Connectors for electrical and electronic equipment - Tests and measurements - Part 99-002: Endurance test schedules - Test 99b: Test schedule for unmating under electrical load

IEC 60512-99-002:2019 is used for testing connectors within the scope of SC 48B that are used in twisted pair communication cabling with remote power, such as ISO/IEC 11801 Class D (or better), balanced cabling in support of IEEE Std 802.3bt™, (PoE Plus – Power over Ethernet Plus).
The object of this document is to detail a test schedule to determine the ability of pairs of connectors to withstand a sequence of tests with a total of 100 engagements and separations. The electrical current is passed through the connectors during the separation (unmating) step only, in accordance with IEC 60512-9-3.
Keywords: Connectors, Engaging and Separating connectors

Connecteurs pour équipements électriques et électroniques - Essais et mesures - Partie 99-002: Programmes d’essais d’endurance – Essai 99b: Programme d’essai pour le désaccouplement sous charge électrique

IEC 60512-99-002:2019. est utilisée pour soumettre à essai des connecteurs relevant du domaine d’application du SC 48B, qui sont utilisés dans les câblages de communication à paires torsadées permettant une alimentation à distance, tels que les câblages symétriques de la classe D (ou d'une classe correspondant à une fréquence supérieure) de l’ISO/IEC 11801, à l’appui de la norme IEEE 802.3bt™ (alimentation électrique par câble Ethernet améliorée/PoE Plus, Power over Ethernet Plus).
L’objet du présent document est de détailler un programme d’essai permettant de déterminer l’aptitude des paires de connecteurs à supporter une séquence d'essais de 100 accouplements et désaccouplements au total. Le courant électrique traverse les connecteurs au cours du désaccouplement uniquement, conformément à l’IEC 60512-9-3.
Mots clés: connecteurs, enclenchement et séparation des connecteurs

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Status
Published
Publication Date
07-Mar-2019
Technical Committee
Current Stage
DELPUB - Deleted Publication
Completion Date
28-Jan-2022
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IEC 60512-99-002
Edition 1.0 2019-03
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connectors for electrical and electronic equipment – Tests and measurements –
Part 99-002: Endurance test schedules – Test 99b: Test schedule for unmating
under electrical load
Connecteurs pour équipements électriques et électroniques – Essais et
mesures –
Partie 99-002: Programmes d’essais d’endurance – Essai 99b: Programme
d’essai pour le désaccouplement sous charge électrique
IEC 60512-99-002:2019-03(en-fr)
---------------------- Page: 1 ----------------------
THIS PUBLICATION IS COPYRIGHT PROTECTED
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---------------------- Page: 2 ----------------------
IEC 60512-99-002
Edition 1.0 2019-03
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connectors for electrical and electronic equipment – Tests and measurements –
Part 99-002: Endurance test schedules – Test 99b: Test schedule for unmating
under electrical load
Connecteurs pour équipements électriques et électroniques – Essais et
mesures –
Partie 99-002: Programmes d’essais d’endurance – Essai 99b: Programme
d’essai pour le désaccouplement sous charge électrique
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 31.220.10 ISBN 978-2-8322-6607-6

Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 60512-99-002:2019 © IEC 2019
CONTENTS

FOREWORD ........................................................................................................................... 3

1 Scope .............................................................................................................................. 5

2 Normative references ...................................................................................................... 5

3 Terms and definitions ...................................................................................................... 6

4 General ........................................................................................................................... 6

5 Preparation of specimens ................................................................................................ 6

6 Test circuit requirements ................................................................................................. 6

6.1 General ................................................................................................................... 6

6.2 Voltage and current ................................................................................................ 7

6.3 Auxiliary equipment ................................................................................................ 8

7 Test methods ................................................................................................................... 8

7.1 Initial cycles ............................................................................................................ 8

7.2 Flowing mixed gas corrosion ................................................................................... 8

7.3 Final cycles ............................................................................................................. 8

8 Tests and test schedule – Test group UEL 1 .................................................................... 8

Annex A (informative) Test voltage and current setting instructions...................................... 11

A.1 General ................................................................................................................. 11

A.2 Rationale .............................................................................................................. 11

A.3 Suggested setting instructions .............................................................................. 11

Bibliography .......................................................................................................................... 12

Figure 1 – Test circuit details .................................................................................................. 7

Table 1 – Maximum electrical circuit current ........................................................................... 8

Table 2 – Test group UEL 1 .................................................................................................... 9

---------------------- Page: 4 ----------------------
IEC 60512-99-002:2019 © IEC 2019 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CONNECTORS FOR ELECTRICAL AND ELECTRONIC EQUIPMENT –
TESTS AND MEASUREMENTS –
Part 99-002: Endurance test schedules –
Test 99b: Test schedule for unmating under electrical load
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 in the subject dealt with

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with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for

Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

consensus of opinion on the relevant subjects since each technical committee has representation from all

interested IEC National Committees.

