Connecting devices - Flat quick-connect terminations for electrical copper conductors - Safety requirements

IEC 61210:2010 applies to non-insulated flat quick-connect terminations consisting of a male tab of size 2,8 mm, 4,8 mm, 6,3 mm or 9,5 mm with hole or dimple detents and a mating female connector for use as either an incorporated or an integrated part of an equipment or of a component, or as a separate entity. This standard establishes uniform requirements for the dimensions, performance characteristics and test program. The connected electrical copper conductors shall be flexible or rigid stranded, having a cross-sectional area up to and including 6 mm2 or rigid solid having a cross-sectional area up to and including 2,5 mm2. This standard shall not be used for connecting aluminum conductors. The rated voltage shall not exceed 1 000 V a.c. with a frequency up to and including 1 000 Hz, and 1 500 V d.c., and having the temperature limits applicable to materials used within this standard. This second edition cancels and replaces the first edition published in 1993 and constitutes a merge between the first edition of IEC 61210 published by SC23F and IEC 60760 published in 1989 by SC48B. This second edition does not introduce major technical modifications.

Dispositifs de connexion - Bornes plates à connexion rapide pour conducteurs électriques en cuivre - Exigences de sécurité

La CEI 61210:2010 s'applique aux bornes plates à connexion rapide non isolées composées d'une languette des séries 2,8 mm, 4,8 mm, 6,3 mm ou 9,5 mm avec un trou ou des empreintes et un clip conjugués pour utilisation soit comme partie incorporée ou intégrée d'un équipement ou d'un composant, soit comme entité séparée. La présente norme établit des exigences uniformes en ce qui concerne les dimensions, les caractéristiques de performance et le programme d'essai. Les conducteurs électriques en cuivre raccordés doivent être câblés souples ou rigides, de section jusqu'à 6 mm2 inclus, ou massifs de section jusqu'à 2,5 mm2 inclus. La présente norme ne doit pas être utilisée pour le raccordement de conducteurs en aluminium. La tension assignée ne doit pas dépasser 1 000 V en courant alternatif avec une fréquence jusqu'à 1 000 Hz inclus, et 1 500 V en courant continu, et pour des températures limites applicables aux matériaux utilisés dans la présente norme. Cette deuxième édition annule et remplace la première édition parue en 1993, et constitue une fusion entre la première édition de la CEI 61210 publiée par le SC23F et la CEI 60760 publiée en 1989 par le SC48B. Cette deuxième édition n'introduit pas de modifications techniques majeures.

General Information

Status
Published
Publication Date
30-Aug-2010
Technical Committee
Current Stage
PPUB - Publication issued
Start Date
31-Aug-2010
Completion Date
31-Aug-2010
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IEC 61210
Edition 2.0 2010-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connecting devices – Flat quick-connect terminations for electrical copper
conductors – Safety requirements
Dispositifs de connexion – Bornes plates à connexion rapide pour conducteurs
électriques en cuivre – Exigences de sécurité
IEC 61210:2010
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 61210
Edition 2.0 2010-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connecting devices – Flat quick-connect terminations for electrical copper
conductors – Safety requirements
Dispositifs de connexion – Bornes plates à connexion rapide pour conducteurs
électriques en cuivre – Exigences de sécurité
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX
ICS 29.120.20 ISBN 978-2-88912-173-1
® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – 61210 © IEC:2010
CONTENTS

FOREWORD...........................................................................................................................4

1 Scope...............................................................................................................................6

2 Normative references .......................................................................................................6

3 Terms and definitions .......................................................................................................7

4 Main characteristics..........................................................................................................7

5 Marking and information ...................................................................................................8

6 Constructional requirements .............................................................................................8

7 General notes for tests ...................................................................................................10

8 Type tests ......................................................................................................................11

8.1 Insertion and withdrawal force ...............................................................................11

8.2 Mechanical overload force (for integral tabs or female connectors)........................11

8.3 Temperature rise...................................................................................................11

8.4 Current loading cyclic............................................................................................12

8.5 Elevated temperature test .....................................................................................12

8.6 Tensile strength test for crimped connections........................................................13

Annex A (informative) Maximum permissible temperature (maximum service

temperature) .........................................................................................................................23

Annex B (informative) Force gauge for testing flat quick-connect female connectors............24

Annex C (informative) Female test connectors for testing with integral tabs .........................29

Annex D (informative) Tables showing approximate relationships between mm and
inches or cross-sectional areas in mm and AWG sizes as used in North America

allowing to use this standard.................................................................................................32

Annex E (informative) Information relating to cross section of conductors and

dimensions of male tabs .......................................................................................................36

Figure 1 – Dimensions of male tabs ......................................................................................18

Figure 2 – Dimensions of round dimple detents (see Figure 1)..............................................19

