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eLibrary > BS EN IEC 60352-2:2024 - TC Tracked Changes. Solderless connections - Crimped connections. General requirements, test methods and practical guidance >

BS EN IEC 60352-2:2024 - TC Tracked Changes. Solderless connections - Crimped connections. General requirements, test methods and practical guidance, 2024

30437443.pdf [Go to Page]
National foreword [Go to Page]
Annex ZA (normative)Normative references to international publicationswith their corresponding European publications
Blank Page
English [Go to Page]
CONTENTS
FOREWORD
INTRODUCTION
1 Scope
2 Normative references
3 Terms and definitions
Figures [Go to Page]
Figure 1 – Examples of crimp contact
Figure 2 – Examples of splice
Figure 3 – Example of insulation support
Figure 4 – Examples of insulation grip
Figure 5 – Examples of crimping tool
Figure 6 – Example of positioner holding the crimp barrel
Figure 7 – Example of positioner holding the stripped wire
Figure 8 – Open crimp barrel
Figure 9 – Closed crimp barrels
Figure 10 – Pre-insulated crimp barrel
Figure 11 – Crimping zones
Figure 12 – Example of crimp funnel
4 Workmanship
5 Prerequisites for basic test schedule [Go to Page]
5.1 Classification by end-product class [Go to Page]
5.1.1 General
5.1.2 Class A – General electrical and electronics products
5.1.3 Class B – Dedicated service electrical and electronics products
5.1.4 Class C – High-performance electrical and electronics products
5.2 Prerequisites for tools
5.3 Prerequisites for crimp barrels [Go to Page]
5.3.1 Crimp barrel materials
5.3.2 Crimp barrel dimensions
5.3.3 Crimp barrel surface finishes
5.3.4 Crimp barrel design features
5.4 Prerequisites for wires [Go to Page]
5.4.1 General
5.4.2 Conductor materials
5.4.3 Conductor dimensions
5.4.4 Conductor surface finishes
5.4.5 Wire insulation
5.4.6 Wire cutting and stripping
Figure 13 – Concentricity of wire insulation
Tables [Go to Page]
Table 1 – Allowable strand damage
5.5 Prerequisites for crimped connections [Go to Page]
5.5.1 Compatibility of combination
5.5.2 Conductor location
5.5.3 Crimping location
5.5.4 Contact deformation
5.5.5 Prerequisites for crimped connections with more than one conductor in the crimp barrel
5.5.6 Adjustment of conductor cross-sectional area to the crimp barrel
5.5.7 Crimp contacts and terminal ends
Figure 14 – Diameter ratio when crimping wires with different individual strand diameters
Figure 15 – Examples of open stamped crimp contacts for automatic production
Figure 16 – Stamped open B-crimp contact with anvil and punch shapes
Figure 17 – Designations on open B-crimp contact
Figure 18 – Examples of crimping dies (press dies)
Figure 19 – Stamped closed crimp barrel (crimp cable lug)
Figure 20 – Different crimp shapes
Figure 21 – Examples of crimping dies for closed crimp barrels
Figure 22 – Tubular cable lugs for class 5 conductors
Figure 23 – Tubular cable lugs for class 6 conductors
Figure 24 – Crimping process of 4-indent crimping with adjustable tools [Go to Page]
5.5.8 Splice crimp barrels
Figure 25 – Pre-insulated stamped close crimp barrel, area definitions
Figure 26 – Pre-insulated closed crimp barrels of various designs
Figure 27 – Examples of pre-insulated crimp cable lugs as strip parts
5.6 Prerequisites for splice crimped connections [Go to Page]
5.6.1 General
5.6.2 Conductor requirements for crimped splices
Figure 28 – Uninsulated splice variants
6 Testing [Go to Page]
6.1 General
Figure 29 – Diameter ratio when crimping wires with different individual strand diameters in splices
Table 2 – Prerequisites of 5.3 for crimp barrels to access the basic test schedule of 8.2
6.2 Standard conditions for testing
6.3 Pre-conditioning
6.4 Recovery
6.5 Mounting of the specimen
Table 3 – Prerequisites of 5.4 for wires to access the basic test schedule of 8.2
7 Test methods and test requirements [Go to Page]
7.1 General examination of crimp barrels and wires
7.2 Examination of crimp dimensions [Go to Page]
7.2.1 Crimp height Ch, crimp width Cw and measurable crimp width Cwm
Table 4 – Magnification aids for visual examination
Figure 30 – Crimp height measurement on open crimp barrel (B-crimp)
Figure 31 – Crimp height measurement on closed crimp barrel (mandrel crimping) [Go to Page]
