IEC 60352-4:2020

IEC 60352-4 ®
Edition 2.0 2020-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Solderless connections –
Part 4: Non-accessible insulation displacement (ID) connections –
General requirements, test methods and practical guidance

Connexions sans soudure –
Partie 4: Connexions autodénudantes (CAD) non accessibles –
Règles générales, méthodes d'essai et guide pratique

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IEC 60352-4 ®
Edition 2.0 2020-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Solderless connections –
Part 4: Non-accessible insulation displacement (ID) connections –

General requirements, test methods and practical guidance

Connexions sans soudure –
Partie 4: Connexions autodénudantes (CAD) non accessibles –

Règles générales, méthodes d'essai et guide pratique

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.20 ISBN 978-2-8322-8413-1

– 2 – IEC 60352-4:2020 © IEC 2020
CONTENTS
FOREWORD . 5
INTRODUCTION . 7
1 Scope . 9
2 Normative references . 9
3 Terms and definitions . 10
4 Workmanship . 14
5 Prerequisites for basic test schedule . 14
5.1 General . 14
5.2 Prerequisites for ID terminations . 14
5.2.1 Non-accessible ID terminations materials . 14
5.2.2 Non-accessible ID terminations dimensions . 14
5.2.3 Non-accessible ID terminations surface finishes . 14
5.2.4 Non-accessible ID terminations design features . 15
5.3 Prerequisites for wires and conductors. 15
5.3.1 Wire and conductors . 15
5.3.2 Conductor materials. 15
5.3.3 Wire and conductor dimensions . 15
5.3.4 Conductor surface finishes . 15
5.3.5 Wire insulation . 15
5.4 Non-accessible insulation displacement connections (ID connections) . 16
6 Testing . 16
6.1 Overview. 16
6.2 General . 16
6.3 Standard conditions for testing . 16
6.4 Preconditioning . 16
6.5 Recovery . 17
6.6 Specimen . 17
7 Tests . 17
7.1 General examination . 17
7.2 Mechanical tests . 17
7.2.1 General . 17
7.2.2 Bending of the cable/wire . 17
7.2.3 Vibration . 18
7.2.4 Repeated connection and disconnection, reusable non-accessible
ID terminations . 19
7.2.5 Microsection . 20
7.3 Electrical tests . 21
7.3.1 General . 21
7.3.2 Contact resistance . 21
7.3.3 Electrical load and temperature . 22
7.4 Climatic tests . 22
7.4.1 General . 22
7.4.2 Rapid change of temperature . 22
7.4.3 Climatic sequence . 23
7.4.4 Flowing mixed gas, corrosion test . 23
7.4.5 Damp heat, cyclic . 23

8 Test schedules . 23
8.1 General . 23
8.1.1 Overview . 23
8.1.2 ID connections with terminations suitable for a range of wire diameters . 24
8.1.3 Multipole connectors . 24
8.2 Basic test schedule . 24
8.2.1 General . 24
8.2.2 Initial examination . 25
8.2.3 Testing of non-accessible ID connections . 25
8.3 Full test schedule . 26
8.3.1 General . 26
8.3.2 Initial examination . 27
8.3.3 Testing of non-accessible ID connections . 27
8.4 Flow charts . 30
Annex A (informative) Practical guidance . 33
A.1 General information on non-accessible ID connections . 33
A.1.1 General . 33
A.1.2 Advantages of non-accessible ID connections . 33
A.2 Current-carrying capacity considerations . 34
A.3 Tool information . 34
A.3.1 Wire insertion tool . 34
A.3.2 Wire extraction tool . 34
A.3.3 Combination tool . 34
A.4 Termination information . 35
A.4.1 General . 35
A.4.2 Design features . 35
A.4.3 Materials . 35
A.4.4 Surface finishes . 35
A.5 Wire information. 35
A.5.1 Type . 35
A.5.2 Dimensions . 35
A.5.3 Surface finishes . 35
A.5.4 Insulation . 35
A.5.5 Ribbon cable . 36
A.6 Connection information . 36
A.6.1 General . 36
A.6.2 ID connections made with more than one wire in one connection slot . 37
Annex B (informative) Application examples . 38
B.1 ID connections . 38
B.1.1 ID connections which can be examined by destructive inspection only . 38
B.1.2 ID connections which can be examined by non-destructive inspection . 39
B.2 General additional information about ID connections as part of a multi-pole
connector . 40
B.2.1 Mounting and bending of wire bundles/cables with contacts having ID
connections . 40
B.2.2 Mating and unmating of multipole connectors with ID contacts . 41
B.3 Examples for good transversal microsection or negative results (see

