upuuteg aug2012

IPC/WHMA-A-620B Comment Resolution Following August 2012 Ballot This report is divided into multiple tables: Table 1 - Actions For Publication (1-2) Table 2 - Resolved Ballot Comments That Effected Criteria (3-11) Table 3 - Ballot Comments Deferred to Next Revision or Other Committees (12-32) Table 4 - Resolved Ballot Comments with Editorial or Changes That Did Not Significantly Affect Criteria (33-108) Table 5 - All Comments Resolved At Previous Meetings (109-492) Table 6 - Comments Deferred to Hdbk-620 or Other Task Groups (from previous meetings) (493-500)

TABLE 1 - ACTIONS FOR PUBLICATION Source Ref. # Recommendation Reason for Recommendation Resolution

NASA MSFC Engineering

4.3 1. lead free symbol should be bigger with better resolution The Pb in the symbol is barely legible and may cause confusion.

STAFF ACTION 7 Apr 10 Will be enlarged at publication


15.2.1.4 2. Propose new: Shield termination Shield Jumper Wire Common Ground Point Requirements for shield jumper wires spliced to a common point ground shall [D1D2D3] be the same as the splice requirements documented in 8.1 or 8.2 for the type of splice called out, e.g., lap.

Criteria accepted. ACTION: Garry McGuire, Marshall SFC to provide pix

TABLE 2 - RESOLVED BALLOT COMMENTS THAT EFFECT REQUIREMENTS Source Ref. # Recommendation Reason for Recommendation Resolution

Bob Potysman, Assembletronics

1.10 3. Define Flowdown, why is this important? Delete section I have no idea what this section is communicating; it really is confusing as to its intent.

This is important for subcontracting. Dave Scidmore will contact Bob to help with understanding.

Randy McNutt, NGC

8.2.3 4. Revise: These criteria apply to crimped end lap splices formed in a machined contact (see Figure 8-56). When attaching multiple wires to a terminal the combined circular mil area of the wires shall [D1D2D3] comply with the circular mil area range for the terminal. 5.3.4 provides criteria for wire barrel crimp 5.3.5 provides criteria for CMA buildup.

Accepted with modification

IPC/WHMA-A-620A 1st Working Draft January 2002

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16.3 provides criteria for shrink sleeving. Target Class 1,2,3 Less than 50% overall wire diameter clearance between the

insulation and contact barrel. Conductors bottomed in the contact. Conductor strands fill the inspection window. Crimp indent is centered between the inspection window and

the wire entry end of the barrel. Crimp indents around the contact barrel are evenly spaced

and of equal depth. Contact has no visible fractures, cracks, or exposed base

metal in crimp barrel area. Machined contact pin cut end does not have sharp edges. Acceptable Class 1,2,3 When using insulating shrink sleeving it is less than 2 wire

group diameters beyond the cut end and is sealed. When using insulation shrink sleeving it is greater than 2 wire

group diameters beyond the cut end. Machined contact pin cut end is insulated with shrink

sleeving or cap. Machined contact is not cracked after cutting off pin. Acceptable Class 1 Process Indicator Class 2 Defect Class 3 End splice insulating shrink sleeving or cap overlaps the wire

less than 1 diameter of the wire group. End splice insulating shrink sleeving or cap is not sealed

when it is less than 2 wire group diameters beyond the cut end.

Defect Class 1,2,3 Machine contact pin is not cut. Machine contact is cracked after cutting off pin. Defect Class 2,3 Insulation is greater than 2 wire diameters from the end of the contact barrel.

Randy McNutt, NGC

9.5.2 5. Add Note to read as follows; This criterion applies only to connectors with unwired contacts inserted.

If installed as shown in cavities without a contact the sealing plug can be inserted to a depth that will cause the plug head to be retained by the contact retention fingers. At that point they are non-removable and the connector is scrap. These instructions will lead to a failure mode.



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Barry Morris, ART

Table 13-1 6. Add in strand damage criteria for 1 (single strand) This has been added to table 3-1 (allowable strand damage). Coaxial cable can have a single (solid) centre conductor. Therefore the table should show maximum allowable damage for this.

Accepted

Blen Talbot L-3 Comm.

13.10.3 7. A123 delete 3rd bullet Trim area offset does not exceed 10% of the cable diameter

(D) beyond the perpendicular angle to the center conductor.

Adds no value, the surface gets trimmed to the face of the connector. If the statement is left as is we need to reference Figure 13-3 for understanding.

Added reference( See Figure 13-3)

Stephen Fribbins, Fribbins Training Services

14.3.2 8. Replace Table 14-1 Minimum Bend Radius Requirements with IPC-A-610E, Table 4-1 Minimum Bend Radius Requirements, but delete Cable Type: Coaxial Cable line as this is covered below in Coaxial Fixed and Flexible Cables.

Table 14-1 does cover bend radius requirements for many of our wires and cables.


Barry Morris, ART

14.3.2 9. Add criteria for Flat ribbon, CAT5, Fibre optic etc. (replace table 14-1 with table 4-1 from IPC-A-610E)

The table 4-1 in A-610E shows a far more comprehensive range of cable, many of these are more common in cable harness assemblies. Therefore is suggest using the table from A-610E.



14.3.4.1 10. Defect 123 adjacent to figure 14-34, delete the last (3rd) bullet Change 3rd bullet to read: Any exposed part of the conductor

Makes more sense if we reference the exposed conductor. Accepted with modification


14.3.4.2 11. D123 Delete 3rd bullet Change 3rd bullet to read: Any exposed part of the conductor

Makes more sense if we reference the exposed conductor. Accepted with modification

TABLE 3 - BALLOT COMMENTS DEFERRED TO NEXT REVISION OR OTHER COMMITTEES

Source Ref. # Recommendation Reason for Recommendation Resolution

Blen Talbot, L-3 Comm.

1.1 12. Add a statement to indicate that requirements apply to stand alone cables, cables installed or assembled inside chassis, sub-assemblies, systems or anywhere similar characteristics exist. Suggest adding after the first sentence. However, where similar characteristics exist (e.g., chassis, drawer or enclosure), this document provides product acceptance criteria.

The committee did not agree to expand the scope of this standard. Box build requirements should be deferred to IPC-A-630.


4.6 Defect Class 2,3 Insulation sleeving overlaps the wire insulation by less than 2 wire diameters (B). add clarifying note 4.0: Where sleeving is used to provide strain relief the overlap shall (Defect 1,2,3) be 2 wire diameters (where sleeving is used to provide insulation protection and the wires are not subject to strain the overlap shall (Defect 1,2,3) be minimum 1 wire diameter.) Define why section 4 and section 8 sleeving overlap conditions are different.

Resolve blue highlighted inconsistency Defer to Rev C.


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4.8.2.4 13. Add to the end of the 2nd and 3rd bullets not shown Examples of side route defects are not shown. No examples were provided by committee members;

Defer to Rev C.

Chad Gyorke, DRS-c3a Rob Boyd, Schleuniger Inc.

5.1.1 14. As an IPC/WHMA CIT I often get asked questions from the engineer and quality groups at my facility, here is a question that I could use some help answering. The insulation crimp tabs on this particular Molex crimp overlap. The conductor crimp is to the book. The contact passes pull testing and the crimper we used was made by the contact manufacturer. Would you deem this contact acceptable for a class 3 product?

620A is mute regarding insulation crimp tabs overlapping

Statement added to introduction Nothing received; deferred to future revision

Rob Boyd, Schleuniger Inc.

5.2.2 15. Need better picture (fig 5-36) ACTION: Bob Grenke, Molex, to see if they can provide better pix. Nothing received; deferred to future revision


5.5 16. 5.5 Shrink Sleeving Wire support Crimped/Soldered Terminals Section applies to both crimped and soldered terminals. Sleeving may be used to cover crimped or soldered termination for stress relief or electrical isolation. The heating processes used to shrink the sleeving insulation shall not damage the crimped device, wire, sleeving adjacent components, nor reflow the solder connection. Target Sleeving extends past the brush but does not extend into the mating area of the terminal. Sleeving extends onto the wire insulation 4 wire diameters. Sleeving is tight on the crimped device and the wire.

Acceptable Sleeving is tight on the crimped device, but not on the wire. Sleeving is flush the end of the brush. Sleeving extends onto the wire insulation a minimum of 2 wire diameters. Defect Sleeving extends into the mating area of the crimped device. Sleeving is damaged e.g., Split, cracked or charred. Sleeving is loose on the crimped device Insulation extends less than 2 wire diameters onto the wire insulation.

New criteria recommendation. Defer to Revision C.


8.2.2 17. Add an introductory paragraph stating that the color code identifies the (AWG) wire range of the splice.

Clarification (2012> Defer to handbook


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9.2.1 18. Target 123, Delete the third bullet and add the following note: NOTE: Clamps must be tightened to fully collapse the split lock washers and secure the jacket, wires or bundle but need not be fully closed (touching).

