Workmanship Standard – Level I

Document Number: WS-003

Revision: M
Effective Date: 10/7/2021
Cable Harness Assembly Point of Contact: Jeffrey LeFevre
Title: Manufacturing Engineer
Requirements: NA

TABLE OF CONTENTS
3. Cable Harness Assembly ................................................................................................................................1
3.1 Requirements and Acceptance for Cable and Wire Harness Assemblies ......................................................1
3.5 Crimp Terminations (Contacts and Lugs) .......................................................................................................2
3.6 Insulation Displacement Connections (ICD) ................................................................................................10
3.9 Connectorization .........................................................................................................................................12
3.10 Over-Molding/Potting ..................................................................................................................................30
3.12 Marking and Labeling ..................................................................................................................................38
3.13 Coaxial and Twinaxial Cable Assemblies ......................................................................................................39
3.14 Securing .......................................................................................................................................................40
3.15 Harness/Cable Electrical Shielding ..............................................................................................................41
3.17 Finishes Assembly Installation .....................................................................................................................44
3.19 Testing .........................................................................................................................................................44
RECORDS ......................................................................................................................................................................................... 45

3. CABLE HARNESS ASSEMBLY

3.1 Requirements and Acceptance for Cable and Wire Harness Assemblies
3.1.1 Scope/Purpose The purpose of this document is to supplement IPC/WHMA-A-620, by providing
additional Class 3 requirements and acceptance criteria applicable to the assembly of cables and
wire harnesses. The criteria may be new where none exists, add clarification to existing criteria or
add criteria that are unique to L3 Communications (CSW’s) products or processes.
Where this does not provide supplemental criteria to IPC/WHMA-A-620, the Class 3 requirements
of IPC/WHMA-A-620 apply, with the exceptions listed in IS-003. These requirements apply to stand
alone cable assemblies as well as LRUs, System integration or anywhere similar characteristics exist.
WS-003 is organized in the same order as the major chapters of IPC/WHMA-A-620. This is
deliberate to simplify its use and to group criteria into areas common to IPC/WHMA-A-620. The
paragraph numbering may skip due to this grouping.
The product classes to which the criteria apply has been omitted; only Class 3 requirements are
addressed in WS-003.
3.1.2 Terms and Definitions
Cable – An assembly of one or more wires carrying electrical current, with connectors on either
end, formed together to create a single assembly. The terms cable and harness are used
interchangeably, but harnesses normally have more than two connectors. RF cables are a special
type of cable that transmit RF signals and use coaxial type of wire and use coaxial type of
connectors.

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3.5 Crimp Terminations (Contacts and Lugs)
This section provides additional crimp termination (contact and Lug) requirements and acceptance criteria
that are currently not in IPC/WHMA-A-620 and are unique to CSW products or processes.
3.5.1 Crimping Solid Leads and Wires
The following criteria are applicable when the design requires a solid lead/wire to be crimped in a
termination. Open or closed barrel contacts, the solid lead/wire shall be soldered to the
termination in the brush inspection window (see Figure 3-1). When solid leads/wires are crimped in
machined contacts without insulation support, the lead/wire shall be soldered to the contact in the
insulation gap (insulation clearance area) (see Figure 3-2). When solid leads/wires are crimped in
machined contacts with insulation support the lead/wire shall be soldered to the contact at the
wire inspection window (see Figure 3-2).
Note: Soldering is performed after the crimping operation.

Figure 3-1 Acceptable

• Solid lead/wire soldered to Terminal. (Fig. 3-1)
• Meets solder requirements.
• Machined contacts may have a thin film of
solder on the outside of the contact but may
not extend onto the locking mechanism or the
electrical mating surface. (Fig. 3-2)
Note: Also applies to open barrel contacts.

Figure 3-2

1. Inspection Window
2. Insulation Gap (clearance area)

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Figure 3-3 Defect
• Solid lead/wire not soldered. (Fig. 3-3 & 3-4)
• Solder does not meet requirements.
• Any evidence of non-wetting to wire or
terminal.
• De-wetting of either wire or terminal.
• Solder buildup that affects form, fit, or
function.
• Machined contacts where the solder extends
onto the locking mechanism or the electrical
mating surface.

Figure 3-4

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3.5.2 Stamped and Formed – Insulation Crimp
See IPC/WHMA-A-620 for criteria.
See IS-003 for exception.
3.5.3 Terminal Lugs – Without Metal Insulation Support
Terminals without a metal insulation support are exempt from the insulation crimp requirements
due to the spring-back action (memory) of the plastic after crimping, all other criteria apply.

Figure 3-5 Acceptable

• Wire insulation does not enter the conductor
crimp area.
• Wire crimp area is well formed and properly
positioned.
• Wire insulation is within the insulation support
barrel. (Fig. 3-5)

Figure 3-6 Defect

• Wire insulation is not within the insulation
support barrel. (Fig. 3-6)
• Wire insulation enters the conductor crimp
area.
• Insulation gap is greater than one wire
diameter.

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3.5.4 Terminal Lugs – For Aluminum/Copper Code Conductors
This section addresses the visual criteria for closed barrel crimped lugs that typically accommodate
wire sizes that range from #10 AWG through 4/0. Some lugs in this range are high conductivity
wrought aluminum approved for aluminum and copper conductors, performing equally well on
both metals. These lugs are filled with a high temperature oxide inhibitor compound. Lugs are
electro tin plated to prevent electrolytic corrosion when in contact with copper.
Caution: The oxide inhibitor must never be removed prior to use.
Note: Insulated terminals may or may not have an insulation crimp depending upon the terminal
and the crimping tool used.

