IEC 60512-99-003:2023

IEC 60512-99-003 ®
Edition 1.0 2023-09
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Connectors for electrical and electronic equipment – Tests and measurements –
Part 99-003: Endurance test schedules – Test 99c: Test schedule for balanced
single-pair connectors separating (unmating) under electrical load

Connecteurs pour équipements électriques et électroniques – Essais et
mesures –
Partie 99-003: Programmes d’essais d’endurance – Essai 99c: Programme
d’essai des connecteurs à une seule paire symétrique lors de la séparation
(désaccouplement) sous charge électrique
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IEC 60512-99-003 ®
Edition 1.0 2023-09
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Connectors for electrical and electronic equipment – Tests and measurements –

Part 99-003: Endurance test schedules – Test 99c: Test schedule for balanced

single-pair connectors separating (unmating) under electrical load

Connecteurs pour équipements électriques et électroniques – Essais et

mesures –
Partie 99-003: Programmes d’essais d’endurance – Essai 99c: Programme

d’essai des connecteurs à une seule paire symétrique lors de la séparation

(désaccouplement) sous charge électrique

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 13.220.40  ISBN 978-2-8322-7561-0

– 2 – IEC 60512-99-003:2023 © IEC 2023
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references . 5
3 Terms, definitions and acronyms . 6
3.1 Terms and definitions . 6
3.2 Acronyms . 6
4 General . 6
5 Preparation of specimens . 6
6 Test circuit requirements . 6
6.1 General . 6
6.2 Voltage and current . 7
6.3 Auxiliary equipment . 8
7 Test methods . 8
7.1 Mechanical operations with electrical load . 8
7.2 Flowing mixed gas corrosion . 8
8 Test and test schedule – Test group UEL 1 . 8
Annex A (informative) Test voltage and current setting instructions. 11
A.1 General . 11
A.2 Rationale . 11
A.3 Suggested setting instructions . 11
Annex B (informative) Discussion of the test circuit elements . 12
B.1 General . 12
B.2 The test circuit elements . 12
B.2.1 Power supply . 12
B.2.2 Inductors . 12
B.2.3 PD load . 12
B.3 An example of calculating voltage and load . 12
Annex C (informative) Development of the test circuit . 13
C.1 Model of the PSE and the PD . 13
C.2 Removal of the semiconductors . 13
C.3 Combination of the elements . 14
C.4 Further adjustments . 14
C.5 Final schematic for unmating under load . 15
Bibliography . 16

Figure 1 – Test circuit diagram for one pole . 7
Figure C.1 – PSE and PD model . 13
Figure C.2 – Removal of the semiconductors . 13
Figure C.3 – Combination of the elements . 14
Figure C.4 – Removal of the capacitors and concentration of the inductors . 14
Figure C.5 – Final schematic . 15

Table 1 – Remote powering test requirements . 7
Table 2 – Test group UEL 1 . 9

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
CONNECTORS FOR ELECTRICAL AND ELECTRONIC
EQUIPMENT – TESTS AND MEASUREMENTS –

Part 99-003: Endurance test schedules –
Test 99c: Test schedule for balanced single-pair connectors
separating (unmating) under electrical load

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
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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.
IEC 60512-99-003 has been prepared by subcommittee 48B: Electrical connectors, of IEC
technical committee 48: Electrical connectors and mechanical structures for electrical and
electronic equipment. It is an International Standard.
The text of this International Standard is based on the following documents:
Draft Report on voting
48B/3058/FDIS 48B/3065/RVD
Full information on the voting for its approval can be found in the report on voting indicated in
the above table.
The language used for the development of this International Standard is English.

– 4 – IEC 60512-99-003:2023 © IEC 2023
A list of all parts in the IEC 60512 series, published under the general title Connectors for
electrical and electronic equipment – Tests and measurements, can be found on the IEC
website.
This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in
accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available
at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are
described in greater detail at www.iec.ch/standardsdev/publications.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under webstore.iec.ch in the data related to the
specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
IMPORTANT – The "colour inside" logo on the cover page of this document indicates
that it contains colours which are considered to be useful for the correct understanding
of its contents. Users should therefore print this document using a colour printer.