Figure B.6) . 41
B.4 Final remarks . 42

– 4 – IEC 60352-4:2020 © IEC 2020
Bibliography . 43

Figure 1 – Example of accessible and non-accessible insulation displacement
connection . 7
Figure 2 – Insulation displacement connection . 11
Figure 3 – Slot . 12
Figure 4 – Beam . 13
Figure 5 – Guiding block . 13
Figure 6 – Test arrangement, bending of the cable/wire . 18
Figure 7 – Test arrangement, vibration . 19
Figure 8 – Non-accessible ID connection made with a stranded conductor . 20
Figure 9 – Non-accessible ID connection made with a solid round conductor . 20
Figure 10 – Test arrangement, contact resistance . 21
Figure 11 – Basic test schedule (see 8.2) . 31
Figure 12 – Full test schedule (see 8.3) . 32
Figure A.1 – Example of a non-accessible ID connection with two conductors with
different cross-sections in one connection slot; wires with stranded conductors . 37
Figure B.1 – Examples of correct ID connections with closed housing design, opened
or visible by microsectioning . 38
Figure B.2 – Parts of connector housings to ensure correct ID connections (examples) . 40
Figure B.3 – Mounting of wire bundles/cables with contacts having ID connections . 40
Figure B.4 – Bending of wire bundles of connectors . 41
Figure B.5 – Mating and unmating of multipole connectors. 41
Figure B.6 – IDC: transversal microsection . 41

Table 1 – Vibration, preferred test severities . 19
Table 2 – Contact resistance of non-accessible ID connections, maximum permitted
values . 22
Table 3 – Number of specimens required . 24
Table 4 – Qualification test schedule – Test group 1 . 25
Table 5 – Qualification test schedule – Test group 2 . 26
Table 6 – Qualification test schedule – Test group 3 . 26
Table 7 – Qualification test schedule – Test group 4 . 26
Table 8 – Qualification test schedule – Test group A . 27
Table 9 – Qualification test schedule – Test group B . 28
Table 10 – Qualification test schedule – Test group C . 28
Table 11 – Qualification test schedule – Test group D . 29
Table 12 – Qualification test schedule – Test group E . 30

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
SOLDERLESS CONNECTIONS –
Part 4: Non-accessible insulation displacement (ID) connections –
General requirements, test methods and practical guidance

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
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agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
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3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
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4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
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between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
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5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
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services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
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.
International Standard IEC 60352-4 has been prepared by subcommittee 48B: Electrical
connectors, of IEC technical committee 48: Electrical connectors and mechanical structures
for electrical and electronic equipment.
This second edition cancels and replaces the first edition, published in 1994, and its
Amendment 1 (2000). This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous
edition:
a) Transferred Clauses 9 to 13 into Annex A (informative).
b) The figures were re-drawn for clarity.

– 6 – IEC 60352-4:2020 © IEC 2020
The text of this International Standard is based on the following documents:
FDIS Report on voting
48B/2804/FDIS 48B/2820/RVD
Full information on the voting for the approval of this International Standard can be found in
the report on voting indicated in the above table.
This document has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 60352 series, published under the general title Solderless
connections, can be found on the IEC website.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under "http://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.
INTRODUCTION
The two following parts of IEC 60352 are available on solderless insulation displacement
connections:
– Part 3: Accessible insulation displacement (ID) connections – General requirements, test
methods and practical guidance;
– Part 4: Non-accessible insulation displacement (ID) connections – General requirements,
test methods and practical guidance.
NOTE In this document the term "insulation displacement" is abbreviated to "ID", for example "ID connection", "ID
termination".
Figure 1 illustrates examples of accessible and non-accessible insulation displacement
connections that clarify the difference among them.
Part 4 includes requirements and relevant tests (normative) as well as a practical guidance in
Annex A (informative) for non-accessible ID connections.
Two test schedules are provided:
– the basic test schedule which applies to insulation displacement connections which
conform to all prerequisites of Clause 5. It is derived from experience with successful
applications of such connections;
– the full test schedule which applies to insulation displacement connections which do not
fully conform to all prerequisites of Clause 5, for example which are manufactured using
materials or finishes not included in Clause 5.
This philosophy permits cost and time effective performance verification using a limited basic
test schedule for established insulation displacement connections and an expanded full test
schedule for connections requiring more extensive performance validation.
The suitability of the non-accessible ID connection implies that the specified requirements and
tests apply to all factors involved in producing a suitable ID connection, namely:
– the ID termination, which may be part of a single-pole or multipole connector;
– the wire (or range of wires) for which the termination is suitable;
– the tools (if any) required to produce that type of solderless connection.
The practical guidance provided in Annex A (informative) serves as a guideline for the
required workmanship. Attention is drawn to the fact that some industries (e.g. automotive,
aerospace, nuclear, military) may have specific workmanship standards and/or quality
requirements, which are outside the scope of this document.