Figure 3-7 Acceptable

• There is visible clearance between the terminal lug
and the conductor insulation. (Fig. 3-7 & 3-9)
• Insulation gap is a maximum of 0.25 inch.
• Crimp indents are not centered, and the terminal is
not bent. (Fig. 3-8)
• Wire entry end of the barrel is not deformed by the
crimp.
• Lug is not cracked or fractured.
• Burnishing, tooling marks and deformation required
to crimp the terminal. (Fig. 3-10)

Figure 3-9

Figure 3-8

Figure 3-10

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Figure 3-11 Defect
• Insulation gap greater than 0.25 inch. (Fig. 3-11)
• Wire strands not contained in the crimp. (Fig. 3-
11)
• Contact is fractured or cracked (not shown).
• Wire entry end of the terminal is deformed.
(Fig. 3-11)
• Terminal insulation damaged exposing metal.
(Fig. 3-12)
• Wire insulation enters barrel of terminal. (Fig.
3-13)
• Terminal is bent (not shown).

Figure 3-12

Figure 3-13

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3.5.5 Stamped and Formed – Wire Braid Terminations
This section addresses the insulation support crimp of Stamped and Formed – Closed Barrel
Terminations. When wire braid is required to be terminated to a crimped lug the braid should be
formed round and concentric to the wire barrel and inserted through the barrel. The crimped
terminal must meet all other criteria for crimped lugs (see IPC/WHMA-A-620). The braid may
continue its round form and extend through the insulation crimp or it may be left flat in the
insulation support area.

Figure 3-14 Acceptable

• Round form or the metal braid extends through
the insulation crimp. (Fig. 3-14)
• Wire braid is flat in the insulation crimp. (Fig. 3-
15)
Note: Heat shrink sleeving has been pulled back for
clarity.

Figure 3-15

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3.5.6 Stamped and Formed – Open Barrel – Soldered Metal Braid
This section addresses open barrel terminals that are hand formed (no crimping tool available) and
terminated to metal braid, then soldered to ensure connection integrity.

Figure 3-17 Acceptable

• Solder is wetted to a minimum of 75% of the
contact area of the braid and the wire barrel
interface.
• Wire braid is flush to the end of the wire crimp
barrel or extends slightly past the crimp barrel.
• The braid end does not extend into the mating
area of the terminal.
• Braid is contained within the wire crimp barrel.
• Braid is contained in the insulation crimp. (Fig.
3-17)
• Less than 6% of the braid strands are cut,
broken, or damaged. (See IPC/WHMA-A-620
Table 13-1)
Figure 3-18 • The wire crimp and the insulation crimp are
gripping the wire braid. (Fig. 3-18)
• Solder has wicked past the insulation crimp in a
smooth even flow. (Fig. 3-19)

Figure 3-19

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Figure 3-20 Defect
• Solder fillet is wetted to less than 75% of the
contact area between the braid and the wire
crimp barrel interface. (Fig. 3-20)
• Wire braid not completely contained within the
wire barrel and or the insulation crimp. (Fig. 3-
21)
• Wire braid extends into the mating area of the
contact (not shown).
• Braid damages see IS-003. (Fig. 3-22)
• Solder ridges, sharp solder flow lines, solder
protrusions or icicles that could cause damage
to product or are a potential safety hazard. (Fig.
3-23 & 3-24)
Figure 3-21
Figure 3-23

Figure 3-22
Figure 3-24

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3.6 Insulation Displacement Connections (ICD)
3.6.1 Connector Damage – Modular connectors (RJ Type)
The following criteria apply to RJ type connectors with or without load bars.
Note: Magnification aid shall not be used to inspect the Polycarbonate plug connector material for
cosmetic imperfection, parting lines, etc.

Figure 3-24 Acceptable (Fig. 3-24 thru 3-27)

• No visible flaws.
• No visible clouding from compression.

Figure 3-26

Figure 3-25

Figure 3-27

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Figure 3-28 Acceptable Continued
• Internal stress cracks. (Fig. 3-28 & 3-29)
• Micro cracking resulting from installation.
• Mold flow lines.
• One hole located at any single wire insert
location is acceptable when under 0.050”. (Fig.
3-30)
• Up to two holes less than 0.050” each and holes
are not adjacent.

Figure 3-29

Figure 3-30

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 Figure 3-31 Defect
• Surface cracks or damage that inhibits the
mating connector function or may become FOD.
• Charred, milky, cloudy in appearance. (Fig. 3-31)
• Contacts are over-inserted.
• A single uncharacteristic hole with a diameter
greater than 0.050 inch (exposed wire).
• Two uncharacteristic holes less than 0.050 inch
diameter in bordering wire insert locations
(both with exposed wires).
• Any RJ45 connector with more than two
uncharacteristic holes less than 0.050 inch
diameter at wire insert locations (all with
exposed wires).

3.9 Connectorization
3.9.2 Strain Relief – Clamp Fit

Acceptable
• Pinched build up tape under clamp is
acceptable.

Figure 3-35
Defect
• Pinched sleeving or wire. (Fig. 3-35)

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3.9.3 Sleeving and Boots
Note: Silicone self-fusing tape may be used within cable assemblies under the cable’s outer jackets
to build up cable diameter, to improve strain relief, and smooth out transitions to prevent sleeving
/boot damage. See IS-001 for tape allowances.

3.9.3.1 Sleeving and Boots – Position

Note: See IPC/WHMA-A-620 section 9 for acceptance criteria for connectors that have strain
relief clamps.
Note: See section 3.9.4 for indoor and outdoor bonding requirements.