Figure 3 – Dimensions of rectangular dimple detents (see Figure 1) .....................................19

Figure 4 – Dimensions of hole detents (see Figure 1) ...........................................................20

Figure 5 – Dimensions of female connectors.........................................................................20

Figure 6 – Double-ended tab.................................................................................................21

Figure 7 – Location of thermocouples ...................................................................................21

Figure 8 – Connections for electrical tests ............................................................................22

Figure B.1 – Force gauge fixture...........................................................................................24

Figure B.2 – Fixture adjustment ............................................................................................25

Figure B.3 – Fixture test tab centering ..................................................................................26

Figure B.4 – In-line and lateral female connectors ................................................................27

Figure B.5 – Fixtureing alignment .........................................................................................28

Figure C.1 – Dimensions of female connectors .....................................................................29

Figure C.2 – Dimensions of female connectors, alternative design........................................30

Table 1 – Dimensions of male tabs in millimetres..................................................................14

Table 2 – Dimensions of female connectors..........................................................................15

---------------------- Page: 4 ----------------------
61210 © IEC:2010 – 3 –

Table 3 – Test sequences and sets of samples .....................................................................15

Table 4 – Tolerances of test tab thickness ............................................................................15

Table 5 – Insertion and withdrawal forces .............................................................................16

Table 6 – Retention force......................................................................................................16

Table 7 – Test current for temperature rise ...........................................................................16

Table 8 – Test current for current loading, cyclic...................................................................16

Table 9 – Pull force for testing the crimped connection .........................................................17

Table A.1 – Maximum permissible temperature (maximum service temperature)...................23

Table C.1 – Dimensions of female connectors in millimetres (see Figure C.1).......................29

Table C.2 – Dimensions of female connectors in inches (see Figure C.1) .............................30

Table C.3 – Dimensions of alternative design female connectors in millimetres (see

Figure C.2) ...........................................................................................................................30

Table C.4 – Dimensions of alternative design female connectors in inches (see Figure

C.2) ......................................................................................................................................31

Table D.1 – Relationship between mm and inches or mm and AWG within the scope..........32

Table D.2 Relationship between mm and inches in Subclause 4.1 .......................................32

Table D.3 – Approximate relationship between cross-sectional area in mm and AWG

sizes in Subclause 4.2 ..........................................................................................................32

Table D.4 – Dimensions of male tabs in inches applicable in Subclauses 6.3 and 8.1

(equivalent with Table 1).......................................................................................................33

Table D.5 – Dimensions of female connectors applicable in Subclause 6.4 (equivalent

with Table 2).........................................................................................................................34

Table D.6 – Tolerances of test tab thickness applicable in Subclause 8.1 (equivalent

with Table 4).........................................................................................................................34

Table D.7 – Insertion and withdrawal forces applicable in Subclause 8.1 (equivalent

with Table 5).........................................................................................................................34

Table D.8 – Retention force applicable in Subclause 8.2 (equivalent with Table 6) ..............34

Table D.9 – Test current for temperature rise applicable in Subclauses 8.3 and 8.5

(equivalent with Table 7).......................................................................................................35

Table D.10 – Test current for current loading, cyclic applicable in Subclause 8.4

(equivalent with Table 8).......................................................................................................35

Table D.11 – Pull force for testing the crimped connection applicable in Subclause 8.6

(equivalent with Table 9).......................................................................................................35

Table E.1 – Relationships between conductors and tabs.......................................................36

---------------------- Page: 5 ----------------------
– 4 – 61210 © IEC:2010
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CONNECTING DEVICES –
FLAT QUICK-CONNECT TERMINATIONS
FOR ELECTRICAL COPPER CONDUCTORS –
SAFETY REQUIREMENTS
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

all national electrotechnical committees (IEC National Committees). The object of IEC is to promote

international co-operation on all questions concerning standardization in the electrical and electronic fields. To

this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,

Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC

Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested

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with the International Organization for Standardization (ISO) in accordance with conditions determined by

agreement between the two organizations.

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services carried out by independent certification bodies.

6) All users should ensure that they have the latest edition of this publication.

7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and

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expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC

Publications.

8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of

patent rights. IEC shall not be held responsible for identifying any or all such patent rights.

International Standard IEC 61210 has been prepared by subcommittee 23F: Connecting

devices, of IEC technical committee 23: Electrical accessories.

This second edition cancels and replaces the first edition published in 1993 and constitutes a

merge between the first edition of IEC 61210 published by SC23F and IEC 60760 published in

1989 by SC48B. This second edition does not introduce major technical modifications.