There can be space between the inner surfaces of the clamps and the connector backshell ears/tongs on both sides. Clarifies the criteria

Defer to Rev C


9.3 19. This section should be rewritten but deferred to the rev C. By default of the section title this section addresses the bonding of both boots and bonded sleeving junctions.

Defer to Rev C


9.3.2 20. in the Defect 123, adjacent to Figure 9-33, 34, 6th bullet we have the following statement : Adhesive is excessive and flowed beyond the boundaries of the joint. How would you explain what is meant by the boundaries of the joint ?

Defer to Rev C


12.6.2 21. I think the criteria thats located in 620, 12.6.2 is ok for cables/harness bundles, but for a single wire where the marker sleeve is the smallest size available and the recovered (shrunk) inside diameter is larger than the wire and there is no other option due to the wire gauge then we need an option to allow this condition to be acceptable. If the marker is captivated between points and there is no way the marker can escape, as shown in the picture (E1). Im referring to the marker that is captivated between two points. In this case between the crimped lug and the point of break out from a wire bundle or any two points (A & B). The other marker (E2) should be a defect because it slides freely and is not captivated between points, and come will come off. In 12.6.2, Acceptable Class 1,2,3, if the text (no sliding) was removed It would help. Because of the no sliding many of the inspectors try and see if the marker will slide if they can move it they fail it. I dont think it adds a lot to the statement. Then the condition above would be acceptable and could even meet the target of being completely shrunk and secure (between point A and B). In the Defect Class 1,2,3 should just state Marker sleeve not secure. ###### The target and the acceptable should be reversed. Leaving no sliding in the acceptable makes the acceptable more restrictive than the target. There should be some relief in the acceptable. If the marking can move more than 12 inches from the end that it references, then we are covered and the criteria for Location and Ordination (12.4) would apply (marker not located properly). Leaving the document as is, creates a problem that is easily resolved. This would apply to a bundle of wires as long as the marker is secure between points that restrict its movement and is located within 12 inches of the end it references. There is currently not a defect for sliding. The defect statement is The marker sleeve is not sufficiently shrunk to remain secure, so since there isnt a defect for sliding I could apply 1.12.7 Conditions not Specified, and accept the marker that moves but is secure.

Defer to Rev C


13.5 22. Change the Target 123 to read the same as the first bullet of Target 123, section 4.8.3.1 Lead extends through the slot and is visible on the exit side. Make the two sections the same where its possible to do so.

Consistency between sections increase ease of use. Allows inspection to become more precise and accurate.

Defer to Rev C


13.6 23. T 123 delete statement and use the target statement of 4.8.3.2 Solder forms a fillet with that portion of the lead that is in contact with the terminal.

The title of the page is Coaxial Connector Center Conductor Solder so this section should reflect solder criteria not wire placement that was addressed in 13.5

Defer to Rev C


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13.6 24. A123 Delete Bullet and replace with 4.8.3.2, A123 bullets Solder Fills The Terminal Slot. Lead or wire end is discernible in the solder on the exit side

of the terminal


Defer to Rev C


13.6 25. Add a defect 123 as in 4.8.3.2 Fillet not formed with 100% of the portion of the wire that is

in contact with the terminal. Lead end not visible in solder on exit side of terminal.


Defer to Rev C

Garry Maguire, MSFC

13.12.2 26. Modify figure as showing in post-ballot draft Target Class 1,2,3 Wire, insulation, or solder does not extend above the ring shoulder (A). Conductor (B) wrap equals or exceeds 180 degrees. Conductor wrap is in contact with the surface to be soldered for the entire wrap. Continuous solder fillet for the entire length of the conductor wrap. Mating surfaces free of solder. Acceptable Class 1,2 Process Indicator Class 3 Solder is present on the surface of the ring but does not prevent assembly of the connecter. Conductor wrap is less than 180 degrees but more than 90 degrees. Conductor wrap of 180 degrees (or more) has solder fillet for 75% of the length of the conductor wrap. Conductor wrap of less than 180 degrees has solder fillet for the complete length of the wrap. Acceptable Class 1 Process Indicator Class 2 Defect Class 3 Conductor does not contact the surface to be soldered for the entire wrap length. The ring (A) has a thin film of solder on the outside surface. With conductor wrap of less than 180 degrees the solder fillet of conductor wrap less than 100% of the

length of the conductor wrap. With conductor wrap of 180 degrees or more the solder fillet of conductor wrap is less than 75% of the

length of the wrap. Defect Class 1,2,3 Solder on any mating surface. Solder on any surface that prevents assembly of the connector. Wire, insulation, or solder, extends above the ring profile. Insulation is melted or charred (not shown). Wire wrap less than 90 degrees.

Defer to Rev C


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14.3.5 27. I think there are a couple of problems where we have similar criteria such as: --In 620A, clause 14.3.5 adjacent to Figure 14-34, A1, P2, D3, its a Defect Class 3, if there is a wrap/strap placed over splices or solder ferrules (same in the draft). --In the Ballet Draft we added in clause 9.2.1, a new picture, Figure 9-14 (from L-3)and a new bullet in the Defect Class 123, that states that its a defect to have a splice or ferrule located under a strain relief clamp. Both of these conflict with 15.2.1.1, where we have a note that states Shield terminations may be located under the strain relief clamps as long as protection is provided under the clamp, i.e., tape, sleeving or grommet. Shield terminations is pretty broad and covers any type termination. I think this is why we went ahead and added into WS-003, 3.9.2 (Internal document), Splice or ferrule under the strain relief is a Defect. Both situations could cause the same results i.e., shorting, damaged insulation, cold flow etc..

Defer to Rev C


16.2.1 28. Change Sealant to adhesive lined or adhesive as appropriate throughout this section: Sleeving/Shrink Tubing Sealant Adhesive Lined

In Australia and Asia we typically use the terms Adhesive Lined as in the Boots and Sleeving section. If this is not changed I am not too concerned.

Defer to Rev C


19.7.2.1 29. John and I got together and looked at Table 19-12, and looked at the tables that were originally used, MIL-T-7928 and MIL-C-390290 and the original tables are different for those wire gauges (Table 19-12 matches). One of the tables didnt address 18 AWG and that is why we have NE in those columns. John can shed more light than I. Something else--In all instances the Silver machined column matches the stamped contact column after 16 gauge, except the 8 gauge row. There the machined is 220, and the stamped is 225. Is this correct or possibly a typo?

Defer to Rev C


13.12.2 30. Recommended content and pix are at the end of this comment list. ACTION: Garry McGuire, Marshall SFC to do editorial review and provide to IPC Deferred to Rev C


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TABLE 4 - RESOLVED BALLOT COMMENTS WITH EDITORIAL OR OTHER CHANGES THAT DID NOT SIGNIFICANTLY AFFECT CRITERIA

Source Ref. # Recommendation Reason for Recommendation ResolutionBob Potysman, Assembletronics

all 31. User, Supplier and Manufacturer are defines nouns I would like to see them capitalized throughout the document. (1.15, 8.0) In some cases we see end-user or end user, where this occurs we would like to see it either replaced by User or define end-user

Editorial: End-user is either redundant to the defined term or would point to the individual or entity putting the device into service.

IPC staff - made upper case chapter 1, will scrub all chapters before publication.


1.7 32. 1.7 Terms And Definitions Terms are consistent with the definitions provided by IPC-T-50. For the understanding of this document, selected definitions pertaining specifically to cable and wire harness manufacturing are listed below and in Appendix A. Editorial note: Change to are listed below, at the beginning of each section or in Appendix A.

Reflects reality Editorial,


1.9 33. The user (customer) has the opportunity to specify alternate acceptance criteria. Capitalize User, Supplier, Manufacturer where used as a defined term would eliminate the need to add (customer) to the text.

Editorial: for consistency Editorial, deleted word

Dan Foster, MDA

1.13.2 34. The first two paragraphs conflict with the third Conflict within the document. The first two paragraphs state you do not have to calibrate class one products but the third paragraph says you have to have documented calibrated systems for all classes.

Conflict removed; changed to N1D2D3

Dan Foster, MDA

1.15.4 35. The manufacturer shall [N1D2D3] document and disposition each defect. This conflicts with 001E 1.5.1

Conflict between the two documents It will remain as N1D2D3; the committee acknowledges that it is different than J001 but these are separate and stand-alone documents.

Dan Foster, MDA

1.15.5 36. User concurrence shall [N1D2D3] be required for use-as-is and shall [N1N2D3] be required for repair dispositions.

