-1

AmericanNationalStandards

Institute(ANSI) 2-1

InternationalOrganizationfor

Standardization(ISO) 2-1

ESDAssociation(ESDA) 2-2

UnitedStatesDepartmentofDefense(DoD) 2-2

InternationalElectrotechnical

Commission(IEC) 2-2

AerospaceIndustriesAssociation(AIA/NAS) 2-2

ElectronicsIndustriesAlliance 2-2

ASTMInternational 2-2

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InstituteofElectricalandElectronics

Engineers 2-2

Preparation 3-1

Stripping 3-2

StrandDamageandEndCuts 3-2

ConductorDeformation/Birdcaging 3-5

TwistingofWires 3-7

InsulationDamage–Stripping 3-8

SolderedTerminations 4-1

Material,ComponentsandEquipment 4-2

Materials 4-2

Solder 4-2

SolderPurityMaintenance 4-3

Flux 4-4

Adhesives 4-4

Solderability 4-5

ToolsandEquipment 4-5

GoldRemoval 4-5

Cleanliness 4-6

Presoldering 4-6

Postsoldering 4-6

ForeignObjectDebris(FOD) 4-6

FluxResidue 4-7

CleaningRequired 4-7

No-CleanProcess 4-7

SolderConnection 4-8

GeneralRequirements 4-10

SolderingAnomalies 4-11

ExposedBasisMetal 4-11

PartiallyVisibleorHiddenSolder

Connections 4-11

Wire/LeadPreparation,Tinning 4-12

WireInsulation 4-14

Clearance 4-14

PostsolderDamage 4-16

InsulationSleeving 4-17

SolderedStrandSeparation(Birdcaging) 4-19

Terminals 4-20

TurretsandStraightPins 4-23

Lead/WirePlacement 4-23

Solder 4-25

Bifurcated 4-26

Lead/WirePlacement–SideRoute 4-26

Lead/WirePlacement–Bottomand

TopRoute 4-28

Lead/WirePlacement–Staked/

ConstrainedWires 4-30

Solder 4-31

Slotted 4-33

Lead/WirePlacement 4-33

Solder 4-34

Pierced/Perforated/Punched 4-35

Lead/WirePlacement 4-35

Solder 4-37

Hook 4-38

Lead/WirePlacement 4-38

Solder 4-40

Cup 4-41

Lead/WirePlacement 4-41

Solder 4-42

SeriesConnected 4-44

Lead/WirePlacement–AWG30and

SmallerDiameterWires 4-45

CrimpTerminations(ContactsandLugs) 5-1

StampedandFormed–OpenBarrel 5-3

InsulationSupport 5-4

InspectionWindow 5-4

Crimp 5-6

InsulationClearanceifNoSupportCrimp 5-8

ConductorCrimp 5-9

CrimpBellmouth 5-11

ConductorBrush 5-13

CarrierCutoffTab 5-15

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IndividualWireSeal 5-16

StampedandFormed–ClosedBarrel 5-18

InsulationClearance 5-19

InsulationSupportCrimp 5-20

ConductorCrimpandBellmouth 5-21

CutoffTabs 5-23

MachinedContacts 5-24

InsulationClearance 5-24

InsulationSupportStyle 5-26

Conductor 5-27

Crimping 5-29

CMABuildup 5-31

TerminationFerruleCrimp 5-33

ShrinkSleeving–WireSupport–

CrimpedTerminals 5-35

InsulationDisplacementConnection(IDC) 6-1

MassTermination,FlatCable 6-2

EndCutting 6-2

Notching 6-3

PlanarGroundPlaneRemoval 6-4

ConnectorPosition 6-5

ConnectorSkewandLateralPosition 6-8

Retention 6-9

TableofContents(cont.)

TableofContents(cont.)

