Information on the most widely used ASTM standards within the materials testing industry
IEC 62852:2020 Connectors for DC-application in photovoltaic systems - Safety requirements and tests.
IEC 62852 applies to connectors used in DC circuits of photovoltaic systems that comply with IEC 61140:2001 Class II, with a rated voltage of up to 1,500 V DC and a rated current of up to 125 A per contact. It is suitable for connectors that do not have breaking capacity but may be mated and unmated under voltage.
The mechanical tests focus on verifying the "structural strength, operational durability, and mechanical protection of connectors." These tests are distributed across Test Group A (Mechanical Test Group), Test Group B (Service Life Test Group B), Test Group C (Service Life Test Group C), and miscellaneous tests.
Below is a detailed explanation organized by test classification, content details, specimen requirements, and test equipment:
I. Core Mechanical Test Classifications and Details
(1) Test Group A: Mechanical Test Group (Table 6, separate tests with no required sequence)
Test Group A is the foundational verification of mechanical properties, covering 10 tests including structural dimensions, marking durability, terminal retention, and mechanical strength:
| Test No. | Test Name | Test Content and Requirements | Test Equipment |
| A3 | Polarity | Test per IEC 60512 test 13e with a force of 20N or 1.5x insertion force (whichever is larger, but not exceeding 80N). Must prevent incorrect mating. | Recommend Tensile testing machine. |
| A4 | Terminal Verification | Inspect mechanical properties of crimp/insulation displacement/press-in terminals per 6.3.15 (e.g., crimp tensile strength, insulation piercing force). Must comply with 5.5. | |
| A5 | Retention of Contacts in Insulator | Apply an axial force of 3x single-contact insertion force (or insertion force + 50N, whichever is smaller) per IEC 60512 test 15a. No axial displacement allowed (5.15.2). | |
| A6.1 | Cable Clamp (Tensile) | Test cable clamp tensile resistance per IEC 60512 test 17c. Must comply with 5.14 and Table 1 (cable anchorage values). | |
| A10 | Effectiveness of Connector Coupling Device | Apply an 80N separating force at a rate of 10N/s per IEC 60512 test 15f. Connector must not disengage (only for locked connectors). | |
| A6.2 | Cable Clamp (Torsion) | Test cable clamp torsion resistance per IEC 60512 test 17d. Same requirements as above. | Torsion testing machine. |
| A7 | Mechanical Strength (Drop) | Free connectors are dropped from 750mm (≤250g) or 500mm (>250g) 8 times (45° steps). Impact with a 1J hammer 4 times (evenly distributed on the circumference). No functional damage allowed. | Drop test bench, impact testing device (IEC 60068-2-75), 20mm-thick steel plate. |
| A8 | Mechanical Strength at Lower Temperatures | Store specimens and test equipment at -40°C (or manufacturer’s minimum temperature) for 5 hours. Impact with a 1J hammer 4 times.No damage and must pass dielectric strength test (6.3.8 b). | Low-temperature chamber (-40°C), impact testing device. |
| A9 | Insertion and Withdrawal Force | Test per IEC 60512 test 13b at a speed of 50mm/min. Withdrawal force ≥50N (only for connectors without locking mechanisms). | Connector Plug-in force Insertion Extraction Tester. |
(2) Test Group B: Service Life Test Group B (Table 7) – Mechanical Operation (B2)
• Purpose: Verify insertion/withdrawal durability of connectors under no electrical load.
• Content: Engage/disengage specimens with a device simulating normal operation (speed ≈0.01m/s, 30s rest in unmated position per IEC 60512 test 9a).
• Specimens: 3 specimens (prepared per Table 4).
• Equipment: Insertion/withdrawal simulation device, timer, speed controller.
• Requirement: No damage impairing function (5.11).
(3) Test Group C: Service Life Test Group C (Table 8) – Bending Test (C1)
• Purpose: Verify cable bending resistance of non-rewirable connectors.
• Content: Fix specimens to a swinging device per IEC 60309-1:1999 24.4. Load the cable with 20N (cross-section >0.75mm²) or 10N (≤0.75mm²), pass rated current, and swing 90° (±45°) at 60 cycles/min for 100 bends (rotate 90° after 50 bends).
• Specimens: Non-rewirable connectors with cables (prepared per Table 4).
• Equipment: Bending test device (Figure 1), weight loader, current source, high-voltage tester (for insulation verification).
• Requirement: No current interruption, cable support sleeve not loosened, insulation undamaged (6.3.6).
II. Summary of Test Equipment
| Equipment Type | Examples |
| Mechanical Testing | Tensile/push-pull gauges, torsion testing machines, impact devices (IEC 60068-2-75), drop test benches |
| Environmental Simulation | Low-temperature chambers (-40°C), high-temperature chambers (+85°C), humidity chambers (85% RH), salt spray chambers (corrosion tests) |
| Electrical Testing | Current sources, high-voltage testers (6.3.8), dielectric strength testers |
| Auxiliary Tools | Visual inspection lamps, dimensional gauges (micrometers/projectors), insertion/withdrawal simulators, bending test devices. |
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