SIST EN 60352-1:2002

SLOVENSKI STANDARD
SIST EN 60352-1:2002
01-september-2002
Solderless connections - Part 1: Wrapped connections - General requirements,
test methods and practical guidance (IEC 60352-1:1997)
Solderless connections -- Part 1: Wrapped connections - General requirements, test
methods and practical guidance
Lötfreie Verbindungen -- Teil 1: Wickelverbindungen - Allgemeine Anforderungen,
Prüfverfahren und Anwendungshinweise
Connexions sans soudure -- Partie 1: Connexions enroulées - Règles générales,
méthodes d'essai et guide pratique
Ta slovenski standard je istoveten z: EN 60352-1:1997
ICS:
29.120.20 Spojni elementi Connecting devices
SIST EN 60352-1:2002 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 60352-1:2002

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SIST EN 60352-1:2002

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SIST EN 60352-1:2002

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SIST EN 60352-1:2002

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SIST EN 60352-1:2002

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SIST EN 60352-1:2002
NORME
CEI
INTERNATIONALE
IEC
60352-1
INTERNATIONAL
Troisième édition
STANDARD
Third edition
1997-08
Connexions sans soudure –
Partie 1:
Connexions enroulées –
Règles générales, méthodes d'essai
et guide pratique
Solderless connections –
Part 1:
Wrapped connections –
General requirements, test methods
and practical guidance
 IEC 1997 Droits de reproduction réservés  Copyright - all rights reserved
Aucune partie de cette publication ne peut être reproduite ni No part of this publication may be reproduced or utilized in
utilisée sous quelque forme que ce soit et par aucun any form or by any means, electronic or mechanical,
procédé, électronique ou mécanique, y compris la photo- including photocopying and microfilm, without permission in
copie et les microfilms, sans l'accord écrit de l'éditeur. writing from the publisher.
International Electrotechnical Commission 3, rue de Varembé Geneva, Switzerland
Telefax: +41 22 919 0300 e-mail: inmail@iec.ch IEC web site http: //www.iec.ch
CODE PRIX
Commission Electrotechnique Internationale
V
PRICE CODE
International Electrotechnical Commission
Pour prix, voir catalogue en vigueur
For price, see current catalogue

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 3 –
CONTENTS
Page
FOREWORD . 5
INTRODUCTION. 7
Clause
1 Scope and object. 9
2 Normative references. 9
3 Definitions. 11
4 Requirements. 15
4.1  Workmanship . 15
4.2  Tools. 15
4.3  Posts . 17
4.4  Wrapping wires. 25
4.5  Wrapped connections . 27
5 Tests. 31
5.1  Testing. 31
5.2  Type tests. 31
5.3  Test schedules . 37
6 Practical guidance. 47
6.1  Current-carrying capacity .47
6.2  Tool information. 47
6.3  Post information . 51
6.4  Wire information. 59
6.5  Connection information .61