Figure 3-40 Acceptable – Clampless Adapters

• Cable jacket/sleeving (B) extends to within
one cable diameter of the clampless adapter
(A). (Fig. 3-40)
Note: Figure 3-40 illustrates a connector with a
clampless adapter. This configuration requires a boot.
• Boot/sleeving (D) extends over the clampless
adapter for at least 50% of the of the adapter
length. (Fig. 3-41)
• Boot/sleeving (D) is securely shrunk on the
rear of the connector adapter (no lateral
movement). (Fig. 3-41)
• Boot/sleeving does not extend onto the
threaded adapter ring (B). (Fig. 3-41)

Figure 3-41

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Figure 3-42 Defect – Clampless Adapter
• Cable jacket/sleeving does not extend to
within one cable diameter of the clampless
adapter.
• Boot/sleeving (A) extends over the clampless
adapter for less than 50% of the of the adapter
length. (Fig. 3-42)
• Boot/sleeving (A) is loose on the rear of the
connector adapter. (Fig. 3-42)
• Boot/sleeving extends onto the threaded
adapter ring.

Figure 3-44 Acceptable – Clamp Adapters

• For indoor bonding requirements:
o Environmental connector - the cable
jacket/sleeving extends into the
sealing grommet (D). (Fig. 3-44)
• For outdoor bonding requirements:
o Environmental connector - the cable
jacket/sleeving extends into the
sealing grommet (D) and be sealed.
(Fig. 3-44)
Note: Environmental connectors as shown in Fig. 3-44
does not require a bonded boot/ sleeving (assembly is
complete).

Figure 3-45 • Cable jacket/sleeving extends slightly past the

adapter clamps. (Fig. 3-45)
• EMI Non-environmental connector shows
braid extending into adapter and sleeving
ending past adapter clamp but not into
adapter. (Fig. 3-45)

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Figure 3-46 Defect – Clamp Adapter
Note: Fig. 3-46 and 3-47 illustrate environmental
connectors.
• On an environmental connector the cable
jacket/sleeving (C) does not extend into the
sealing grommet (D). (Fig. 3-46)
• For outdoor bonding requirements:
o On an environmental connector the
jacket/sleeving extends into the
sealing grommet but is not sealed
360°. (Fig. 3-47).

Figure 3-47

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 Figure 3-50 Defect – Sleeve/Boot
• Boot /Sleeving is damage i.e., tears, cuts,
cracks, splits or translucent. (Figs. 3-50 & 3-51)

Figure 3-51

3.9.3.2 Sleeving and Boots - Bonding

Bonding has two levels of requirements identified as indoor and outdoor. Drawings may
have one or both levels of requirements across the various joints.
Sleeving or boots overlapped on clampless (banding) adaptors or connectors are required to
be adhesive bonded in place and shall meet the bonding requirements for indoor or outdoor
applications, as applicable. Adhesive lined sleeving or boots satisfies the bonding
requirements when specified on the engineering bill of material. When adhesive lined
sleeving or boots is used, evidence of the adhesive may not be visible at the overlapped
junction.
Other sleeving overlapped junctions are not required to be adhesive bonded unless specified
per engineering documentation. However, when adhesive bonding material is not listed on
the engineering bill of material, a harnessing adhesive may be applied to any interface
between the connector backshell or the connector and the cable jacket as part of the
standard process. A harnessing epoxy may also be applied to any sleeving overlap, junction,
or splice as part of the standard process. See IS-001 for epoxy allowances. See W-576 for
Epoxy Application process.

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 3.9.3.2.1 Indoor Bonding Requirements
Cable or wire harness joints may be designated as indoor application. This section
addresses the adhesive bonding criteria for indoor applications.
When adhesive bonding is used for indoor applications it shall be bonded for a
minimum of 270º (75%) of the circumference of the sleeving, unless specified
otherwise on the drawing. For example, adhesive may be applied at breakouts with
Teflon wire jackets where minimal bonding is required per drawing notes.
Drawing practices have changed over time. Below are keys to determine if a bonding
requirement is for indoor application.
• Drawing note to bond for indoor application
• At connectors, balloon calls out epoxy in the connector stack up only; not
shown on opposite end of boot
• Balloon call outs at any joint without a note specifying an outdoor bond
requirement.

Figure 3-55 Acceptable

• The boot/sleeving is bonded (B) to the
clampless adapter for a minimum of 270º (75%)
of its circumference. (Fig. 3-55)
• The boot is bonded along longest sides on a
micro-D, but no bonding on the small sides near
the hardware. (Fig. 3-56)
Note: The boot/sleeving is not required to be bonded to
the cable jacket/sleeving.

Figure 3-56

No
epoxy No
epoxy

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 Figure 3-57 Defect
• The boot/sleeving is bonded less than 270º
(75%) of the circumference of the clampless
adapter.
• Adhesive is on any electrical mating surface.
• Adhesive has flowed beyond the boundaries of
the joint.
• Adhesive is on a surface that prevents proper
mating or mechanical attachment of the
connector.

3.9.3.2.2 Outdoor Bonding Requirements

Cable or wire harness joints may be designated on the engineering drawing as
outdoor application. This section addresses the adhesive bonding and sealing criteria
of overlapped tubing splices, overlapped breakout junctions, and sealing of the cable
jacket/sleeving to the connector for outdoor applications.

When adhesive bonding is used for outdoor applications it shall be sealed per
IPC/WHMA-A-620 requirements.

