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
|