7.2.2 Contact deformation after crimping
Figure 32 – Crimp height measurement on closed crimp barrel (4-indent crimping)
Table 5 – Example of permissible tolerances for crimp height measurements [Go to Page]
7.2.3 Visual examination of insulation distance and conductor overhang
Figure 33 – Example of holding and measuring points for contact deformation
Figure 34 – Insulation distance and conductor overhang [Go to Page]
7.2.4 Visual examination of splice crimped connections
7.2.5 Visual examination of crimped connections on closed (machined) crimp barrels
7.2.6 Visual examination of crimped connections on B-crimp open crimp barrels
7.2.7 Visual examination of crimped connections with open crimp barrel with insulation grip
Table 6 – Insulation distance and conductor overhang on closed crimp barrels
Figure 35 – Examples of insulation grip die shapes
Figure 36 – Examples of insulation grip
7.3 Mechanical tests [Go to Page]
7.3.1 Tensile strength
Table 7 – Pull-out force of crimped connections [Go to Page]
7.3.2 Microsection
7.3.3 Insulation grip effectiveness
7.3.4 Bending test (uninsulated crimp barrels with insulation grip)
Figure 37 – Test arrangement
Figure 38 – Bending test of crimped connections with uninsulated crimp barrels [Go to Page]
7.3.5 Bending test (pre-insulated crimp barrels with insulation grip)
Figure 39 – Bending test of crimped connections with pre-insulated crimp barrels [Go to Page]
7.3.6 Bending test on splice crimped connections
7.3.7 Vibration test
Figure 40 – Bending test on splice crimped connections
7.4 Electrical tests [Go to Page]
7.4.1 Crimp resistance
Figure 41 – Arrangement for vibration test
Table 8 – Vibration, preferred test severities
Figure 42 – Test arrangement for measurement of crimp resistance of single-conductor crimped connection
Figure 43 – Measuring of crimp resistance of splices or multiple-conductor crimp connections
Figure 44 – Crimp resistance RC of crimped connections with copper barrels and copper conductor (K = 1)
Table 9 – Example of other materials [Go to Page]
7.4.2 Voltage proof (crimped connection with pre-insulated crimp barrels)
7.4.3 Current-carrying capacity test with temperature rise
Figure 45 – Test setup for temperature rise measurements under current load
Table 10 – Minimum wire length L as a function of conductor cross-sectional area S
7.5 Climatic tests [Go to Page]
7.5.1 General
7.5.2 Rapid change of temperature
Figure 46 – Temperature chamber with ventilation opening for current-temperature derating measurements [Go to Page]
7.5.3 Dry heat
7.5.4 Climatic sequence
7.5.5 Current loading, cyclic
Figure 47 – Examples of test arrangements
Figure 48 – Test current for crimped connections [Go to Page]
7.5.6 Crimping at low temperature (crimped connections with pre-insulated crimp barrels)
Table 11 – Current values (tentative) – alternative current loading, cyclic method
7.6 Miscellaneous tests [Go to Page]
7.6.1 Fluid resistance of pre-insulated crimp barrels
7.6.2 Flowing mixed gas corrosion test
8 Test schedules [Go to Page]
8.1 Preparation and type of test specimens [Go to Page]
8.1.1 Preparation of test specimens
8.1.2 Type A specimen (for testing according to 8.2, 8.2.3.3 if required, 8.3.2, 8.3.4 if required)
8.1.3 Type B specimen (for tests according to 8.2.3.1 and 8.3.3.2)
Figure 49 – Examples of type A specimens [Go to Page]
8.1.4 Type C specimen (for insulation grip effectiveness tests, see 8.2.3.3 and 8.3.4)
Figure 50 – Examples of type B specimens [Go to Page]
8.1.5 Type D specimen (for testing of pre-insulated crimp barrels only, see 8.2.3.4, 8.3.9.2 and 8.3.9.3)
8.1.6 Type E specimen (for tests according to 8.2.3.2, 8.2.3.4, 8.3.3.5)
Figure 51 – Examples of type C specimens
Figure 52 – Example of type D specimen (pre-insulated) [Go to Page]
8.1.7 Type F specimen (for testing of pre-insulated crimp barrels according to 8.3.9.4)
Figure 53 – Examples of type E specimen [Go to Page]
8.1.8 Type G specimen (for testing according to 8.2.3.2, 8.3.3.4, 8.3.3.5 and 8.3.6)
8.1.9 Type H specimen (for testing according to 8.2.2, 8.2.3.1, 8.2.3.3, 8.3.2, 8.3.3.2, 8.3.3.3 and 8.3.4)
Figure 54 – Example of type F specimen
Figure 55 – Type G specimen (splice) [Go to Page]
