Guidelines for Production Testing of Wired Assemblies

This table recommends guidelines for production testing of wired assemblies.  These guidelines are not meant to replace the various ASME, ASTM, DOD:MIL, NASA, UL, NEC, ITA, ANSI, and DIN test standards.

Type of Assembly Minimal Testing Additional Testing for Good Practice Additional Testing for Critical Quality
IDC Ribbon Cable Assemblies
  • Opens and shorts testing (threshold levels not critical)
  • Repetitive testing (with a test time <1 sec.) eliminates passing by "wiggle and jiggle"
  • Low resistance (<1.2X nominal value)
  • High voltage (1000Vdc is often used on ribbon cable with 0.050" pitch)
High Volume Automotive and Appliance Harnesses
  • Single pass opens and shorts (threshold levels not critical)
  • Repetitive testing
    (<1 sec. intermittents)
  • Crimp force monitoring
  • Detecting presence of mechanical features such as locks, seals, and fasteners
  • Push-back tests for contacts in connectors
  • Low resistance (<1.2X nominal value)
  • High voltage (1000VDC) if possibility of air gaps <.1"
Data Cables
  • Opens and shorts testing (threshold levels not critical)
  • Repetitive testing (<1 sec. intermittents)
  • Low resistance (<1.2X nominal value)
  • High voltage (up to 1000VDC depending on spacing)
Network Patch Cables and High-Speed Twisted-Pair Data Cables
  • Opens and shorts testing (threshold levels not critical)
  • Twisted-pair testing for double miswires
  • CAT-5/6 (NEXT and FAR attenuation) testing or as specified
Assemblies with Components such as Diodes, Resistors, Capacitors, and ICs
  • Components recognized if missing and polarity of diodes detected
  • Wrong components detected. Accuracy sufficient to detect passive components with wrong value
  • Components measured to within specified tolerance
  • Functional testing if active components present
Military/Aerospace Assemblies
  • Manual ring-out (continuity) tests with ohmeter measuring values
  • High voltage tests of each conductor to shield
  • Opens and shorts testing
  • Low resistance (<1.2X nominal value)
  • High voltage (1500VDC or 1000VAC)
  • Special requirements testing as specified by customer