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DiscreteWireTermination 6-10

General 6-10

PositionofWire 6-11

Overhang(Extension) 6-12

InsulationCrimp 6-13

DamageinConnectionArea 6-15

EndConnectors 6-16

PassThroughConnectors 6-17

WiremountConnectors 6-18

SubminiatureD-Connector(Series

BusConnector) 6-19

ModularConnectors(RJType) 6-21

UltrasonicWelding 7-1

InsulationClearance 7-2

WeldNugget 7-3

Splices 8-1

SolderedSplices 8-2

Mesh 8-3

Wrap 8-5

Hook 8-7

Lap 8-8

TwoorMoreConductors 8-9

InsulationOpening(Window) 8-12

HeatShrinkableSolderDevices 8-13

CrimpedSplices 8-15

Barrel 8-15

DoubleSided 8-18

Contact 8-21

WireIn-LineJunctionDevices(JiffyJunctions).8-23

UltrasonicWeldSplices 8-24

Connectorization 9-1

HardwareMounting 9-2

Jackpost–Height 9-2

Jackscrews–Protrusion 9-3

RetainingClips 9-4

ConnectorAlignment 9-5

StrainRelief 9-6

ClampFit 9-6

WireDress 9-7

StraightApproach 9-8

SideApproach 9-9

SleevingandBoots 9-10

Position 9-10

Bonding 9-11

ConnectorDamage 9-15

Criteria 9-15

Limits–HardFace–MatingSurface 9-16

Limits–SoftFace–MatingSurfaceor

RearSealArea 9-17

Contacts 9-18

InstallationofContactsandSealing

PlugsintoConnectors 9-19

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InstallationofContacts 9-19

InstallationofSealingPlugs 9-21

Over-Molding/Potting 10-1

Over-Molding 10-4

MoldFill 10-4

Inner 10-4

Outer 10-7

Mismatch 10-10

Fit 10-11

Cracks,FlowLines,ChillMarks

(KnitLines)orWeldLines 10-14

Color 10-16

BlowThrough 10-17

Position 10-18

Flashing 10-21

WireInsulation,JacketorSleeving

Damage 10-23

Curing 10-24

Potting(ThermosetMolding) 10-25

Filling 10-25

FittoWireorCable 10-29

Curing 10-31

Over-MoldingofFlexibleFlatRibbon 10-32

MountingandAlignmentFeature

Adhesion 10-35

AdhesionBetweenRibbonand

ConnectorPotting 10-36

MountingHardware 10-37

MeasuringCableAssembliesandWires 11-1

Measuring–CableandWire

LengthTolerance 11-2

Measuring–Cable 11-2

ReferenceSurfaces–Straight/Axial

Connectors 11-2

ReferenceSurfaces–Right-Angle

Connectors 11-3

Length 11-3

Breakout 11-4

BreakoutMeasurementPoints 11-4

BreakoutLength 11-5

Measuring–Wire 11-6

ElectricalTerminalReferenceLocation 11-6

Length 11-7

Marking/Labeling 12-1

Content 12-2

Legibility 12-2

Permanency 12-4

LocationandOrientation 12-5

Functionality 12-6

MarkerSleeve 12-7

WrapAround 12-7