This conflicts with 001E 12.2 for class two J001F draft is N1D2D3

It will remain as N1N2D3 for repair concurrence

Dan Foster, MDA

1.17.1 37. Sampling Manufacturers shall [N1D2D3] define a sampling inspection program as part of a documented process control plan.

conflicts with 001 11.2.3 class 2 J001F draft is N1P2D3

No change

Doug Holand, Ultrax Aerospace

3 38. Add a table for allowable strand damage to the shield braid on a twisted pair. Existing Table 13-1 is specific to coaxial cables and cant be applied to simple twisted pair with shield.

Not need; chapter 15 Shielding sets the strand damage of Table 13-1 as requirements for this shielding.


3.2 39. Adjacent to Figure 3-2, A123, 3rd bullet, delete There are Adds no value to the statement. Statement should just say Attached burrs that will not be dislodged during process or operation.

Editorial, changed


3.4 40. The word pigtails is used should define what is meant by the term.

Better understanding difficult to explain and there isnt a definition in the appendix or IPC-T-50.

The word was deleted


9


4 41. Third paragraph Change the word sleeves to devices Consistency throughout the document. Title of clause 8.1.5 is Heat Shrinkable Solder Devices. It makes it difficult for those folks that English is a second language to use two different words for the same thing.

Editorial, changed

Vicki Hagen, Delta Group Electronics, Inc.

4.3 42. The solder connection wetting angle (solder to lead and solder to terminal) shall not [D1D2D3] exceed 90

Wrong brackets used. fixed


4.4 43. Don't delete: Limited solder wicking during tinning or soldering of wire is permissible as long as the solder does not extend to a portion of the wire that is required to remain flexible.

This is acceptability statement Committee did not accept; this is covered elsewhere


4.6 44. change Defect Class 2,3 to Defect Class 1,2,3 DLF has a few comments without recommendations Resolve DLF comment to match 8.1.1 and 8.1.4.1 and 610 where sleeving over solder joint has been specified

D1,2,3 changed Feb 2012 All DLF comments are resolved

Barry Morris, ART

4.8 45. The reference to additional stress relief criteria shown on the last line on this page is incorrect 6.2.7 should be 6.2.8 and 15.3.3 should be 15.3.3

fixed


4.8.1.1 46. Note 1: A wire that is wrapped more than 360 and remains in contact with the terminal post is considered an overwrap or spiral wrap (see Figure 4-18-A).

Wrong figure referenced. fixed

Barry Morris, ART

4.8.2.2 47. Note 1 below the table references figure 6-18-A, it should be 4-18-A

fixed

Barry Morris, ART

4.8.2.2 48. The fourth bullet for the target condition references figure 4-26 it should be figure 4-32

fixed


4.8.3.1 49. Figure 4-41 Defect 123, change statement to read the inverse of acceptable 123: Lead or wire end not discernible on the exit side of the terminal

A123 adjacent to Figure 4-43, states that the minimum requirement is that: the lead or wire is discernible on the exit side of terminal. This creates a conflict because the defect infers flush is acceptable which conflicts with the acceptable statement. Flush may not be discernible.

If it cannot be discerned as flush it would not be acceptable.


4.8.3.1 50. Combine the two Defect 123, adjacent to Figure 4-44. Both statements are a defect all three classes. Editorial, completed


4.8.4.1 51. In Table 4-5, bottom row add nonadjacent after two Consistency, should be and contact two nonadjacent sides of the terminal. It makes it difficult for those folks that English is a second language to use two different words for the same thing.

Changed to non-common


4.8.4.1 52. Change to: Acceptable - Class 1 Defect - Class 2,3 Wire does not contact 2 nonadjacent sides of the terminal

when wire wrap is less than 900.

Acceptable - Class 1 Defect - Class 2,3 Wire does not contact 2 nonadjacent sides of the terminal when wire wrap is less than 900 is not consistent with Table 4-5



4.8.4.1 53. Add in: Acceptable - Class 2,3 Wire wrap equal to or greater than 90 or wire contacts two

sides of the terminal.

No A2 A3, although shown in Table 4-5 Accepted with modification


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4.8.4.1 54. In the Target 123, second bullet change the word opposite to nonadjacent .

Consistency in the document. . It makes it difficult for those folks that English is a second language to use two different words for the same thing.



4.8.7 55. In Defect 123, adjacent to Figure 4-70 Add (A) after any 2 terminals (A)

There is a key A in Figure 4-70, that is not referenced in the text.

The arrows are referenced in the bullet.


5 56. The seventh paragraph needs further explanation of what is meant by support filler.

This needs to be explained so that all users understand what is meant. Is this the addition of heat shrink applied to a wire in the area of the insulation support tabs on a stamped and formed, open barrel terminal to increase its size in order to meet acceptance criteria?



5 57. In the 12th paragraph delete As an exception from the first paragraph, Then move the paragraph above paragraph 10.

There is no exception. Rearranging the paragraphs makes a better flow.

The exception is to the clause above this statement requiring use of the terminal mfrs documented tooling.


5.1.2 58. Add key to picture Reference is made to D and C in the text but not included in the illustration.

Deleted "D" and "C" from bullets; the words adequately convey the intent.


5.1.3 59. These criteria apply to stamped and formed contact with insulation support (see Figure 5-14) or without (see Figure 5-15).

Missing parentheses. fixed

David McCary 5.1.5 60. And 5.2.2, duplicate pictures with different criteria Fixed in ballot Blen Talbot L-3 Comm.

5.3.5 61. Figure 5-69 A123, 3rd bullet add to the end and does not violate electrical clearance

Strands one wire diameter in length beyond the contact in some instances may violate electrical clearance.

The Defect bullet adequately covers this


5.3.5 62. Add an introduction that states: When CMA build-up is required by engineering documentation, the criteria of this section apply. When CMA build-up is required `it may be achieved by using one of the following methods: The conductor folded or bent back to achieve the correct

CMA. The conductor area is increased by the use of bare (non-

insulated) filler conductors as required to achieve the correct CMA build-up.

A combination of both the foldback and the filler method are used to achieve the correct CMA buildup.

Special CMA Adaptor Bushings are used when called out on the assembly documentation. (Use of these adaptors will usually require special additional insulating coverage requirements.)

Delete everything in the Target but the last bullet.

Its an engineering function to determine the appropriate wire gauge and method of CMA build-up. This is not an operator function and we shouldnt infer that it is. Most of the Target Information is how too design and should be deleted. If engineering determines that a foldback and a cretin gauge filler wire is required or if only a filler wire is required, it should be listed as a note on the engineering drawing. Maybe this should be located at the beginning of Section 5 and reworded so that it can apply anytime CMA build-up is required. Or create a new section and move all CMA build-up material for both Stamped and Formed and Machined Contacts into one section.

"how to" should be deferred tot he handbook


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5.4 63. Add an introduction: These ferrules are intended to terminate stranded wire for insertion into terminal blocks and are available insulated and non-insulated.

Add usage information. Editorial, added the first part of the sentence; did not add info about the different kinds of ferrules that are available.

Barry Morris, ART

5.4 64. The figure below 5-74 is shown as figure 5-5, it should be figure 5-75

fixed


6.2.1 65. First paragraph replace the word connector with the word contact

What is shown in Figure 6-20 is a discrete contact not a connector.

Editorial, changed


6.2.1 66. Add a key to Figure 6-20 to identify the side beams. The side beams are referenced in the Defect 12, Figure 6-34, but not in the main figure where all other parts of the contact are identified.

The side beams are adequately identified the only place they are mentioned.


6.2.6 67. Change: Acceptable Class 1,2,3 Wire extends at least 50% of the distance between the contact edge and the back wall of the connector. To: Length (L) of the wire past the electrical (second) contact is equal or greater than 50% overall wire diameter.

These two dot points in 6.2.6 are inconsistent: Acceptable - Class 1,2,3 Wire extends at least 50% of the distance between the contact edge and the back wall of the connector. Defect - Class 1,2,3 Length (L) of the wire past the electrical (second) contact is less than 50% overall wire diameter.

A1,2,3 is stating the desirable condition but it doesn't become a defect unless the condition is as stated in the defect. The 50% distance to the back wall can vary but the concern is that the wire extension through the electrical (back) slot is at least 50% D.


6.2.9 68. Change the Target to: The wire ends are from flush to less than 0.5 mm [0.02 in] past the termination plate (1).

Clarity and readability

Not accepted


6.2.9 69. Figure 6-46 After Wire recessed add (not visible in the free space past the cover plate).