CONNECTORS FOR ELECTRICAL AND ELECTRONIC
EQUIPMENT – TESTS AND MEASUREMENTS –

Part 99-003: Endurance test schedules –
Test 99c: Test schedule for balanced single-pair connectors
separating (unmating) under electrical load

1 Scope
This part of IEC 60512 is used for the assessment of connectors within the scope of SC 48B
that are used in balanced single-pair communication cabling with remote power, in support of
e.g., IEEE 802.3 remote powering applications for point-to-point connections.
The object of this document is to detail a test schedule to determine the ability of sets of single-
pair connectors as defined in the IEC 63171 series to withstand a minimum of 100 mechanical
operations with electrical load, where an electrical current is being passed through the
connector in accordance with IEC 60512-9-3 during the separation (unmating) step.
This document does not cover multidrop powering applications of single-pair connectors.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60050-581, International Electrotechnical Vocabulary (IEV) – Part 581: Electromechanical
components for electronic equipment
IEC 60512-1, Connectors for electrical and electronic equipment – Tests and measurements –
Part 1: Generic specification
IEC 60512-1-1, Connectors for electronic equipment – Tests and measurements – Part 1-1:
General examination – Test 1a: Visual examination
IEC 60512-2-1, Connectors for electronic equipment – Tests and measurements – Part 2-1:
Electrical continuity and contact resistance tests – Test 2a: Contact resistance – Millivolt level
method
IEC 60512-3-1, Connectors for electronic equipment – Tests and measurements – Part 3-1:
Insulation tests – Test 3a: Insulation resistance
IEC 60512-4-1, Connectors for electronic equipment – Tests and measurements – Part 4-1:
Voltage stress tests – Test 4a: Voltage proof
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 60512-11-7, Connectors for electronic equipment – Tests and measurements – Part 11-7:
Climatic tests – Test 11g: Flowing mixed gas corrosion test

– 6 – IEC 60512-99-003:2023 © IEC 2023
IEC 63171 (all parts), Connectors for electrical and electronic equipment – Shielded or
unshielded free and fixed connectors for balanced single-pair data transmission with current-
carrying capacity – General requirements and tests
IEEE Std 802.3cg™-2019, IEEE Standard for Ethernet – Amendment 5: Physical Layer
Specifications and Management Parameters for 10 Mb/s Operation and Associated Power
Delivery over a Balanced single-pair of Conductors
3 Terms, definitions and acronyms
3.1 Terms and definitions
For the purposes of this document, the terms and definitions of IEC 60050-581, IEC 60512-1,
and IEC 63171 apply.
ISO and IEC maintain terminology databases for use in standardisation at the following
addresses:
• IEC Electropedia: available at https://www.electropedia.org/
• ISO Online browsing platform: available at https://www.iso.org/obp
3.2 Acronyms
PSE Power Source Equipment
PD Powered Device
4 General
Although separating (unmating) connectors under the scope of this document, while used for
remote powering, is a misuse of the connector, it may occur in practice.
This test schedule is suitable for verification of separating (unmating) of connectors under
electrical load conditions representative for remote powering applications as specified in
IEEE 802.3cg. An application-specific current and the associated open circuit voltage are
specified, that correspond with the current and voltage of the supported application.
5 Preparation of specimens
The specimen shall consist of a set of mated connectors with its terminations. Specimens shall
conform to the relevant IEC connector standard. Each free and 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 the appropriate IEC standard(s). Fixed connectors may alternatively
be terminated using a printed circuit board which shall not influence the test results.
For each specimen, both circuits (mated contacts) shall be wired in parallel as given in
IEC 60512-9-3, and both circuits shall be assessed at the same time.
6 Test circuit requirements
6.1 General
The values for the circuit components and the details of the test circuit shall be as shown in
Figure 1. The elements and the simplification of the test circuit are discussed in Annex B.
Annex C provides further insight of the development of the test circuit.