Figure 1 – Example of accessible and non-accessible
insulation displacement connection

– 8 – IEC 60352-4:2020 © IEC 2020
IEC Guide 109 advocates the need to minimise the impact of a product on the natural
environment throughout the product life cycle.
It is understood that some of the materials permitted in this document can have a negative
environmental impact.
As technological advances lead to acceptable alternatives for these materials, they will be
eliminated from the document.
SOLDERLESS CONNECTIONS –
Part 4: Non-accessible insulation displacement (ID) connections –
General requirements, test methods and practical guidance

1 Scope
This part of IEC 60352 is applicable to non-accessible ID connections for which the tests and
measurements according to Clauses 6 through 8 are suitable and which are made with:
– appropriately designed ID terminations;
– wires having solid round conductors of 0,25 mm to 3,6 mm nominal diameter;
2 2
– wires having stranded conductors of 0,05 mm to 10 mm cross-sectional area;
for use in electrical and electronic equipment and components.
Information on materials and data from industrial experience is included in addition to the test
procedures to provide electrically stable connections under prescribed environmental
conditions.
There are different designs and materials for ID terminations in use. For this reason, only
fundamental parameters of the termination are specified, while the performance requirements
of the wire and the complete connection are specified in full detail.
The purpose of this document is:
– to determine the suitability of non-accessible ID connections under specified mechanical,
electrical and atmospheric conditions;
– to provide a means of comparing test results when the tools used to make the
connections, if any, are of different designs or manufacture.
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 – Part 581: Electromechanical
components for electronic equipment
IEC 60068-1, Environmental testing – Part 1: General and guidance
IEC 60228, Conductors of insulated cables
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 1­1:
General examination – Test 1a: Visual examination

– 10 – IEC 60352-4:2020 © IEC 2020
IEC 60512-2-1, Connectors for electronic equipment – Tests and measurements – Part 2­1:
Electrical continuity and contact resistance tests – Test 2a: Contact resistance – Millivolt level
method
IEC 60512-2-2, Connectors for electronic equipment – Tests and measurements – Part 2­2:
Electrical continuity and contact resistance tests – Test 2b: Contact resistance – Specified
test current method
IEC 60512-2-5, Connectors for electronic equipment – Tests and measurements – Part 2­5:
Electrical continuity and contact resistance tests – Test 2e: Contact disturbance
IEC 60512-6-4, Connectors for electronic equipment – Tests and measurements – Part 6­4:
Dynamic stress tests – Test 6d: Vibration (sinusoidal)
IEC 60512-9-2, Connectors for electronic equipment – Tests and measurements – Part 9­2:
Endurance tests – Test 9b: Electrical load and temperature
IEC 60512-11-1, Connectors for electrical and electronic equipment – Tests and
measurements – Part 11­1: Climatic tests – Test 11a – Climatic sequence
IEC 60512-11-4, Connectors for electronic equipment – Tests and measurements – Part 11­4:
Climatic tests – Test 11d: Rapid change of temperature
IEC 60512-11-7, Connectors for electronic equipment – Tests and measurements – Part 11­7:
Climatic tests – Test 11g: Flowing mixed gas corrosion test
IEC 60512-11-9, Connectors for electronic equipment – Tests and measurements – Part 11­9:
Climatic tests – Test 11i: Dry heat
IEC 60512-11-10, Connectors for electronic equipment – Tests and measurements –
Part 11­10: Climatic tests – Test 11j: Cold
IEC 60512-11-12, Connectors for electronic equipment – Tests and measurements –
Part 11­12: Climatic tests – Test 11m: Damp heat, cyclic
3 Terms and definitions
For the purposes of this document, the terms and definition provided in IEC 60050-581 and
the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
conductor
part of the cable or wire intended to carry electric current
Note 1 to entry: The conductor may be
a) solid – made of a single strand of circular cross-section;
b) stranded – made of several strands of circular cross-section assembled either by laying up concentrically or by
bunching, and without insulation between them.
Note 2 to entry: The properties of the copper are in accordance with IEC 60228.
[SOURCE: IEC 60189-1:2018, 3.1, modified – Note 2 to entry has been added.]