Tubular 12-9

FlagMarkers 12-10

Adhesive 12-10

TieWrapMarkers 12-10

CoaxialandBiaxialCableAssemblies 13-1

Stripping 13-2

CenterConductorTermination 13-4

Crimp 13-4

Solder 13-6

SolderFerrulePins 13-8

General 13-8

Insulation 13-10

CoaxialConnector–PrintedWire

BoardMount 13-11

CoaxialConnector–CenterConductor

Length–RightAngleConnector 13-12

CoaxialConnector–CenterConductor

Solder 13-13

CoaxialConnector–TerminalCover 13-15

Soldering 13-15

PressFit 13-16

ShieldTermination 13-17

ClampedGroundRings 13-17

CrimpedFerrule 13-18

CenterPin 13-20

Position 13-20

Damage 13-21

SemirigidCoax 13-22

BendingandDeformation 13-23

SurfaceCondition 13-25

Solid 13-25

ConformableCable 13-27

DielectricCutoff 13-28

DielectricCleanliness 13-30

CenterConductorPin 13-31

Point 13-32

Damage 13-34

Solder 13-34

Swage-TypeConnector 13-36

SolderingandStrippingofBiaxial/

Multi-AxialShieldedWire 13-37

JacketandTipInstallation 13-37

RingInstallation 13-39

Securing 14-1

TieWrap/LacingApplication 14-2

Tightness 14-7

Damage 14-8

Spacing 14-8

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Breakouts 14-9

IndividualWires 14-9

Spacing 14-10

Routing 14-13

WireCrossover 14-13

BendRadius 14-14

CoaxialCable 14-15

UnusedWireTermination 14-16

ShrinkSleeving 14-16

FlexibleSleeving 14-17

TiesoverSplicesandFerrules 14-17

BroomStitching 14-18

Harness/CableElectricalShielding 15-1

Braided 15-2

DirectApplied 15-3

Prewoven 15-5

ShieldTermination 15-6

ShieldJumperWire 15-6

AttachedLead 15-6

Solder 15-7

Crimp 15-11

ShieldBraid 15-12

Woven 15-12

CombedandTwisted 15-12

DaisyChain 15-13

CommonGroundPoint 15-13

NoShieldJumperWire 15-14

ShieldNotFoldedBack 15-14

ShieldFoldedBack 15-15

ShieldTermination–Connector 15-16

Shrink 15-16

Crimp 15-18

ShieldJumperWireAttachment 15-20

Soldered 15-21

ShieldTermination–SplicingPrewoven 15-21

Soldered 15-22

Tie/TapeOn 15-24

Tapes–BarrierandConductive,

AdhesiveorNonadhesive 15-25

Conduit(Shielding) 15-26

ShrinkTubing–ConductiveLined 15-27

Cable/WireHarnessProtectiveCoverings 16-1

Braid 16-2

DirectApplied 16-2

Prewoven 16-4

Sleeving/ShrinkTubing 16-6

Sealant 16-7

SpiralPlasticWrap(SpiralWrapSleeving) 16-8

WireLoomTubing–SplitandUnsplit 16-9

Tapes,AdhesiveandNonadhesive 16-9

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FinishedAssemblyInstallation 17-1