Clarification Accepted with modification


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6.2.10 71. Add the key number in the criteria statements i.e., Target - Class 1,2,3 All wires are bottomed in connector and visible through the front of the connector. The primary strain relief (4)is crimped tightly against the cable jacket. The cable jacket extends past the point of the strain relief (4). For connector without a loading bar (1), the secondary strain Relief (3) is crimped so that it is in contact with the insulation. The terminals (5) are crimped so that no parts of the terminals (5) are above the plane created by the top of the plastic dividers between the Terminals (5). Acceptable - Class 1,2,3 Wires are not bottomed but all are within 0.5 mm [0.02 in] (2) or less of the end wall and all are inserted at least past the terminal (5). Terminals meet the connector manufacturers crimp height specification. Defect - Class 1,2,3 The primary strain relief (4) is not in tight contact against the cable jacket or is not latched. The cable jacket does not extend past the primary strain Relief (4). Wire ends are not within 0.5 mm [0.02 in] (2)or less of the contact end wall or are not inserted past the terminal (5). All wire ends are not visible through the face of the connector. Connector without loading bar (1) the secondary strain relief (3) is not in contact with the wires or is not latched. The terminals (5)are not crimped sufficiently and extend above the plane created by the top of the plastic dividers between the terminals (5).

Easier to relate to the illustration when the keys are used in the text.

Editorial; most changes made. A feature is only referenced to a key number the first time it appears in this clause.


6.2.10 72. Replace all occurrences of the word contacts with Terminals (6 places)

Should be consistent and keep the term the same as what is used in the key of Figure 6-50 Its difficult for those folks that English is a second language to use two different words for the same thing.

Editorial, changed


8.1.4 73. Reword 5th paragraph to: Solder shall wet all elements of the termination forming a fillet joining the wires for the length of the overlapped area of the splice. Individual strands should remain visible.

Statement is incomplete (see the published 620A, 8.1.4) This paragraph was changed Sep 2010..


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8.1.4.1 under Acceptable-Class 1,2,3

74. Conductor strands form a smooth joined section.

Statement is listed twice, delete one statement. fixed


8.1.4.1 under Acceptable-Class 1,2,3

75. Sleeve or wire insulation is slightly discolored but not burned or charred.

Statement is listed twice but with different wording, delete one statement.

fixed


8.1.4.1 76. Figure 8-24 Delete Process Indicator 23 and move criteria to Defect 123

Picture is actually showing reflowed solder under the sleeving and was a defect all classes in rev A.

This paragraph was changed Sep 2010..


8.1.4.1 77. A123 8th bullet delete from the end of the bullet and the cut end is sealed. Also A1P2D3 Delete 2nd bullet

I dont understand why sealing the cut end is imposed here and not for an unused wire (14.3.4), why is this now a requirement?. Could also drive costs by adding material and processing to the product?

The committee discussed why seals are required and did not agree to delete the bullets related to seals.

Randy McNutt, NGC

8.1.5 78. Acceptable Class 1, 2, 3: Remove new 10th bullet Duplicate of requirement in 3rd bullet Editorial, corrected


8.1.5 under Defect Class 1,2,3

79. Wire strands are exposed (not shown). Missing r in strands. fixed

Barry Morris, ART

8.2.1 80. The third, single line, paragraph references 16.3, it should be 16.2 fixed


8.2.1 81. Figure 8-42 Acceptable 123, 5th Bullet makes no sense to reference Figure 8-42. Delete the bullet

I dont understand why sealing the cut end is imposed here and not for an unused wire (14.3.4), why is this now a requirement?. Could also drive costs by adding material and processing to the product. Bullet 6 adequately addresses the criteria for end splices

Correct reference is 4-83.


8.2.1 82. Target 123 delete Bullet 6, If applicable, meltable sealing rings have flowed.

Typically sleeving with meltable sealing rings does not apply or used with this type of splices.

Committee did not agree to remove; the if applicable words establish when this is needed


8.2.4 83. Delete the 4th paragraph Why would one use this and then plug the end? Seals are required; this was not accepted


14


9.1.4 85. Add: Change the second paragraph to indicate that the locking teeth are not visually inspectable; and should be determined by process control. It should be noted that the interlocking teeth are not visible that the locking ring has been removed.

The pictures give the impression that the interlocking teeth are visible when they are not because they are covered by the locking ring.



15


14.1 97. Cable tied with a bowknot or other non-locking knot (Figure 14-10).

Wrong figure is referenced; figure should be 14-11. fixed


14.2.2 98. Note: Figures 14-19 through 14-23 provide examples of typically acceptable restraining configurations.

Figure numbers have changed it should be 14-19 through 14-24.

Fixed


14.3.2 99. Routing Bend Radius Table 14-1 does not align with the IPC-A-610E Table 4-1which is a better table, more complete.

Use the same table as in IPC-A-610E.


14.3.4.1 100. Wire may extend straight down length of bundle (Figure 14-32) or be folded back (Figure 14-31).

Figures have changed to 14-33 and 14-32. fixed

Barry Morris, ART

14.3.4.2 101. The figure referenced in the first acceptable bullet are incorrect The first reference should be (Figure 14-33) and the second reference should be (Figure 14-32)

Fixed

Garry McGuire, MSFC

15.2.1.1.1 102. Delete solder/heat shrinkable solder device from the title and add a paragraph under the title that points to 8.1.5 for criteria specific to heat shrinkable solder devices.

This clauses title makes this specific to heat shrinkable solder devices. The method is often done by soldering a lead to the shield and then covering with shrink sleeving (not a solder sleeve).


Randy McNutt, NGC

15.3.2 103. Change throughout Band-It Clamp with Metal shield termination band

Band-it is a registered trademark of Band-It IDEX Corp., so we should use the generic term used in AS85049. There is more than one company that makes these type bands and as written their bands many not be inspected.

Corrected


16.1.1 104. Conflict between the measurements of acceptable which states there is a overlap of 40 mm and defect which states that it is a defect for class 3 if the overlap is less then 38 mm.

For Defect Class 3 if the overlap is less than 40 mm. Fixed to 38

Randy McNutt, NGC

17.2 105. Revise 2nd paragraph to read: All hardware shall [D1D2D3] be assembled in accordance with the suppliers (1.7) specifications, or documented process procedure.

As written any company with an internal process document cant use it. I know that many of the major airframe manufactures use common tooling to install multiple vendor parts and as such part of the qualification for each vendor to supply parts is that they work with the common set of tools, even if not their own or documented as such.

Accepted

Barry Morris, John Vickers, ART

17.2.3 106. The first Acceptable bullet : Remove words after the comma but a few strands have unravelled in tightening the screw.

This is more accurately described in the second Acceptable bullet Less than 1/3 of the wire diameter protrudes from under the screw

Accepted


16

TABLE 5 - ALL COMMENTS RESOLVED AT PREVIOUS MEETINGS Source Ref. # Recommendation Reason for Recommendation Resolution

620AS meeting All 107. All references to Table 3-1 should be changed to 3.2; there is amplifying information that needs to be considered in addition to the table.

Table 3-1 doesnt go away. IPC ACTION to scrub document; change references for strand damage from Table 3-1 to clause 3.2 Completed

1.12 108. Table 1-2, need dimensions for last two rows ACTION: Brett Miller, USA Harness to provide dimensions: Completed

620AS meeting 3.4 109. Add Defect: There is residual twist (over-twist, kinking, pig-tails) in

individual wires.

Criteria added; need better pix. ACTION: Jon Vermillion to provide pix Completed


4.3 110. Figure 4-1 Create a new figure that is not specific to printed circuit boards. The new figure should include a defect of >90 wetting angle. This figure should include an example of a defect condition. It may also help if the entire figure was replaced by something more applicable to cables or harnesses (D shows a solder mask defined padnot something youd see in a harness).

The current Figure is not representative of the technology this standard represents. To associate the figure with something more akin to a cable assembly rather than a printed circuit assembly

There is a Defect Class 1,2,3 620A, 4.9.4 and 4.9.5 STAFF ACTION 7 Apr 10 Completed

Dan Foster, MDA

4.3 111. wetting angle exceeding 90 (Figure 4-1, C, D) when it is created by the solder contour extending over the edge of the solderable termination area.

Close out item from 001E 610E 620B alignment This is in the Feb 2012 draft

IPC ACTION to correct figure 4-1 Completed

John VanHaren, Unison Industries

5.2 112. The section heading states that this section is for both insulated and uninsulated terminals. The crimp of an uninsulated terminal looks quite different than those of an insulated type, especially the terminals which do not capture the wire insulation. In the next revision, if possible, can there be photos of what is acceptable, and what is not, for uninsulated terminals without the wire insulation capture?

ACTION: anyone on committee to provide usable photos Completed

Committee meeting

5.2 113. ACTION Committee members are requested to provide stamped and formed terminal insulation clearance pictures for this new section. Completed


17

Committee meeting

5.2 114. IPC Action to modify Figure 5-32 Completed

Rick Hawthorne Tyco Rob Boyd, Schleuniger Inc.

5.4 115. Missing all illustrations which are included in the PPT file Are pictures needed for this?

Add illustrations IPC Action Suitable pictures added

Heather Farren, Midcon Cables Co.

8.1.4 116. I would like to add what we call the Butt-End Splice, this is a hand soldered splice with two or more conductors, but the conductors are all going the same direction and the stripped ends lay parallel to each other. (Like Figure 8-14 on page 8-7 of the A revision but without the white conductor.)

