Iec 60352 6 1997

NORME INTERNATIONALE CEI IEC INTERNATIONAL STANDARD 60352 6 Première édition First edition 1997 08 Connexions sans soudure – Partie 6 Connexions à percement d''''isolant – Règles générales, méthodes d''''es[.]

Exécution

Les connexions doivent ờtre exộcutộes de faỗon soignộe et dans les rốgles de l'art.

Outils

Les outils doivent être vérifiés et utilisés en accord avec les instructions données par le ou les fabricants des outils et/ou des connecteurs.

Les outils doivent être capables d'effectuer des connexions à percement d’isolant uni- formément fiables pendant leur durée de vie.

Les outils doivent être de conception telle que des dommages inacceptables à la connexion à percement d’isolant et ou aux conducteurs soient évités.

Les outils à main doivent être équipés d’un mécanisme de contrôle de fin de cycle.

Les outils automatiques doivent être équipés d’un mécanisme de contrôle de fin de cycle ou d’un système de sécurité équivalent.

Les outils sont évalués en essayant les connexions à percement d’isolant réalisées avec ceux-ci.

LICENSED TO MECON Limited - RANCHI/BANGALORE FOR INTERNAL USE AT THIS LOCATION ONLY, SUPPLIED BY BOOK SUPPLY BUREAU.

3.1.2 insulation piercing connection with flat conductors or flat flexible circuitries: An insulation piercing connection formed by lances which pierce and penetrate the flat conductor

Figure 2 – Example of an insulation piercing connection with flat conductor

The insulation piercing barrel connection utilizes lances within a barrel to penetrate the insulation and establish contact with the stranded conductors or tinsel wires This method ensures a reliable electrical connection while maintaining the integrity of the insulation.

Figure 3 – Example of an insulation piercing connection in a barrel with stranded wires

3.2 insulation piercing termination: A termination to accept different types of insulated conductors for the purpose of establishing an insulation piercing connection [IEV 581-03-63]

3.3 insulation piercing zone: That portion of the contact designed and intended to effect the piercing of the insulation and provide contact with the conductor (see 6.3.1) [IEV 581-03-53]

The connections shall be processed in a careful and workmanlike manner, in accordance with good current practice.

Tools shall be used and inspected according to the instructions given by the manufacturer(s) of the tool and/or the connector.

The tools shall be able to make uniformly reliable insulation piercing connections during their lifetime.

The tools shall be designed to operate in such a manner that unacceptable damage to the insulation piercing termination and/or conductors is avoided.

Hand tools shall be provided with a full cycle mechanism.

Automatic tools shall be provided with a full cycle mechanism or equivalent safeguard.

Tools are evaluated by testing insulation piercing connections made with the tools to be evaluated.

Contacts à percement d’isolant

Les nuances adaptées du cuivre ou des alliages de cuivre, telles que les cuivre-étain

(bronze), les cuivre-zinc (laiton) ou les cuivre-béryllium doivent être utilisées.

Pour les connexions à percement d’isolant suivant 3.1.1, la matiốre du boợtier du composant doit être du polycarbonate ou toute matière plastique équivalente.

Pour les connexions à percement d’isolant suivant 3.1.3, l’isolant du fil doit être en PVC ou une autre matière appropriée pour cette technique de connexion.

The quality of an insulation piercing connection relies on the dimensions of the insulation piercing contact These dimensions must be suitable for divided conductor wires, including faux gold stranded wires, insulated flat cables, and flexible circuits as specified in section 4.4.

La surface de contact doit être brute ou revêtue d'étain, d'étain plomb, d’argent, d'or, de palladium ou de leurs alliages.

La surface doit être exempte de contamination et de corrosion néfastes pour les performances.

Insulation piercing contacts must be designed so that the lance tips and sharp edges of the insulation piercing areas penetrate the insulation of the insulated conductors, establishing a connection through controlled penetration or deformation of the conductors The insulation piercing area and the body of the contact should deform around the conductors to maintain a secure connection.

Pour les connexions à percement d’isolant suivant 3.1.1, la fonction de guidage du boợtier du composant sur les fils isolés insérés est importante.

Conducteurs isolés

Des fils à conducteurs divisés, à brins d’or faux, des câbles plats, des circuits souples doivent être utilisés.

Les conducteurs utilisés doivent être en cuivre recuit.