8.1.10 Number of specimens required
Figure 56 – Type H specimen (splice)
Table 12 – Number of specimens
8.2 Basic test schedule [Go to Page]
8.2.1 General
8.2.2 Initial examination
8.2.3 Testing of crimped connections
Table 13 – Test group B0
Table 14 – Test group B1
Table 15 – Test group B2
Table 16 – Test group B3
8.3 Full test schedule [Go to Page]
8.3.1 General
Table 17 – Test group B4
Table 18 – Test group B5 [Go to Page]
8.3.2 Initial examination
8.3.3 Testing of crimped connections
Table 19 – Test group F0
Table 20 – Test group F1
Table 21 – Test group F2
Table 22 – Test group F3 [Go to Page]
8.3.4 Testing of insulation grip effectiveness, test group F5
Table 23 – Test group F4
Table 24 – Test group F5 [Go to Page]
8.3.5 Testing of stability of splice crimped connections under bending
8.3.6 Test group F7, if required
8.3.7 Test group F8, if required
8.3.8 Test group F9, if required
Table 25 – Test group F6
Table 26 – Test group F7
Table 27 – Test group F8 [Go to Page]
8.3.9 Testing of crimped connections with pre-insulated crimp barrels
Table 28 – Test group F9
Table 29 – Test group F10
8.4 Flow charts
Table 30 – Test group F11
Table 31 – Test group F12
Figure 57 – Basic test schedule (see 8.2)
Figure 58 – Full test schedule (see 8.3)
Annex A (informative) Practical guidance [Go to Page]
A.1 General information on crimped connections [Go to Page]
A.1.1 General
A.1.2 Advantages of crimped connections
A.1.3 Current-carrying capacity considerations
A.2 Tool information
A.3 Crimp barrel information [Go to Page]
A.3.1 General
Figure A.1 – Open crimp barrels [Go to Page]
A.3.2 Materials
A.3.3 Surface finishes
A.3.4 Shapes of crimped connections
Figure A.2 – Closed crimp barrels
Figure A.3 – Crimping shape in the wire axis
Figure A.4 – Crimping shape 90° angled to the wire axis
Figure A.5 – Crimping shape without insulation grip
A.4 Wire information [Go to Page]
A.4.1 General
Figure A.6 – Crimping shape with pre-insulated crimp barrel
Figure A.7 – Crimping shape without pre-insulated crimp barrel [Go to Page]
A.4.2 Conductor materials
A.4.3 Conductor surface finishes
A.4.4 Wire stripping information
Figure A.8 – Crimped connections using solid round conductors
Figure A.9 – Stripping length
Table A.1 – Stripping of stranded conductors (good to sufficient requirements)
A.5 Crimped connection information [Go to Page]
A.5.1 General
Table A.2 – Stripping of stranded conductors (faults or conditions according to Table 1) [Go to Page]
A.5.2 Additional information
Table A.3 – Condition of closed machined crimp barrels
Table A.4 – Condition of open crimp barrels (B-crimp) [Go to Page]
A.5.3 Crimped connections made with more than one wire in a crimp barrel
Table A.5 – Minimum dimensions and tolerances for input funnel on a B-crimping zone
Table A.6 – Condition of position of wire insulation in the insulation grip [Go to Page]
A.5.4 Dimensions after crimping
A.5.5 Conductor and crimp barrel materials and finishes selection
A.6 Crimping process [Go to Page]
A.6.1 Crimping of contacts with open crimp barrel
A.6.2 Crimping of contacts with open crimp barrel, loose piece contacts
A.6.3 Processing instruction
Figure A.10 – Example of parallel (in-line) process crimping and angled crimping process
A.7 Correct crimped connections (additional information) [Go to Page]
A.7.1 Correct crimped connections of contacts with open crimp barrel
Figure A.11 – Crimping process of an open crimp barrel (B-crimp)
Figure A.12 – Correct crimped connections of contacts with open crimp barrel [Go to Page]
A.7.2 Measuring of crimp height or depth
Figure A.13 – Measuring instructions [Go to Page]
A.7.3 Pull-out force
Figure A.14 – Crimp height measuring procedure
Figure A.15 – Pull-out force test for crimped connections with pull speed 50 mm/min
Table A.7 – Pull-out force recommended minimum values for electrolytic copper conductors with tensile strength 200 N/mm2 (e.g. according to EN 13602)
Figure A.16 – Determination of the intrinsic tensile strength of the conductor (50 mm/min)
Table A.8 – Examples of pull-out force values (break) of commercially available European stranded conductors
Table A.9 – Examples of pull-out force values (break) of commercially available American stranded conductors
