IPC/WHMA-A-620B TRAINING AND CERTIFICATION PROGRAM · PDF fileipc/whma-a-620b training and...

IPC/WHMA-A-620B TRAINING AND CERTIFICATION PROGRAM

FOR CERTIFIED IPC TRAINERS (CIT)

© 2013, IPC, Bannockburn, IL All rights reserved. For use only in IPC Training Programs leading to Official IPC Certification

S1-41

5. Module(s) _________________are prerequisite training for IPC/WHMA-A-620 Certified IPCApplication Specialist (CIS) certification.

A. 1 and 3B. 1 and 2C. 1 through 18D. 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 daysB. 1 monthC. 1 weekD. 2 weeks

Answer: D Reference: Page 8, Clause 8.0.1 Policy

7. CIS retesting (of previously failed training modules) may be administered only after a minimum study/review period not sooner than…

A. 24 hoursB. 1 weekC. 60 daysD. 30 days

Answer: A Reference: Page 7, Clause 6.4.1 Policy




S1-42

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© 2013, IPC, Bannockburn, IL All rights reserved.

For use only in IPC Training Programs leading to

Official IPC Certification S2-75

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 1.17.1.2 Magnification Aids

2. The manufacturer shall __1__2__3 have a documented calibration system.

Answer: N1D2D3

Reference: Page 1-4, Clause 1.13.2 Calibration

3. Conditions that are not specified as defective or as a process indicator are considered _______

Answer: Acceptable

Reference: Page 1-6, Clause 1.15.7 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 1.15.4 Defect

5. Illumination at the surface of workstations should be _______________ minimum.

Answer: 1000 lm/m2

(Lumens per square meter)

Reference: Page 1-6, Clause 1.17.1.1 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 1.15.1 Target






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



© 2013, IPC, Bannockburn, IL All rights reserved. For use only in IPC Training Programs leading to Official IPC Certification S5-53

Slide S5-52 Instructor Activity: Instructor Notes:

Review CMA buildup requirements. Continued on next page.

5.3.5 Machined Contacts – CMA Buildup 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 CMA buildup.

o 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.





Review CMA buildup requirements.

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. 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.






Slide S5-56

Instructor Activity:

Instructor Notes:

Session review

Review




S5-58

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 5.1.1.2 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 arenot equal in length, the condition is [__1__2__3].

Answer: Acceptable - Class 1,2,3 Reference: Page 5-19, Clause 5.2.3 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 is2X 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 5.1.4 Stamped and Formed – Open Barrel – Crimp Bellmouth

4. On a machined crimp contact, if the crimp is not centered but the inspection window is notdeformed, the condition is [__2__3].

Answer: Acceptable - Class 2,3 Reference: Page 5-27, Clause 5.3.4 Machined Contacts – Crimping

5. On an open barrel stamped and formed contact, any loose conductor strands that are outside thecrimp area, trapped strands, or folded back strands are [__1__2__3].

Answer: Defect - Class 1,2,3 Reference: Page 5-10, Clause 5.1.3 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 amachined contact is [__1__2__3].

Answer: Defect - Class 1,2,3 Reference: Page 5-30, Clause 5.3.5 Machined Contacts – CMA Buildup





Figure 8-6 shows a proper wrap splice with at least 3 wraps of wire. Continued on next page.

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 S8-15


Instructor Notes:

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.

8.1.2 Soldered Splices – Wrap

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.





Explain the general requirements for Jiffy Junctions. Continued on next page.

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. Crimp contacts are terminated onto conductors (see Figure 8-59) and then inserted into the in-line junction device as it would be with a rear-entry 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 5.3.5. As an exception to 9.5.2, when a sealing plug is required it shall [D1D2D3] be inserted shaft first.






Slide S8-49


Instructor Notes:

Review the defect conditions for Jiffy

Junctions.

Publication should state Defect – Class

1,2,3.

Continued on next page.

8.2.4 Wire In-Line Junction Devices (Jiffy

Junctions)

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 5.3.1.

The conductor location does not meet the


Crimping does not meet the requirements of

5.3.4.

CMA buildup, when used, does not meet the


Contact installation does not meet the

requirements of 9.5.

Qualification of crimped connection fails

Pull Force/Tensile Test per 19.7.2.

Mated assembly fails Pull Test Contact

Retention Verification Test per 19.7.5.





Official IPC CertificationS9-43

REVIEW QUESTIONS

SESSION 9 – CONNECTORIZATION

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 9.3.1 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 9.4.3 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 9.5.1 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 9.4.2 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 9.2.1 Strain Relief – Clamp Fit






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REVIEW QUESTIONS

SESSION 14 – SECURING

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 14.3.1 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 14.1.2 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].



Defect - Class 3


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].



Defect - Class 3

Ref: Page 14-12, Clause 14.2.2 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







7. Spot ties or wraps placed over splices or ferrules contained in the wire bundle are [__1__2__3].



Defect - Class 3

Ref: Page 14-17, Clause 14.3.5 Routing – Ties over Splices and Ferrules






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 15.1.1 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 15.3.1 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 15.2.1.1.1 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].


Defect - Class 2,3

Ref: Page 15-15, Clause 15.2.2.1 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].


Process Indicator - Class 2,3

Ref: Page 15-22, Clause 15.4.1 Shield Termination – Splicing Prewoven – Soldered






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 15.2.2.1 Shield Termination – No Shield Jumper Wire – Shield Not

Folded Back

IPC/WHMA-A-620B TRAINING AND CERTIFICATION PROGRAM · PDF fileipc/whma-a-620b training and...

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