Drawing practices have changed over time. Below are keys to determine if a bonding
requirement is for outdoor application.
• Drawing note to bond for outdoor application
• At connectors, balloon calls out epoxy in the connector stack up and at the
opposite end of the boot
• Balloon calls out epoxy at any joint with a note specifying an outdoor
requirement

When a general drawing note calls for bonding for outdoor application, it is applicable
to the following areas:
o Sleeve to clampless adapters (Fig. 3-60)
o Breakouts where there is sleeving on all legs (Fig. 3-61)
o Sleeve splices (Fig. 3-62)
Other areas requiring outdoor bonding shall be specified on the drawing with bubble
callouts and/or notes specific to the bonding location.

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Figure 3-60 Acceptable
• Boot/sleeving is bonded with evidence of a 360º
seal (C) at each end. (Fig. 3-60)
• Bonding adhesive does not extend onto the
threaded adapter ring (B). (Fig. 3-60)
• Boot/sleeving or bonding adhesive does not
interfere with the connector coupling ring. (Fig.
3-60)
• Visual evidence of a 360º seal (B) of the
overlapped junction or a 360º seal around each
branch of an overlapped breakout junction. (Fig.
3-61 & 3-62)
• Tactile evidence (perceived by touch) of
adhesive between sleeving layers (overlap
interface) a minimum of 1 cable diameter or
0.25 inch whichever is greater. (Fig. 3-62 & 3-
63)
Figure 3-61

Figure 3-62 Figure 3-63

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Figure 3-64 Defect
• Not bonded and sealed (B) for 360º of
circumference of the boot/sleeving (either
end). (Fig. 3-64)
• Bonding adhesive extends onto the threaded
adapter ring.
• Boot/sleeving or bonding adhesive interferes
with the connector coupling ring.
• No evidence of a 360º seal (B) of the
overlapped junction or a 360º seal around
each branch of an overlapped breakout
junction. (Fig. 3-65)
• Adhesive has not adhered to the sleeving.
• Voids or separation in the adhesive.
• Adhesive has flowed beyond the boundaries of
Figure 3-65 the joint. (Fig. 3-66)
• No tactile evidence (perceived by touch) of
adhesive between sleeving layers (overlap
interface) less than 1 cable diameter or 0.25
inch whichever is less.

Figure 3-66

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3.9.4 Connector, Adapter, or Cap Damage – Cadmium Plated Surfaces
This section addresses visual acceptance criteria of cadmium plated surfaces e.g., connectors,
adaptors, dust caps, etc. This criterion takes exception to IPC/WHMA-A-620, 9.4.1, Defect – Class 2,
3, that does not allow exposure of base metal.
Note: Surface finish inspection shall be performed without magnification.
Note: Connector, Adapter, or Cap that have wear blemishes from mating or proper handling is not
cause for rejection. These blemishes may include scratches on threads, pins, or small cad, gold
platting particles. Small particles that are not foreign to the part are not cause for rejection
providing the particles don’t affect the functionality. Example: cad plating that wears off during
insertion is a natural occurring blemish.
Note: Connectors that incorporate a jam nut retaining ring (Fig. 3-72) as part of the cap restraining
mechanism (chain/lanyard), the positioning of the jam nut retaining ring is not defined, unless
dimensioned on the engineering drawing; however the retaining ring tab may not obscure any
panel marking.

Figure 3-70 Acceptable

• Wear indicator band fully or partially visible.
(Fig. 3-70 & 3-71)
• Gasket material (located inside the cap) is in
place (not shown).

Figure 3-71

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Figure 3-72 Acceptable - Continued
• Free of scratches, mars, burrs, gouges, groves,
scores, or other damage (Fig. 3-72) or
scratched, marred or burnished. (Fig. 3-73 thru
3-75)

Figure 3-75

Figure 3-73

Figure 3-74

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Figure 3-76 Defect
• Scored, notched, or gouged. (Fig. 3-76 & 3-77)
(Burrs not shown)
• Jam nut retaining ring (when used) (see Fig. 3-
72 (A)) obscures panel marking (not shown).
• Wear indicator band is missing (not shown).

Figure 3-77

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3.9.5 Connector Damage – Connector Molding Compound – Socket Style
This section addresses the molding compound that is used around the center core of the connector
insert during the fabrication of socket style, Amphenol Connectors.

Figure 3-80 Acceptable

• Exposed molding compound around the center
core of the connector. (Fig. 3-80)
Note: The molding compound is not required to be
visible for 100% of the perimeter of the connector center
core.

Defect
• Molding compound is flaking.
• Molding compound causes an interference
condition.

3.9.6 Installation of Sealing Plugs

3.9.6.1 Connector sealing plug length may be trimmed as need to prevent sealing plug dislodgement
or provide backshell clearance as needed. Sealing plugs shall not be trimmed below the top
surface of the connector grommet.
3.9.6.2 Installation of Sealing Plugs into shorting blocks.
This section addresses sealing plugs that are installed into Terminal Junction/Shorting blocks.
Figure 3-43 illustrates a typical sealing plug (A). It should be noted that sealing plugs that
feature a head are installed into the Terminal Junction/Shorting Block with the shaft first and
the head against the insert grommet and the head completely visible.

Figure 3-85 Acceptable

(Shorting Blocks Only)
• Sealing plug (A) is installed with the shaft first.
(Fig. 3-85)
• Sealing plug shaft is captured by the insert
grommet (head is visible).

Note: Where a sealing plug is installed, a contact will not

be installed.