3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

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4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

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

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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 60512-99-002 has been prepared by subcommittee 48B: Electrical

connectors, of IEC technical committee 48: Electrical connectors and mechanical structures for

electrical and electronic equipment.
The text of this International Standard is based on the following documents:
FDIS Report on voting
48B/2703/FDIS 48B/2725/RVD

Full information on the voting for the approval of this International Standard can be found in the

report on voting indicated in the above table.

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

---------------------- Page: 5 ----------------------
– 4 – IEC 60512-99-002:2019 © IEC 2019

Future standards in this series will carry the new general title as cited above. Titles of existing

standards in this series will be updated at the time of the next edition.

A list of all parts in the IEC 60512 series, published under the general title Connectors for

electrical and electronic equipment – Tests and measurements, can be found on the IEC

website.

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

stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to

the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 6 ----------------------
IEC 60512-99-002:2019 © IEC 2019 – 5 –
CONNECTORS FOR ELECTRICAL AND ELECTRONIC EQUIPMENT –
TESTS AND MEASUREMENTS –
Part 99-002: Endurance test schedules –
Test 99b: Test schedule for unmating under electrical load
1 Scope

This part of IEC 60512 is used for testing connectors within the scope of SC 48B that are used

in twisted pair communication cabling with remote power, such as ISO/IEC 11801 Class D (or

better), balanced cabling in support of IEEE Std 802.3bt™, (PoE Plus – Power over Ethernet

Plus).

The object of this document is to detail a test schedule to determine the ability of pairs of

connectors to withstand a sequence of tests with a total of 100 engagements and separations.

The electrical current is passed through the connectors during the separation (unmating) step

only, in accordance with IEC 60512-9-3.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements 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 60512-1-1, Connectors for electronic equipment – Tests and measurements – Part 1-1:

General examination – Test 1a: Visual examination

IEC 60512-2-1, Connectors for electronic equipment – Tests and measurements – Part 2-1:

Electrical continuity and contact resistance tests – Test 2a: Contact resistance – Millivolt level

method

IEC 60512-3-1, Connectors for electronic equipment – Tests and measurements – Part 3-1:

Insulation tests – Test 3a: Insulation resistance

IEC 60512-4-1, Connectors for electronic equipment – Tests and measurements – Part 4-1:

Voltage stress tests – Test 4a: Voltage proof

IEC 60512-9-3:2011, Connectors for electronic equipment – Tests and measurements – Part 9-

3: Endurance tests – Test 9c: Mechanical operation (engaging and separating) with electrical

load

IEC 60512-11-7, Connectors for electronic equipment – Tests and measurements – Part 11-7:

Climatic tests – Test 11g: Flowing mixed gas corrosion test
IEC 60512-99-001, Connectors for electronic equipment – Tests and measurements –

Part 99-001: Test schedule for engaging and separating connectors under electrical load – Test

99a: Connectors used in twisted pair communication cabling with remote power

ISO/IEC 11801(all parts): Information technology – Generic cabling for customer premises

ISO/IEC TS 29125: 2017, Information technology – Telecommunications cabling requirements

for remote powering of terminal equipment
---------------------- Page: 7 ----------------------
– 6 – IEC 60512-99-002:2019 © IEC 2019
TIA-568-A:1995, Commercial building telecommunications cabling standard

TIA-568-B.2:2001, Commercial building telecommunications cabling standard, Part 2: Balanced

twisted-pair cabling components

TIA TSB-184-A:2017, Guidelines for supporting power delivery over balanced twisted-pair

cabling
3 Terms and definitions
No terms and definitions are listed in this document.

ISO and IEC maintain terminological databases for use in standardization at the following

addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
4 General

An application-specific current and the associated open circuit voltage are specified, that

correspond with the current and voltage of the supported application. This test schedule is

suitable for verification of separating of connectors under PoE Plus load conditions; although it

is a misuse of the connector, it may occur in practice.

As it is recognized that not all connectors will see these currents and voltage, this test schedule

is regarded as an optional test, not normative for all connectors.
5 Preparation of specimens

Each specimen shall consist of a mated connector pair with its terminations. Specimens shall

be conformant to their relevant IEC connector standard. Each free connector shall be terminated

with 3 m (max.) of the maximum conductor size cable for which it is intended to be terminated,

according to the appropriate IEC standard(s). A printed circuit board may be used for the fixed

connectors, so as not to influence the test results. Fixed connectors may alternatively be

terminated as the free ones. For each specimen, all of the circuits shall be wired in parallel as

given in IEC 60512-9-3, (see Figure 1).
6 Test circuit requirements
6.1 General

The values for the circuit components and the details of the test circuit, referenced in

IEC 60512-9-3, shall be as shown in Figure 1.
---------------------- Page: 8 ----------------------
IEC 60512-99-002:2019 © IEC 2019 – 7 –
IEC
Key
W Cables in accordance with 5
Q1 Connector under test
L1 Inductor L = 100 μH
R1 Variable resistor (e.g. 50 Ω to 300 Ω)
Capacitor 5 µF
E1 Voltage source
S1 Switch
Figure 1 – Test circuit details

NOTE Only one circuit of the connector under test, as referenced in IEC 60512-9-3, is shown for clarity. Items W,

Q1, L1, R1 and C1 are replicated for each circuit of the connector. Item E1 may be single or multiple.