General 17-2

HardwareInstallation 17-3

ThreadedFasteners 17-4

MinimumTorque 17-6

Wires 17-8

SolidWires 17-9

StrandedWires 17-11

SafetyWiring 17-12

SafetyCable 17-14

Wire/HarnessInstallation 17-15

StressRelief 17-15

WireDress 17-16

ServiceLoops 17-17

Clamping 17-18

TieWrapLacing 17-18

Raceways 17-19

Grommets 17-20

Wire/Cable/BundleSealingNotRequired 17-20

Wire/CableSealingRequired 17-21

SolderlessWrap 18-1

Testing 19-1

NondestructiveTests 19-2

TestingAfterReworkorRepair 19-2

IntendedTableUsage 19-2

ElectricalTest 19-3

Selection 19-3

ElectricalTestMethods 19-4

Continuity 19-4

Shorts 19-5

DielectricWithstandingVoltage(DWV) 19-6

InsulationResistance(IR) 19-7

VoltageStandingWaveRatio(VSWR) 19-8

InsertionLoss 19-8

ReflectionCoefficient 19-9

UserDefined 19-9

MechanicalTest 19-10

Selection 19-10

MechanicalTestMethods 19-11

CrimpHeight(DimensionalAnalysis) 19-11

TerminalPositioning 19-12

PullForce(Tensile) 19-13

WithoutDocumentedProcessControl 19-14

CrimpForceMonitoring 19-18

CrimpToolQualification 19-18

ContactRetentionVerification 19-18

RFConnectorShieldPullForce(Tensile) 19-19

RFConnectorShieldFerruleTorsion 19-20

UserDefined 19-20

HighVoltageApplications 20-1

AppendixATermsandDefinitions A-1

AppendixBReproducibleTestTablesB-1

AppendixCGuidelinesforSolderingTools

andEquipmentC-1

TableA-1ElectricalClearanceA-5

Table1-1 MagnificationAidApplications–

WireandWireConnections 1-6

Table1-2 MagnificationAidApplications–

Other 1-6

Table3-1AllowableStrandDamage 3-4

Table4-1MaximumLimitsofSolderBathContaminant 4-3

Table4-2SolderConnectionAnomalies 4-11

Table4-3TurretandStraightPinTerminal

Lead/WirePlacement 4-23

Table4-4BifurcatedTerminalLead/Wire

Placement–SideRoute 4-26

Table4-5BifurcatedTerminalLead/Wire

Placement–BottomRoute 4-28

Table4-6StakingRequirementsofSideRouteStraightThroughConnections–

BifurcatedTerminals 4-30

Table4-7Pierced/Perforated/PunchedTerminalLead/WirePlacement 4-35

Table4-8HookTerminalLead/WirePlacement 4-38

Table4-9AWG30andSmallerWireWrapRequirements 4-45

Table10-1DefinitionsofMolding/Potting

VisualAnomalies 10-2

Table11-1Cable/WireLengthMeasurementTolerance 11-2

Table13-1CoaxialandBiaxialShieldand

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CenterConductorDamage 13-2

Table13-2SemirigidCoaxDeformation 13-24

Table13-3DielectricCutoff 13-28

Table14-1MinimumBendRadius

Requirements 14-14

Table17-1MinimumSwagedFerrule

Pull-OffLoad 17-14

Table19-1ElectricalTestRequirements 19-3

Table19-2ContinuityTestMinimum

Requirements 19-4

Table19-3ShortsTest(lowvoltageisolation)MinimumRequirements 19-5

Table19-4DielectricWithstandingVoltage

Test(DWV)MinimumRequirements 19-6

Table19-5InsulationResistance(IR)Test

MinimumRequirements 19-7

Table19-6VoltageStandingWaveRatio

(VSWR)TestParameters 19-8

Table19-7InsertionLossTestParameters 19-8

Table19-8ReflectionCoefficientTest

Parameters 19-9

Table19-9MechanicalTestRequirements 19-10

Table19-10CrimpHeightTesting 19-11

Table19-11PullForceTestingMinimum

Requirements 19-14

Table19-12PullTestForceValues 19-15

Table19-13PullTestForceValues(Classes

1&2)ForUL,SAE,GMandVolvo 19-16

Table19-14PullTestForceValues(Classes

1&2)ForIEC 19-17

Table19-15RFConnectorShieldPull

ForceTesting 19-19

4SolderedTerminations

4.8Terminals(cont.)

5CrimpTerminations(ContactsandLugs)

4-22

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January2020

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1

25%R

R 50%R

2

25%R

50%R

R

Acceptable–Class1ProcessIndicator–Class2,3

Wire/leadnotdiscernibleinsolderconnection.

Defect–Class1,2

Depressionofsolderbetweenthepostandthewrapofthewireisdeeperthan50%ofwireradius(r)(seeFigures4-21-1and4-22-A).

Defect–Class3

Depressionofsolderbetweenthepostandthewrapofthewireisdeeperthan25%ofwireradius(r)(seeFigures4-21-1and4-22-A).

Defect–Class1,2,3

Forterminalswitharequiredminimumwrapoflessthan180°,solderiswettedlessthan100%oftherequiredmini-mumwraparea.

Forterminalswitharequiredminimumwrapof180°ormore,solderiswettedlessthan75%oftherequiredmini-mumwrap.

Figure4-21

Asshown,solderdepressionisadefectforClass3.

Asshown,solderdepressionisacceptableforallthreeProductClasses.

Figure4-22

5.1.5StampedandFormed–OpenBarrel–ConductorBrush(cont.)

Figure5-27

Figure5-28

Figure5-29

Figure5-30

Defect–Class1,2,3

Wireendislessthanflushtotheendoftheconductorcrimparea(seeFigure5-27).

Anyconductorstrandsextendingbeyondtheouterperim-eterofthecrimpbarrel(seeFigures5-28,29).

Theconductorstrandsextendintothematingareaofthecontact(seeFigure5-30).

5CrimpTerminations(ContactsandLugs)

5.1.7StampedandFormed–OpenBarrel–IndividualWireSeal

5CrimpTerminations(ContactsandLugs)

5-16

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Thesealshall[D1D2D3]remaininthecorrectpositionwhenthecrimpedcontactisinsertedintotherequiredconnectorhous-ingcavity.