3.2
wire
insulated conductor or assembly of several insulated conductors, laid up together and which
may be provided with a screen
Note 1 to entry: The wire may be
a) single – consists of a single insulated conductor;
b) multiple – consists of several insulated conductors.
[SOURCE: IEC 60189-1:2018, 3.2, modified – deletion of "low frequency" in the title and the
Note 2 to entry listing designations.]
3.3
insulation displacement connection
ID connection
solderless electrical connection made by inserting a single wire into a precisely controlled slot
in a termination such that the sides of the slot displace the insulation and deform the
conductor of a solid wire or the strands of a stranded wire to produce a gas-tight connection
SEE: Figure 2.
Figure 2 – Insulation displacement connection
3.3.1
accessible insulation displacement connection
accessible ID connection
ID connection in which it is possible to access test points for carrying out mechanical tests
(for example, transverse extraction force) and electrical measurements (for example, contact
resistance) without deactivation of any design feature intended to establish and/or maintain
the ID connection (see IEC 60352-3)
3.3.2
non-accessible insulation displacement connection
non-accessible ID connection
ID connection in which it is not possible to access test points for carrying out mechanical tests
such as transverse extraction force and some electrical measurements (for example, contact
resistance) without deactivation of any design feature intended to establish and/or maintain
the ID connection, mainly where the ID connection is enclosed in a component
3.4
insulation displacement termination
ID termination
termination designed to accept a wire for the purpose of establishing an ID connection

– 12 – IEC 60352-4:2020 © IEC 2020
3.4.1
reusable insulation displacement termination
reusable ID termination
ID termination that can be used more than once
3.4.2
non-reusable insulation displacement termination
non-reusable ID termination
ID termination that can be used only once
3.5
slot
specially shaped opening in an ID termination suitable to provide either connection or strain
relief
SEE: Figure 3.
Figure 3 – Slot
3.5.1
connection slot
specially shaped opening in an ID termination suitable to displace the insulation of a wire and
to ensure a gas-tight connection between the termination and the conductor(s) of the wire
Note 1 to entry: In certain cases a second connection slot is used to provide for a double connection.
3.5.2
strain relief slot
specially shaped opening in an ID termination suitable to provide for strain relief
3.6
beam
specially shaped metallic part of an ID termination on each side of the slot

SEE: Figure 4.
Figure 4 – Beam
3.7
apparent diameter
diameter of the circumscribing circle of the bundle of strands
3.8
guiding block
specially shaped part of a component, for example, a connector, which guides/inserts the
wire(s) into the slot(s); additionally it may provide for other mechanical features, for example,
fixing the wire(s) in correct position(s), strain relief of the ID connection(s), secondary loading
on the ID termination(s) or beams
SEE: Figure 5.
Figure 5 – Guiding block
3.9
wire insertion tool
hand or power operated tool for producing an insulation displacement connection by inserting
the wire(s) in a controlled manner to a predetermined position into the slot(s)
[SOURCE: IEC 60050-581:2008, 581-24-27]
3.10
wire extraction tool
device for extracting the wire(s) from the insulation displacement termination
[SOURCE: IEC 60050-581:2008, 581-24-28]

