APPENDIX B

Reproducible Test Tables

Pages B-2 through B-13 are a summary of test requirements as a convenient format for passing information between user and manufacturer and can be copied freely.

These pages may also be downloaded as editable electronic files from .

IPC/WHMA-A-620B Test Criteria

Table 19-1

Electrical Test Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Clause / Test / Requirements / Requirement Decision
19.5.1 / Continuity Test Parameters / Required (see Table 19-2) / [ ] Not Required
19.5.2 / Shorts Test (low voltage isolation) Parameters / Required unless DWV or IR tests performed
(see Table 19-3) / [ ] Required
[ ] Not Required
19.5.3 / Dielectric Withstanding Voltage (DWV) Test Parameters / Required for Class 3 and some Class 2
(see Table 19-4) / [ ] Required
[ ] Not Required
19.5.4 / Insulation Resistance (IR) Test Parameters / Required for Class 3 and some Class 2
(see Table 19-5) / [ ] Required
[ ] Not Required
19.5.5 / Voltage Standing Wave Ratio (VSWR) Test Parameters / User Specified / [ ] Required
19.5.6 / Insertion Loss Test Parameters / User Specified / [ ] Required
19.5.7 / Reflection Coefficient Test / User Specified / [ ] Required
19.5.8 / User Defined Electrical Tests / User Specified / [ ] Required

IPC/WHMA-A-620B Test Criteria

Table 19-2

Continuity Test Minimum Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Class 1 / Class 2 /
Class 3
/ Other Defined Value
Max Resistance / Tester Default / 2 ohms or 1 ohm plus the maximum specified resistance of wire whichever is greater / ____ Ohms
Max Current / Tester Default / ____ mA
Max Voltage / Tester Default / ____ Volts

IPC/WHMA-A-620B Test Criteria

Table 19-3

Shorts Test (low voltage isolation) Minimum Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Class 11 / Class 21 with clearance/creepage distances (air gaps) ≥ 2 mm [0.079 in] / Class 22with clearance/creepage distances (air gaps) < 2 mm [0.079 in] / Class 31 /
Other Defined Value
Min
Resistance / Tester Default / NA / NA / ____ Ohms
Max Current / Tester Default / ____ mA
Max Voltage2 / Tester Default / ____ Volts

Note 1: Shorts Test (low voltage isolation) is not required when Dielectric Withstanding Test or Insulation Resistance Test has been performed.

Note 2: A maximum voltage and or current should be specified when components within an assembly may be damaged by these tests.

IPC/WHMA-A-620B Test Criteria

Table 19-4

Dielectric Withstanding Voltage Test (DWV) Minimum Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Class 1 / Class 2
with clearance distances (air gaps or creepage) ≥2 mm [0.079 in] and not coaxial/biaxial/triaxial assemblies / Class 2
withclearance distances (air gaps or creepage) <2 mm [0.079 in] or coaxial/biaxial/triaxial assemblies
/
Class 3
/
Other Defined Value
Voltage Level1 / Test Not Required / Test Not Required / 1000 VDC or equivalent peak AC voltage2 / 1500VDC or equivalent peak AC voltage2 / ____ VDC
or
____ VAC
Max Leakage Current / 1 mA / 1 mA / ____ mA
Dwell time / 0.1 Seconds / 1 Second / ____ Second(s)

Note 1: See 19.1

Note 2:Voltage Level is applicable when clearance distance tested is ≥0.58 mm [0.019 in]. When clearance distances are <0.58 mm [0.019 in] an agreement between the User and Manufacturer to de-rate these test levels would be expected.

IPC/WHMA-A-620B Test Criteria

Table 19-5

Insulation Resistance (IR) Test Minimum Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Class 1 / Class 2 with clearance distances (air gaps or creepage)
≥ 2 mm [0.079 in] /
Class 2 with clearance distances (air gaps or creepage) <2 mm [0.079 in]
/
Class 3
/ Other Defined Value
Voltage Level1 / Test Not Required / Test Not Required / DC DWV Voltage or tester default / ____ VDC
Minimum Insulation Resistance2 / ≥ 100M ohms for assemblies ≤ 3 meters [118 in]
≥ 10M ohms for assemblies > 3 meters [118 in]
≥ 500 Meg ohms for coaxial cable of any length / ____ M Ohms
Max Dwell Time / 10 Seconds / ____ Seconds

Note 1: Non-destructive tests (procedure/parameters/stimuli/fixtures) shall be selected and applied in a manner that does not cause damage to the unit under test.

Note 2: IR levels specified applicable at less than 80% relative humidity. When relative humidity exceeds 80% an agreement between User and Manufacturer to de-rate these tests levels would be expected.

