IEC 60512-99-001:2012

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

IEC 60512-99-001:2012 used for the assessment of 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 802.3at - 2009 (latest edition (PoE Plus - Power over Ethernet Plus). The object of this standard is to detail a test schedule to determine the ability of connectors to withstand a minimal number of engagements and separations when an electrical current is being passed through the connector in accordance with IEC 60512-9-3. Keywords: connectors, engaging and separating connectors

Connecteurs pour équipments électroniques - Essais et mesures - Partie 99-001: Programme d'essai relatif aux connexions et déconnexions sous charge électrique - Essai 99a: Connecteurs utilisés dans le câblage de communication à paires torsadées permettant une alimentation à distance

La CEI 60512-99-001:2012 est utilisée pour l'évaluation des connecteurs entrant dans le domaine d'application du SC 48B, qui sont utilisés dans le câblage de communication à paires torsadées permettant une alimentation à distance, comme par exemple la Classe D de l'ISO/CEI 11801, ou plus, le câblage à paires symétriques associé aux applications de l'IEEE 802.3 at (PoE Plus - Power over Ethernet Plus). Cette norme a pour objet de détailler un programme d'essai afin de déterminer l'aptitude des connecteurs à résister à un nombre limité de connexions et déconnexions, lorsqu'un courant électrique circule à travers le connecteur, conformément à la CEI 60512-9-3. Mots clé: connecteurs, connexions et déconnexions

General Information

• Status: Published
• Publication Date: 12-Aug-2012
• ICS: 31.220.10 - Plug-and-socket devices. Connectors
• Technical Committee: SC 48B - Electrical connectors
• Current Stage: PPUB - Publication issued
• Start Date: 13-Aug-2012
• Completion Date: 30-Jun-2012

Overview

IEC 60512-99-001:2012 is an international standard developed by the International Electrotechnical Commission (IEC) focusing on connectors for electronic equipment, specifically their performance during engaging and separating under electrical load. This standard, part of the IEC 60512 series, defines a comprehensive test schedule (Test 99a) to assess the endurance and electrical robustness of connectors used in twisted pair communication cabling with remote power-such as seen in ISO/IEC 11801 Class D or better balanced cabling supporting IEEE 802.3at (Power over Ethernet Plus, PoE Plus). The objective is to verify the reliability of these connectors when repeatedly connected and disconnected while carrying electrical current, ensuring continued performance in demanding environments.

Key Topics

• Assessment Scope
  IEC 60512-99-001:2012 addresses connectors designed for use in remote-powered, twisted pair communication cabling systems. It is intended for connectors evaluated under SC 48B and used in structured cabling infrastructures that support both data and power transmission, such as those conforming to PoE Plus requirements.

• Test Schedule
  The standard details a rigorous test sequence that includes:

  • Preparation of mated connector specimens wired in parallel, conforming to relevant IEC standards
  • Application of defined electrical loads (current and voltage) during repeated mating and unmating cycles
  • Measurement and monitoring of parameters such as contact resistance, insulation resistance, and voltage proof to ensure connector integrity

• Performance under Load
  The tests are designed to replicate real-world conditions where connectors are engaged and separated while under electrical load, revealing durability limits and ensuring safety and functionality over time.

• Reference to Related Standards
  The tests refer to other IEC standards such as IEC 60512-9-3 for testing methodology and IEC 61156 for cabling requirements, ensuring harmonization with globally recognized practices.

Applications

IEC 60512-99-001:2012 is highly relevant for industries and organizations involved in electronic equipment manufacturing, telecommunications infrastructure, and networks deploying structured cabling with integrated power delivery. Its practical benefits include:

• Quality Assurance for Connectors
  Ensures that connectors used in Power over Ethernet (PoE, PoE Plus) systems can withstand real-world use, minimizing the risk of connection failures or electrical hazards due to repeated mating cycles under load.

• Compliance and Product Development
  Supports manufacturers in certifying their products for demanding applications, meeting the requirements for both data and remote power transmission in enterprise and commercial installations.

• Enhanced Network Reliability
  By applying these test schedules, network designers and installers can select components that guarantee robust performance, reducing maintenance, downtime, and potential safety concerns.

• Structured Cabling Support
  Provides assurance for connectors used within ISO/IEC 11801 Class D or superior cables, especially in environments where both communication and electrical power are delivered through the same cabling infrastructure.

Related Standards

• IEC 60512 Series
  General and specific test methods for connectors, including contact resistance and voltage proof tests.

• IEC 60512-9-3
  Procedures for mechanical operation (engagement and separation) with electrical load.

• IEC 61156 Series
  Specifications for multicore and symmetrical pair/quad cables for digital communications.

• ISO/IEC 11801
  International standard for generic cabling in customer premises.

• IEEE 802.3at
  Specification for Power over Ethernet Plus (PoE Plus) applications.