4.4.2.1 Dimensions des conducteurs isolés pour les connexions à percement d’isolant suivant 3.1.1

Elles sont définies dans la spécification particulière.

Suitable grades of copper or copper alloy such as copper-tin (bronze), copper-zinc (brass) or beryllium copper shall be used.

For insulation piercing connections according to 3.1.1 the component housing material shall be polycarbonate or similar plastic material.

For insulation piercing connections according to 3.1.3 the wire insulation shall be PVC or another material appropriate for this connecting technique.

The effectiveness of an insulation piercing connection is influenced by the dimensions of the termination These dimensions must be appropriate for various types of stranded wires, including tinsel wires, as well as insulated flat conductors and flat flexible circuitries, as outlined in section 4.4.

The contact area of the termination shall be unplated or plated with tin or tin-lead or silver, gold, palladium or their alloys.

The surface shall be free of contamination or corrosion which degrades performance.

Insulation piercing terminations must be engineered to ensure that the lances or sharp edges effectively penetrate the insulation of insulated conductors, creating a reliable connection through either penetration or controlled deformation Additionally, the design should allow the insulation piercing zones and termination body to deform around the conductors, ensuring a secure and stable connection.

For insulation piercing connections according to 3.1.1 the guiding function of the component housing for the inserted insulated wires is important.

Wires with stranded wires, tinsel-wires, flat conductors or flat flexible circuitries shall be used.

The conductors used shall be annealed copper.

4.4.2.1 Dimensions for insulated conductors used for insulation piercing connections according to 3.1.1

Specified in the detail specification.

La surface des conducteurs doit être brute ou les conducteurs doivent être revêtus d’étain, d’étain plomb ou d’argent.

La surface des conducteurs doit être exempte de contamination et de corrosion néfastes pour les performances.

La spécification particulière concernant les composants utilisant des contacts à percement d’isolant doit spécifier

– l’épaisseur de l’isolant des fils, et

– les diamètres extérieurs ou les dimensions extérieures des fils qu’ils doivent accepter.

Insulating materials must possess properties that are compatible with the insulation piercing process, meaning they should be easily penetrable by piercing zones In the case of split conductor wires or faux gold strands, the insulation must also ensure that the strands are securely held in place, preventing excessive movement during the connection process.

Pour les câbles plats, l’isolant entre les conducteurs ainsi que l’éventuel isolant formant le câble doivent avoir aussi l’aptitude d’être aisément percés par les zones de percement.

Connexions à percement d’isolant

a) La combinaison des conducteurs isolés, du contact et des outils de câblage doit être compatible. b) Pendant l’opération de raccordement, le contact à percement d’isolant du composant doit

– percer l’isolant sans effet néfaste;

To ensure a reliable electrical connection without damaging the conductor, it is essential to either deform or pierce the conductor appropriately The contact design must facilitate the precise positioning of the insulated conductor within the connection area The conductor should be accurately placed in the insulation-piercing contact according to specific guidelines, maintaining a sufficient distance between the contact and the conductor's end This minimum distance varies based on the type of conductor used and must align with the specified requirements Additionally, when the contact includes an insulating support or sleeve, the insulation must be correctly positioned within that support or sleeve.

Conductors shall be unplated or plated with tin, tin-lead or silver.

The conductor surface shall be free of contamination or corrosion which degrades performance.

The specification for the components using the insulation piercing termination shall specify

– the insulation thickness of the wires, and

– the outer diameters or the outer dimensions of the wires that shall be accommodated.

The insulation material must be suitable for the insulation piercing process, allowing easy piercing by the designated zones For stranded conductors or tinsel wires, the insulation should also securely hold the strands in position to prevent excessive movement during the connection process.

For flat cables the insulation between the conductors, including any additional insulation forming the cable, shall additionally be capable of being readily pierced by the piercing zones.

4.5 Insulation piercing connections a) The combination of insulated conductors, termination and connection tools shall be compatible. b) During the connection process the insulation piercing termination of the component shall

– pierce the insulation without detrimental effect;

To ensure a reliable electrical connection without damaging the conductor, it is essential to deform or pierce the conductor appropriately, avoiding issues such as cracking The termination design must maintain the correct alignment between the insulated conductor and the piercing zone Additionally, the conductor must be accurately positioned within the insulation piercing termination, adhering to the specifications outlined in the detail specification, which also stipulates a minimum distance between the termination and the conductor end based on the type of conductor used Furthermore, if the termination includes an insulation support or grip, the insulation must be properly positioned within that support or grip.