We use this type of splice in many of our cable harness assemblies and need something for our operators to reference.

Added ACTION IPC TO REPLICATE IN 8.2.1 Bob Cooke to provide additional pix. Completed

Rhonda Troutman, Actronix

10.1.7 now 10.1.5

117. Add new Picture5.jpg position to be determined. Use this in new 10.1.5 flashing, replace 620A-10-36 with this, crop off right side, enlarge and circle flash Completed

Meeting 1/2012 10.2.1 118. Associated with Figure 10-61 IPC ACTION TO REMOVE TABS FROM FIGURE Completed

Rich Broga, Radiall

13.10.2.2 119. The criteria for Conformable cable "very tightly woven braid outer shield" is the same as in the 13.10 section. New criteria and pix for conformable cable solder coverage Picture B1 is acceptable for Class 1,2 Process Indicator - Class 3. Slight depression in solder no void in braid. Picture A3 is a defect - Class 1,2,3 Voids in solder. T-Flex cable falls under 13.1. The difference between T-Flex and Conformable cable is that conformable is a braided cable that is completely immersed in solder when the cable is produced. T-Flex is made as a Flex cable and at connector termination the ends are dipped to receive a Semi-Rigid type of connector termination

Photos added to document IPC Action to add split 13.10.2; current criteria 13.10.2.1 and this new becomes 13.10.2.2 A1,2,3 no voids D1,2,3 voids Completed

Lisa Maciolek, Raytheon

13.12.1 120. Defect Class 1,2,3 bullet one needs clarification. Compare terminology to figure 13-76 was this meant to read Shield extends


18


14.1 121. We need to see if we can incorporate these pictures into 610, 4.4.X and 620, 14.1.X. These are pictures of the newer flat (low profile) ties, where the end of the strap comes out the side of the locking device rather than the top.

Pictures provided GRAPHICS GROUP Completed

IPC Staff 14.1 122. Remove inset from 620A Fig 14-4 and put it into Fig 14-5 IPC ACTION Completed

620AS meeting 14.1 123. Fig 14-3 add clove hitch under the surgeon knot so it shows as a complete connection, not just the finishing knot.

IPC ACTION Couldnt figure out how to draw this; defer to Rev C


16.4 124. Add photo or description for Containment Loom Not sure everyone knows what it is Changed header name to make this easier to understand.

Rob Boyd, Schleuniger Inc. G. H. A Gosenshuis, Thales Nederland Rob Boyd, Schleuniger Inc.

19.7.2 125. Complete Pull Test Value List is provided at end of this comment list. Excel version can be provided if necessary. The test force values for the stamped contacts and terminal lugs in Table 19-12 have too high value. For this kind of crimp components we use values according to IEC 60352-2 International Standard Solderless connections - Part 2: Crimped connections - General requirements, test methods and practical guidance. The values in 620A are about 50% higher than the machined connector contact. Boyd: Add more columns for to show other specs such as UL and IEC. Forces listed at end of this comment list. This would make it clear that different standards exist and an agreement has to be made between the user and mfr. It should be indicated however that the SAE list shall be used by class 3.

The table from the IEC document was provided by the commenter Boyd: Table 9-12 uses Mil-spec pull forces which are considerably higher than other specs such as UL or IEC. Although the user and mfr are able to agree on different values, this can cause confusion and the user might always expect the higher values listed in the A620. For some applications, it may be difficult to achieve these values.

ACTION: Brett Miller to contact Rob Boyd, confirm values and get table in Excel Completed

IPC Staff Append A 126.

If anyone has additional recommended terms they need to be submitted no later than 30 March.

Cosmetic anomalies from Chapter 10 have been incorporated into this Appendix. Completed

IPC Staff Append B 127. Recommend to delete these four pages of metric conversion table. In todays technology most users have smart phones, computers or other means to quickly make any of these conversions. This appendix isnt referenced anyplace in the Standard. To publish printed is just killing trees.

Accepted

IPC Staff Append C 128.

Rename to Append B if appropriate. IPC Staff Action to update to final tables in Chapter 19 after ballot.

IPC ACTION Completed


19

Richard Rumas, Honeywell Aerospace

1 129. Add Health, Safety, and Environment section: The use of some materials and processes used to meet the requirements of this standard may be hazardous, or may cause injury. To provide for personnel and environmental safety, follow the applicable plant requirements and government regulations.

There is no section currently for Health, Safety, and Environment.

Added, combined with new statement regarding eating, drinking

Les Bogert, Bechtel

1 130. Revise 620 Section 3 to change the title to Handling & Preparation and add a Handling section 3.1. Re-number the existing paragraphs as 3.2 through 3.6. Action: IPC and Les Bogert, Bechtel Plant Machinery to develop proposal for task group review Recommended 3.1 text is at the end of this comment list.

Since cable or wire harness assemblies may contain integral sub-assemblies containing ESD sensitive items, or otherwise fiber optic or coaxial cables that could be damaged from improper handling practices, it is appropriate to add a handling section to 620. To preclude the need to re-number all the sections in 620, I recommend the new section be added to existing section 3.

Deferred to HDBK-620

Les Bogert, Bechtel

1 131. Revise 620 Forward section to add the requirements of 001, paragraph 4.2.4 for consistency with 001. Action from Teresa Rowe & Bettye Causion, AAI & Dan Foster, MDA completed Sep2010: XXXX Field Assembly Operations Field Assembly Operations In field Assembly operations on Class 3 products where the controlled environmental conditions required by this standard cannot be effectively achieved, precautions shall [D1D2D3] be taken to maximize the quality of solder connections and minimize the effects of the uncontrolled environment on the operation being performed on the hardware.

Recommended for consistency with 001. Accepted with modification

Les Bogert, Bechtel

1 132. Revise 620 to add the flow down requirements of 001, paragraph 1.9.

Recommended for consistency with 001. Accepted to add

Les Bogert, Bechtel

1 133. Revise 620 to add the requirements of 001, paragraph 1.10, for consistency with 001.

Recommended for consistency with 001. Accepted to add

Les Bogert, Bechtel

1 134. Revise 620 Section 1 to include the 001, paragraph 11.3 criteria. Revise 620 section 1 to include the 001 requirements pertaining to the use of SPC for consistency with 001 in event the supplier elects to implement an SPC process control program. Although 001 does not mandate an SPC program, it does mandate compliance with the 001 SPC requirements in event the supplier elects to implement an SPC program. Revise 620, paragraph 1.1 to add the requirements of 001E, paragraph 11.3, for consistency with 001.

Recommended for consistency with 001. Action: Teresa Rowe, AAI Corp, Dan Foster, DAI, Les Bogert Bechtel to develop proposed wording for committee review. Accepted as shown in the draft

Les Bogert, Bechtel

1 135. Revise 620, Section 1 to include the 001, paragraph 12.3 requirement.

Required for consistency with 001 and cleaning should be performed after any rework or repair to ensure all traces of any detrimental contamination or foreign material is removed.

Action: Jeff Rawlings, Actronix, Dan Foster, DAI, Teresa Rowe, AAI, Les Bogert, Bechtel, to propose global reorganization of rework/repair criteria. Accepted as shown in the draft


20

620A CIT beta class Apr07

1 136. Add hardware compatibility clause like 001: Components (e.g., electronic devices, mechanical parts, printed boards) selected for assembly shall [D1D2D3] be compatible with all materials and processes, e.g., temperature ratings, used to manufacture the assembly/product.

The task group determined that this is a design issue and beyond control of the assembler. The recommendation was not accepted.

Gabriel Rosin, Elbit System Ltd

1 137. FOD - Foreign Objects Damage - Company shall supply to the customers products at the required quality, there rises a need to prevent damage caused by infiltration of foreign objects into products. Prevention of foreign objects within products, in accordance with MIL-STD-980 requirements.

Quality from the beginning (development through process and un the end our customers) MIL-STD-980 requirements

Task Group feels that 1.12.7 provides adequate coverage for contamination/foreign object requirements and did not agree to accept this recommendation.

IPC staff from various

1.1 138. change first sentence from: This standard is a collection of visual, electrical and mechanical quality acceptability requirements for Cable, Wire and Harness Assemblies. to: This standard prescribes practices and requirements for the manufacture of Cable, Wire and Harness Assemblies.

Accepted

Les Bogert, Bechtel

1.1 139. Add a new paragraph 1.24 as follows: 1.24 Acceptance Requirements All products shall [D1D2D3] meet the requirements of the assembly drawing(s)/ documentation and the requirements for the applicable product class specified herein. Manufacturers shall [N1D2D3] perform 100% inspection unless sampling inspection is defined as part of a documented process control plan (see 1.23).

