IPC/WHMA-A-620B TRAINING AND CERTIFICATION PROGRAM FOR CERTIFIED IPC TRAINERS (CIT)

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1 5. Module(s) are prerequisite training for IPC/WHMA-A-620 Certified IPC Application Specialist (CIS) certification. A. 1 and 3 B. 1 and 2 C. 1 through 18 D. 1 Answer: D Reference: Lecture 6. CITs should forward (electronically) the training report form for CIS training to the IPC within of the completion of each training session. A. 2 days B. 1 month C. 1 week D. 2 weeks Answer: D Reference: Page 8, Clause Policy 7. CIS retesting (of previously failed training modules) may be administered only after a minimum study/ review period not sooner than A. 24 hours B. 1 week C. 60 days D. 30 days Answer: A Reference: Page 7, Clause Policy S1-41

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3 REVIEW QUESTIONS SESSION 2 REQUIREMENTS AND ACCEPTANCE FOR CABLE AND WIRE HARNESS ASSEMBLIES AND APPLICABLE DOCUMENTS 1. The tolerance for magnification aids is Answer: ±15% Reference: Page 1-6, Clause Magnification Aids 2. The manufacturer shall have a documented calibration system. Answer: N1D2D3 Reference: Page 1-4, Clause Calibration 3. Conditions that are not specified as defective or as a process indicator are considered Answer: Acceptable Reference: Page 1-6, Clause Conditions Not Specified 4. A condition that fails to meet the acceptance criteria of IPC/WHMA-A-620B and negatively affects the form, fit or function of the assembly in its end use environment is. Answer: Defect Reference: Page 1-5, Clause Defect 5. Illumination at the surface of workstations should be minimum. Answer: 1000 lm/m 2 (Lumens per square meter) Reference: Page 1-6, Clause Lighting 6. In the case of a discrepancy between the written criteria or the illustrations, which takes precedence? Written criteria Illustrations Answer: Written Criteria Reference: Page 1-5, Clause 1.14 Figures and Illustrations 7. A condition that is close to perfect defines a condition. Answer: Target Reference: Page 1-5, Clause Target S2-75

4 8. When inspecting a 22 AWG wire the inspection magnification range shall be Answer: 1.5X 3X Reference: Page 1-6, Clause 1.17,1,2 Magnification Aids (Table 1-2) 9. The criteria defined in the IPC/WHMA-A-620B reflect three product classes: Class 1, Class 2 and, Class 3 Answer: General Electronic Products Dedicated Service Electronic Products High Performance Electronic Products Reference: Page 1-3, Clause 1.8 Classes of Product S2-76

5 5.3.5 Machined Contacts CMA Buildup Slide S5-52 Instructor Activity: Review CMA buildup requirements. Continued on next page. Instructor Notes: Target - Class 1,2,3 The CMA of the conductor is built up so that it falls within the minimum and maximum CMA range of the contact. The CMA range is built up using one of the methods listed below: o The conductor is folded or bent back to achieve the correct CMA buildup. o The conductor area is increased by the use of bare (noninsulated) filler conductors as needed to achieve the correct CMA buildup. o A combination of both the foldback and the filler method are used to achieve the correct o CMA buildup. Special CMA Adapter Bushings are used when called out on the assembly documentation. (Use of these adapters will usually require special additional insulating coverage requirements.) The filler is visible at the wire entry end of the barrel. Acceptable - Class 1,2,3 The filler conductors and/or the wire conductor are visible in the inspection window of the contact. The filler conductor is of the same type conductor as the wire being crimped into the contact. (Gauge can be different as needed but the base metal and the plating, if any, needs to be the same.) Fill conductor extends beyond the contact a maximum of one wire diameter of the primary wire (red arrow). The flair or splay of any fill conductor does not extend past or exceed the contact diameter. S5-53

6 5.3.5 Machined Contacts CMA Buildup Defect - Class 1,2,3 Fill conductor extends beyond the contact more than 1 wire diameter of the primary wire. Fill conductor or foldback are not visible at wire entry end. Fill conductor not the same type as primary conductor. Slide S5-53 Instructor Activity: Review CMA buildup requirements. Defect - Class 1,2,3 Solid conductors used to build up the CMA. The filler conductors and/or the wire conductor are not visible in the inspection window. The flair or splay of any filler conductor used extends past or exceeds the contact diameter. Exposed conductor violates minimum electrical clearance. Instructor Notes: S5-54