Généralités sur les essais

Comme expliqué dans l’introduction, deux programmes d'essai doivent être appliqués dans les conditions suivantes:

– les connexions à percement d’isolant conformes à toutes les exigences de l’article 4 doivent être essayées et répondre à toutes les exigences du programme de qualification de 5.3.2;

Insulation piercing connections that are part of a component and have already been qualified according to all the requirements of Article 4 must be tested and meet all the criteria outlined in the application program 5.3.3, which should be included in the specific specification.

Sauf indication contraire, tous les essais doivent être effectués dans les conditions normales d'essai définies dans la CEI 60512-1.

La température ambiante et l'humidité relative auxquelles les mesures sont effectuées doivent être mentionnées dans le rapport d'essai.

En cas de désaccord sur les résultats d'essai, l'essai doit être répété suivant l'une des conditions d'arbitrage indiquées dans la CEI 60068-1.

Lorsque cela est spécifié, les connexions doivent être préconditionnées dans les conditions normales d'essai durant 24 h, suivant la CEI 60512-1.

Lorsque cela est spécifié, les connexions doivent être soumises aux conditions normales d'essai durant 1 h à 2 h après l'épreuve.

When assembly is required for a test, specimens must be mounted using standard methods unless otherwise specified A test specimen should consist of a component with a defined connection or a specific number of connections to an insulation piercing contact, with an insulated wire inserted into each insulation piercing contact.

Méthodes d’essai et exigences

Note: When a testing method is described in this standard, it is agreed that the description will be replaced by a reference to the relevant section of IEC 60512 as soon as the corresponding testing method is included.

Les essais doivent être effectués conformément à l’essai 1a: Examen visuel, et à l’essai 1b:

Examen de dimension et de masse, de la CEI 60512-2 L'examen visuel peut être effectué avec un grossissement d'environ cinq fois.

Toutes les pièces doivent être examinées pour s'assurer qu'elles sont conformes aux exigences de 4.3 à 4.5.

As explained in the introduction, there are two test schedules which shall be applied according to the following conditions:

– insulation piercing connections which conform to all the requirements of clause 4 shall be tested and shall meet the requirements of the qualification test schedule of 5.3.2;

Insulation piercing connections, as integral components that comply with all requirements outlined in clause 4, must undergo testing according to the application test schedule specified in section 5.3.3 This testing protocol should be incorporated into the detailed specification.

Unless otherwise specified, all tests shall be carried out under standard conditions for testing, as specified in IEC 60512-1.

The ambient temperature and the relative humidity at which the measurements are made shall be stated in the test report.

In case of dispute about the test results, the test shall be repeated at one of the referee conditions of IEC 60068-1.

Where specified, the connections shall be preconditioned under standard conditions for testing for a period of 24 h, in accordance with IEC 60512-1.

Where specified, the specimens shall be allowed to recover under standard conditions for testing for a period of 1 h to 2 h after conditioning.

When mounting is necessary for testing, the standard mounting method should be used unless specified otherwise The test specimen must include the component with one or a designated number of insulation piercing connections, each containing one insulated wire inserted into the respective termination.

5.2 Test methods and test requirements

This standard indicates that the test methods outlined will be updated to reference the relevant sections of IEC 60512 once those specific test methods are incorporated into IEC 60512.

The tests shall be carried out in accordance with test 1a: Visual examination, and test 1b:

Examination of dimension and mass, of IEC 60512-2 The visual examination test may be carried out with magnification up to five times.

All parts shall be examined to ensure that the applicable requirements of 4.3 to 4.5 have been met.

L’essai doit être effectué conformément à l’essai 16t: Tenue mécanique (sortie câblée de connexions sans soudure), de la CEI 60512-16-20, Méthode A ou Méthode B (selon accord entre utilisateur et fabricant).

La tenue à la traction des connexions à percement d’isolant ne doit pas être inférieure à 20 N par fil, sauf indication contraire de la spécification particulière.

The purpose of this essay is to assess the ability of an insulated piercing connection to withstand the mechanical stresses caused by the bending of the insulated wire/cable when connected under specified conditions.

Le spécimen d'essai est constitué

Multiple connections can be made to a multi-contact component Such specimens can be connected to several discrete wires, wires formed into a cable, or a multi-conductor flat cable as outlined in sections 3.1.1 and 3.1.2 (see figures 1 and 2).