– 14 – IEC 60352-4:2020 © IEC 2020
4 Workmanship
The manufacturer of non-accessible ID terminations or of components (e.g. multipole
connectors) using such terminations shall provide instructions for the assembly of non-
accessible ID connections.
Non-accessible ID connections shall be processed in a careful and workmanlike manner, in
accordance with good current practice.
Annex A (informative) provides practical guidance and may constitute a benchmark for the
assessment of workmanship.
NOTE Some industry sectors (e.g. automotive, aerospace, marine, nuclear, military) use workmanship standards
which can be considered upon agreement between manufacturer and user.
5 Prerequisites for basic test schedule
5.1 General
Non-accessible ID connections which fulfil the following prerequisites, which are based on the
experience by the industry, shall be assessed in accordance with the basic test schedule.
All prerequisites are essential at the same level of importance. Non-accessible ID
connections, which do not comply with all these prerequisites but are covered by the scope of
this document, shall be assessed in accordance with the full test schedule.
5.2 Prerequisites for ID terminations
5.2.1 Non-accessible ID terminations materials
Suitable grades of copper alloy, such as copper-tin (bronze), copper-zinc (brass), etc. shall be
used.
If copper-zinc alloys are used, care should be taken regarding stress corrosion cracking
effects.
5.2.2 Non-accessible ID terminations dimensions
The quality of a non-accessible ID connection depends on the dimensions of the non-
accessible ID termination, particularly of its slot and beams, together with the characteristics
of the materials used.
The dimensions shall be chosen so as to be suitable for the wire or range of wires for which
the non-accessible ID termination is designed. The suitability is verified by applying the test
schedule given in Clauses 6 to 8.
5.2.3 Non-accessible ID terminations surface finishes
The contact area of a non-accessible ID termination shall be plated with tin or with silver,
gold, palladium or their alloys. The surface of the contact area shall be free of detrimental
contamination or corrosion.
5.2.4 Non-accessible ID terminations design features
Non-accessible ID terminations may be distinguished according to reusability conditions and
according to a range of wire sizes that can be accommodated. This results in the following
types:
a) reusable ID terminations, designed for one specified nominal conductor diameter or cross-
section;
b) reusable ID terminations, designed for a specified range of conductor diameters or cross-
sections;
c) non-reusable ID terminations, designed for one specified nominal conductor diameter or
cross-section;
d) non-reusable ID terminations, designed for a specified range of conductor diameters or
cross-sections.
The edges of the beams shall be smooth and free of burrs to avoid unintentional damage to
the conductor(s) or insulation.
5.3 Prerequisites for wires and conductors
5.3.1 Wire and conductors
Ribbon cables or single wires with solid round conductors or stranded conductors with seven
single strands according to IEC 60228 class 2 shall be used.
5.3.2 Conductor materials
The conductor material shall be annealed copper. It shall have an elongation at break of not
less than 10 %.
5.3.3 Wire and conductor dimensions
Different ranges of wires shall be used:
to
– single solid round conductors of 0,25 mm to 1,4 mm diameter (converted 0,049 mm
1,5 mm ); or
2 2
to 1,5 mm cross-sectional
– stranded conductors of seven strands only and 0,075 mm
area.
5.3.4 Conductor surface finishes
Solid round conductors shall be unplated or plated with tin, or silver. Stranded conductors
shall have strands unplated or plated with tin or silver.
5.3.5 Wire insulation
The detail product specification or the manufacturer's specification of the non-accessible ID
termination or of the connector using said non-accessible ID termination shall specify the
outside diameter of the wire that can be accommodated.
The insulation material shall be compatible with the insulation displacement process, i.e. the
insulation material shall be capable of being readily displaced by the inner edges of the
beams without cutting the conductor or conductor strands. In case of stranded conductors, the
insulation shall, in addition, be capable of keeping the strands in place so that they are not
unduly displaced when making the ID connection.
For ribbon cables, the insulation between the conductors including any additional insulation
forming the ribbon shall additionally be capable of being readily penetrated by the tips of the
beams.
– 16 – IEC 60352-4:2020 © IEC 2020
5.4 Non-accessible insulation displacement connections (ID connections)
a) The combination of wire, non-accessible ID termination and, if applicable, connection tool
shall be compatible.
b) When inserting the wire into the connection slot of the non-accessible ID termination, the
inner sides of the beams shall displace the wire insulation and deform:
– the diameter of a solid round conductor
or
– the apparent diameter of a stranded conductor (i.e. the circumscribing circle of the
bundle of strands) and, in addition, the diameter of those strands which are in contact
with the beams in order to produce a gas-tight connection.
c) The wire shall be correctly located in the connection slot of the non-accessible ID
termination as specified by the detail product specification or the manufacturer's
specification (either of the accessible ID termination or of the connector using such
termination). There shall be a sufficient distance between the termination and the wire
end. The minimum value of that distance depends on the wire used and shall be as
specified by the detail product specification or the
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