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IEC 62852 Mechanical Test: Solar connector for DC-application in photovoltaic systems

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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 NameTest Content and RequirementsTest Equipment
A3Polarity

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. 
A4Terminal VerificationInspect 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.
A5Retention of Contacts in InsulatorApply 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).
A6.1Cable Clamp (Tensile)Test cable clamp tensile resistance per IEC 60512 test 17c. Must comply with 5.14 and Table 1 (cable anchorage values).
A10Effectiveness of Connector Coupling DeviceApply an 80N separating force at a rate of 10N/s per IEC 60512 test 15f. Connector must not disengage (only for locked connectors).
A6.2Cable Clamp (Torsion)Test cable clamp torsion resistance per IEC 60512 test 17d. Same requirements as above.Torsion testing machine.
A7Mechanical 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.
A8Mechanical 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.
A9Insertion and Withdrawal ForceTest 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 TypeExamples
Mechanical TestingTensile/push-pull gauges, torsion testing machines, impact devices (IEC 60068-2-75), drop test benches
Environmental SimulationLow-temperature chambers (-40°C), high-temperature chambers (+85°C), humidity chambers (85% RH), salt spray chambers (corrosion tests)
Electrical TestingCurrent sources, high-voltage testers (6.3.8), dielectric strength testers
Auxiliary ToolsVisual inspection lamps, dimensional gauges (micrometers/projectors), insertion/withdrawal simulators, bending test devices.


Related products and device

IEC 62852 Solar connector Plug-in force Insertion Extraction Tester

Connector Plug-in force Insertion Extraction Tester/ Insertion and withdrawal force tester/ Connector Reliability Tester is a precision testing device specifically used to test the plug-in force performance of electronic connectors, plugs and sockets, and various plug-in components.

IEC 62852 Solar connector Torsion Testing Machine

Torsion tester is mainly used to execute torsion test for various kinds materials, manual loading, high accuracy torsion transducer to measure torque, photoelectric encoder to measure torsion angle, digital display test result.

IEC 62852 Solar connector Tensile Testing Machine

WDW Series Computer Control Electronic Universal Testing Machine made by UNITEDTEST range from 100N to 600KN load capacity with various models like single columns, table type, door frame type etc., is used to perform tension, compression, flexure/bending, shearing, peeling etc., test for metal and nonmetal specimens.

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