The text of this standard is based on the following documents:
FDIS Report on voting
23F/200/FDIS 23F/202/RVD

Full information on the voting for the approval of this standard can be found in the report on

voting indicated in the above table.
---------------------- Page: 6 ----------------------
61210 © IEC:2010 – 5 –

This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

The committee has decided that the contents of this publication will remain unchanged until

the stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data

related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 7 ----------------------
– 6 – 61210 © IEC:2010
CONNECTING DEVICES –
FLAT QUICK-CONNECT TERMINATIONS
FOR ELECTRICAL COPPER CONDUCTORS –
SAFETY REQUIREMENTS
1 Scope

This International Standard applies to non-insulated flat quick-connect terminations consisting

of a male tab of size 2,8 mm, 4,8 mm, 6,3 mm or 9,5 mm with hole or dimple detents and a

mating female connector for use as either an incorporated or an integrated part of an

equipment or of a component, or as a separate entity. This standard establishes uniform

requirements for the dimensions, performance characteristics and test program.

The connected electrical copper conductors shall be flexible or rigid stranded, having a cross-

sectional area up to and including 6 mm or rigid solid having a cross-sectional area up to and

including 2,5 mm . This standard shall not be used for connecting aluminum conductors.

The rated voltage shall not exceed 1 000 V a.c. with a frequency up to and including

1 000 Hz, and 1 500 V d.c., and having the temperature limits applicable to materials used

within this standard.

NOTE 1 This standard, where applicable, may be used for conductors made of material other than copper.

NOTE 2 For reasons of safety, it is recommended that flat quick-connect terminations beyond the scope of this

standard should not be interchangeable with those of this standard.

NOTE 3 This standard does not apply to female connectors with positive locking means.

NOTE 4 The flat quick-connect terminations covered by this standard are not intended to be disconnected by

pulling on the cable.
NOTE 5 Annex D provides additional information on non international units.
2 Normative references

The following referenced documents are indispensable for the application of this document.

For dated references, only the edition cited applies. For undated references, the latest edition

of the referenced document (including any amendments) applies.
IEC 60068-1:1988, Environmental testing − Part 1: General and guidance
IEC 60352-2:2006, Solderless connections − Part 2: Crimped connections – General
requirements, test methods and practical guidance

ISO 1456:2009, Metallic and other inorganic coatings − Electrodeposited coatings of nickel,

nickel plus chromium, copper plus nickel and of copper plus nickel plus chromium

ISO 2081:2008, Metallic and other inorganic coatings – Electroplated coatings of zinc with

supplementary treatments on iron or steel
ISO 2093:1986, Electroplated coatings of tin − Specification and test methods
---------------------- Page: 8 ----------------------
61210 © IEC:2010 – 7 –
3 Terms and definitions
For the purpose of this document the following terms and definitions apply:
3.1
flat quick-connect termination

electrical connection consisting of a male tab and a female connector which can be inserted

and withdrawn with or without the use of a tool
3.2
male tab

that portion of a flat quick-connect termination which receives the female connector

3.3
male test tab

male tab manufactured with tighter tolerances for the specific purpose of conducting

mechanical tests with production female connectors
3.4
female connector

that portion of a flat quick-connect termination which is pushed onto the male tab

3.5
detent

dimple (depression) or hole in the male tab which engages a raised portion on the female

connector to provide a latch for the mating parts
3.6
maximum permissible temperature
maximum service temperature

highest temperature which the flat quick-connect termination is allowed to attain in normal use

4 Main characteristics

4.1 Flat quick-connect terminations are classified into sizes according to the nominal width

and thickness of the male tabs. This standard covers the following nominal sizes:

– 2,8 mm × 0,5 mm
– 2,8 mm × 0,8 mm
– 4,8 mm × 0,5 mm
– 4,8 mm × 0,8 mm
– 6,3 mm × 0,8 mm
– 9,5 mm × 1,2 mm
NOTE Relationship between millimetres and inches is shown in Table D.2.
2 2 2

4.2 The preferred conductor cross-sectional areas shall be 0,2 mm , 0,34 mm , 0,5 mm ,

2 2 2 2 2 2
0,75 mm , 1,0 mm , 1,5 mm , 2,5 mm , 4,0 mm and 6,0 mm .

NOTE The approximate equivalent relationship between cross-sectional area in mm and AWG sizes is shown in

Table D.3.
---------------------- Page: 9 ----------------------
– 8 – 61210 © IEC:2010
5 Marking and information

5.1 The manufacturer of male tabs and/or female connectors supplied separately and the

manufacturer of the component with integral tabs and/or female connectors shall provide

adequate information to ensure that the flat quick-connect termination can be applied in the

intended manner and that the testing authority can perform the relevant tests in accordance

with this standard.

5.2 This information shall be provided in the following methods, as detailed in 5.3:

– by marking (Ma)
The information shall be clearly and indelibly marked on the male tab and on the
female connector.