IPC/WHMA-A-620B Test Criteria

Table 19-6

Voltage Standing Wave Ratio (VSWR) Test Parameters

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Defined Value
Frequency Range / _____ MHz
Ratio of input power to reflected power / ____:____

IPC/WHMA-A-620B Test Criteria

Table 19-7

Insertion Loss Test Parameters

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Defined Value
Frequency Range / ____ MHz
Max Loss / ____ Decibels

IPC/WHMA-A-620B Test Criteria

Table 19-8

Reflection Coefficient Test Parameters

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Defined Value
Frequency Range / ____ MHz
Max Loss / ____ Decibels

IPC/WHMA-A-620B Test Criteria

Table 19-9

Mechanical Test Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Clause / Test / Requirement1 / Requirement Decision
19.7.1 / Crimp Height Testing / Required for Class 1 and 2 if Pull Force Testing not Performed (see 19.7.2)
(Table 19-10) / [ ] Required for each new setup and again every:
[ ] ____ parts
[ ] shift(s),
[ ] ___ workday(s)
[ ] Not Required
19.7.2 / Pull Force/Tensile Testing / Required for Class 3
Required for Class 1 and 2 if Crimp Height Testing not Performed (see 19.7.1)
(Table 19-11) / [ ] Required for each new setup and again every:
[ ] ____ parts
[ ] shift(s),
[ ] ___ workday(s)
[ ] Not Required
19.7.3 / Crimp Force Monitoring / User Specified / [ ] Required
19.7.5 / Contact Retention / In-Process requirement for Classes 1, 2, and 3 / [ ] Not Required
19.7.6 / RF Connector Shield Pull Test / User Specified / [ ] Required
19.7.7 / RF Connector Shield Ferrule Torsion Test / User Specified / [ ] Required
19.7.8 / User Defined Mechanical Tests / User Specified / [ ] Required

Note 1: In the absence of specific agreed on test requirements between User and Manufacturer or an agreement by the user to accept the manufacturer’s documented test requirements, Table 19-9 defines minimum test requirements for each Class.

IPC/WHMA-A-620B Test Criteria

Table 19-10

Crimp Height Testing

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Requirement / Other Defined Value
Max Flash Height / 0.5x material stock thickness / ____ mm
____ [ in]
True Crimp Height / Use terminal supplier’s specification1 / ____ mm
____ [ in]
Width
(noncircular crimp, i.e., Lugs) / ____ mm
____ [ in]

Note 1: If the user or manufacturer has objective evidence indicating that the terminal supplier’s specification is not sufficient, other values may be agreed upon between User and Manufacturer.

IPC/WHMA-A-620B Test Criteria

Table 19-11

Pull Force Testing Minimum Requirements

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter / Class 1 / Class 2 /
Class 3
/
Other Defined Value
Pull Force / Appropriate Industry Standard (UL, IEC, SAE, Table 19-12 or 19-13) 1 / Table 19-12 / ____ N
____ Kp
____ Pounds
Pull-Rate2 / Not Specified / Controlled Rate / ≤1 inch/minute / ____/minute
Method / Not Specified / Not Specified / Not Specified / [ ] Pull & Break
[ ] Pull & Return
[ ] Pull & Hold
[ ] Pull, Hold & Break
Hold Time3 / Not Specified / Not Specified / Not Specified / Seconds

Note 1: It is the responsibility of the harness manufacturer and/or the user to determine which set of tensile test values is appropriate.

Note 2: Controlled rate indicates a specified pull rate that is held constant throughout the pull.

Note 3: The Hold Time parameter is relevant only if the “Pull & Hold” or “Pull, Hold & Break” method is used.

IPC/WHMA-A-620B Test Criteria

Table 19-14

RF Connector Shield Pull Force Testing

Assembly Identification ______

Testing required for a [ ] Class 1, [ ] Class 2, [ ] Class 3 assembly.

Test requirements established by

[ ] A-620 default minimum test requirements for this class except as modified below.

[ ] User’s acceptance of manufacturer’s documented test requirements except as modified below.

Requirements below are defined by [ ] Manufacturer, or [ ] User.

Date ______Name______

Parameter /
Defined Value
Pull Force / ____ N
____ Kp
____ Pounds
Pull-Rate1 / ____/minute
Method / [ ] Pull & Break
[ ] Pull & Return
[ ] Pull & Hold
[ ] Pull, Hold & Break
Hold Time2 / ____ Seconds

Note 1: Controlled rate indicates a specified pull rate that is held constant throughout the pull.

Note 2: The Hold Time parameter is relevant only if the “Pull & Hold” or “Pull, Hold & Break” method is used.

©Copyright 2012. IPC, Bannockburn, Illinois and Wire Harness Manufacturers Association, Eden Prairie, Minnesota. All rights reserved under both international and Pan-American copyright conventions. Reproduction of this page is authorized. Electronic copies of these tables may be downloaded from