Table A.10 – Determination of the minimum pull-out forces in relation to the respective cross-sectional area and the intrinsic tensile strength of the conductor
Figure A.17 – Relationships between crimp height (Ch), pull-out force, crimp force (indentation depth), and electrical conductivity
A.8 Examination by microsection [Go to Page]
A.8.1 Microsection image creation
Figure A.18 – Pull-out force test of splice crimp connections (50 mm/min)
Table A.11 – Pull-out force values for butt splice crimped connections [Go to Page]
A.8.2 Graphical representation of the microsection image requirements
Figure A.19 – Illustration of the parting plane on the crimp barrel centred in the crimping zone (X)
Figure A.20 – Example of end-feed (length feed) open barrel crimp contacts
Figure A.21 – Cutting the crimped connection [Go to Page]
A.8.3 Microsection terminology
Figure A.22 – Dimensions on the microsection for B-crimp barrels
Figure A.23 – Dimensions on the microsection for closed tube and crimped cable lugs
Figure A.24 – Dimensions on the microsection for 4-indent closed crimp barrels
Figure A.25 – Dimensions on the microsection for hexagonal crimp barrels [Go to Page]
A.8.4 Porosity ratio of crimped connections in microsections
Figure A.26 – Dimensions on the microsection for crimp barrels (also pre-insulated)
Figure A.27 – Examples of microsections of crimp barrels [Go to Page]
A.8.5 Crimp compression ratio of the crimped connection in the microsection
A.8.6 Ratio of crimp height to crimp width in the microsection
Figure A.28 – Ratio of crimp height Ch to crimp width Cw [Go to Page]
A.8.7 Requirements for B-crimped connections in the microsection
Figure A.29 – Ratio of distance between crimp face ends CFE and base material thickness S
Figure A.30 – Support angle αw of the crimp flanks
Figure A.31 – Support height La of the crimp flanks
Figure A.32 – Crimp edge distance to floor (Fa)
Table A.12 – Values for the support height La [Go to Page]
A.8.8 Condition of microsections
Figure A.33 – Resulting bottom thickness Sb after crimping
Figure A.34 – Requirements for the acceptance of a burr formation
Table A.13 – Condition of microsections [Go to Page]
A.8.9 Insulation grip
Table A.14 – Condition "Good" of insulation grip for B-crimp and O-crimp (asymmetrical and symmetrical overlap and enclosure crimp)
Table A.15 – Condition "PID" of insulation grip for B-crimp and O-crimp (asymmetrical and symmetrical overlap and enclosure crimp)
Table A.16 – Condition "Fault" of insulation grip for B-crimp, O-crimp (asymmetrical and symmetrical overlap and enclosure crimp)
A.9 Faults with crimped contacts having open crimp barrels
A.10 Splices
A.11 Crimp resistance test [Go to Page]
A.11.1 General
Table A.17 – Features of splice crimp barrels
Figure A.35 – Diagrams for resistance values (A and B) for electrolytic copper conductors (K = 1) and for material with K = 3,8
Figure A.36 – Replacement circuit diagram for the crimp resistance
Table A.18 – Crimp resistance (maximum allowed initial values A) for K = 1 (electrolytic copper)
Table A.19 – Crimp resistance (after loading, RCR) for K = 1 (electrolytic copper)
Table A.20 – Crimp resistance (maximum allowed initial values A) for K ≈ 3,8 (nickel-brass, bright)
Table A.21 – Crimp resistance (after loading, RCR) for K ≈ 3,8 (nickel-brass, bright)
Table A.22 – Crimp resistance (maximum allowed initial values A) for K = 6,4 (tin-plated bronze)
A.12 General information about crimp contacts as part of a multipole connector [Go to Page]
A.12.1 Insertion of crimped contacts into the contact cavities of the connector insert
Table A.23 – Crimp resistance (after loading, RCR) for K = 6,4 (tin-plated bronze) [Go to Page]
A.12.2 Removal of inserted contacts
A.12.3 Mounting and bending of wire bundles or cables with crimped contacts
Figure A.37 – Insertion of crimped contacts into contact cavities
Figure A.38 – Mounting of wire bundles/cables with crimped contacts [Go to Page]
A.12.4 Mating and unmating of multipole connectors with crimped contacts
A.13 Final remarks
Figure A.39 – Bending of wire bundles of connectors
Figure A.40 – Mating and unmating of multipole connectors
Bibliography [Go to Page]

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