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

La CEI 60512-9-3:2011 précise une méthode d'essai normalisée pour évaluer l'endurance fonctionnelle mécanique et électrique, c'est-à-dire les cycles d'accouplement et de désaccouplement, des connecteurs en mode de fonctionnement normal sous une charge électrique spécifiée. Cette deuxième édition annule et remplace l'Essai 9c de la CEI 60512-5, parue en 1992, et constitue une révision technique. Les modifications principles par rapport à l'édition précédente sont les suivantes: - Ajout d'une exigence au 4.1 qui précise que lorsqu'il y a plus d'un circuit électrique câblée pour les essais, le câblage doit être fait dans un circuit électrique parallèle. - Les paragraphes 4.3. à 4.7 ont été supprimés et remplacés par les paragraphes 4.2 à 4.4.  Cette publication doit être lue conjointement avec la CEI 60512-1:2001 et la CEI 60512-1-100:2006.

Connecteurs pour équipements électroniques - Essais et mesures - Partie 9-3: Essais d'endurance - Essai 9c: Fonctionnement mécanique (d'accouplement et de désaccouplement) avec charge électrique

La CEI 60512-9-3:2011 précise une méthode d'essai normalisée pour évaluer l'endurance fonctionnelle mécanique et électrique, c'est-à-dire les cycles d'accouplement et de désaccouplement, des connecteurs en mode de fonctionnement normal sous une charge électrique spécifiée. Cette deuxième édition annule et remplace l'Essai 9c de la CEI 60512-5, parue en 1992, et constitue une révision technique. Les modifications principles par rapport à l'édition précédente sont les suivantes: - Ajout d'une exigence au 4.1 qui précise que lorsqu'il y a plus d'un circuit électrique câblée pour les essais, le câblage doit être fait dans un circuit électrique parallèle. - Les paragraphes 4.3. à 4.7 ont été supprimés et remplacés par les paragraphes 4.2 à 4.4.  Cette publication doit être lue conjointement avec la CEI 60512-1:2001 et la CEI 60512-1-100:2006.

General Information

• Status: Published
• Publication Date: 21-Jun-2011
• ICS: 31.220.01 - Electromechanical components in general
• Technical Committee: SC 48B - Electrical connectors
• Current Stage: PPUB - Publication issued
• Start Date: 22-Jun-2011
• Completion Date: 31-Jul-2011

Relations

• Revises: IEC 60512-9-3:2006 - Connectors for electronic equipment - Tests and measurements - Part 9-3: Endurance tests - Test 9c: Mechanical operation (engaging/separating) with electrical load
• Effective Date: 05-Sep-2023

Overview

IEC 60512-9-3:2011 is an international standard published by the International Electrotechnical Commission (IEC). It specifies a standardized method for endurance testing of connectors used in electronic equipment. The focus of this part (Part 9-3) is on Test 9c, which evaluates the mechanical operation of connectors during engaging and separating cycles while subjected to an electrical load. This test assesses the functional mechanical and electrical endurance of connectors under normal operating conditions, simulating real-world usage where connectors repeatedly mate and unmate under electrical stress.

This second edition replaces the earlier 1992 edition (Test 9c of IEC 60512-5), and introduces technical revisions including circuit wiring in parallel for multi-circuit connectors, and updated test procedure clauses.

Key Topics

• Test Scope and Objective
  The test measures the durability of connectors when subjected to mechanical engagement and separation cycles combined with electrical load, ensuring connectors maintain performance throughout their service life.

• Preparation of Specimens
  Specimens include connectors fully assembled with terminations and cables as per detailed specifications. Mounting follows manufacturer instructions or specific test details.

• Electrical Loading
  The test requires connectors to be engaged and separated while carrying a specified electrical load. The load parameters-current, voltage type (AC/DC), and frequency-are defined in the detail specification for the connector. Typical circuits include resistive, capacitive, and inductive elements to simulate real operational conditions.

• Mechanical Operation Parameters
  Connectors are cycled at a controlled speed of 50 ± 5 mm/s for engaging and separating unless otherwise specified. Each full cycle consists of one engagement and one separation with a pause of at least 20 seconds between operations.

• Environmental Conditions
  Tests are normally conducted under IEC standard conditions (IEC 60068-1). If required, tests can be performed at low air pressure simulating high-altitude environments, consistent with IEC 60068-2-13.

• Measurements and Assessments
  The testing process includes:

  • Initial visual inspections and measurements for contact resistance, insulation resistance, voltage proof, and sealing performance.
  • Monitoring contact resistance during cycling.
  • Final evaluations to verify connector integrity and performance after endurance testing.

• Specification and Documentation
  Detail specifications must include parameters such as specimen preparation, applied electrical loads, mechanical operation speeds, number of cycles, and environmental conditions.