Incorporate the requirements of J-STD-001E, paragraph 1.11 since we need to ensure products are either 100% inspected or otherwise a process control program is in place as these are important considerations for the manufacture of cable or wire harness assemblies.

First paragraph added as lead-in to 1.3. Added 2nd paragraph (modified) as new (renumbered) 1.16.1


1.2 140. Change first sentence from: This publication describes tests and acceptability criteria for producing crimped, mechanically secured, or soldered interconnections and the associated lacing/restraining criteria associated with cable and harness assemblies. To: This standard describes materials, methods and acceptance criteria for producing crimped, mechanically secured, or soldered interconnections and the acceptance criteria for related assembly activities associated with cable and harness assemblies.



21

Gabriel Rosin, Elbit Systems LTD

1.4 141. Shall or Should The word shall is used in the text of this document where ever there is a requirement for material, preparation , process control or acceptance. Where the word shall leads to a hardware defect for at least one class the requirement for each class are annotated in text boxes located adjacent to that occurrence in the text. The word "should" reflects recommendations and is used to

Better explanation why we use it here on this standard. Accepted with modification to add wording from J-STD-001E

Les Bogert, Bechtel

1.5 142. Revise 620, paragraph 1.5 to add the requirements from 001, paragraph 1.13.2.


Les Bogert, Bechtel

1.5 143. Delete the paragraph beginning with The development--- and replace with the following new paragraph: The development should include user involvement. The acceptance criteria shall [N1N2D3] have user agreement. Requirements for specialized processes and/or technologies not specified herein shall [N1D2D3] be performed in accordance with documented procedures which are available for review.

Incorporate the requirements of J-STD-001E, paragraph 1.13.2, second sub-paragraph since this is considered important for the manufacture of cable or wire harness assemblies.


Les Bogert, Bechtel

1.5.1.3 144. Revise 620, paragraph 1.5 1.3 to add "shall" pertaining to user agreement for acceptance criteria for special processes, with CL1-NE, CL2-NE and CL3-D, for consistency with 001, paragraph 1.13.2.

Recommended for consistency with 001. Resolved through other changes made to the clause 1.5.

Les Bogert, Bechtel

1.7 145. Revise 620, paragraph 1.7 to add the requirements of 001, paragraph 1.11, for consistency with 001.


Blen Talbot, L-3 Communications

1.9 146. After paragraph h add a new paragraph number. This paragraph addresses what is required for a documented calibration system and the requirements are listed using alpha characters a through e.

Editorial, broke clause into control and calibration sections


1.9 147. Add a reference to some Guidelines for Soldering Tools and Equipment like that in J-STD-001E, Appendix A.

The document should provide some guidance for this type of equipment i.e. Irons and Soldering Pots.


Les Bogert, Bechtel

1.9 148. Add a new item I to the paragraph as follows: i. Soldering tools and equipment shall [D1D2D3] be selected, used and maintained such that no damage or degradation that would be detrimental to the designed function of parts or assemblies result from their use. Soldering irons, equipment, and systems shall [D1D2D3] be chosen and employed to provide temperature control and isolation from electrical overstress or ESD when ESD sensitive parts or assemblies are involved. A tool used to cut leads shall not [D1D2D3] impart shock that damages a component lead seal or internal connection.

Incorporate the requirements of J-STD-001E, paragraph 3.9 since this is an important consideration for cable or wire harness assemblies. Since some cable or wire harness assemblies may have an integral sub-assembly connected therein, ESD is an important consideration if such integral assemblies contain ESDS components.



22


1.9 149. Add the following to section 1.9: Crimping tools, torque tools, measuring equipment, and mechanical and electrical test equipment (including contact retention testers), shall be calibrated.

Specifically call for these types of tooling / equipment to be calibrated, as there is some ambiguity.



1.10 150. 1.10 expand to include testing criteria or results from testing Accept modify

IPC Staff 1.12 151. Delete the reference to red plague; there is no discussion an no other mention of red plague anyplace in the document. There are no comments to add red plague content.

Accepted


1.12.5 152. For Class 3 only, replace 3rd sentence with: User concurrence shall be required for use-as-is and repair dispositions.

Tighten requirements. Accepted with modification


1.13 153. Use the sentence we already have in J001D and 610D: Violation of minimum electrical clearance is a defect condition.

We dont care why minimum electrical clearance was violated! The sentence, as revised above, should be added to the text following Table 1-1 and a Text Box specifying D 1, 2, 3 should be associated with the sentence.

Accepted


1.16.2 154. Add the following paragraph: Magnification aids shall be capable of rendering true colors, proportional dimensions, and adequate resolution at the chosen magnification to perform the specified inspection. The light source shall provide shadowless illumination of the area being viewed unless directional or oblique lighting is specifically required.

Important criteria missed. Added to ballot draft of 620AS. Also, similar wording (should, not shall) on shadows added in J-STD-001E.

Accepted with modification to use 001E lighting wording.


1.17 155. Add MIL-STD-1686 after ANSI S20.20. Also, remove the date from the end of the ANSI S20.20 document number, as it is incorrect / superseded (and should always be the latest revision).

To allow for some sites that comply with MIL-STD-1686 to avoid having to do a gap analysis to the ANSI standard.


Les Bogert, Bechtel

1.19 156. Add the following to paragraph 1.19: The electrical and mechanical integrity of components and assemblies shall [D1D2D3] be retained after exposure to processes employed during manufacture and assembly (e.g., handling, baking, fluxing, soldering, and cleaning).

Incorporate the requirements of J-STD-001E, paragraph 1.12 since they are important to the manufacture of cable and wire harness assemblies.

Current wording, while not verbatim, adequately covers this requirement and the recommendation was not accepted.


1.xx 157. (new) Add Health and Safety section: The use of some materials referenced in this standard may be hazardous. To provide for personnel safety, follow the applicable local and Federal Occupational, Safety and Health Regulations.

There is no section currently for Health and Safety. The text is the same as J-STD-001E. Also accepted on 620AS ballot draft.

Accepted through separate action.

Les Bogert, Bechtel

1.xx 158. Add new paragraph 1.20 as follows: 1.20 Facilities Cleanliness and ambient environments in all work areas shall [D1D2D3] be maintained at levels that prevent contamination or deterioration of soldering tools, materials, and surfaces to be soldered. Eating, drinking, and/or use of tobacco products shall[D1D2D3] be prohibited in the work area.

Incorporate requirements of J-STD-001E, paragraph 4.2 since some cable or wire harness assembly manufacture may involve soldering.

Accepted as shown in the draft


23

Les Bogert, Bechtel Richard Rumas, Honeywell Aerospace

1.xx.1 159. Add new paragraph 1.xx.1 as follows: (Bogert) 1.20 Environmental Controls The soldering facility should be enclosed, temperature and humidity controlled, and maintained at a positive pressure. (Rumas) When humidity decreases to a level of 30% or lower, the manufacturer shall [N1D2D3] verify that electrostatic discharge control is adequate, and that the range of humidity in the assembly area is sufficient to allow soldering and assembly materials to function correctly in the process, based on vendor recommendations or documented evidence of process performance. For operator comfort, solderability maintenance or to help mitigate red plague (see XXX), the temperature should be maintained between 18C [64.4F] and 30C [86F] and the relative humidity should not exceed 70%. For process control, more restrictive temperature and humidity limits may be required.

Incorporate requirements of J-STD-001E, paragraph 4.2.1 since some cable or wire harness assembly manufacture may involve soldering. There is no section currently for Temperature and Humidity. The text is the same as J-STD-001E. Also accepted on 620AS ballot draft.


Les Bogert, Bechtel

1.xx 160. Add new paragraph 1.21 as follows: 1.21 Requirements Flowdown When this standard is contractually required, the applicable requirements of this standard (including product class - see 1.7) shall [D1D2D3] be imposed on all applicable subcontracts, assembly drawing(s), documentation and purchase orders. Unless otherwise specified the requirements of this standard are not imposed on the procurement of commercial-off-the-shelf (COTS or catalog) assemblies or subassemblies. When a part is adequately defined by a specification, then the requirements of this standard should be imposed on the manufacture of that part only when necessary to meet end-item requirements. When it is unclear where flowdown should stop, it is the responsibility of the manufacturer to establish that determination with the user.

Recommended addition for consistency with J-STD-001E, paragraph 1.9, except that reference to daughter boards in 001 was not included. Since some manufacturing on cable or wire harness assemblies may be sub-contracted, we need to identify appropriate flow-down requirements in 620.

