Appendix b reproducible Test Tables




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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 www.ipc.org/downloads.

IPC/WHMA-A-620A 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-620A 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-620A 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 22 with 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-620A 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
with clearance 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-620A 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-620A 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-620A 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-620A 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-620A 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-620A 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-620A 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-620A 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 www.ipc.org/downloads.


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