Applications

IEC 60512-9-3:2011 is widely applicable to manufacturers, testing laboratories, and quality assurance teams involved in the design and validation of electrical connectors for electronic devices. It is crucial for ensuring:

• Reliability of Connectors in Electronics
  The standard ensures connectors can withstand repetitive mechanical operations and electrical loads without degradation, a key requirement for connectors in consumer electronics, industrial machinery, telecommunications equipment, and aerospace applications.

• Product Qualification
  Assists manufacturers in qualifying connector designs to meet specified endurance and operational performance criteria.

• Quality Control
  Provides a repeatable, standardized test method for quality control during production and before product release.

• Safety and Compliance
  Helps ensure that connectors meet international safety and performance standards, reducing the risk of electrical failures and associated hazards.

Related Standards

IEC 60512-9-3:2011 is part of the broader IEC 60512 series titled "Connectors for electronic equipment – Tests and measurements." It should be used alongside:

• IEC 60512-1:2001 – General tests and measurements for connectors, including structural test methods.
• IEC 60512-1-100:2006 – Overview of applicable publications and test methods within the IEC 60512 series.
• IEC 60068-1 – Environmental testing general guidance.
• IEC 60068-2-13 – Environmental test methods, specifically low air pressure testing.
• Auxiliary tests related to electrical performance such as:
  • Contact resistance tests (IEC 60512-2 series)
  • Insulation resistance tests (IEC 60512-3)
  • Voltage proof tests (IEC 60512-4)

Following these standards ensures a comprehensive testing regime covering mechanical, electrical, and environmental endurance of electronic connectors.

---

By implementing IEC 60512-9-3:2011 test methods, manufacturers and engineers can enhance connector reliability, improve product lifecycles, and achieve compliance with global quality and safety requirements. This standard is integral for advancing connector technology in increasingly demanding electronic environments.

Standards Content (Sample)

IEC 60512-9-3 ®
Edition 2.0 2011-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connectors for electronic equipment – Tests and measurements –
Part 9-3: Endurance tests – Test 9c: Mechanical operation (engaging and
separating) with electrical load

Connecteurs pour équipements électroniques – Essais et mesures –
Partie 9-3: Essais d’endurance – Essai 9c: Fonctionnement mécanique
(d’accouplement et de désaccouplement) avec charge électrique

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IEC 60512-9-3 ®
Edition 2.0 2011-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Connectors for electronic equipment – Tests and measurements –
Part 9-3: Endurance tests – Test 9c: Mechanical operation (engaging and
separating) with electrical load

Connecteurs pour équipements électroniques – Essais et mesures –
Partie 9-3: Essais d’endurance – Essai 9c: Fonctionnement mécanique
(d’accouplement et de désaccouplement) avec charge électrique
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX J
ICS 31.220.01 ISBN 978-2-88912-550-0

– 2 – 60512-9-3  IEC:2011
CONTENTS
FOREWORD . 3
1 Scope and object . 5
2 Normative references . 5
3 Preparation . 6
3.1 Preparation of specimen . 6
3.2 Mounting . 6
4 Test method . 6
4.1 General . 6
4.2 Electrical load . 6
4.3 Mechanical operation . 6
4.4 Environmental test conditions . 7
4.5 Measurements . 7
4.5.1 Initial measurements . 7
4.5.2 Measurements during the test. 7
4.5.3 Final measurements . 7
5 Details to be specified . 7
Annex A (informative) Typical circuit diagram . 9

Figure A.1 – Example of circuit(s) – (diagrammatic) . 9
Figure A.2 – Example of circuit(s) – (circuit diagram) . 9

60512-9-3 © IEC:2011 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CONNECTORS FOR ELECTRONIC EQUIPMENT –
TESTS AND MEASUREMENTS –
Part 9-3: Endurance tests –
Test 9c: Mechanical operation (engaging and separating)
with 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 may participate in this preparatory work. International, governmental and non-
governmental organizations liaising 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
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
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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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other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
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 60512-9-3 has been prepared by subcommittee 48B: Connectors,
of IEC technical committee 48: Electromechanical components and mechanical structures for
electronic equipment.
This second edition cancels and replaces the first edition, published in 2006, and constitutes
a technical revision.
The main technical changes with regard to the previous edition are as follows:
– An additional requirement to 4.1 stating that if more than one electrical circuit is wired for
testing, the wiring shall be carried out in a parallel electrical circuit.
– Subclauses 4.3 through 4.7 were removed and replaced by 4.2 through 4.4.