Each circuit of the specimen may be wired in parallel with the other circuits of the specimen,

and all circuits of each specimen shall operate simultaneously. The variable resistor(s) shall be

used to adjust the current(s) to the specified value.
6.2 Voltage and current

ISO/IEC TS 29125 specifies a maximum current as shown in Table 1 and an open circuit voltage

of 55 V DC. The test current has been set to 2,0 A because a maximum of 4 contact pairs can

be connected in parallel. In the highly probable case that one contact is separated after all

others, this contact will carry this 2,0 A just before disconnecting.

As the resistive load is likely to rise due to heating and due to wear of contacts in the connector

under test, care should be placed in keeping the value of test current within the specified

tolerance range e.g. by means of a suitable feedback control circuit acting on the value of the

variable resistor. See Annex A (informative) for further guidance.

The test procedures for Type 1 and Type 2 are defined in IEC 60512-99-001. For Type 3 and

Type 4 the variable resistor(s) shall be set so that the electrical current in each circuit (mated

+0,05

contacts) of the specimen is 2,0 A . When the specimen is unmated, the open circuit

voltage, in all circuits, shall be 55 V DC V DC. When the specimen is mated, the open circuit

voltage, in all circuits, shall be 0 V DC by operating the switch, S1, before each connector

engagement (mating).
---------------------- Page: 9 ----------------------
– 8 – IEC 60512-99-002:2019 © IEC 2019
Table 1 – Maximum electrical circuit current
PSE Type Nominal highest Number of Channel pairset Minimum cabling type
current per pair powered maximum DC loop
(I ,A) pairs resistance (R ,Ω)
Cable Ch
Type 1 0,350 2 20,0 Class D (ISO/IEC 11801) or Category 5
(ANSI/EIA/TIA-568-A: 1995)
Type 2 0,600 2 12,5 Class D (ISO/IEC 11801) or Category 5
(ANSI/EIA/TIA-568-A: 1995)
Type 3 0,600 2 or 4 12,5 Class D (ISO/IEC 11801) or Category 5
(ANSI/EIA/TIA-568-B.2:
2001)
Type 4 0,960 2 or 4 12,5 Class D (ISO/IEC 11801) or Category 5
(ANSI/EIA/TIA-568-B.2: 2001)

In Type 3 and Type 4 operation, the current per pairset may be impacted by pair-to-pair system

resistance unbalance. See 33.2.8.5.1 of ISO/IEC TS 29125:2017. For additional information on

Type 4 current unbalance, see TIA TSB-184-A and ISO/IEC TS 29125.
6.3 Auxiliary equipment

Switches may be used to reverse polarity. However, use of such switches shall not influence

the test parameters.
7 Test methods
7.1 Initial cycles

An electrical load, current and open circuit voltage, as detailed in Clause 6, shall be applied to

each specimen during the separation step only.

For the purpose of this test one connector shall be fixed and the other disengaged at a speed

of 150 mm/s ± 10 mm/s.
One engagement and one separation constitute one cycle.

25 cycles at one polarity of the DC source shall be performed. And then the polarity of the DC

source shall be reversed, and 25 further cycles at the other polarity shall be performed,

(50 cycles total). The electrical current shall be applied during the separation step only.

7.2 Flowing mixed gas corrosion

The flowing mixed gas corrosion test (method 1) shall be performed for 4 days. Half of the

samples mated; half of the samples unmated.
7.3 Final cycles

25 cycles at one polarity of the DC source shall be performed. And then the polarity of the DC

source shall be reversed, and 25 further cycles at the other polarity shall be performed

(50 additional cycles total). The electrical current shall be applied during the separation step

only.
8 Tests and test schedule – Test group UEL 1

A minimum of 8 specimens shall be prepared for this group; then tested according to Table 2.