Key
W Cables in accordance with Clause 5
Q1 Specimen under test (one mated set of its pair of contacts)
L1 Inductor, L = 1,88 mH
R1 Variable resistive load (e.g., R = 20 Ω to 50 Ω)
C1 Capacitor, C = 100 μF
E1 Voltage source (see 6.2)
S1 Switch (to mate without voltage on Q1)
Figure 1 – Test circuit diagram for one pole
NOTE 1 Only one circuit of the specimen under test, as referenced in IEC 60512-9-3, is shown in Figure 1 for clarity.
Items W, L1, R1 and C1 are replicated for each circuit of the specimen. Items E1 and S1 may be single or multiple.
Both circuits of the specimen are wired in parallel with appropriate duplication of circuit components, and both circuits
of the specimen are operated simultaneously.
NOTE 2 The variable resistor is used to adjust the current to the specified value.
6.2 Voltage and current
The variable resistive load in Figure 1 shall be set so that the electrical current in each circuit
(mated contacts) of the specimen is according to Table 1.
During the separation (unmating) step, the open circuit voltage, shall be as given in Table 1
(test voltage). During the engagement (mating) step, the open circuit voltage shall be 0 V DC
by operating the switch before each connector engagement (mating).
Table 1 – Remote powering test requirements
Test voltage Test current
+1 +0,05
48 V DC 1,6 𝐴𝐴
As the variable resistive load is likely to rise due to heating and due to wear of contacts in the
connector under test, care should be placed in keeping the value of test current within the
specified tolerance range e.g., by means of a suitable feedback control circuit acting on the
value of the variable resistor, see Annex A and Annex B for further guidance.

– 8 – IEC 60512-99-003:2023 © IEC 2023
6.3 Auxiliary equipment
Switches may be used to reverse polarity. However, use of such switches shall not influence
the test parameters.
7 Test methods
7.1 Mechanical operations with electrical load
An electrical load, current and voltage, as detailed in Table 1, shall be applied to the (engaged
(mated)) specimen. For the purpose of this test, one connector shall be fixed and the other
separated at a speed of 150 mm/s ± 10 mm/s.
One engagement and one separation constitute one cycle. The test shall be performed
according to test 9c of IEC 60512-9-3, but the current shall be applied during the separation
step (unmating) only.
25 cycles at one polarity of the DC source shall be performed. The polarity of the DC source
shall then be reversed and 25 further cycles at the other polarity shall be performed (50 cycles
in total).
7.2 Flowing mixed gas corrosion
A flowing mixed gas corrosion test shall be performed according to test 11g of IEC 60512-11-7,
method 1, with a test duration of 4 days. During the test, half of the specimens shall be unmated,
and the other half shall be left mated during the test.
8 Test and test schedule – Test group UEL 1
A minimum of 8 specimens shall be prepared for this group; then assessed according to Table 2.

Table 2 – Test group UEL 1
Test Test Measurement to be performed
Phase
Title IEC 60512 Severity or condition Title IEC 60512 Requirements
Part No of test Part No
(Test No.) (Test No.)
UEL 1.1 General  Visual 1-1 There shall be no
examination examination (1a) defects that would
impair normal
operation
UEL 1.2  Contact 2-1 As specified in
resistance- the relevant
(2a)
Millivolt level connector
method Standard
UEL 1.3  100 V DC Insulation 3-1 500 MΩ minimum
resistance (3a)
Method A
Mated connectors
UEL 1.4  Contact to contact Voltage proof 4-1 There shall be no
1 000 V DC or (4a) breakdown or
1 000 V AC peak flashover
All signal contacts to
shield and test panel,
as applicable:
1 500 V DC or
1 500 V AC peak
Method A
Mated connectors
UEL 1.5 Mechanical 9-3 Per 7.1 .
operations with (9c)
electrical load
UEL 1.6  Contact 2-1 20 mΩ maximum
resistance- (2a) change from
Millivolt level initial
method
Flowing mixed 11-7
UEL 1.7 Per 7.2
gas test. (11g)
UEL 1.8  Contact 2-1 20 mΩ maximum
resistance- (2a) change from
Millivolt level initial
method
UEL 1.9 Mechanical 9-3 Per 7.1
operations with (9c)
electrical load.
UEL 1.10  Contact resistance Contact 2-1 20 mΩ maximum
resistance- (2a) change from
Millivolt level initial
method
UEL 1.11  100 V DC Insulation 3-1 500 MΩ minimum
resistance (3a)
Method A
Mated connectors
– 10 – IEC 60512-99-003:2023 © IEC 2023
Test Test Measurement to be performed
Phase
Title IEC 60512 Severity or condition Title IEC 60512 Requirements
Part No of test Part No
(Test No.) (Test No.)
UEL 1.12  Contact to contact
Voltage proof 4-1 There shall be no
1 000 V DC or (4a) break down or
1 000V AC peak flashover
All signal contacts to
shield and test panel,
as applicable:
1 500 V DC or
1 500 V AC peak
Method A
Mated connectors
UEL 1.13 General 1 Visual 1-1 There shall be no
examination examination (1a) 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.
Annex A
(informative)
Test voltage and current setting instructions
A.1 General
In this Annex a set of informative instructions as to how to set the required voltages and currents
is given.
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 overvoltage 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 DC source voltage and variable resistor should be adjusted such that the current in the
circuit is the required value of 1,6 A when engaged (mated) and the open circuit voltage is the
required value, e.g., 55 V, when separated (unmated). For the test circuit the suggested setting
instructions are as follows.
a) With the DC power supply off and the 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 as in Table 1.
c) Turn on the power supply.
d) Adjust the constant voltage setting to the required voltage. Reduce the resistance of the
variable resistor in the circuit until the required current value is flowing in the circuit.