Accepted through separate action


24

Les Bogert, Bechtel Richard Rumas, Honeywell Aerospace

1.xx 161. Add new paragraph 1.22 as follows: (Bogert) 1.22 Personnel Proficiency All instructors, operators, and inspection personnel shall [N1D2D3] be proficient in the tasks to be performed. Objective evidence of that proficiency shall [N1D2D3] be maintained and be available for review. Objective evidence should include records of training to the applicable job functions being performed, work experience, testing to the requirements of this standard, and/or results of periodic reviews of proficiency. Supervised on-the-job training is acceptable until proficiency is demonstrated. (Rumas) above, plus: Training shall be in accordance with the IPC A-620 Training and Certification Program or User approved training program. All training shall be traceable to a Master IPC Trainer (MIT).

Incorporate the requirements of J-STD-001E paragraph 1.10 since personnel proficiency is an important consideration for cable and wire harness assemblies.

Accepted with modification; added new 1.20.

7-31fs 1.xx 162. (new) Add Personnel Proficiency section: All instructors, operators, and inspection personnel shall be proficient in the tasks to be performed. Objective evidence of that proficiency shall be maintained and be available for review. Objective evidence should include records of training to the applicable job functions being performed, work experience, testing to the requirements of this standard, and/or results of periodic reviews of proficiency.

There is no section currently for Personnel Proficiency. The text is the mostly the same as J-STD-001E and exactly the same as 620AS.

Accepted


25

Les Bogert, Bechtel

1.xx 163. Add a new paragraph 1.23 as follows: 1.23 Process Control Requirements The primary goal of process control is to continually reduce variation in the processes, products, or services to provide products or processes meeting or exceeding customer requirements. Process control tools such as IPC-9191, EIA-557-1 or other user-approved system may be used as guidelines for implementing process control. Manufacturers of Class 3 products shall [N1N2D3] develop and implement a documented process control system. A documented process control system, if established, shall [N1D2D3] define process control and corrective action limits. This may or may not be a statistical process control system. The use of statistical process control (SPC) is optional and should be based on factors such as design stability, lot size, production quantities, and the needs of the manufacturer. Process control methodologies shall [N1D2D3] be used in the planning, implementation and evaluation of the manufacturing processes used to produce cable or wire harness assemblies.. The philosophy, implementation strategies, tools and techniques may be applied in different sequences depending on the specific company, operation, or variable under consideration to relate process control and capability to end product requirements. When a decision or requirement is to use a documented process control system, failure to implement process corrective action and/or the use of continually ineffective corrective actions shall [N1D2D3] be grounds for disapproval of the process and associated documentation.

Implement the requirements of J-STD-001E, paragraph 11.3 on process control since process control is an important consideration for the manufacture of cable or wire harness assemblies. I did not feel that the other sub-paragraphs of 11.3 need to be incuded in 620.



1.xx 164. (new) Add Shelf Life section: Limited shelf life items shall be stored and controlled in accordance with material manufacturers recommendations, or in accordance with the manufacturers documented procedures for controlling shelf life and shelf life extensions.

There is no section currently for Shelf Life. The text is the same as IPC-620AS ballot draft.

Accepted


3.1 165. Add the following for Class 3: Mechanical strippers shall only be of the non-adjustable fixed

die type. Thermal wire stripping tools shall not be used to remove

insulation from wires containing a fiberglass barrier. Stripping tool part numbers shall be specified in the shop

floor documentation.

Avoid operator adjustable mechanical strippers. Nicks and cuts on the wire are the most common root causes for failed crimped connections. Also add requirement for fiberglass insulation.

This comment was not accepted.


26

IPC Staff 06/11 3.2 166. Draft still has Rev A Table 3-1. The first data row of this table was modified in 001E & 610E from less than 7 to 2-6 and a new Note 3 was added. Note 3: Damaged strands have nicks or scrapes exceeding 10% of cross sectional area. Added to draft July 2011 for committee review.

As discussed for 001E/610E, the table isnt applicable to single strand (solid conductor) wires/leads. Note 3 defines that 10% damages is per strand not 10% of the strand bundle.

Criteria modified

Barry Morris, ART

3.2 167. The note see 13.1 and 16.2 for shield strand damage Should read see 13.1 and 15.2 for shield strand damage

Wrong reference 16.2 is for protective covering not shielding

Corrected

Barry Morris, ART

3.2 168. Table 3-1 Although the first column (number of strands) has been amended to read 2-7 it should read 2-6

Conflict with the second row 7-15 Corrected

Gregg Owens, WaveStream

3.2 169. I dont know what partial or incomplete cuts of strand groups or partial cuts of a strand group mean. I am more familiar with scraped nicked or severed word usages. If I dont cut a wire squarely off at the end I re-cut the ends it until the finished wire relatively straight. What I envision from these statements is a wire with strands still extended from what should be the end of the wire. At this point the operator should trim it back not insert it into a crimp connector. Not acceptable in my book even if done by an automatic wire stripping machine though just my opinion.

Crimp requirements address strand length issues. No specific recommendation provided.


3.2 170. Defect Class 1,2,3 Remove bullet 2 and 3 I dont understand the intent of this exception is there and it leads to confusion

Criteria modified


3.2 171. For Class 3, replace Table 3-1 criteria with the following, making it the same as 620AS: Table 3-1 does not apply; there shall be no nicked, scraped or broken wire strands. For plated wires, a visual anomaly that does not expose basis metal is not considered to be strand damage. Smooth indentations, e.g. tooling marks, up to 10% of the conductor diameter that do not expose basis metal are not considered to be strand damage. Defect Variation in strand length within a strand group that prevent

installation to the full depth of the crimp contact area. Severed (broken) wire strands. Deformation exceeding 10% of the diameter of the conductor. Base metal is exposed.

The operator will not know how many strands there will be in a wire. It is not practical to count strands or to write this information in a shop procedure. Same as 620AS ballot draft.

This comment was not accepted.

Charles Gamble, NASA MSFC

3.2 172. Defect Class 3 Variation in strand length within a strand group that prevent installation to the full depth of the crimp contact area.

Withdrawn April2010


27

Rick Hawthorne Tyco

3.2 173. Table 3-1 should be on the bottom of pg 3-2 because its first referenced in the Shall Not statement there

Move table from pg 3-1 to 3-2 IPC Staff comment: This document is translated in multiple languages and there has to be sufficient white space on a page to permit longer text blocks. There just isnt room on p3-3 for Table 3-1.

Defer to leaders until the document is reformatted April2010

Rick Hawthorne Tyco

3.2 174. A1,2,3 1st & 2nd bullet approximately conflict with the shall statements on pg 3-2

Change pg 3-3 to match pg 3-2 IPC Staff comment: Approximately perpendicular cutting and uniform cut ends of the same length are easy to understand. The real conflict is that variation in strand length the prevents installation (Fig 3-3) is a D1,2,3 but the shall statement on p 3-2 is N1D2,3. This needs to be addressed at next rev.

Accept modify deleted lead in paragraph April2010


3.2 175. Delete everything in the introduction on page 3-2 except: (all the other criteria are provided as bullets next to figures and there are some conflicts) See 13.1 and 16.1.2 for shield strand damage criteria.

Committee could not reach consensus April2010


3.2 176. Tools utilized to accomplish wire cuts shall (N1 D2 D3) (D1 D2 D3) be selected, maintained and used (see 1.9) to provide repetitive and consistent wire cut terminations that meet the following criteria.

Accept Modify Committee deleted entire sentence. It is already covered in 1.9 April2010


3.2 177. Add the exception of damaged strands mentioned in the defects to the up front information about Strand damage.

A user could look at the table see that they are within the limits and not look at the defects.

Added to intro


3.2 178. Delete the last paragraph. The process of wire cutting Shall be performed such that the cut ends are uniform and of the same length.

This is outside the scope of the document. Accepted


3.3 179. Defect 3 Should this be aligned with J-STD-001 Birdcaging requirement conflicts with J-STD. One strand vs. outside diameter of insulation

Committee does not believe that strand separation greater than 1 strand diameter should be a defect for Class 2. Deferred to 001F task group.

Francois Cornu, IFTEC France

3.4 180. Recommend modification of title of Table 3-1 from Strand Damage to Allowable Strand Damage to more clearly identify the purpose of the table.

This will align to table title in J-STD-001E Editorial, leaders approved


3.5 181. Add the following: Frayed insulation at stripped wire ends for insulations with a fiberglass barrier may be allowed to remain provided that they dont represent more than 10 percent of the total fiberglass stranding.

Not covered. Statement added to introduction


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Les Bogert, Bechtel

4 182. Revise section 4 of 620 to add a new paragraph entitled Component Stress Relief and add the requirement and figure from 001, or otherwise create another figure more appropriate for 620.

Although 620 was not intended to address PWAs, there will be instances where 620 processing will connect wires to components (e.g., a component may be an integral part of a wire harness), and therefore, we need to address component stress relief in 620.

Task group did not feel this was necessary. Stress relief for wires to terminals added to 4.8 intro.

620AS meeting 4 183. Any reference to wire end overlaps itself isnt correct- it should be wire overlaps itself.