---------------------- Page: 10 ----------------------
IEC 60512-99-002:2019 © IEC 2019 – 9 –
Table 2 – Test group UEL 1
Test Measurement to be performed
Test
Title IEC 60512 Severity or Title IEC 60512 Requirements
phase
test No. condition of test test No.
UEL General Visual 1-1 There shall be
1.1 examination examination no defects that
would impair
normal operation
UEL Contact 2-1 As specified in
1.2 resistance- the relevant
Millivolt connector
level standard
method
UEL
100 V DC Insulation 3-1 As specified in
1.3 resistance the relevant
Method A
connector
standard
Mated connectors
UEL Contact to contact Voltage 4-1 There shall be
1.4 proof no break down
1 000 V DC. or
or no flashover
1 500 V AC peak.
All signal contacts to
shield and test
panel, as applicable
Method A
Mated connectors
UEL Mechanical 9-3 Per 7.1 .
1.5 operations
with electrical
load
UEL Flowing 11-7 Per 7.2: Method 1,
1.6 mixed gas
4 days
test
UEL Mechanical 9-3 Per 7.3
1.7 operations
with electrical
load
UEL Contact 2-1 As specified in
1.8 resistance- the relevant
Millivolt connector
level standard
method
UEL General Visual 1-1 There shall be
1.9 examination examination no defects that
would impair
normal
operation.
However,
physical
deterioration of
the contacts may
be observed.
Such
deterioration
shall not be
cited as a failure
of this test.
UEL Contact resistance Contact 2-1 As specified in
1.10 resistance- the relevant
Millivolt connector
level standard
method
UEL 100 V DC Method A Insulation 3-1 500 MΩ
1.11 Mated connectors resistance minimum
---------------------- Page: 11 ----------------------
– 10 – IEC 60512-99-002:2019 © IEC 2019
Test Measurement to be performed
Test
Title IEC 60512 Severity or Title IEC 60512 Requirements
phase
test No. condition of test test No.
UEL Contact to contact Voltage 4-1 There shall be
1.12
proof no break down
1 000 V DC or
or no flashover
1 500 V AC peak.
All signal contacts to
shield and test
panel, as applicable
Method A
Mated connectors
---------------------- Page: 12 ----------------------
IEC 60512-99-002:2019 © IEC 2019 – 11 –
Annex A
(informative)
Test voltage and current setting instructions
A.1 General

It is possible that confusion as to how to set the required voltages and currents may arise. Given

below are a set of informative instructions as to how this may be achieved.
A.2 Rationale

The open circuit voltage requirement is stated such that during unmating under load, the stated

voltage is available to ‘drive’ arcing.

Some power sources have an ‘open circuit’ setting which is used to clamp the voltage to prevent

an over voltage condition. As no source voltage is stated for the supply in a constant voltage

mode, an interpretation of the requirements could be to set some level of source voltage (the

DC supply constant voltage setting) below (e.g.) 55 V, and to set the maximum open circuit

voltage at (e.g.) 55 V. But, under this interpretation, upon unmating the constant voltage setting

would not allow the voltage to reach the intended open circuit level.
A.3 Suggested setting instructions

The DC source voltage and variable resistors should be adjusted such that the current in each

circuit (each mated pair of contacts within the connector under test) is the required value

(e.g. 1,0 A) when mated and the open circuit voltage is the required value (e.g. 55 V) when

unmated. For each test circuit the suggested setting instructions are as follows.

a) With the DC power supply off and all variable resistors adjusted at a suitably high value

(e.g. 200 Ω), perform the initial mating of the connector.

b) Place the power supply in a constant voltage mode with the voltage adjustment set at 0 V,

and the current adjustment at its maximum setting.
c) Turn on the power supply.
d) Adjust the constant voltage setting to the required voltage.

e) Reduce the resistance of the variable resistor in each circuit until the required current value

is flowing in the circuit being adjusted.
---------------------- Page: 13 ----------------------
– 12 – IEC 60512-99-002:2019 © IEC 2019
Bibliography

IEC TR 62652, Effects of engaging and separating under electrical load on connector interfaces

in cabling used to support IEEE 802.3af (power-over-ethernet) applications

IEEE 802.3 Standard for Information technology – Telecommunications and information

exchange between systems — Local and metropolitan area networks – Specific requirements

– Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD) Access Method

and Physical Layer Specifications – Amendment 3: Data Terminal Equipment (DTE) – Power

via the Media Dependent Interface (MDI) Enhancements
___________
---------------------- Page: 14 ----------------------
– 14 – IEC 60512-99-002:2019 © IEC 2019
SOMMAIRE

AVANT-PROPOS .................................................................................................................. 15

1 Domaine d'application ................................................................................................... 17

2 Références normatives .................................................................................................. 17

3 Termes et définitions ..................................................................................................... 18

4 Généralités .................................................................................................................... 18

5 Préparation des spécimens ........................................................................................... 18

6 Exigences relatives au circuit d’essai ............................................................................ 18

6.1 Généralités ........................................................................................................... 18

6.2 Tension et intensité ............................................................................................... 19

6.3 Équipement auxiliaire ............................................................................................ 20

7 Méthodes d’essai ........................................................................................................... 20

7.1 Cycles initiaux ................
...

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