– 12 – IEC 60512-99-003:2023 © IEC 2023
Annex B
(informative)
Discussion of the test circuit elements
B.1 General
The goal of the test circuit specified in 6.1 is to generate a voltage and a current that match the
maximum according to the remote powering application, e.g., by IEEE 802.3, with worst-case
expected circuit elements. To meet this goal, the system would have in case of Table 1, 55 V
and 1,6 A at the test connector. Discussion of each element of this test circuit is given in
Clause B.2. The below information is based on normal operation modes and not on maximum
currents of 2,0 A.
B.2 The test circuit elements
B.2.1 Power supply
It is expected to be in the range of 51 V to generate 50 V at 1,579 A at the test connector.
Therefore, the test circuit will need an adjustable supply.
B.2.2 Inductors
• Inductance at 100 kHz, 0,1 V , 0 A DC): 470 µH ± 10 %
RMS
• DC resistance: 0,2 Ω typical, 0,23 Ω maximum
• Self-resonant frequency: 1,35 MHz typical
• Saturation current (at 25 °C): 10 % drop at 2,4 A; 20 % drop at 2,7 A; 30 % drop at 2,8 A
• Temperature rise: 20 °C rise at 1,39 A ; 40 °C rise at 2,10 A
RMS RMS
It is recommended to choose an inductor similar to the “MSS1812T 474”. This inductor has a
typical DC resistance of 0,2 Ω.
B.2.3 PD load
This can be implemented with power resistors, but is better achieved by a programmable load.
This load has to dissipate as much as 80 W, but the power dissipated in the PD coupling
inductors, series resistors, and diodes would need to be subtracted. A programable load in
combination with a variable DC supply for the PSE will allow dialling in the proper source voltage
and PD load to achieve the 50 V, 1,579 A target at the PSE.
B.3 An example of calculating voltage and load
The DC resistance of the specified inductors is 0,2 Ω. Two 0,1 Ω resistors and two 0,2 Ω DC
resistance inductors equal 0,6 Ω total. 0,6 Ω × 1,579 A = 0,94 V. Set the power supply to 51 V.
Same 0,6 Ω in the PD also equalling a 1 V drop, plus the diode, 1,7 V yields 48,3 V at the load.
48,3 V / 1,579 A = 30,6 Ω load at 77 W. Set the programmable load to 30,6 Ω or 77 W. Do fine
tuning from there to get 50 V and 1,579 A at the test connector.

Annex C
(informative)
Development of the test circuit
C.1 Model of the PSE and the PD
Figure C.1 is a schematic diagram of the PSE and PD model circuits.

Figure C.1 – PSE and PD model
As a starting point the PSE and PD layout shall be considered. To get to the test circuit diagram
unnecessary parts can be removed.
C.2 Removal of the semiconductors

Figure C.2 – Removal of the semiconductors
First the semiconductors have to be removed as shown in Figure C.2. They are used as safety
parts for the data transmission.

– 14 – IEC 60512-99-003:2023 © IEC 2023
C.3 Combination of the elements

Figure C.3 – Combination of the elements
In Figure C.3, the inductors with their real resistance are combined. As a next step, all the parts
on the left side are shifted to the right side, and further combined as possible.
C.4 Further adjustments
Figure C.4 – Removal of the capacitors and concentration of the inductors
Finally, in Figure C.4 the capa
...