IPC/WHMA-A-620 Operator Training

IPC/WHMA-A-620 is the first industry consensus standard for cable and wire harness fabrication and installation. Classes of products are defined and include criteria for Target, Acceptable, Process Indicator and Defect conditions. These criteria are supported by over 500 full-colour illustrations. It is a theory only course designed to provide students with the ability to understand and utilise the accept / reject criteria for a variety of subjects.

Students who successfully achieve 70% or greater in the exams will receive a recognised IPC certificate which is valid for two years. Certification demonstrates commitment to customer requirements and greatly facilitates certification to ISO-9001 or other quality assurance initiatives. By having earned this portable credential, you’ll receive immediate recognition, legitimacy and value throughout the electronics industry.

This course has been recently revised and updated to revision A. There is now 1 mandatory module and 7 optional ones. The optional modules can be chosen depending on company requirements and can be added in if necessary during the 2 year certification period, although the certification on all modules expires at the same time (2 years after the date at which the mandatory modules were completed).

The following section provides a breakdown of the content of each of the modules. A multiple choice exam needs to be successfully completed at the end of each module to allow inspection of these subjects.

Mandatory Module

 Module 1      

This module covers all of the following topics:

o    IPC Professional Policies and Procedures

o    Cable/Wire preparation

o    Measuring cable assemblies and wires

o    Testing cable assemblies 

Optional Modules

 Module 2      

This module covers all of the following topics:

o    Crimp terminations

• Stamped and formed contacts
• Machined crimp contacts

o    Insulation Displacement Connections (IDC)

• Mass termination, flat cable
• Discreet wire termination

Module 3      

This module covers all of the following topics:

o    Wire preparation, tinning

o    Parts preparation, gold removal

o    Cleanliness

o    Insulation

o    Flexible sleeve insulation

o    Birdcaged wire (soldered)

o    Connection requirements

o    Solder requirements

Module 4     

This module covers all of the following topics:

o    Connectorization

o    Molding / Potting

Module 5     

This module covers all of the following topics:

o    Soldered splices

o    Splices – crimped

o    Splices – ultrasonic welded

Module 6      

This module covers all of the following topics:

o    Marking and Labelling

o    Wire bundle securing

o    Shielding

o    Cable/wire harness protective coverings

Module 7

This module covers all of the following topics:

o    Coaxial and twinaxial cable assemblies

• Stripping
• Centre conductor termination
• Solder ferrule pins
• Coaxial connector – printed wire board mount
• Coaxial connector – centre conductor length – right angle connector
• Terminal cover – soldering
• Shield termination
• Centre pin position
• Semirigid coax
• Swage – type connector
• Soldering and stripping of biaxial or twinaxial wire – low temperature insulation

Module 8

This module covers all of the following topics:

o    Solderless wire wraps

• Number of turns
• Turn spacing
• End tails, insulation wrap
• Raised turns overlap
• Connection position
• Wire dress
• Wire slack
• Plating
• Damage

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