Quality
Every joint is built to IPC/WHMA-A-620 Class 3 and proven by pull testing and micrograph analysis. Serialized traceability. Full material documentation.
At a glance
- Class 3Workmanship
- IPC/WHMA-A-620 Class 3
- ISOQuality system
- ISO 9001 compliant processes
- PPAPDocumentation
- PPAP levels 1 through 5
- ULUL assemblies
- Listed and recognized components
- FilesUL wire files
- Five, one per product
- WarrantyWarranty
- Limited Lifetime, sealed cables
What the shop runs to
Credentials, not adjectives. Class 3 is the highest acceptance class in the cable and harness standard. Most shops advertise Class 2.
IPC/WHMA-A-620 Class 3
For assemblies where continued performance is required and downtime is not tolerable. Class 3 governs crimp height, strand containment, insulation clearance, shrink coverage, and workmanship at every joint.
ISO 9001 compliant processes
Processes and documentation run to ISO 9001. Certification is pending. The same system governs the build records and material certifications that ship with an order.
Serialized traceability
A finished assembly traces back to the wire it was made from and the components crimped onto it.
PPAP documentation levels 1 through 5
Available where a program requires them. Say so at quote time. A first article is a deliverable with its own schedule.
How a crimp is proven
Large-gauge crimping cannot be inspected from the outside, so it carries a measurement.
Pull testing
A crimp is loaded until the conductor leaves the barrel. The force is recorded. That is the measurement that says the joint holds.
Micrograph analysis
The finished crimp is cross-sectioned, polished, and examined. Strand deformation and voids inside the barrel show up here.
Thermal, vibration, and load cycling
Assemblies are run under thermal, vibration, and load-cycle conditions. The failures that matter show up after cycles, not on the bench.
Custom tooling
Where a stock die does not produce the section the joint needs, dies, terminals, and crimp profiles are developed here.
Five UL wire files. UL assemblies on top.
Polar Wire builds UL assemblies from UL listed and recognized components and processes. That is separate from the five UL wire files below.
Arctic Ultraflex BlueFile E196955 · UL Recognized AWM
Multi-listed flexible wireFile E321440 · UL Listed MTW, THHW and boat cable- Premium boat cableFile E321438 · UL Listed BC-5W2
- Industrial power cordFile E224869 · UL Listed SEOOW
- Diesel locomotive cableFile E18321 · UL Listed RHH and RHW-2
Compression lugs and splices are UL Listed and CSA Certified to 194°F (90°C) and rated for 35 kV applications on copper conductor.
Limited Lifetime Warranty
Polar Wire offers a Limited Lifetime Warranty to the original buyer on custom cables it manufactures and identifies with the warranty seal. Coverage follows what Polar Wire builds. The seal on the listing is how you tell.
- What is covered
- Materials and workmanship on cable assemblies Polar Wire manufactures, identified by the seal. Eye-to-eye battery, golf cart, side-mount, series, and jumper assemblies that carry the seal.
- What is not
- Wire sold by the foot. Parts in every category: clamps, bags, dust covers, connectors, nuts and bolts.
- What lifetime means
- The lifetime of the components and materials. Not the length of anyone's ownership.
- How a claim works
- Bring the cable in or send pictures. An approved claim is repaired, replaced, or refunded at Polar Wire's option. Liability is capped at the purchase price paid.
Limited Lifetime Warranty
This is a summary. The published terms, including the full exclusion list, are on the online store. Where this page and those terms differ, the terms govern.
Full terms: store.polarwire.com/cable-warranty. Also on the jumper cables page.
What customers say, on the online store
The Polar Wire store holds 286 customer reviews across 137 products, averaging 4.96. 57 percent sit on a product in the jumper cable hub, on the listing that sold it.
Read the reviews on the online storeOpens store.polarwire.com
Frequently asked questions
IPC/WHMA-A-620 Class 3. Pull testing and micrograph analysis. ISO 9001 compliant processes. Limited Lifetime Warranty on sealed custom cables.
Does Polar Wire run ISO 9001 processes?
Yes. Polar Wire runs ISO 9001 compliant processes and documentation. Certification is pending. Alongside it: IPC/WHMA-A-620 Class 3 workmanship, serialized traceability with full material documentation, and PPAP documentation levels 1 through 5 where a program needs them.
What is IPC/WHMA-A-620 Class 3?
It is the highest of the three acceptance classes in the IPC and WHMA standard for cable and wire harness assemblies. Class 1 is general electronic, Class 2 is dedicated service, and Class 3 covers assemblies where continued performance is required and downtime is not tolerable. Most assembly shops advertise Class 2. Class 3 governs crimp height, strand containment, insulation clearance, shrink coverage and workmanship at every joint.
How is a large-gauge crimp validated?
By pull testing and micrograph analysis. A pull test measures the force the joint holds before the conductor leaves the barrel. A micrograph is a cross-section of the finished crimp, polished and examined, which shows strand deformation and voids that no external inspection can see. Assemblies are also run through thermal, vibration and load-cycle testing, and custom dies and crimp profiles are developed where a stock die does not produce the section.
What does the Limited Lifetime Warranty cover?
Cable assemblies Polar Wire manufactures and identifies with the Limited Lifetime Warranty seal. It runs to the original buyer and is not transferable. "Lifetime" means the lifetime of the components and materials, because every material degrades with use and exposure. Wire sold by the foot is outside it, and so is every parts SKU, because Polar Wire does not build those. The remedy is repair, replacement or refund at Polar Wire's option, and liability is capped at the purchase price paid. Full terms are published at store.polarwire.com/cable-warranty.
Request a quote
A stocked cable is on the online store with a seal you can check. A documentation package or a first article goes to sales.