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 Figure 3-86 Defect
(Shorting Blocks Only)
• Sealing Plug (A) installed head end first (head
not visible). (Fig. 3-86)

3.9.7 Raychem MTC 50 Connector Termination

Figure 3-90 Acceptable
• The wire overlaps the terminal a minimum of
two stripped wire diameters. (Fig. 3-90)
• The solder pre-form is completely melted and
there is no remnant of the solder pre-form
shape.
• There is an acceptable solder fillet between the
wire and the terminal.
• The heat shrinkable sleeving (A) is fully shrunk
onto the wire and the terminal. (Fig. 3-91)
• The heat shrinkable sleeving is not burnt or
charred and does not have any splits or tears.
Figure 3-91
• The minimum electrical clearance between
electrically conductive surfaces. (B) is greater
than .015 inch. (Fig. 3-91)
• Side overhang of the wire does not exceed 25%
of the stripped wire diameter. (Fig. 3-92)
• The minimum electrical clearance between
electrically conductive surfaces (B) is a
minimum of .015 inch.
• There is a visible fillet between the wire and the
terminal.
Note: Heat shrinkable sleeving has been partially
removed for clarity.
Figure 3-92

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 Figure 3-93 Defect
• Side overhang of the wire exceeds 25% of the
stripped diameter. (Fig. 3-93)
• The minimum electrical clearance between
electrically conductive surfaces is less than .015
inch.
• Wire overlap is less than two stripped wire
diameters.
• Heat shrinkable sleeving not completely shrunk.
• The heat shrinkable sleeving is charred, split or
torn.
Figure 3-94 • The solder pre-form not completely flowed.
(Fig. 3-94)
• Wire insulation overlaps the solder termination
area.

3.9.8 Raychem MTC 100 Connector Termination

Figure 3-95 Information

Solder ferrule (heat shrinkable device) consist of an
outer shrinkable sleeve (1), two meltable sealing rings
(2) and a solder ring (3). See Figure 3-95.

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Figure 3-96 Acceptable
• Refer to Figure 3-96.
• The stripped conductor extends the full length
of the cupped area (4) of the solder terminal.
• The stripped conductor overlaps the solder
terminal (4) a minimum of two stripped wire
diameters.
• The stripped conductor is parallel to the solder
terminal.
• The wire insulation (5) has not entered the
solder terminal area.
• The meltable sealing ring (3) is overlapping the
wire insulation.
• The end of solder ferrule sleeve (2) is within
.040 inch of the connector body (1).
Figure 3-97 • Solder pre-form has flowed properly leaving no
evidence of solder ring.
• The meltable sealing rings (3) have melted and
flowed.
• Shrinkable sleeve is discolored but is not burnt
or charred.
• No pits or cracks are visible in the connector
body. (Fig. 3-97)
• Side overhang of the wire does not exceed 25%
of the stripped wire diameter. (Fig. 3-98)
• Conductors have not ruptured or damaged the
ferrule (shrinkable) sleeve.
Figure 3-98 • Solder fillet is visible between the lead and the
terminal.

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 Figure 3-99 Defect
• Side overhang of the wire exceeds 25%. (Fig. 3-
99)
• Conductor strands are protruding through the
solder ferrule sleeve.
• Wire overlap is less than 2 wire diameters.
• Incomplete reflow of the solder pre-form.
• The shrinkable sleeving is charred, split or torn.
• Wire insulation overlaps the solder termination
area.

Figure 3-100 • Solder fillet not visible between the lead and
the terminal.
• Pits or cracks are visible in the connector body
(applies to both MTC 50 and MTC 100
connectors). (Fig. 3-100)

3.9.8.1 Raychem MTC 50 & MTC 100 Connector Termination – Sealing Boot
Note: Criteria apply to both MTC 50 and MTC 100 connectors.
MTC 100 and MTC 50 sealing boots consist of heat shrinkable sleeve and meltable adhesive
inside the boot (see Fig. 3-101).

Figure 3-101 Acceptable

• Sealing boot is shrunk (boot is tight).
• Meltable adhesive has properly flowed.
• Insulating boot is discolored but is not split,
torn, burnt, or charred.
• Boot is properly positioned (overlaps onto the
connector and the wire insulation). (Fig. 3-102)

Figure 3-102

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 Defect
• Boot is loose.
• Meltable adhesive has not completely flowed.
• Boot is split, torn, burnt, or charred.
• Pits or cracks are visible in the connector body.

3.9.8.2 Raychem MTC 50 & MTC 100 Connector Termination – Flat Cable

Figure 3-103 Acceptable

• Flat cable is oriented correctly (color strip or
numbers or letters identify pin one).
• Cable is not misaligned (skewed).
• Boot is not damaged.
• Acceptable solder fillets are evident. (Fig. 3-103)
• Conductor side overhang is less than 25% of the
conductor width.
• Shrinkable sleeving or boot discolored but not
burnt or charred.

Figure 3-104 Defect

• Flat cable misaligned, side overhang is greater
than 25% of the conductor width or violates
electrical clearance.
• Flat cable is oriented incorrectly (color strip or
numbers or letters) not matching connector pin
one.
• Overheated or disturbed solder.
• Shrinkable sleeving or boot is split, torn, or
charred.
• Solder rings not completely flowed. (Fig. 3-104)
• Meltable adhesive not flowed.
• Boot is loose or not completely shrunk.
• Connector body damage pits or cracks.