7 Review Slide S5-56 Instructor Activity: Session review Instructor Notes: S5-57

8 REVIEW QUESTIONS SESSION 5 Crimp Terminations (Contacts and Lugs) 1. If both insulation crimp tabs are not in contact with the top of the insulation, the condition is [ 1 2 3]. Answer: Defect - Class 1,2,3 Reference: Page 5-7, Clause Stamped and Formed Open Barrel Insulation Support Crimp 2. If multiple leads extend past the bellmouth on a stamped and formed closed barrel contact but are not equal in length, the condition is [ 1 2 3]. Answer: Acceptable - Class 1,2,3 Reference: Page 5-19, Clause Stamped and Formed Closed Barrel Conductor Crimp and Bellmouth 3. If the bellmouth height at the conductor entry end of a stamped and formed open barrel contact is 2X the thickness of the contact or terminal base metal, the condition is [ 1 2 3]. Answer: Target - Class 1,2,3 Reference: Page 5-11, Clause Stamped and Formed Open Barrel Crimp Bellmouth 4. On a machined crimp contact, if the crimp is not centered but the inspection window is not deformed, the condition is [ 2 3]. Answer: Acceptable - Class 2,3 Reference: Page 5-27, Clause Machined Contacts Crimping 5. On an open barrel stamped and formed contact, any loose conductor strands that are outside the crimp area, trapped strands, or folded back strands are [ 1 2 3]. Answer: Defect - Class 1,2,3 Reference: Page 5-10, Clause Stamped and Formed Open Barrel Conductor Crimp 6. A solid conductor used to build up the circular mil area (CMA) of an under size conductor on a machined contact is [ 1 2 3]. Answer: Defect - Class 1,2,3 Reference: Page 5-30, Clause Machined Contacts CMA Buildup S5-58

9 8.1.2 Soldered Splices Wrap Wrapped splices require a longer amount of wire to complete the splice. Strip wire to allow a minimum of 3 wraps (not twists) of each wire around the other. Slide S8-14 Instructor Activity: Figure 8-6 shows a proper wrap splice with at least 3 wraps of wire. Continued on next page. Instructor Notes: S8-15

10 8.1.2 Soldered Splices Wrap Slide S8-15 Instructor Activity: Figure 8-7 shows the same wrapped wire after being soldered. Figure 8-8 shows insulation sleeving over the spliced area with a minimum of 1 wire diameter overlap. Continued on next page. Acceptable - Class 1,2,3 Interlocking of 2 wires into a smooth joined section for a minimum of 3 wraps of each conductor. Solder is wetted forming a visible solder fillet joining the wires for the length of the splice contact area. Individual wire strands are discernible. Conductor strands form a smooth joined section. Conductor strands are covered with sleeving. Sleeving is snug to the splice and wire insulation. No conductor strands piercing the sleeving. Sleeving is not split or damaged. Sleeving covers wire insulation on both ends of the spliced area by a minimum of 1 wire diameter. Sleeve or wire insulation is slightly discolored but not charred. Instructor Notes: S8-16

8.2.4 Wire In-Line Junction Devices (Jiffy Junctions) Wire in-line junction devices, sometime referred to as Jiffy Junctions, are essentially feed through environmentally resistant disconnect

11 8.2.4 Wire In-Line Junction Devices (Jiffy Junctions) Wire in-line junction devices, sometime referred to as Jiffy Junctions, are essentially feed through environmentally resistant disconnect components for joining wires. Slide S8-48 Instructor Activity: Explain the general requirements for Jiffy Junctions. Continued on next page. Crimp contacts are terminated onto conductors (see Figure 8-59) and then inserted into the inline junction device as it would be with a rearentry machined contact connector (see Figure 8-60 shown in cross-section). The tooling, tooling verification, crimping processes, and completed terminations shall [D1D2D3] comply with the requirements for tool control and machined contact crimped terminations in Chapters 1 (Forward), 5 (Crimp Terminations) and 19 (Testing). When the CMA of the conductor needs to be built up so that it falls within the minimum and maximum CMA range of the contact, CMA buildup shall [D1D2D3] be in accordance with Instructor Notes: As an exception to 9.5.2, when a sealing plug is required it shall [D1D2D3] be inserted shaft first. S8-49

8.2.4 Wire In-Line Junction Devices (Jiffy Junctions) Slide S8-49 Instructor Activity: Review the defect conditions for Jiffy Junctions. Publication should state Defect Class 1,2,3.

12 8.2.4 Wire In-Line Junction Devices (Jiffy Junctions) Slide S8-49 Instructor Activity: Review the defect conditions for Jiffy Junctions. Publication should state Defect Class 1,2,3. Defect - Class 1,2,3 Multiple wire attachments, when used, do not meet the requirements of 5.3. Insulation clearance does not meet the requirements of The conductor location does not meet the requirements of Crimping does not meet the requirements of CMA buildup, when used, does not meet the requirements of Contact installation does not meet the requirements of 9.5. Qualification of crimped connection fails Pull Force/Tensile Test per Mated assembly fails Pull Test Contact Retention Verification Test per Continued on next page. Instructor Notes: S8-50