• IEC/TR 62652
  Guidance on the effects of engaging and separating connectors under electrical load, particularly relevant for PoE applications.

Keywords: connectors, engaging and separating connectors, electrical load, PoE Plus, structured cabling, IEC 60512, remote power, twisted pair communication, endurance testing, telecommunication connectors.

Standards Content (Sample)

IEC 60512-99-001 ®
Edition 1.0 2012-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
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
Connecteurs pour équipements électroniques – Essais et mesures –
Partie 99-001: Programme d'essai relatif aux connexions et déconnexions sous
charge électrique – Essai 99a: Connecteurs utilisés dans le câblage de
communication à paires torsadées permettant une alimentation à distance

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IEC 60512-99-001 ®
Edition 1.0 2012-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
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
Connecteurs pour équipements électroniques – Essais et mesures –

Partie 99-001: Programme d'essai relatif aux connexions et déconnexions sous

charge électrique – Essai 99a: Connecteurs utilisés dans le câblage de

communication à paires torsadées permettant une alimentation à distance

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX L
ICS 31.220.10 ISBN 978-2-88912-000-0

– 2 – 60512-99-001 © IEC:2012
CONTENTS
FOREWORD . 3
1 Scope and object . 5
2 Normative references . 5
3 General . 5
4 Preparation of specimen . 6
5 Test circuit requirements . 6
5.1 General . 6
5.2 Voltage and current . 6
5.3 Auxiliary equipment . 7
6 Tests and test schedule . 7
6.1 Test group UEL 1 . 7
Annex A (informative) Test voltage and current setting instructions . 10
Bibliography . 11

Figure 1 – Test circuit details . 6

Table 1 – Test group UEL 1 . 7

60512-99-001 © IEC:2012 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
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

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,
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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 60512-99-001 has been prepared by subcommittee 48B:
Connectors, of IEC technical committee 48: Electromechanical components and mechanical
structures for electronic equipment.
The text of this standard is based on the following documents:
FDIS Report on voting
48B/2291/FDIS 48B/2306/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.

– 4 – 60512-99-001 © IEC:2012
A list of all parts of 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.
60512-99-001 © IEC:2012 – 5 –
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

1 Scope and object
This part of IEC 60512 is used for the assessment of connectors within the scope of SC 48B
that are used in twisted pair communication cabling with remote power, such as
IEEE Std 802.3at™-2009
ISO/IEC 11801 Class D, or better, balanced cabling in support of
(PoE Plus – Power over Ethernet Plus).
The object of this standard is to detail a test schedule to determine the ability of connectors to
withstand a minimal number of engagements and separations when an electrical current is
being passed through the connector in accordance with IEC 60512-9-3.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and
are indispensable for its application. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60512 (all parts): Connectors for electronic equipment – Tests and measurements
IEC 60512-1-100: Connectors for electronic equipment – Tests and measurements –
Part 1-100: General – Applicable publications
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 61156 (all parts): Multicore and symmetrical pair/quad cables for digital communications
3 General
The current carrying capacity of a mated connector, including the corresponding current de-
rating for temperature, shall be specified in the detail specification. Although many
applications are configured such that the current is not drawn until after full engagement of
the connector has been achieved (i.e. the connector does not “make” the current), this test
schedule is suitable for verification of engaging and separating of connectors under PoE Plus
load conditions where this may occur in practice.
An application specific current, and associated open circuit voltage, is specified that
corresponds with the current and voltage of the supported application.
The circuitry and test conditions given in this standard correspond to the conditions
associated with ISO/IEC 11801 Class D, or better, balanced cabling in support of
IEEE 802.3at (PoE Plus – Power over Ethernet Plus)

– 6 – 60512-99-001 © IEC:2012
Further information on the possible effects of such operations may be found in IEC TR 62652.
NOTE The above documents are not essential for the application of this standard but are given as source of
information, as such, they may be found in the Bibliography.
4 Preparation of specimen
Each specimen shall consist of a mated connector with its terminations. Specimens shall be
conformant to the relevant IEC connector standards. Each free connector and each fixed
connector shall be terminated with 3 m (max.) of the maximum conductor size cable for which
it is intended to be terminated, according to IEC 61156 series. For each specimen, all of the
circuits (mated contacts) shall be wired in parallel, as given in IEC 60512-9-3, and all of the
circuits shall be tested (see Figure 1). If necessary, a printed circuit board may be used which
shall not influence the test results.
5 Test circuit requirements
5.1 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.