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 3.10 Over-Molding/Potting
Terms and Definitions
Blow Through: any location where mold material migrates through the connector insert or contacts.
Braid Fold-Back: portion of the braid that is folded back to allow a solder connection between the braid
and the foil.
Connector Insert: usually the Green, Black or Blue plastic piece inside the vendor supplied connector.
Cable/Wire Bundle and Mold Interface: the location where the cable enters the molded connector.
Connector/Mold Interface: the location where the connector is in contact with the mold.
Float: internal components visible at the surface of the mold material.
Injection gate: location on the mold where the material is injected into the mold cavity.
Injection Molding: see IPC/WHMA-A-620 for definition.
Lap Joint: when a piece of foil is positioned to lie on top of another conductive surface (i.e. connector,
other foil etc.).
Mismatch: where matched mold parts are not properly aligned.
Potting (Thermoset) Molding: see IPC/WHMA-A-620 for definition. Adhesive tape or other materials
may be used to form a shape when molding.
Pull out (Pop out): where the sleeve, cable jacket or insulation is pulled out of the molded connector.
Solder Wicking: capillary movement of solder between metal surfaces such as strands of wire.
Streaking: discoloration of the part usually fanning out from the injection gate.
Surface Imperfections: rough surfaces on the molded component.
3.10.1 Injection & Potting (Thermoset) Mold fill – Inner

Figure 3-108 Acceptable

• Mold material is in contact with the connector
and has no gaps, no cracks and the connector
is secure in the mold material. (Fig. 3-108)
• Mold material does not interfere with fit or
function of connector/contacts.
• No mold material on the mating surfaces of the
connector/contacts. (Fig. 3-108)

Defect
• Voids of any size that expose conductors.

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3.10.2 Injection Mold Fill – Outer

Figure 3-110 Acceptable

• Mold material is in contact with the wire(s),
sleeve or cable jacket but may have
separation/gaps providing internal
components (e.g., wires, shielding, etc.) are
not visible and connector is secure.
• No mold material on the mating surfaces of the
connector/contacts.
• Mold material is in contact with connector, but
may have small separations/gaps, providing:
o Connector is secure in mold material.
o Connector/backshell acts
substantially as a single structural
unit.
• Mold material does not interfere with fit or
function of connector/contacts. (Fig. 3-111)
Figure 3-111
• Part lines discernible but not raised. (Fig. 3-
111)
• No sink marks, or rough edges.
• No exposed wire, foil, insulation, ferrules,
braid, etc.
• Textured surface visible after the removal of
flash. (Fig. 3-113)
Note: Flash must be secure without potential for
creating Foreign Object Debris (FOD).

Figure 3-113
Figure 3-112

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Figure 3-114 Acceptable, Continued
• Flash has been removed without damage to
the cable, wire, insulation, sleeve, or jacket.
• Flash less than 1/16 (.06) inch at the
cable/wire bundle and mold connector
interface. (Fig. 3-114)
• Molding captures cable jacket, insulation,
sleeve, or boot. Adhesion is not required,
unless specified. (Fig. 3-115)

Figure 3-115

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Figure 3-116 Defect
• Cracks or separations at the surface. (Fig. 3-116
thru 3-118)
• Rework/touch-up that affects form, fit or
function.
• Rework/touch-up material is different than the
original material used.

Figure 3-117

Figure 3-118

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3.10.3 Potting (Thermoset) Mold Fill – Outer

Figure 3-119 Acceptable

• Mold Material adheres to entire
circumference of the wire(s) or cable jacket
when the engineering documentation
requires the material to bond to the wire(s) or
cable jacket. (Fig. 3-119 & 3-120)
• No mold material on the mating surfaces of
the connector/contacts.
• Mold material is in contact with connector,
but may have small separations/gaps,
providing:
o Connector is secure in mold material.
o Connector/backshell acts
substantially as a single structural
Figure 3-120 unit.
• Mold material does not interfere with fit or
function of connector.
• No exposed wire, foil, insulation, ferrules,
braid, etc.
• Textured surface visible after the removal of
flash.
• Flash less than 1/16 (.06) inch at the
cable/wire bundle and mold connector
interface.
• Flash has been removed without damage to
the cable, wire, insulation, sleeve, or jacket.

Note: Flash must be secure without potential for

creating Foreign Object Debris (FOD).

• Molding captures cable jacket, insulation,

sleeve, or boot. Adhesion is not required,
unless specified.

Defect
• Rework/touch-up that affects form, fit or
function.
• Rework/touch-up material is different than the
original material used.
• Voids greater than 1mm diameter.

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3.10.4 EMI-RFI Shielding – Foil
Figure 3-121 Acceptable
• Foil lap joints are soldered for the full length.
• Cumulative 75% minimum fillet along any
length of a lap soldered joint. (Fig. 3-121)
• Foil soldered to the folded back portion of braid
(cable braid foil interface). (Fig. 3-122)
• Cumulative 90% minimum wetting of fold-back
braid and foil interface.
• Braid fold-back solder is not bridged to cable
braid – preferred. (Fig. 3-123)
Or
Fold back foil solder is bridged to the cable
braid - acceptable. (Fig. 3-124)
Figure 3-122

Figure 3-124
Figure 3-123

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 Figure 3-125 Acceptable Continued
• No holes or open locations in the foil.
Openings or damage covered with a foil patch
soldered in place. (Fig. 3-125)
• Solder flow visible on connector. (Fig. 3-126)

Figure 3-126

Before After

Figure 3-127 Defect

• Cumulative solder fillet is less than 75% of the
length of any lap solder joint. (Fig. 3-127)
• Less than 90% cumulative wetting of fold-back
braid and foil interface.
• Holes or open locations in foil. (Fig. 3-128)

Figure 3-128

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3.10.5 Hardware Installation – Jackscrews
The criteria in this section addresses the installation of connector mounting hardware (i.e.,
jackscrews or jackposts) in Injection Molded or Potted (Thermoset) connectors.
Note: A trial mating of connector to connector or connector to assembly may be required for final
acceptance.