Thecorrectcombinationofseal,wire,andterminalisimportanttoensurethecriteriainthissectioncanbemet.

A

B

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Figure5-33

A

A.SealingRibs B.SealRetentionCrimp

Acceptable–Class1,2,3

Thesealisfirmlysecuredbytheinsulationsupportcrimp.

Theendofthesealisvisibleintheinsulationinspectionwindow.

Thewireinsulationdoesnotprotrudefromundertheseal,butisvisibleundertheseal(seeFigure5-35).

Insulationcrimpheightiswithinthemanufacturer’sspecifiedtolerances(seeFigure5-36).

Forsealsthatincludearetentionring,theretentionringisnotcrimpedandextendsfullyintotheinsulationinspectionwindow(seeFigure5-34).

Figure5-34

A.Sealingretentionring(optional)

Figure5-35

A

Figure5-36

5.2.2StampedandFormed–ClosedBarrel–InsulationSupportCrimp

Figure5-43

Figure5-44

Figure5-45

Acceptable–Class1,2,3

Irregularshapedinsulationcrimpcontactsthewireinsulationprovidingsupport(seeFigure5-44-A,B,C,D).

Wireinsulationcrimp(seeFigure5-44-D)hasbeendeformedbythecrimpingtool(andmaynotcontact/gripthewireinsulation).

Nodamagetowireinsulation.

Nodamagetoterminalinsulation.

Terminalinsulationissecuretotheterminal.

Fillerwire(seeFigure5-44-E)iswithintheinsulationcrimpanddoesnotextendbeyondtheouterluginsulation.

Defect–Class1,2,3

Thewireinsulationisnotwithintheinsulationcrimparea(seeFigure5-45-A).

Wireinsulationdamageexceedsthecriteriaof3.5(seeFigure5-45-B).

Outerinsulationofterminalisnotsecureontheterminal(seeFigure5-45-C).

Fillerwireextendsbeyondtheterminalinsulation(seeFigure5-45-D).

Noevidenceofdeformationoftheinsulationsupportcrimp.

Wirestrandsfoldedbackorvisibleintheinsulationcrimp(seeFigure5-45-E).

5CrimpTerminations(ContactsandLugs)

5CrimpTerminations(ContactsandLugs)

IPC/WHMA-A-620D

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5.2.3StampedandFormed–ClosedBarrel–ConductorCrimpandBellmouth

ThebellmouthareaidentifiedinFigure5-40isconsideredtobepartoftheconductorcrimpbarrelwhentoolingisintendedtoformabellmouth.

Figure5-46

Figure5-47

Acceptable–Class1,2,3

Theconductor(andfillerifspecified)isflushtotheendofthebellmouth.

Conductorstrandsdonotextendintothematingareaoftheterminal.

Bellmouthisevidentateachendoftheconductorcrimparea.

Multipleconductorsextendpastthebellmouthbutmaynotbeequalinlength.

5.2.3StampedandFormed–ClosedBarrel–ConductorCrimpandBellmouth(cont.)

Figure5-48

Figure5-49

Figure5-50

Acceptable–Class1,2ProcessIndicator–Class3

Terminalinsulationdamagednotexposingmetalnoraffect-ingitsintendedapplication.

Minordeformingoftheterminaldoesnotalteritsform,fit,functionorreliability.

Conductorcrimpnotcenteredbutlocatedoncrimpbarrel.

Crimpindentationsnotuniformbutdonotaffectform,fit,functionorreliability.

Defect–Class1,2,3

--`,```,`````,,``,,`,,`,```,,,``-`-`,,`,,`,`,,`

Wireendislessthanflushtotheendofthebellmouth(seeFigure5-49).

Bellmouthnotevidentateachendoftheconductorcrimpareawhentoolingisintendedtoformabellmouth(notshown).

Terminalinsulationdamagedexposingmetal(seeFigure5-50-A).

Conductorextendsintothematingareaoftheterminal(seeFigure5-50-B).

5.2.4StampedandFormed–ClosedBarrel–CutoffTabs

Figure5-51identifiescarriercutofftabs(arrows).