NOTE In the case of integral tabs (e.g. in switches for appliances) the marking may be located on the

switch itself.
– by documentation (Do)
The information shall be provided by a separate document, which may consist of a

leaflet, label or a specification sheet, supplied with the smallest package unit or

supplied separately. The content of the document shall be available to the end user or

to the component or equipment manufacturer and to the testing authority, as

appropriate, in any suitable format. The format in which this information is presented is

not within the scope of this standard.
– by declaration (De)

This information shall be provided to the testing authority for the purpose of testing

and in a manner agreed between the testing authority and the manufacturer.
5.3 The following information shall be supplied by the methods indicated.

a) Manufacturer's name or trade mark ............................................ Ma (see note 1)

b) Type reference........................................................................... Do (see note 2)

c) Nominal series designation (size: width and thickness, see 4.1).. Do (see note 2)

d) Maximum permissible temperature if higher than 85 °C ............... Do (see note 3)

e) The most onerous combination of the tab and the female connector ................Do

f) Type of conductor(s) for which that part of the termination is suitable..............Do

g) Conductor cross-sectional area for which that part of the termination

is suitable ......................................................................................................Do

h) The recommended method of attaching the conductor to the termination

(i.e. tool, stripping length, any special preparation, etc.) .................................Do

i) The material(s) and type of coating ................................................................De

NOTE 1 The information for integrated tabs or female connectors may be given together with the equipment or

component.
NOTE 2 An appropriate code may be used for this information.

NOTE 3 The insulation of the cable and of the contact-carrying plastic parts should be compatible with the

declared maximum permissible temperature.

NOTE 4 In Japan, tab thickness marking on the female connector is 5 for 0,5 mm and 8 for 0,8 mm.

6 Constructional requirements

6.1 Flat quick-connect terminations shall be so designed and constructed that in normal use

their performance is reliable and without danger to the user or surroundings.
---------------------- Page: 10 ----------------------
61210 © IEC:2010 – 9 –
Compliance is checked by the tests of 8.1 to 8.6.

6.2 Male tabs and female connectors shall be of a metal having mechanical strength,

electrical conductivity and resistance to corrosion adequate for their intended use.

Compliance is checked by inspection, by the tests of 8.1 to 8.6 and, if necessary, by chemical

analysis.

Examples of suitable metals, when used within the permissible temperature range and under

standard atmospheric conditions, are
– copper (for tabs only);

– an alloy containing at least 58 % copper for parts made from rolled sheet (in cold

condition) or at least 50 % copper for other parts;

– stainless steel containing at least 13 % chromium and not more than 0,09 % carbon;

– steel provided with an electroplated coating of zinc (for earthing conductors only),

according to ISO 2081;
– steel provided with an electroplated coating of nickel, according to ISO 1456;
– steel provided with an electroplated coating of tin, according to ISO 2093.

NOTE The choice of material and coating is left to the relevant product committees who should consider the

pollution conditions occurring in the equipment or component where the flat quick-connect termination is mounted.

6.3 The dimensions of male tabs shall comply with those specified in Table 1 and Figures 1,

2, 3 and 4 where the dimensions A, B, C, D, E, F, J, M, N and Q are mandatory.

NOTE 1 The shapes of the various parts may deviate from those given in the figures, provided that the specified

dimensions are not influenced and the test requirements are complied with, for example: corrugated tabs, folded

tabs, etc.
NOTE 2 Dimensions of male tabs in inches are shown in Table D.4.
Compliance is checked by inspection and measurement.

6.4 The dimensions of female connectors shall comply with those specified in Table 2 and

Figure 5 where L , B and 1,5 mm maximum are mandatory.
2 3

NOTE Dimensions of female connectors for tab size in inches are shown in Table D.5.

Compliance is checked by inspection and measurement.

6.5 Male tabs and female connectors shall be so designed and constructed as to allow the

correct insertion and withdrawal of either the female connector or the tab without damage or

loosening of other components.
Compliance is checked by the insertion and withdrawal force test of 8.1.

6.6 Male tabs and female connectors integral with equipment or components shall be

securely retained.
Compliance is checked by the mechanical overload force test of 8.2.

6.7 Male tabs and female connectors shall be so designed and constructed that the

temperature rise in normal use does not reach values likely to impair their further use.

Compliance is checked by the temperature rise test of 8.3.
---------------------- Page: 11 ----------------------
– 10 – 61210 © IEC:2010

6.8 Male tabs and female connectors shall be so designed and constructed that their

electrical performances are reliable and their further use is not impaired.
Compliance is checked by the cyclic current loading test of 8.4.

6.9 Male tabs and female connectors having a maximum permissible temperature higher

than 85 °C shall be so designed and constructed that in normal use their electrical

performances are reliable and their further use is not impaired.
Compliance is checked by the elevated temperature test of 8.5.
Examples of maximum permissible temperatures of male ta
...

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