– d’un fil discret raccordé à un composant monovoie suivant 3.1.3 (voir figure 3).

The test specimen must be securely held in a position where the wire or flat cable hangs along its longitudinal axis in the connection An axial load \( F \) should be applied to the free end of the wire or wires, or the flat cable, to keep them straight.

La valeur de cette charge doit être

– de 5 % à 10 % de la tenue à la rupture du fil pour l’essai d’un seul fil;

The applicable load for flat cables ranges from 10 N to 50 N, depending on factors such as the number of wires, wire diameter, and the type or material of the insulation This load must be clearly specified in the component's specifications and should be evenly distributed along the entire length of the cable.

Le fil doit alors être plié suivant deux directions perpendiculaires Un pliage suivant le parcours 1,

The sections 2 and 3 should be viewed as a cycle, while the sections 4, 5, and 6 represent an additional cycle (refer to Figure 4) Unless otherwise specified, the bending angle must be set at 30°.

Le pliage du fil/câble est réalisé en utilisant un dispositif d’essai approprié, par exemple suivant les figures 4 et 5.

When testing discrete wires connected to a multi-contact component, the wire bending test must be conducted on a specified number of discrete wires (samples) per component, as outlined in the specific requirements.

Les spécimens doivent être essayés en séquence ou simultanément, comme indiqué dans la spécification particulière.

Le nombre de cycles doit être de 10, sauf indication contraire de la spécification particulière.

La perturbation de contact doit être contrôlée durant l'essai de pliage conformément à l’essai 2e: Perturbation de contact, de la CEI 60512-2.

La limite de la durộe de la perturbation de contact doit ờtre de 1 às, sauf indication contraire de la spécification particulière.

The test will be conducted following test 16t: Mechanical strength of wired terminations in solderless connections, as outlined in IEC 60512-16-20, utilizing either Method A or Method B, based on the agreement between the user and the manufacturer.

The tensile strength of insulation piercing connections shall be not less than 20 N per wire, unless otherwise specified by the detail specification.

5.2.2.2 Bending of the wire/cable

This test evaluates the strength of an insulation piercing connection by measuring its ability to endure mechanical stress from bending the attached insulated wire or cable in a defined manner.

The test specimen shall consist of

– multiple connections to a multipole component Such specimens may include multiple single wires, wires in cable constructions or multiconductor flat cable according to 3.1.1 and

– a single wire connected to a single component according to 3.1.3 (see figure 3).

The test specimen must be firmly positioned to ensure that the wire(s) or flat conductor align with its longitudinal axis during the connection An axial load, denoted as F, should be applied to the free end of the wire(s) or flat conductor to maintain their straightness.

The value of this load shall be

– 5 % to 10 % of the breaking strength of the wire where single wires are to be tested;

Flat conductors are tested with loads ranging from 10 N to 50 N, which depend on factors such as the number of wires, wire diameter, and the type or material of insulation The specific load requirements will be outlined in the detail specification, and it is essential that the load is evenly distributed across the entire conductor.

The wire must be bent at right angles in both directions, with bends at distances 1, 2, and 3 constituting one cycle, and bends at distances 4, 5, and 6 forming another cycle (refer to figure 4) Unless stated otherwise in the detail specification, the bending angle should be set at 30°.

Bending of the wire/conductor shall be carried out using a suitable test arrangement, for example as indicated in figure 4 or 5.

Programmes d’essai

When the testing sequence requirements for a connector utilizing this type of connection already encompass all or part of the testing requirements specified, those tests do not need to be repeated.

Before testing, specimens must be prepared Each specimen should consist of an insulating piercing contact and a wire inserted through the contact, unless otherwise specified in the particular specification.

NOTE – L’essai 5.2.3.1.1 nécessite des spécimens câblés aux deux extrémités (voir figure 7).

When testing connections made with contacts that accommodate a range of wire dimensions, it is essential to conduct trials on: a) the number of specimens specified in Table 3 using wires with conductors at the minimum dimensions of the range, and additionally, b) the number of specimens specified in Table 3 using wires with conductors at the maximum dimensions of the range.

Lorsque des composants multicontacts sont essayés, le nombre requis de spécimens doit être uniformément réparti.