Figure5-51

Figure5-52

Acceptable–Class1,2,3

Nodamagetocontactorterminal.

Cutoffdoesnotpreventcompletematingofthecontact/terminal.

ProcessIndicator–Class2,3

Cutofftablengthatmatingendisgreaterthan2Xitsthick-nessbutdoesnotimpedemating.

Cutofftablengthatconductorentryendisgreaterthan2Xitsthicknessbutdoesnotprotrudewheninsertedintocon-nectorbody.

Defect–Class1,2,3

Removalofcutofftabhasdamagedcontactorterminal(notshown).

Cutofftabatconductorentryendprotrudesfromconnectorbodywhencontacthasbeeninserted(notshown).

Matingendcutofftabinterfereswithcompletemating.

Note:Contact/terminalneedstomeetform,fit,functionandreliabilityrequirements.Atrialmatingmayberequiredforfinalacceptance.

5CrimpTerminations(ContactsandLugs)

5.3MachinedContacts

5CrimpTerminations(ContactsandLugs)

5.3.1MachinedContacts–InsulationClearance(cont.)

5-24

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Figure5-53definesthepartsofamachinedcrimpcontact.See5.3.2formachinedcrimpcontacts–insulationsupportstylecriteria.

Figure5-53

--`,```,`````,,``,,`,,`,```,,,``-`-`,,`,,`,`,,`

Insulationclearance

Conductorcrimp

Inspectionwindow

5.3.1MachinedContacts–InsulationClearance

Figure5-54

Figure5-55

Acceptable–Class1,2,3

Insulationisflushtotheendofthecontactbarrel.

Conductorisvisiblebetweentheinsulationandcontactbar-relbutnotgreaterthanonewirediameter.

Acceptable–Class1ProcessIndicator–Class2,3

Insulationisgreaterthanonebutlessthantwowirediam-etersfromtheendofthecontactbarrel.

Figure5-56

Figure5-57

Defect–Class1,2,3

Insulationisgreaterthantwowirediametersfromtheendofthecontactbarrel.

Insulationextendsintothebarrelofcontact.

--`,```,`````,,``,,`,,`,```,,,``-`-`,,`,,`,`,,`

Exposedconductorviolatesminimumelectricalclearance.

Figure5-58 Figure5-59

5CrimpTerminations(ContactsandLugs)

5.4TerminationFerruleCrimp

IPC/WHMA-A-620D

January2020

5-33

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IPC/WHMA-A-620D

Terminationferrulesaretypicallyusedtoterminatestrandedwiresintoterminalblocks.

Acceptable–Class1,2,3

Ferrulecavitycompletelyfilledbytheconductor.

Crimpshapeissymmetrical.

Figure5-82

Figure5-83

Figure5-84

Acceptable–Class1ProcessIndicator–Class2Defect–Class3

Conductorrecessedmorethan0.5mm[0.020in].Conductorprotrudingmorethan0.5mm[0.020in].Nonsymmetricalcrimpshape.

6InsulationDisplacementConnection(IDC)

6.2.9DiscreteWireTermination–SubminiatureD-Connector(SeriesBusConnector)(cont.)

Figure6-44

Figure6-45

Defect–Class1,2,3

Wireislessthanflush(notvisibleinthefreespacebeyondthecoverplate)(seeFigure6-44).

Wireisbentupwardsinthefreespaceoverthetopoftheconnectorbody(seeFigure6-45).

Terminationcoverplateisbrokenordeformed(seeFigures6-46,47).

Contactbasismetalisexposed(notshown).

Contactisbentafterterminationanddoesnotfitwithintheterminationcoverslots(notshown).

--`,```,`````,,``,,`,,`,```,,,``-`-`,,`,,`,`,,`

Coversarenotfullyseatedagainstconnectorhousingatcoverendsorcoverisclearlyconvexatthecenter(notshown).

Figure6-46 Figure6-47

8-16

January2020

IPC/WHMA-A-620D

13-14

January2020

IPC/WHMA-A-620D

8Splices

8.2.1CrimpedSplices–Barrel(cont.)

`,,`,```,,,``-`-`,,`,,`,`,,`