13 REVIEW QUESTIONS SESSION 9 CONNECTORIZATION IPC/WHMA-A-620B 1. A boot overlapping the cable sleeving or jacket at least cable diameters in length is Target Class 1,2,3. Answer: 3 Ref: Page 9-10, Clause Sleeving and Boots Position 2. A soft face connector that has material missing with no damage to the dielectric between cups is [ 1 2 3]. Answer: [A1P2P3] Ref: Page 9-17, Clause Connector Damage Limits Soft Face Mating Surface or Rear Seal Area 3. Contact(s) missing when unused positions are required to be filled are [ 1 2 3]. Answer: [D1D2D3] Ref: Page 9-20, Clause Installation of Contacts 4. Hard face connector chipping that does not extend from one cavity to the outer diameter of any adjacent cavity is [_1_2_3] Answer: [A1P2D3] Ref: Page 9-16, Clause Connector Damage Limits Hard Face Mating Surface 5. If strain relief sleeving is visible between the clamp and connector and the split-lock washers are collapsed, the condition is [ 1 2 3]. Answer: [Target 1, 2, 3] Ref: Page 9-6, Clause Strain Relief Clamp Fit S9-43

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15 REVIEW QUESTIONS SESSION 14 SECURING IPC/WHMA-A-620B 1. Cable lacing begins and ends with a. Answer: Locking knot Ref: Page 14-4, Clause 14.1 Tie Wrap/Lacing Application 2. Wires in a wire bundle that twist and crossover underneath a restraining device are [ 1 2 3]. Answer: Acceptable - Class 1 Process Indicator - Class 2 Defect - Class 3 Ref: Page 14-13, Clause Routing Wire Crossover 3. Damage on restraining devices such as minor fraying, nicks, or wear of less than of the device thickness is Acceptable Class 1,2, Defect Class 3. Answer: 25% Ref: Page 14-7, Clause Tie Wrap/Lacing Application Damage 4. When applying a tie wrap, if the cut end protrusion is greater than the tie wrap thickness, the condition is [ 1 2 3]. Answer: Acceptable - Class 1 Process Indicator - Class 2 Defect - Class 3 Ref: Page 14-3, Clause 14.1 Tie Wrap/Lacing Application 5. If the spacing of the first restraint from a breakout is more than 3 diameters of the breakout wire bundle, the condition is [ 1 2 3]. Answer: Acceptable - Class 1 Process Indicator - Class 2 Defect - Class 3 Ref: Page 14-12, Clause Breakouts Spacing 6. Spot ties or wraps placed over splices or ferrules contained in the wire bundle are [_1_2_3]. Answer: Acceptable - Class 2,3 Ref: Page 14-4, Clause 14.1 Tie Wrap/Lacing Application S14-43

16 7. Spot ties or wraps placed over splices or ferrules contained in the wire bundle are [ 1 2 3]. Answer: Acceptable - Class 1 Process Indicator - Class 2 Defect - Class 3 Ref: Page 14-17, Clause Routing Ties over Splices and Ferrules S14-44

17 REVIEW QUESTIONS SESSION 15 HARNESS/CABLE ELECTRICAL SHIELDING 1. A back braid lock stitch (Direct Applied) of at least is Acceptable Class 1, 2, 3. Answer: 13 mm [0.5 in] Ref: Page 15-3, Clause Braided Direct Applied 2. A shrink shield termination on a connector is Target Class 1,2,3 if the shield is approximately from the backshell. Answer: 3 mm [0.12 in] Ref: Page 15-16, Clause Shield Termination Connector Shrink 3. Strip length on braid and shield wire on an attached lead with a heat shrinkable solder device is Acceptable Class 1,2,3 if it does not exceed and is greater than. Answer: 6 mm [0.24 in] - 3 mm [0.12 in] Ref: Page 15-8, Clause Shield Termination Shield Jumper Wire Attached Lead Solder 4. For a shield termination with no shield wire, when the sleeving overlaps less than 1 wire or bundle diameter, the condition is [ 1 2 3]. Answer: Acceptable - Class 1 Defect - Class 2,3 Ref: Page 15-15, Clause Shield Termination No Shield Jumper Wire Shield Not Folded Back 5. A shield termination splice in which a solder fillet is present around the entire shield overlap area, the area is flexible, and the shield weave pattern is disturbed is [_1_2_3]. Answer: Acceptable - Class 1 Process Indicator - Class 2,3 Ref: Page 15-22, Clause Shield Termination Splicing Prewoven Soldered S15-61

18 6. Tape overlap (barrier or conductive) of is Target Class 1,2,3. Answer: 50% Ref: Page 15-24, Clause 15.5 Tapes Barrier and Conductive, Adhesive or Nonadhesive 7. On a shield termination with no shield wire, an exposed shield equal to or less than 3 mm [0.12 in] is [ 1 2 3]. Answer: Acceptable - Class 1,2,3 Ref: Page 15-14, Clause Shield Termination No Shield Jumper Wire Shield Not Folded Back S15-62

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