Avant de préparer les spécimens, on doit vérifier que: a) les contacts et les fils adaptés sont utilisés; b) lorsque les connexions sont réalisées avec un outil

– que l’outil correct est utilisé;

– que l’outil fonctionne correctement; c) l’opérateur est capable de faire des connexions conformes à 4.5.

5.2.4.3 Flowing mixed gas corrosion test

The test shall be carried out in accordance with test 11g: Flowing mixed gas corrosion test, of IEC 60512-11-7.

Unless otherwise specified by the detail specification, the following details shall apply:

NOTE – This test is a method with two mixed gases.

The test shall be carried out in accordance with test 11m: Damp heat, cyclic, of IEC 60512-6

(future IEC 60512-11-12) Unless otherwise specified by the detail specification the following details shall apply:

Where the requirements of the test sequence for a connector, employing these connections, include all or part of the test requirements of this specification, duplication of testing shall be excluded.

Before testing, it is essential to prepare specimens, each comprising an insulation piercing termination with a single wire inserted into one termination, unless the detail specification indicates otherwise.

NOTE – Test 5.2.3.1.1 requires double-ended test specimens (see figure 7).

To test connections with terminations suitable for various wire dimensions, it is essential to conduct tests using a specified number of specimens as outlined in table 3 These tests should include specimens made with wires that have both the minimum and maximum conductor dimensions within the designated range.

When multipole components are to be tested, the required number of specimens shall be distributed uniformly.

Before the specimens are prepared, it shall be verified that: a) the correct terminations and wires are used; b) where the connections are made by tools

– the correct tool is used;

– the tool works correctly; c) the operator is able to produce connections which comply with 4.5.

Tableau 3 – Nombre de spécimens requis

Exigé dans tous les cas quand des connexions à percement d’isolant sont essayées

Exigé en plus lorsque des connexions à percement d’isolant pour une gamme de dimensions de fils sont essayées

Lorsque le programme d’essai de qualification est nécessaire (voir 5.1.1), le nombre requis de spécimens du tableau 3 doit être préparé, puis soumis à l’examen initial suivant 5.3.2.1.

Tous les spécimens requis doivent être soumis à l’essai 1a: Examen visuel, de la CEI 60512-2

5.3.2.2 Essai des connexions à percement d’isolant

In cases where the contact encompasses a range of wire dimensions, the specimens must include maximum wire dimensions as well as an equivalent number of minimum dimensions within that range.

Ces spécimens doivent être divisés en quatre groupes d’essai.

20 spécimens ou 2 × 20 spécimens, selon le cas.

Phase d’essai Titre Paragraphe Titre

AP1 Tenue à la traction 5.2.2.1 Tenue mécanique 16t 5.2.2.1

Phase d’essai Titre Paragraphe Titre

BP1 Résistance de contact 2a ou 2b 5.2.3.1

BP2 Pliage du fil/câble 5.2.2.2 Perturbation de contact 2e 5.2.2.2

BP3 Charge électrique et température

BP4 Résistance de contact comme BP1 5.2.3.1

Table 3 – Number of specimens required

Required in all cases, when insulation piercing terminations are to be tested

Additionally required when insulation piercing terminations suitable for a range of wire dimensions are to be tested

Where the qualification test schedule is necessary (see 5.1.1), the required number of specimens specified in table 3 shall be prepared and subjected to the initial examination according to 5.3.2.1.

All specimens required shall be subjected to test 1a: Visual examination, of IEC 60512-2

5.3.2.2 Testing of insulation piercing connections

When termination encompasses various wire sizes, it is essential to select specimens for both the maximum and minimum wire sizes within that range, ensuring an equal number of each.

These specimens shall be divided into four test groups.

20 specimens, or 2 × 20 specimens, as applicable.

Test Measurement to be performed Requirement

Test phase Title Subclause Title

AP1 Tensile strength 5.2.2.1 Mechanical strength 16t 5.2.2.1

Test phase Title Subclause Title

BP2 Bending of the wire/cable 5.2.2.2 Contact disturbance 2e 5.2.2.2

BP3 Electrical load and temperature

BP4 Contact resistance as BP1 5.2.3.1

CP1 Résistance de contact 2a ou 2b 5.2.3.1

CP2 Vibrations 5.2.2.3 Perturbation de contact 6d et 2e 5.2.2.3

CP3 Variations rapides de température

CP5 Résistance de contact comme CP1 5.2.3.1

DP1 Résistance de contact 2a ou 2b 5.2.3.1

DP2 Essai de corrosion dans un flux de mélange de gaz

DP3 Résistance de contact comme DP1 5.2.3.1

Lorsque le programme d’essai d’application est nécessaire (voir 5.1.1), le nombre requis de spécimens du tableau 3 doit être préparé, puis soumis à l’examen initial suivant 5.3.3.1.