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
_________
SOLDERLESS CONNECTIONS –
Part 1: Wrapped connections –
General requirements, test methods and practical guidance
FOREWORD
1) The IEC (International Electrotechnical Commission) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of the IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, the IEC publishes International Standards. Their preparation is
entrusted to technical committees; any IEC National Committee interested in the subject dealt with may
participate in this preparatory work. International, governmental and non-governmental organizations liaising
with the IEC also participate in this preparation. The IEC collaborates closely with the International Organization
for Standardization (ISO) in accordance with conditions determined by agreement between the two
organizations.
2) The formal decisions or agreements of the 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 interested National Committees.
3) The documents produced have the form of recommendations for international use and are published in the form
of standards, technical reports or guides and they are accepted by the National Committees in that sense.
4) In order to promote international unification, IEC National Committees undertake to apply IEC International
Standards transparently to the maximum extent possible in their national and regional standards. Any
divergence between the IEC Standard and the corresponding national or regional standard shall be clearly
indicated in the latter.
5) The IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with one of its standards.
6) Attention is drawn to the possibility that some of the elements of this International Standard may be the subject
of patent rights. The IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60352-1 has been prepared by subcommittee 48B: Connectors, of
IEC technical committee 48: Electromechanical components and mechanical structures for
electronic equipment.
This third edition cancels and replaces the second edition published in 1983, of which it
constitutes a technical revision.
The text of this standard is based on the following documents:
FDIS Report on voting
48B/590/FDIS 48B/635/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
The contents of the corrigendum of October 1998 have been included in this copy.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 7 –
INTRODUCTION
This part of IEC 60352 includes requirements, tests and practical guidance information.
Two test schedules are provided.
The basic test schedule applies to wrapped connections which conform to all the requirements
of clause 4.
These requirements are derived from experience with successful applications of such wrapped
connections.
The full test schedule applies to wrapped connections which do not fully conform to all the
requirements of clause 4, for example those which are manufactured using materials or
finishes not included in clause 4.
This approach permits cost- and time-effective performance verification using a limited basic
test schedule for established wrapped connections and an expanded full test schedule for
wrapped connections requiring more extensive performance validation.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 9 –
SOLDERLESS CONNECTIONS –
Part 1: Wrapped connections –
General requirements, test methods and practical guidance
1 Scope and object
This part of IEC 60352 is applicable to wrapped connections made with single solid round wires
with nominal diameters of 0,16 mm minimum and appropriately designed posts for use in
telecommunications equipment and in electronic devices employing similar techniques.
Information on materials and data from industrial experience are included in addition to the test
procedures to provide electrically stable connections under prescribed environmental conditions.
The object of this standard is to determine the suitability of wrapped connections under
specified mechanical, electrical and atmospheric conditions, and to provide a means of
comparing test results when the tools used to make the connections are of different design or
manufacture.
2 Normative references
The following normative documents contain provisions which, through reference in this text,
constitute provisions of this part of IEC 60352. At the time of publication, the editions indicated
were valid. All normative documents are subject to revision, and parties to agreements based
on this part of IEC 60352 are encouraged to investigate the possibility of applying the most
recent editions of the normative documents indicated below. Members of IEC and ISO maintain
registers of currently valid International Standards.
IEC 60050(581): 1978, International Electrotechnical Vocabulary (IEV) – Chapter 581: Electro-
mechanical components for electronic equipment
IEC 60068-1: 1988, Environmental testing – Part 1: General and guidance
Amendment 1 (1992)
IEC 60352-5: 1995, Solderless connections – Part 5: Solderless press-in connections –
General requirements, test methods and practical guidance
IEC 60512-1: 1994, Electromechanical components for electronic equipment – Basic testing
procedures and measuring methods – Part 1: General
IEC 60512-2: 1985, Electromechanical components for electronic equipment; basic testing
procedures and measuring methods – Part 2: General examination, electrical continuity and
contact resistance tests, insulation tests and voltage stress tests
Amendment 1 (1994)
IEC 60512-6: 1984, Electromechanical components for electronic equipment; basic testing
procedures and measuring methods – Part 6: Climatic tests and soldering tests
IEC 60512-8: 1993, Electromechanical components for electronic equipment; basic testing
procedures and measuring methods – Part 8: Connector tests (mechanical) and mechanical
tests on contacts and terminations
IEC 60979: 1989, Wires for wire wrapping applications
ISO 468: 1982, Surface roughness – Parameters, their values and general rules for specifying
requirements
ISO 1337: 1980, Wrought coppers (having minimum copper contents of 99,85 %) – Chemical
composition and forms of wrought products
ISO 6507-1: 1982, Metallic materials – Hardness test – Vickers test – Part 1: HV 5 to HV 100

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 11 –
3 Definitions
For the purpose of this part of IEC 60352, the terms and definitions included in IEC 60050(581)
and IEC 60512-1 and the following additional terms and definitions apply.
3.1 wrap post: A termination generally rectangular with sharp corners made to accept a
wrapped connection. [IEV 581-03-34, modified]
NOTE – In this standard, the term "wrap post" is shortened to "post".
3.2 wrapped connection: A solderless connection achieved by wrapping a solid conductor
around a wrap post (see figure 1). [IEV 581-03-10, modified]
IEC  1 019/97
Figure 1 – Wrapped connection
3.3 conventional wrapped connection: A solderless connection achieved by wrapping a
solid conductor around a wrap post without any contact of the wire insulation to the post (see
figure 2a). [IEV 581-03-45]
3.4 modified wrapped connection: A solderless connection achieved by wrapping a solid
conductor around a wrap post with the wire insulation wrapped around at least three corners of
the post (see figure 2b). [IEV 581-03-44]
3.5 turn of wire: A single helical ring of wire wrapped 360° around a wrap post. [IEV 581-03-65]
3.6 reference corner: That corner of the wrap post at which the stripped wire makes
its first indentation and from which the number of wrapped turns is counted (see figure 2).
[IEV 581-03-38]

