To introduce wiring harness and cable assembly basic knowledge.

1. Basic
Antoine Chen
antoine@everbiz.com.tw

2.  Application and
Marketing
 What is it?
 Standard
 IPC
 What’s wire & Cable
 Assembly Process
 Producing Machine
 Testing Machine

4. SATA
ATA-1（IDE）、ATA-2
SCSI

5. DVI
VGA
DVI
HDMI

6. LAN Cable
Patch Cord
RJ45
Keystone
Mobile Phone Cable

7. RCA
DC Jack
BNCDC Plug
DC Jack
RCA

8. RCA
RCA
Phone
Plug
RCA
Phone Plug Phone PlugRCA
BNC
DC
Jack
Phone Plug
Connector

11.  To transmit two eclectronic devices with power
and single.
 Electrical Connector
 Cable and Wire
 Accessories parts.

12.  Evnironment
◦ Temp：High、Cool
 Ex：Teflon、94V0、
Sillicon …
◦ Humidity：Wet、Dry
 Ex：Waterproof, IPX8
◦ Special：Chemical、
Medical、Miltry、Under
Water、Outdoor、Flame、
Wear-Resistance、Weight、
Flexable、Clean Room
 Features
◦ Electric：Current、Voltage、
Resistance
 Ex：Silver Wire、OFC…
◦ Noise：EMC、EMI、EMS
 Ex：IEC 60950
◦ High Frequency
 Ex：RF Cable、LVDS、
HDMI…
 Mechanism
◦ Exterior：Circle、Flat、
Color
 Ex：Circel Connector、
DSUB….
◦ Size：Thick、Thin
 Ex：Micro Coaxial Cable
◦ Weight：Light、Heavy
 Ex：Aerospace Cable
◦ Safty
 Ex：CE、UL、JIS…

13.  Electronics：IPC-A-620、UL486A（for Terminals and Copper
conductors only）、 UL486C（for Butt Splices, Parallel Splices, Closed End Connectors,
and Wire Nuts）、UL310（for Quick Disconnects, Flag and Couplers）、 DIN
41611-4（Solderless electrical connections; clip connections; terminology,
requirements, testing）
 Vehicle：SAE/USCAR-21（Performance Specification for Cable-to-Terminal
Electrical Crimps）
 Aerospace：NASA STD 8739.4（Crimping, Interconnecting Cables,
Harnesses, and Wiring）
 Airplne：SAE AS 50881（Wiring Aerospace Vehicle）
 Boat：ABCY E-11（American Boat & Yacht Council）Flow UL310
 Military：MIL-T-7928G（Terminals, Lug; Splices, Conductor crimp styple,
Copper, General Specification for Military）、SAE AS 7928A-2008、MIL-
STD-704（Aircraft Electric Power Characteristics）
 Testing：EIA-364-38、EIA-364-08
 USB、HDMI、Display Port、LVDS..

15. Requirements and Acceptance for Cable
and Wire Harness Assemblies
IPC-A-620
Acceptability of Electronic Assemblies
IPC-A-610
Requirements for Soldered Electronic
Assemblies
J-STD-001,IPC-HDBK-001,IPC-AJ-820
Acceptability Standard for Manufacture, Inspection, &
Testing of Electronic Enclosures
IPC-A-630
Acceptability of Printed Boards
IPC-A-600
Qualification for Printed Boards
IPC-6011, 6012, 6013, 6017
Base Materials for Printed Boards
IPC-4101, 4104, 4202, 4203, 4204
Design & Land Patterns
IPC-2220 系列 +7351
Data Transfer and Electronic Product
Documentation
IPC-2581 Series, IPC2610 Series
Mark & Label
J-STD-609
Coper Foils
IPC-4562
Solder Mask
IPC-SM-840
Assembly
Materials
J-STD-004
J-STD-005
IPC-HDBK-005
J-STD-006
IPC-SM-817
IPC-CC-830
HDBK-830
Repair
IPC-7711/21
Solderability
J-STD-002
J-STD-003
Stencil Design
Guidelines
IPC-7525
Design
PCB
PCBA
Materials
Declaration
IPC-1751
IPC-1752
Electrical Test
IPC-9252
Surface Finishes
IPC-4552
IPC-4553
IPC-4554
Test Methods
IPC-TM650
IPC-9691
High
Speed/Frequency
IPC-2141
IPC-2251
BGACSPHDI
Advanced
Packaging
J-STD-030
IPC-7094
IPC-7095
Storage &
Handling
J-STD-020
J-STD-033
J-STD-075
DESIGN AND CRITICAL PROCESS
REQUIREMENTS FOR OPTICAL FIBER, OPTICAL
CABLE AND HYBRID WIRING HARNESS
ASSEMBLIES
IPC-D-640
IPC-D-620
Design and Critical. Process
Requirements for Cable and
Wiring. Harnesses.