Tous les spécimens doivent être soumis à l’essai 1a: Examen visuel, de la CEI 60512-2 (future

5.3.3.2 Essai des connexions à percement d’isolant

In cases where the contact encompasses a range of wire dimensions, specimens must include both maximum wire dimensions and an equivalent number of minimum dimensions within that range.

Après l’examen initial de 5.3.3.1, les spécimens doivent être divisés en deux groupes d’essai.

CP2 Vibration 5.2.2.3 Contact disturbance 6d and 2e 5.2.2.3

CP3 Rapid change of temperature

CP5 Contact resistance as CP1 5.2.3.1

DP2 Flowing mixed gas corrosion test

DP3 Contact resistance as DP1 5.2.3.1

Where the application test schedule is applicable (see 5.1.1), the number of specimens specified in table 3 shall be prepared and subjected to the initial examination according to 5.3.3.1.

All specimens shall be subjected to test 1a: Visual examination, of IEC 60512-2 (future

5.3.3.2 Testing of insulation piercing connections

When termination encompasses various wire sizes, it is essential to choose specimens for both the maximum and minimum wire sizes within that range, ensuring an equal number of each is selected.

After initial examination, 5.3.3.1, all specimens shall be divided into two test groups.

20 spécimens ou 2 × 20 spécimens, selon le cas, doivent être soumis aux essais suivants.

P1.2 Pliage du fil /câble 5.2.2.2 Perturbation de contact 2e 5.2.2.2

Après l’examen initial de 5.3.3.1, les 20 spécimens restants ou 2 × 20 spécimens, selon le cas, doivent être soumis à l’essai suivant.

P2 Tenue à la traction 5.2.2.1 Tenue mécanique 16t 5.2.2.1

20 specimens, or 2 × 20 specimens, as applicable, shall be subjected to the following tests.

P1.2 Bending of the wire/cable 5.2.2.2 Contact disturbance 2e 5.2.2.2

After initial examination, 5.3.3.1, the remaining 20 specimens, or 2 × 20 specimens, as applicable, shall be subjected to the following test.

Pour une orientation rapide, les programmes d’essai détaillés en 5.3.2 et 5.3.3 sont répétés sous forme de tableaux synoptiques de manière simplifiée sur les figures 9 et 10.

– Essai de corrosion dans un flux de mélange de gaz Essai 11g

– Vibrations et perturbations de contact Essai 6d et 6e

– Variations rapides de température Essai 11d

– Pliage du fil/câble et perturbation de contact 5.2.2.2 Essai 2e

– Charge électrique et température Essai 9b

Examen initial des connexions à percement d’isolant de 5.3.2.1

80 spécimens de connexions à percement d’isolant

2 × 80 spécimens de connexions à percement d’isolant adaptés à une gamme de conducteur, selon le cas

Examen général des contacts à percement d’isolant de 5.2.1 et des fils

80 ensembles de pièces de contact à percement d’isolant

2 × 80 ensembles de pièces de contact à percement d’isolant adaptés à une gamme de conducteur, selon le cas

– Examen de dimensions et de masse Essai 1b

Essais des connexions à percement d’isolant

Figure 9 – Programme d’essai de qualification (voir 5.3.2)

For quick orientation, the test schedules detailed in 5.3.2 and 5.3.3 are repeated as flow charts in a simplified manner in figures 9 and 10.

– Vibrations and contact disturbance Test 6d and 6e

– Rapid change of temperature Test 11d

– Bending of the wire/cable and contact disturbance 5.2.2.2 and Test 2e

Initial examination of insulation piercing connections, of 5.3.2.1

80 specimens for insulation piercing connections

2 × 80 specimens for insulation piercing connections, suitable for a conductor range, as applicable

General examination of insulation piercing terminations of 5.2.1 and wires

80 sets of parts of insulation piercing terminations

2 × 80 sets of parts for insulation piercing terminations, suitable for a conductor range, as applicable

– Examination of dimensions and mass Test 1b

Testing of insulation piercing connections

Figure 9 – Qualification test schedule (see 5.3.2)