– 4 – 60512-9-3  IEC:2011
This standard is to be read in conjunction with IEC 60512-1 and IEC 60512-1-100, which
explains the structure of the IEC 60512 series.
The text of this standard is based on the following documents:
FDIS Report on voting
48B/2238/FDIS 48B/2244/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.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 60512 series, under the general title Connectors for electronic
equipment – Tests and measurements, can be found on the IEC website.
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.
60512-9-3  IEC:2011 – 5 –
CONNECTORS FOR ELECTRONIC EQUIPMENT –
TESTS AND MEASUREMENTS –
Part 9-3: Endurance tests –
Test 9c: Mechanical operation (engaging and separating)
with electrical load
1 Scope and object
This part of IEC 60512, when required by the detail specification, is used for testing
connectors within the scope of IEC technical committee 48. This test may also be used for
similar devices when specified in a detail specification.
The object of this standard is to define a standard test method to assess the mechanical and
electrical operational endurance, i.e. engaging and separating cycles, of a connector in an
operating mode which includes a specified electrical load.
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, Environmental testing – Part 1: General and guidance
IEC 60068-2-13, Environmental testing – Part 2-13: Tests – Test M: Low air pressure
IEC 60512-1, Connectors for electronic equipment – Tests and measurements – Part 1:
General
IEC 60512-1-1, Connectors for electronic equipment – Tests and measurements – Part 1-1:
General examination – Test 1a: Visual examination
IEC 60512-1-100, Connectors for electronic equipment – Tests and measurements – Part 1-
100: General – Applicable publications
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 60512-2-2, Connectors for electronic equipment – Tests and measurements – Part 2-2:
Electrical continuity and contact resistance tests – Test 2b: Contact resistance – Specified
current 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

– 6 – 60512-9-3  IEC:2011
3 Preparation
3.1 Preparation of specimen
The specimen shall consist of a component with its terminations and cables according to
Clause 5, a), unless otherwise specified in the detail specification. Any preconditioning given
in the detail specification shall be applied.
3.2 Mounting
The specimen under test shall be mounted per the manufacturer’s instructions or as described
in the detail specification.
4 Test method
4.1 General
The specimen shall be subjected to any electrical load and mechanical operational endurance
test in accordance with the requirements of the detail specification or other applicable
specification.
The specimen shall be operated (engaged/separated) to make and break the current load as
specified in the detail specification or other applicable specification.
In the case of specimen(s) having more than one circuit, the circuits shall be wired in parallel,
with appropriate duplication of other circuit components.
A circuit diagram, typical of that which may be specified, is shown in Annex A.
4.2 Electrical load
The type of electrical load, current, d.c. or a.c. voltage and frequency shall be stated in the
detail specification or other applicable specification.
An ‘equivalent circuit’ is intended to simulate a typical wiring installation including electrical
load and cable.
The equivalent circuit is specified by a resistance R, a capacitance C and an inductance L.
A typical circuit diagram is shown in Annex A.
In the case of specimen(s) having more than one circuit, the circuits shall be wired in parallel,
with appropriate duplication of other circuit components.
+5
During the mating cycles, the current and open-circuit voltage tolerances shall be within %
of the rated values specified in the detail specification.
4.3 Mechanical operation
The specimen shall be operated (engaged and separated) to make and break the current load
as specified below.
Speed, duty cycles and number of operations shall be stated in the detail specification or
other applicable specification. One engaging and one separating constitutes one operation.

60512-9-3  IEC:2011 – 7 –
Mechanical aids which simulate normal operation without introducing abnormal stresses may
be used unless otherwise specified by the detail specification.
The engaging and separating speed shall be (50 ± 5) mm/s, if not otherwise specified in the
detail specification or other applicable specification.
There will be a pause between operations of not less than 20 s if not otherwise specified, in
the detail specification or other applicable specification.
4.4 Environmental test conditions
These shall be standard conditions according to IEC 60068-1, unless otherwise stated in the
detail specification.
This test may be required at low air pressure. In this case, the atmospheric conditions shall
be in accordance with test M: Low air pressure of IEC 60068-2-13. The severity shall be as
specified in the detail specification or other applicable specification.
4.5 Measurements
4.5.1 Initial measurements
Before testing according to 4.1 above, the following tests shall be performed:
a) visual examination (IEC 60512-1-1);
b) contact resistance – Millivolt level method (IEC 60512-2-1) ;
c) insulation resistance (IEC 60512-3-1) ;
d) voltage proof (IEC 60512-4-1) ;
e) sealing (IEC 60068-2-13), if applicable.
4.5.2 Measurements during the test
Contact resistance may be monitored during the test according to Contact resistance –
Specified current method (IEC 60512-2-2).
4.5.3 Final measurements
a) Visual examination (IEC 60512-1-1).
b) Contact resistance – Millivolt level method (IEC 60512-2-1).
c) Insulation resistance (IEC 60512-3-1).
d) Voltage proof (IEC 60512-4-1).
e) Sealing (IEC 60068-2-13), if applicable.
The values and requirements shall be in accordance with those details referenced in Clause 5
below.
5 Details to be specified
When this test is required by the detail specific
...