2 3
IEC  1098/12
Key
1 Cables in accordance with 4.1
2 Connector under test
Inductor 100 μH
Variable resistor (e.g. 50 Ω to 300 Ω)
Capacitor 5 μF
6 Power source
NOTE 1 Only one circuit of the connector under test, as referenced in IEC 60512-9-3, is shown for clarity. Items
1, 3, 4, 5, and 6, are replicated for each circuit (engaged contacts) of the connector. Item 6 may be single or
multiple. Each circuit of the specimen shall be wired in parallel with the other circuits of the specimen, and all
circuits of each specimen shall operate simultaneously.
NOTE 2 The variable resistor(s) are used to adjust the current(s) to the specified value.
Figure 1 – Test circuit details
5.2 Voltage and current
The variable resistor(s) shall be set so that the electrical current in each circuit (mated
contacts) of the specimen is 0,6 A. When specimen is unmated, the ‘open circuit’ voltage, in
all circuits, shall be 55 V d.c. See Annex A.
IEEE 802.3 at specifies a maximum current of 0,3 A per conductor and an open circuit voltage
of 55 V d.c. The test current has been doubled to 0,6 A in order to represent the high

60512-99-001 © IEC:2012 – 7 –
probability that one contact of any given pair will separate before the other. Therefore as in
the cited application, where current is carried by pairs of contacts in multiple parallel circuits,
the last contact to break will do so carrying all the current (twice the nominal).
5.3 Auxiliary equipment
The test laboratory may choose to use switches to reverse polarity. However, use of such
switches shall not influence the test parameters.
6 Tests and test schedule
6.1 Test group UEL 1
A minimum number of 8 specimens shall be prepared for this group; then tested according to
Table 1.
Table 1 – Test group UEL 1
Test Test Measurement to be performed
Phase
Title IEC 60512 Severity or condition of Title IEC 60512 Requirements
test No. test test No.
UEL General 1 Visual 1a There shall be no
1.1 examination examination defects that would
impair normal
operation
UEL Contact Millivolt level 2a Contact resistance
1.2 resistance method
20 mΩ maximum
UEL  100 V d.c. Insulation 3a
500 MΩ minimum
1.3 resistance
Method A
Mated connectors
UEL  Contact to contact Voltage proof 4a 1 000 V d.c. or a.c.
1.4 peak
All signal contacts to shield
and test panel, as 1 500 V d.c. or a.c.
applicable peak
Method A
Mated connectors
UEL  An electrical load, current Mechanical 9c
1.5 and open circuit voltage, as operations with
detailed in Clause 5, shall electrical load
be applied to each
specimen.
For the purpose of this test
one connector shall be
fixed and the other
disengaged at a speed of
150 ± 10 mm/s.
One engagement and one
separation constitute one
cycle.
25 cycles shall be
performed.
The polarity of the d.c.
source (direction of the
electrical current) shall be
reversed and 25 further
cycles performed.
– 8 – 60512-99-001 © IEC:2012
Table 1 (continued)
Test Test Measurement to be performed
Phase
Title IEC 60512 Severity or condition of Title IEC 60512 Requirements
test No. test test No.
UEL 1.6 Flowing 11g 4 days. 11g
mixed gas
Half of the samples mated;
test.
half of the samples
Method 1 unmated
UEL 1.7  Contact 2a 20 mΩ maximum
resistance-
change from initial
Millivolt level
method
UEL 1.8  An electrical load, current Mechanical 9c
and open circuit voltage, as Operations
with electrical
detailed in Clause 5, shall
be applied to each load.
specimen.
For the purpose of this test
one connector shall be
fixed and the other
disengaged at a speed of
150 ± 10 mm/s.
One engagement and one
separation constitute one
cycle.
25 cycles shall be
performed.
The polarity of the dc.
source (direction of the
electrical current) shall be
reversed and 25 further
cycles performed.
The specified testing is
done with voltage present
during engagement. If a
specimen does not “pass”
the test sequence, the test
shall be repeated with a
new specimen, without
applied voltage during
engagement, but the
appropriate voltage and
current shall be applied
during disengagement. A
connector passing the test
in this manner shall be
reported as such in test
reports. Further, this
information shall be made
evident in the all relevant
documentation of the
manufacturer and supplier
regarding this mode of
complying with this test
schedule requirement.
60512-99-001 © IEC:2012 – 9 –
Table 1 (continued)
Test Test Measurement to be performed
Phase
Title IEC 60512 Severity or condition of Title IEC 60512 Requirements
test No. test test No.
UEL 1.9 General 1 Visual 1a There shall be no
examination examination 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 1.10  Contact resistance Millivolt level 2a
20 mΩ maximum
method
change from initial
UEL 1.11  100 V d.c. Method A Mated Insulation 3a
500 MΩ minimum
connectors resistance
UEL 1.12  Contact to contact Voltage proof 4a 1 000 V d.c. or a.c.
peak
All signal contacts to shield
and test panel, as 1 500 V d.c. or a.c.
applicable
peak.
Method A
Mated connectors
– 10 – 60512-99-001 © IEC:2012
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 d.c. 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. 0,6 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 d.c. 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.
...