– Pliage du fil/câble et perturbation de contact

5.2.2.2 et Essai 2e – Variations rapides de température

Essai 11d – Chaleur humide, cyclique Essai 11m

Examen initial des connexions à percement d’isolant de 5.3.3.1

40 spécimens de connexions à percement d’isolant

2 × 40 spécimens de connexions à percement d’isolant adaptés à une gamme de conducteur, selon le cas

Examen général des contacts à percement d’isolant de 5.2.1 et des fils

40 ensembles de pièces de contact à percement d’isolant

2 × 40 ensembles de pièces de contact à percement d’isolant adaptés à une gamme de conducteur, selon le cas

– Examen de dimensions et de masse Essai 1b

Figure 10 – Programme d’essai d’application (voir 5.3.3)

– Mechanical strength Test 16t – Contact resistance Test 2a/2b

– Bending of the wire/cable and contact disturbance 5.2.2.2 and Test 2e

– Rapid change of temperature Test 11d

Initial examination of insulation piercing connections of 5.3.3.1

40 specimens for insulation piercing connections

2 × 40 specimens for insulation piercing connections, suitable for a conductor range, as applicable

General examination of insulation piercing terminations of 5.2.1 and wires

40 sets of parts of insulation piercing terminations

2 × 40 sets of parts for insulation piercing terminations, suitable for a conductor range, as applicable

– Examination of dimensions and mass Test 1b

Figure 10 – Application test schedule (see 5.3.3)

Courant limite

In general, the total contact area between the conductor and the insulation piercing contact should be less than the cross-section of the wire used As a result, the current limit of an insulation piercing connection may be lower than that of the wire itself Additionally, the quality and characteristics of the wire's insulation impact the stability of insulation piercing connections.

Informations sur les outils

To ensure effective insulation piercing connections, tools must function properly without damaging components A high-quality connection requires a tool with a mechanism that controls the entire cycle The insulation piercing operation should be performed in a single action to avoid successive operations Removable parts, such as dies and positioners, should be designed to fit the tool correctly Additionally, tools should include a device to ensure proper positioning of components during the operation They should be designed to allow only necessary adjustments The tool's action should enable all insulation piercing connections of a component to be completed in one operation Furthermore, the design should ensure that dies are interchangeable with those of similar tools, and if not, they should be marked for identification Lastly, the tool should allow for die verification using gauges to assess wear, following the manufacturer's specified control method.

The total contact area between the conductor and the insulation piercing termination, as per this standard, is typically smaller than the wire's cross-section Consequently, the current-carrying capacity of an insulation piercing connection may be lower than that of the wire Additionally, the quality and characteristics of the wire insulation significantly influence the stability of the insulation piercing connection.

Tools must ensure a proper insulation piercing connection without damaging components, utilizing a full cycle mechanism for effective operation The insulation piercing process should be executed in a single step to avoid rework Removable parts, such as dies and location devices, must be designed for correct fitting only Additionally, tools should facilitate proper alignment of components during operation and allow only necessary adjustments The design should ensure that all insulation piercing terminations are pressed simultaneously in one action Furthermore, dies should be interchangeable among similar tools, and if not, they must be clearly marked for identification Lastly, the design should incorporate a gauging method for assessing die wear, as specified by the manufacturer.

Informations sur les contacts

Les contacts à percement suivants sont des exemples types:

– contact à percement d’isolant faisant partie d’un composant multicontact (voir note), voir figure 11 (voir les figures 1 ou 16 pour le contact câblé).

Figure 11 – Exemple de contact à percement d’isolant faisant partie d’un composant

NOTE – Un exemple d’application est la fiche définie dans la CEI 60603-7.

– contact à percement d’isolant pour une ou plusieurs connexions, voir figure 12 (voir la figure 2 pour le contact câblé).

Figure 12 – Exemple de contact à percement d’isolant pour câble plat

– contact à percement d’isolant (fût), voir figure 13 (voir les figures 3 ou 17 pour le contact câblé).

Figure 13 – Exemple de contact à percement d’isolant pour fil à conducteur divisé

The following insulation piercing terminations are typical:

– insulation piercing terminations as parts of a multipole component (see note), see figure 11

(wired termination see on figure 1 or 16).

Figure 11 – Example of an insulation piercing termination as an integral part of a component

NOTE – An example for the application is the free connector according to IEC 60603-7.