Figure 3-135 Acceptable

• Mold design provides clearance for hardware
installation. (Fig. 3-135)
• Mates with mating connector hardware. (Fig.
3-136)
• Molding material does not obstruct or
interfere with the mounting hardware.
• Mold obstruction adjacent to the mounting
hardware is trimmed flush to the surface to
provide hardware clearance.

Figure 3-136

Figure 3-137 Figure 3-138

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 Figure 3- 139 Defect
• Connector hardware is misaligned due to
molding obstruction. (Fig. 3-139 & 3-140)
• Will not mate with mating connector
hardware.
• Trimming or damage to the molding material
that exposes the foil or connector housing.

Figure 3- 140

3.12 Marking and Labeling

3.12.1 For fiber optic cables the spacing between markers, including any overwrap, shall be a minimum of
1.5 inches

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3.13 Coaxial and Twinaxial Cable Assemblies
3.13.1 Center Conductor Termination – Coax Pin Insulation Gap
Note: Center conductor must be inserted for the full depth of the cup.
Figure 3-145 Acceptable
• Insulation end (dielectric) is positioned within
solder cup and support barrel area (A). (Fig. 3-
145)
• Insulation end contacts the solder cup but does
not prevent the formation of an acceptable
solder connection. (Fig. 3-146)

Figure 3-146

Figure 3-147 Defect

• Insulation (dielectric) end is not positioned
within solder cup and support barrel area (A).
(Fig. 3-147)
• Insulation end prevents the formation of an
acceptable solder connection (not shown).

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 3.14 Securing
3.14.2 Excess Wire Length– Loop in Bundle
Note: This section only applies to wires terminated from point to point. Does not apply to pick-off
or drain wires.

Figure 3-150 Defect

• Excess wire length can’t be folded back or
looped around.

Figure 3-151

Figure 3-152

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 3.15 Harness/Cable Electrical Shielding
3.15.1 Shield Termination – Braided pick off
Figure 3-155 Acceptable (unsleeved)
• Solder ring is completely melted wetting the
braid and the cable shield and meets the
requirements of IPC/WHMA-A-620 Section 15.
(Fig. 3-155)
• Crimp termination meets the requirements of
IPC/WHMA-A-620.
• Braid is undamaged, see IPC/WHMA-A-620
table 13-1.

Figure 3-156 Acceptable (sleeved)

When the braided pick off is required to be sleeved
the following are met:
• Solder ring is completely melted wetting the
braid and the cable shield and meets the
requirements of IPC/WHMA-A-620 section 15.
(Fig. 3-156)
• Sleeving is tight on the braid- no lateral
movement.
• No cracks, tears or burns.
• The braid sleeving is flush to the heat shrink
device and less than 2 sleeve diameters.
• The braid sleeving extends into the insulation
crimp area of the crimped termination.

Defect
• When required to be sleeved, braid is not
sleeved.
• When sleeved the insulation gap between the
sleeving and the heat shrink device is greater
than 2 sleeving diameters.
• Violation of soldering requirements, see
IPC/WHMA-A-620 Section 15.
• Violation of crimping requirements, see
IPC/WHMA-A-620 Section 5.
• Braid is damaged, see IPC/WHMA-A-620 table
13-1.

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3.15.2 Shield Termination – Soldered to Connector Housing
This section is only applicable when specified by engineering documentation. This section
addresses wires soldered to metal connector housings. Typically, this type of termination requires
the plating to be removed from a limited portion of the connector housing in order to create a
solder able surface.

Figure 3-160 Acceptable

• Wire overlap to the metal surface is greater
than 3, less than 5 wire diameters.
• The wire is in contact with and parallel to the
metal surface of the connector. (Fig. 3-160)
• Solder is wetted and forms a fillet from the wire
to the metal connector housing a minimum of 3
wire diameters.
• Wire contour is visible in the solder.
• Damage to the non-metal portion of the
connector has not distorted the contact cavity.
• Insulation gap is within 2 wire diameters of
solder fillet.
• Connector is clean and free of flux residue and
foreign matter.
• The buffed metal area of the connector is
covered with wetted solder or other approved
coating.

Figure 3-161 Defect

• Wire or insulation damage beyond limits.
• Soldered portion of the ground wire is not
parallel to the connector surface. (Fig. 3-161)
• Wire is not in contact with the metal surface.
• Wire overlap is less than 3 or greater than 5
wire diameters.
• Solder wetting at the connector and wire
interface is less than 3 wire diameters in length.
• Solder is de-wetted or no-wetted.
• Contact cavity (dielectric) of the connector is
distorted.
• Insulation gap greater than 2 wire diameters
from solder fillet.
• Flux residue or foreign matter evident on solder
connection, connector, or connector contacts.
• The buffed metal area of the connector is not
covered with wetted solder or other approved
coating.

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3.15.3 Shield Termination – Connector – Spring Band

Figure 3-165 Acceptable

• Shield is secured/retained.
• Shield is flush against “boot groove” and not
visible (not shown).
• Shield is visible between spring band and the
“boot groove”.
• Shield weave pattern is intact (A). (Fig. 3-165)

Figure 3- 166 Defect

• Shield extends beyond the “boot
groove” (B). (Fig. 3-166)
• Backshell is damaged (not shown).
• Spring band is not completely
wrapped around backshell (not
shown).
• Spring band is not within the
“banding channel”. (Fig. 3-167)

Figure 3- 167

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 3.15.4 Shield Termination – EMI Braid to Braid
When braids overlap other braids, the contact areas must be cleaned and electrically bonded
together. Soldering is the preferred connection method. Conductive epoxy may be called out if
wire under the braids may be damaged by soldering temperatures. When conductive epoxy is used
to bond the braids, the bond shall be verified to be less than 2.5 milliohms after curing.