19. • IPC-A-610 Telecom Addendum
• IPC-HDBK-610 Communication
• IPC/J-STD-001 Space
• IPC/WHMA-A-620 Space
• IPC-6012 Space

20. http://www.rrkabel.co
m/products/tri-rated-
cable/#accordion-1-t6

21. https://www.quora.com/What-are-
the-technical-cable-requirements-
for-Fire-Alarm-System

22.  Singal Shield/AE/Al Mylar+Earth Wire）
 Double Shield/AEB/Al Mylar+Earth
Wire+Braid
 Ribbon

23.  Cable is made by conductor, insulator, shield
and strength elements.
 Conductor
◦ Silver、Copper、Aluminum、Gold、Steel, Alloy
 Insulation
◦ Plastic、Rubber、PVC、PU、TFE(Teflon)、PE、
Sillicon。
 Shield
◦ Copper Braid, Aluminum Braid, Al Mylar.
 Strength
◦ Paper, Cotton Wire.

24.  Solid
 Bare Strand
 Tined Bare

25.  Features
◦ Wire, Cable, Ribbon Cable, Network Cable/LAN
Cable/Patch Cord CAT 5e, CAT 6, CAT 7, Telephone
Cable, Bare Copper Wire, Vehicle（AVS/AVSS）,
Enameled/Magnet Wire, Special Transformer Triple Wire,
Flexable, Hard, Coil, High Voltage
 Temperature
◦ High Tem Resistance、Cool Tem、Flame
 Specical Condition
◦ Oil Resistance, UV Resistance、High Frequency、Anti-
Rat、Medical、Antibacterial
 Exterior
◦ Circle、Flat

26.  UL 13：Power-Limited Tray Cable
 UL 44：Thermoset-Insulated Wires and Cables
 UL 62：Flexible Cords and Cables
 UL 66：Fixture Wire
 UL 83：CSA 75 | Thermoplastic-Insulated Wires and Cables
 UL 444：CSA 214 | Communications Cable
 UL 758：Appliance Wiring Material（UL 1581/UL 2556 Test
Protocols）
 UL 1063：Machine Tool Wires and Cables
 UL 1277：Tray Cable
 UL 1309：CSA 245 | Marine Shipboard Cable
 UL 1426：Electrical Cables for Boats
 UL 1569：Metal-Clad Cable
 UL 2250：Instrumentation Tray Cable
 UL 2277：Flexible Motor Supply Cable
 UL 2571：Irrigation Feeder, Control and Signal Cables

27. 1007 E193578 AWM VW-1 80℃ 300V
WATEH CSA TR-64 LL112407 90℃ 16AWG LF
E132276 (UL) CM 75℃ 4PR 24AWG CSA
LL64151 CMG FT4 ETL VERIFIED TO TIA/EIA-
568-B.2-1 CAT .6 PATCH CORD --- UTP

28. AWM 20276 VW-1 80℃ 30V E138961
CHUAN WEI (L.F)
LIAN YU AWM 2651 VW-1 105℃ 300V
28AWG E128076 RoHS

29.  1007： UL 758 AWM Style Type
 E193578 ：UL 758 AWM e number.
 ：UL mark.
 AWM：Appliance Wiring Materials
 VW-1：Vertical-Wire Flame Test
 80℃：Rating Temperature
 300V：Rating Voltage
 22AWG：American Wire Gage
 LL84201: CSA File Number
 I/II：AWM Class（CLASS I：Internal, CLASS II：
External）
 A/B：CSA Group（A： Where not subjected to
mechanical abuse； B： Where may be subjected to
mechanical abuse ）

30.  Style 1000-1999& 10000-：
Single Conductor, Thermoplastic-insulated wire
 Style 2000-2999 & 20000 - ：
Multi Conductor，Thermoplastic-insulated and
jacket wire
 Style 3000-3999：
Single Conductor，Thermosetting-insulated wire
 Style 4000-4999：
Multi Conductor，Thermosetting-insulated and
jacket wire
 Style 5000-5999：
Single and multi Conductor specialty items

31.  Li：Stranded Conductor/Flexible cable
 Y：Insulating cover of polyvinylchloride
（PVC/SR-PVC）
 2Y：Polyethylene sheath.（PE）
 4Y：Polyamide (PA)
 6Y：Tetrafluoroethylene hexafluoropropylene
(FEP)
 7Y：Ethylen tetrafluoroethylene (ETFE)
 9Y：Polypropylene (PP)
 (ST)：Static shield of plastic-backed aluminium
foil.
 C：Shield of braided copper wire.
 V：Tinned copper conductor.