The overlap may be in a turn and not the wire end. Changes made to Chapter 4 of Feb 2012; this term isnt used anyplace else in the document.

Editorial, leaders approved

620AS meeting 4 184. References to depression greater than would be easier to understand if the words are deeper than

Changes made to Chapter 4 of Feb 2012; this term isnt used anyplace else in the document.

Editorial, leaders approved


4.1.1 185. Move both paragraphs to Section 1, Forward This material applies to more than Soldered terminations. It also applies to potting and adhesives etc.

This information is now in section 1 as well as here.

620AS meeting 4.1.1 186. Replace content with See 1.13.3. 1.13.3 covers the present statements plus adds more. Accepted IPC Staff 07/11 4.1.1.1 187. IPC Action to update solder

alloy designators to current J006 but ran into problem. The September 2011 draft has info. Decision is to use the same alloys published in J001E. Accepted


4.1.1.5 188. Add: In addition to the tool controls of Clause 1.9, soldering tools and equipment

Soldering tools or etc. may need to be added to clause 1.9. I can not see someone limiting the control to only the tools listed in clause 1.9, when soldering is included in the document. Cabling or wiring could be soldering.



4.1.2 189. For Class 3, change the first sentence from: Gold shall be removed from the surface to be soldered when the thickness of gold exceeds 2.5 m [0.0001 in]. To: Gold shall be removed from the surface to be soldered.

Gold shall be removed regardless of thickness. Accepted

Dan Foster, MDA

4.1.2 190. Gold shall [N1P2D3] be removed from the surface to be soldered.

Close out item from 001E 610E 620B alignment In June 2011 the committee removed thickness requiring removal regardless of thickness. In Feb 2012 it was discussed that this is a big cost driver to remove gold when it isnt necessary to remove gold. The decision was to restore the thickness threshold.


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Dan Foster, MDA

4.1.2 4.2.2 4.2.2.1 4.2.2.2.2 4.3 4.4 4.6 4.7

191. Resolve differences between 001E, 610E and 620B Comments highlighted in the draft Accepted with modification


4.2 192. Add the following: The cleaning process shall be documented and controlled. All soldered connections shall be cleaned within one hour of the soldering operation using a batch cleaning system. During assembly, operators shall periodically brush clean manually soldered joints with isopropyl alcohol. The cleaning process shall have no deleterious effect on the parts, connections, and materials being cleaned. Assemblies prone to moisture entrapment shall be cleaned using vapor degreasing, or as specified in the applicable work instruction. Handling of cleaned assemblies shall only be done in such a way as to prevent re-contamination.

Important controls and requirements for cleaning that should be added.

Accepted with modification to add the last sentence to section 1.


4.2.1 193. Change from: The assembly should be clean of any matter that will inhibit compliance to the requirements of this standard. To: The assembly shall be clean of any matter that will inhibit compliance to the requirements of this standard.

Change from should to shall. Why recommend something when it could cause possible defects?

Comment withdrawn after discussion; too hard to verify.


4.2.2 194. For Class 3, replace 2nd paragraph with: Solder connections produced using no-clean processes and materials shall be cleaned. No-clean processes shall be qualified.

Control the use of no-clean processes better for Class 3. Comment withdrawn after discussion

Jeannette Plante, NASA GSFC

4.2.2 195. Assembly of solder-type connectors Contact mating surfaces, solder joints, and the rear surfaces of connectors shall be cleaned after soldering. Connector interfaces *SHALL be cleaned by brushing with solvent, vacuum procedures, or a combination thereof until particulate and residue contaminants have been removed.. Contact surfaces of pins, sockets, and connector bodies shall be free of flux residue, solder splash, metal flakes, moisture, and other contaminants that may jeopardize the integrity of the connector system. The internal surfaces of dust covers and connector covers *SHALL be cleaned by solvent brushing before the covers are fitted onto cleaned connectors.

1. Post-soldering does not specifically address cleaning of areas other than the solder connections. Words need to be broadened to include mating surfaces and rear of connectors.

2. Request that particulate contamination be added to the paragraph.

3. Specifically add the phrase contact surfaces to emphasize the importance of these areas.

4. Address cleaning of dust covers. [ref. para 8739.4 para 13.3]

Not accept. Committee determined that the areas were covered in subsequent paragraphs to an adequate extent. 7 Apr 10


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Dan Foster, MDA

4.2.2 196. Solder connections produced using processes and materials that are required to be cleaned, e.g., rosin/resin fluxes, shall [D1D2D3] be cleaned


Editorial changes accepted

Dan Foster, MDA

4.2.2.1 197. D1,2,3


Decision was no changes

Dan Foster, MDA

4.2.2.2.2 198. Acceptable Class 1 Process Indicator Class 2,3 Flux residue does not inhibit visual inspection. Flux residue does not inhibit access to test points of the

assembly. Defect - Class 1,2,3 Wet, tacky, or excessive flux residues that may spread onto

other surfaces. No-clean flux residue on any electrical mating surface.


Decision was no changes


4.2.2.2.2 199. For Class 3, replace the section with: Solder connections produced using no-clean processes and materials shall be cleaned in accordance with the cleanliness requirements of section 4.2.2 and this document. No-clean processes shall be qualified.

Control the use of no-clean processes better for Class 3. Comment withdrawn after discussion


4.3 200. Add the following: The number of reworks per solder joint shall be limited to a maximum of three.

No criteria currently exists. Limiting rework will prevent possible thermal damage to the components being soldered.

Comment withdrawn after discussion


4.3 201. 4th paragraph, 1st sentence. Reword from: The solder connection wetting angle (solder to lead and solder to terminal) is not to exceed 90 (Figure 4-1, A, B). To: The solder connection wetting angle (solder to lead and solder to terminal) shall not to exceed 90 (Figure 4-1, A, B).

The words is not may or may not be interpreted as a hard requirement. Changing it to a shall clears up any ambiguity.

Accept modify. Changed to add the class requirements and wording to read correctly. 7 Apr 10


4.3.1 202. Add a defect: Blowholes, pinholes, and voids (where the bottom and all sides are not visible).

Criteria not covered. Comment was not accepted


4.3.1 203. D1,2,3, last bullet. Change from Solder wicking inhibits required flexibility where required. To: Solder wicking inhibits flexibility where required.

The first required is redundant. Accept 7 Apr 10


4.3.2.2 204. Adds no value; recommend deleting Accept 7 Apr 10


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4.4 205. Insert as a new 3rd paragraph: Conductors shall not be cut or modified in any manner to reduce circular mil area to fit a termination.

There is no requirement that prohibits modifying conductors for soldered connections (I have already taken action to submit for inclusion in A-620B when that effort starts).

Accept modify; added to section 3.2; assigned class requirements as D12D2D3. 7 Apr 10


4.4 206. Add the following: When wires are tinned, the solder used for tinning shall be the same alloy used in the subsequent soldering process.

To ensure solder alloys are not mixed and to ensure all materials in the design are known / defined.

Accept modify. 7 Apr 10


4.4 207. Under Acceptable - Class 1 Process Indicator - Class 2 Defect - Class 3 Change the first bullet to a Defect - Class 2,3 Pinholes, voids or dewetting/nonwetting exceed 5% of the area required to be tinned.

As written one could have 25%, 50%, 95% or more of the area required to be tinned showing evidence of dewetting/nonwetting pinholes or voids and the wire would be considered usable for Class 2.

Not accept; there is no consensus for C2 that this is an issue. 7 Apr 10

John Kwaak, CDI Corp

4.4 208. Related to solder extruding from heat-shrink splice; current 4.4 tinning optional when heat shrinkable solder devices are used but the optional statement should also include a reminder that Tinning may add to much solder to the junction making conformance of a contoured overlapped wire appearance difficult to maintain. I think vertical positioning of the splice and off positioning of the splice had something to do with this too.

Related to pix John provided of solder extruding from heat-shrink splice.

Not accept. Move this sentence with the second paragraph to the handbook. 7 Apr 10


4.4 209. Change from: Wires will be formed into splices (other than mesh) and

optional when heat shrinkable solder devices are used. To: Wires will be formed into splices (other than mesh) Wires will be used in heat shrinkable solder devices.

Remove optional tinning for heat shrinkable solder devices. Was adopted in 620AS final ballot draft.

Recommendation was not accepted; it needs to be optional

Dan Foster, MDA

4.4 210. When wires are tinned using alloys other than those listed in section 4.1.1.1, the solder used for tinning shall [D1D2D3] be the same alloy used in the subsequent soldering process.


No action needed


4.5.1 211. Change the process indicator (below) to a defect for Classes 2 and 3: The insulation clearance is greater than 2 wire diameters or 1.5 mm [0.060 in], whichever is greater, but does not permit shorting to adjacent conductors.

This is a defect birdcaging! Accepted with modification; changed to A1P2D3 and removed the wo

upuuteg aug2012

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