The cable or harness system is often overlooked, but it controls the flow of electronic information between components. The IPC/WHMA-A-620 document has its roots in the last century and is the result of long term cooperation between the IPC 620 Committee and the Wire Harness Manufacturers Association. Soon after the original publication, a Training/Certification Program was developed along the same lines as that of the IPC-A-610, a document keyed to inspection and acceptance criteria. Like many of other IPC documents, IPC-A-620 is divided into sections covering topics of interest from general requirements and document structure to testing requirements for wiring and cables.

The EMPF offers operator proficiency training for IPC/WHMA-A-620. This specification describes the accept and reject criteria for producing crimped, mechanically secured or soldered interconnections as well as the lacing and restraining criteria related to cable and wire harness assemblies. The duration of the training program can range from 1 to 3 days, depending on the modules selected. Proficiency is determined through a series of written, standardized exams developed by the IPC/WHMA. Operators will be tested on each module in which they are trained and will receive a portable certification (valid for 2 years) in the areas where proficiency is demonstrated. Following is a brief description of each of the modules available.

Modules 1 and 2 (prerequisites for modules 3 - 18)
Covers the purpose and scope of the document, general criteria, and related applicable industry specifications. Students will learn how to properly interpret the acceptability requirements, understand the differences between the classes of electronics, and become familiar with commonly used terminology. Companies can select additional training for the various other cable and wire assembly acceptance requirements.

Module 3 - Preparations
Covers the allowable amount of conductor strand damage, wire separation, and insulation damage.

Module 4 - Solder Terminations
Covers the requirements for tinning and gold removal of wires, cleanliness, insulation, flexible sleeve insulation, wire separation, wire attachment, and solder requirements for wires attached to common terminals.

Module 5 - Crimp Terminations
Covers the requirements and allowable deformation for stamped/formed contacts and machined crimp contacts.

Module 6 - Insulation Displacement Connections (IDC)
Covers the acceptance criteria for mass termination, flat cable, and discreet wire terminations.
Module 7 - Ultrasonic Welding
Covers insulation clearance and weld nugget criteria.

Module 8 - Splices
Covers soldered splices, crimped splices, and ultrasonic welded splices.

Module 9 - Connectorization
Covers acceptance criteria for hardware mounting, strain relief, sleeving, boots, and allowable amount of connector damage.

Module 10 - Molding Potting
Covers the requirements for molding and potting of cables and wires.

Module 11 - Cable Assembly and Wires
Covers the identification of reference designators and surfaces and how to properly measure wire lengths.

Module 12 - Marking and Legibility
Covers the requirements for marking content, legibility, permanency, location, functionality, and marker sleeves.

Module 13 - Coaxial and Twinaxial Assemblies
Covers the requirements for stripping, center conductor terminations, solder ferrule pins, coaxial connectors, terminal covers, shield terminations, center pin position, semi-rigid coax, swage-type connector, and soldering and stripping of biaxial or twin axial wires.

Module 14 - Wire Bundle Securing
Covers the proper tie wrap and lacing application, requirements for wire breakouts, and wire bundles.

Module 15 - Shielding
Covers the requirements for electrical shielding. Operators will learn requirements for braided shielding, shield termination, proper tape wrapping, conduit shielding, conductive coating, and shrink tubing.

Module 16 - Cable and Wire Harness Protective Coverings
Covers protective coverings used for cable and wire harness assemblies. Subjects include braid, taping, sleeving, and spiral plastic wrap.

Module 17 - Installation
Covers the requirements for installation of hardware and wire harness installation. Operators will learn the proper assembly sequence for hardware and the stress relief required for wires.

Module 18 - Solderless Wrap
Covers the acceptance requirements for solderless wrap connections. Topics include number of turns, turn spacing, end tails, insulation wrap, raised turns, connection position, wire dress, wire slack, plating, and damage.

Employees who attend a regimented training program will be better equipped to recognize acceptable products from defective ones. For further information, please contact the EMPF registrar at (610) 362-1295 or registrar@empf.org.