32. H 03 V V H2 - F 0.75mm2 2 G
H：Harmonized 協調式(歐規標準)
A：Ｎon Harmonized 非歐規標準
03：300/300V
05：300/500V
07：450/750V
V：PVC
R：Rubber(Natural or Synthetic)天然或人造橡膠
N：Polychloroprene Rubber氯丁橡膠
S：Silicone Rubber 矽膠
G：Glass Fiber Construction纖維結構
V：PVC
R：Rubber(Natural or Synthetic)天然或人造橡膠
N：Polychloroprene Rubber氯丁橡膠
T：Textile Construction編織結構
H：Flat, Separated Cable 扁型、分隔電線
H2：Flat, Non-Separated Cable 扁型、不分隔電線
U：Solid 單芯線
R：Stranded 絞線
K：Fine Wire-Stantionary Install 細線-固定裝置
H：Fine Wire-Flexible Cordage 細線-軟線
F：Extra-Fine Wire-Flex Cordage 特細線-軟線
Y：Tinsel Cord 漆包線
0.75mm2 導線截面積
導體數目
G：With Ground Conductor 有地線導線
X：Without Ground Conductor 沒有地線導線
Types
種類
Voltage Rating
額定電壓
Conductor
Insulation
導體絕緣
Cable Jacket
電線外被
Construction
Detail
整體結構
Conductor
Construction
導體結構
截面積

33.  AWG：American Wire Gauge. Flow Brown & Sharpe(B&S)
standard. The diameter over conductor of cable is inch.
 BWG：Birmingham Wire Gauge. The diameter over
conductor of cable is millimeter（mm）.
 SWG：Standard Wire Gauge. The diameter over conductor
of cable is millimeter（mm）.
 CWG：Chinese Wire Gauge. The diameter over conductor
of cable is millimeter（mm）.
 MMG： Millimeter Wire Gauge. The diameter over
conductor of cable is millimeter（mm）.
 mm2：Metric Imperial. The cross-sectional area of cable is
meillimeter.

34.  Wire
UL1007#18 Black
◦ ＃18：18AWG
 Cable
UL2464#26 AEB 9C Jacket:Black
◦ #26：26AWG
◦ Shield：
 Aluminum-Foil/Myla：A
 Spiral：S
 Braid：B
 Drain：e
◦ 9C：9 conductors
◦ Jacket：The color of cable.

35.  Multi-Conductor Cable
 UL2919#28 (3COX+6C)+e
◦ 3COX：3 Coxial Cable
◦ 6C：6 Conductors
◦ E：Earth wire
 UL2990#28 10P AEB
◦ 10P：10 Paris
 UL2725 #28*1P+#24*2C AEB USB Cable
◦ 28 Awg * 1 Pairs（Twisting）+24 Awg *
2Conductors + AlE

36.  Board to Board
 Wire to Board
 Wire to Wire
Board to Board
Wire to Board
Wire to Wire
Wire to Wire
Wire to Board

37.  Pitch：It is for internel device. To select
connector base on pitch of connector.
 Condition：Base on condition and standard
of connector. Ex. USB, HDMI…
USB
HDMI

38.  Crimpping
 Insulation Displace
 Wrapped
 Soldering
Crimpping
Insulation Displace
Soldering
Wrapped

39.  Terminal/Contact
To joint with wirs’ conductor and mate to the
other.
 Housing：
To protect terminal, isolate the electrical, to
fixed latch, interruped nosie and flame
resistande etc.
 Shell：
There are multi-shell of connector. Ex.
Molding injection, assembly, plastic, metal
etc.

40. Metall will
displacement cable.
The connector will be contacted wire.

41. Insulation Crimp
Conductor Crimp

43. Housing
Contact is being
insered into ousing
Lock
Shape

44.  Strip
◦ Strip Jacket
◦ Strip Insulation of Conductor
 Cut Off
 Strand
 Tin
 Twist
 Solder
 Ultrasonic Weld
 Injection Molding
 Contact Insert Into Housing
 Stick Label
 Heat Shirk
 Routing/Packing

45.  Heat Shirk Tube
 Cable Tie
 Acrylic Acetate Tape
 Conductive Fabric Tape
 Copper Braid Sleeve
 Nylon Braid Sleeve
 Label
 Mark Tube
 Ferrite Core
 Switch
 Vinyl Sleeve
 Spiral Wrapping Brand
 LED