Figure 3- 170 Acceptable: (Fig. 3-170)

• Solder joint (Bonding) is continuous around
360°of the connection area.
• Solder joint (Bonding) length is 0.5 to 1.0 of the
diameter of the largest braid.
• Solder joint (Bonding) is smooth with limited
wicking.

Defect:
• Solder joint (Bonding) is NOT continuous around
360° of the connection area.
• Solder joint is not wetted to other braids
around the 360° solder joint.
• Solder joint (Bonding) length exceeds one
Diameter of the largest braid.
• Solder joint (Bonding) length is less than 0.5
Diameter of the largest braid.
• Solder joint (Bonding) is rough and/or uneven.
• Solder wicking is excessive creating rigid
sections where wires will be damaged.

3.17 Finishes Assembly Installation

60083155, Specification of Standard Torque limits for Threaded Hardware, establishes torque and
retention requirements for threaded hardware used at L3 CSW.
P-553, Torque Application Procedure, describes requirements and responsibilities of applying torque to
product.
W-572, Connector & Adapter Torque Application, provides an acceptable approach to applying torque to
adapters and connectors on cable assemblies.
3.19 Testing
60100697, Specification for Dielectric Withstanding Voltage (DWV) for Cable Assemblies, provides
guidance when it is appropriate to reduce dielectric withstanding voltage (DWV) for Class 3 cable
assemblies tested per IPC/WHMA-A-620.
Note: Pull tests shall be performed per W-083 Wire Crimp Pull Tests.

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RECORDS
There are no records associated with this document.

END OF DOCUMENT

DOCUMENT INFORMATION

Responsible Organization: Operations

Function/Sub-function: Workmanship Standards

Governing Document(s): Y-001, Quality Management System

IPC-WHMA-A-620, Requirements and Acceptance for Cable and Wire Harness
Assemblies

Subordinate Document(s): N/A

Related Document(s): 1M-160, Manage Tool Services (Calibration Services)

IS-001, Use of Alternate Size Hardware
IS-002, Alternate Piece Marking Method
IS-003, Workmanship Acceptability of Electronic Assemblies
IS-008, Part Number/Suffix Configuration
IS-010, Unique Identification Number (UID)
P-047, Inspection
P-553, Torque Application Procedure
W-103, Heat Shrink Terminations for Shielded Wire
W-404, Inspection of Connector Contact/Pin Seating
W-442, Unique Identification (UID) Piece Marking Label Printing and Verification
W-572, Connector & Adapter Torque Application
W-576, Epoxy S1125 Application Guidelines
W-083, Wire Crimp Pull Tests
60083155, Specification of Torque and Retention Requirements for Threaded
Hardware
60100697, Specification for Dielectric Withstanding Voltage (DWV) for Cable
Assemblies
60102381, Guideline for Interpreting L3 Communications Cable Drawings

Related Training: N/A

Approval Requirements: Manager, Manufacturing Engineering

Manager, Quality Engineering
Manager, Design Engineering

Review Requirements: Inspection Representative

Design Representative
Revision History Summary

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Revision # Description of Change Date
A-H Initial release through revision H. VARIOUS
I Added “, Adapter, or Cap” and removed “Only dust caps are shown due to the 06/06/2018
ease of displaying visual surface appearance.” From section 3.9.4. Removed
“natural occurring” and “natural wear” from 2nd note in section 3.9.4 and
added “, Adapter, or” and “proper handling”. Removed reference to WS-018
from section 3.10. Added new sections 3.10.1. through 3.10.7. Added
“Bundle or tie wrap is loose” to Defect for Figure 3-68. Added “Adhesive has
flowed beyond the boundaries of the joint” to Defect items listed in section
3.16.2.3.
J Major revision to remove redundancy between IPC-620 and this document. 4/2/2019
Also added acceptable and defect definition ’or RJ-45's. Deleted several
figures and renumbered applicable figures throughout.
K In section 3.9.2, Added “Wear indicator band fully visible (Fig 3-29B)” to 11/13/2019
Target section. Added new figure 3-29B and added “Portions of wear band
are visible (Fig. 3-30D)” in Acceptable section. Added new figure Figure 3-30D
and added “Wear indicator band is missing. (not shown)” to the Defect
section. Added new section 3.12.1, “For fiber optic cables the spacing
between markers, including any overwrap, shall be a minimum of 1.5 inches.”
Removed first note in section 3.16.2 which indicated “Unless otherwise
specified on the engineering drawing, all cable and wire harness assemblies
are considered to be designed for an indoor environment.” In section
3.16.2.2, added new figure 3.76B and added “EMI Non-environmental
connector shows braid extending into adapter and sleeving ending past
adapter clamp but not into adapter Figure 3-76B” to the Acceptable section.
L Major revision. Reorganized to better match IPC-WHMA-A-620 layout. 5/11/2021
Blending of Target conditions with Acceptable conditions to match IPC-
WHMA-A-620 format. Reformat pictures and Acceptable / Defect conditions
into tables to help clarify conditions. Moved bonding and sleeving section
from 3.16 to 3.9 to better match IPC-WHMA-A-620. Reworked molding
section to remove duplicate requirements from IPC-620. Rework bonding and
sleeving sections to better clarify indoor and outdoor bonding requirements.
Add allowance for micro-d to not have seal on short edge for indoor
conditions. Removed sections that only referred to IPC-WHMA-A-620. Added
reference to W-576 in section 3.9.3.2.
NA Updated sections to correcting numbering sequence. No revision upgrade 5/27/2021
necessary.
M Added P-553 and W-572 to section 3.17 and Related Documents list. 10/7/2021

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