– contacts with single and multiple insulation piercing terminations, see figure 12 (wired termination see on figure 2).

Figure 12 – Example of an insulation piercing termination for flat conductor

– contacts with insulation piercing termination (barrel), see figure 13 (wired termination see on figure 3 or 17).

Figure 13 – Example of an insulation piercing termination for stranded wires

Il convient de n’utiliser, pour les contacts à percement d’isolant, que les matières spécifiées en 4.3.1.

Il convient d’utiliser des contacts à percement d’isolant, revêtus ou non des matières spécifiées en 4.3.3.

Industrial experience has demonstrated that carefully selected combinations of insulation piercing contacts, wire dimensions, outer insulation diameter, and appropriate tools lead to acceptable insulation piercing connections.

Informations sur les conducteurs

Il convient normalement d’utiliser des fils à conducteur multibrin y compris les fils à brins d’or faux, des câbles plats et des circuits souples pour les connexions à percement d’isolant (voir 4.4).

Il convient de ne pas utiliser d’autres types de conducteurs tels que des multibrins rendus solidaires par refusion de l’étamage des brins.

Selon 4.4.1, les conducteurs en cuivre recuit sont les plus communément utilisés pour les connexions à percement d’isolant.

Il convient d’utiliser des conducteurs de sections ou de diamètres suivant 4.4.2.

Il convient d’utiliser des conducteurs multibrins ou plats, revêtus ou non des matières spécifiées en 4.4.3.

Il convient que le traitement de surface soit lisse et uniforme.

The component specification should clearly define the maximum and minimum diameters of the wire insulation, or ensure that these measurements align with the recommendations provided by the manufacturer of the insulation-piercing contact.

The insulation should be made of PVC or other materials compatible with the insulation piercing technique It is essential that the thickness of the insulation is uniform and that the conductor is properly centered.

Only materials specified in 4.3.1 should be used for insulation piercing connections.

Insulation piercing terminations unplated or plated with materials specified in 4.3.3 should be used.

Industrial experience has shown that correct combination of insulation piercing termination, wire dimension, insulation outside diameter and correct tooling result in an acceptable insulation piercing connection.

For insulation piercing connections, it is recommended to use wires with stranded conductors, including tinsel-wires, flat conductors, and flat flexible circuitries In contrast, other types of conductors, such as fused conductors, should be avoided for these connections.

According to 4.4.1, conductors made of annealed copper are commonly used for insulation piercing connections.

Conductor diameters or cross-sections specified in 4.4.2 should be used.

Flat conductors and stranded conductors unplated or plated with finishes as given in 4.4.3 should normally be used.

The surface finish should be smooth and uniform.

The wire insulation's minimum and maximum diameter must be defined by the detail specification or align with the guidelines provided by the insulation piercing termination manufacturer.

For optimal performance, the insulation material must be PVC or a compatible alternative suitable for the insulation piercing technique It is essential that the insulation wall thickness remains consistent, and the conductor is properly centered.

6.4.6 Information sur le dénudage des câbles (cordon) et des fils

For multi-contact connectors with insulation-piercing contacts, round, oval, or flat sheathed cables are commonly used The outer sheath of the cable must be removed according to the manufacturer's component instruction sheets.

On doit prendre soin de ne pas couper l’isolant du conducteur pendant l’opération de dénudage de la gaine L’isolant du conducteur ne doit pas être dénudé (voir figure 15).

Figure 14 – Exemple de câble gainé rond, ovale et plat

Figure 15 – Exemple de circuit souple ou conducteur en feuille

Conducteurs isolés, gaine extérieure retirée

Conducteur en feuille ou circuits souples isolés d’un ou des deux côtés

6.4.6 Stripping information for cables (cords) and wires

Multipole connectors with insulation piercing terminations typically utilize round, flat, or flat oval sheath cables It is essential to strip the outer cable jacket insulation according to the manufacturer's instructions, ensuring that the conductor insulation remains intact during this process Importantly, the insulation of the conductor itself should not be stripped.

Figure 14 – Examples of round, flat and flat oval sheath cable

Figure 15 – Example of a flexible circuitry

Insulated conductors, outer jacket removed

Flat cable Flat oval cable

Flexible circuitries insulated on one or both sides

Workmanship

The connections shall be processed in a careful and workmanlike manner, in accordance with good current practice.

Tools