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 13 –
IEC  1 020/97 IEC  1 021/97
Figure 2a – Conventional Figure 2b – Modified
wrapped connection wrapped connection
Figure 2 – Reference corner

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 15 –
3.7 end tail: The final portion of the last turn of wire in a wrapped connection which extends
beyond the last corner of contact (see figure 3). [IEV 581-03-54]
Figure 3 – End tail
3.8 gas-tight area: The part of the contact area that is not affected by gases under specified
conditions (see figure 1). [IEV 581-03-64]
3.9 stripping force: The force applied to the wrapped connection along the major axis of the
post which breaks the gas-tight areas. [IEV 581-03-55]
NOTE – The gas-tight areas are broken by the initial movement of the connection along the post.
3.10 effective wrapping length: That portion of a wrap post suitable and available for the
application of the wrapped connection for which all requirements are fixed. [IEV 581-03-60]
3.11 total post length: The length of a post from the mounting plane to the tip. [IEV 581-03-61]
3.12 hoop stress: The tension in the wire induced by the wrapping operation and maintained
by the wire being locked on the corners of the post. [IEV 581-03-50]
4 Requirements
4.1 Workmanship
The connections shall be processed in a careful and workmanlike manner, in accordance with
good current practice.
4.2 Tools
Tools shall be used and inspected according to the instructions given by the manufacturer.
4.2.1 Wrapping tools
The wrapping tool shall be capable of making uniformly reliable connections during its lifetime.
It shall also make a neat closure of the last turn, without causing undue mutilation of the
wrapping wire or post. The hole in the bit shall have a depth sufficient to accommodate the
total length of the post (see 6.2.1 and 6.3.5.3).
Tools are evaluated by testing wrapped connections made with the tools to be evaluated.
4.2.2 Unwrapping tools
Unwrapping tools shall not damage the post and shall completely remove the unwrapped wire
from the post (see 6.2.2).

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 17 –
4.3 Posts
4.3.1 Materials
Copper alloys with Vickers hardness of 95 HV 5 to 220 HV 5 when tested in accordance with
ISO 6507-1 shall be used. Suitable alloys are brass, phosphor bronze, nickel-silver. When the
hardness of the post is to be measured and Vickers hardness cannot be used due to the size
of the indent, another suitable method such as diamond pyramid hardness or Knoop hardness
may be used.
NOTE – The hardness range 95 HV 5 to 120 HV 5 is mainly used for busbars incorporating wrap posts.
4.3.2 Cross-section
Table 1 lists 11 groups of post sizes and the relevant wire sizes for each.
Table 1 – Post and wire sizes
Post size Wire size
Nominal conductor diameter
mm
Diagonal Preferred
2)
group (nominal)
0,16 0,26 0,32 0,4 0,5 0,65 0,8 1,0
sizes
1)
Maximum insulation diameter
mm
mm mm
0,27 0,7 0,9 1,17 1,27 1,32 1,5 1,78
0,41 – 0,431 Mod. / / / / / /
0,3 × 0,3
3)
0,46 – 0,51 Mod. Mod. / / / / / /
0,4 × 0,4
0,5 – 0,565 Mod. Mod. / / / / / /
0,4 × 0,4
0,69 – 0,77 / Mod. / / / /
0,5 × 0,5
0,76 – 0,86 / Mod. Mod. Mod. // / /
0,6 × 0,6
or Con.
3)
0,77 – 0,825 / Mod. Mod. Mod. // / /
0,635 × 0,635
or Con.
0,84 – 0,91 / Mod. Mod. Mod. // / /
0,635 × 0,635
or Con.
0,95 – 1,20 / Mod. Mod. Mod. // /
0,8 × 0,8
or Con.
1,35 – 1,78 / Mod. Mod. Mod. Mod. /
1,0 × 1,0
or Con. or Con. or Con. or Con.
0,8 × 1,4
0,8 × 1,6
1,6 – 1,86 / Mod. Mod. Mod. Mod. Mod.
1,2 × 1,2
or Con. or Con. or Con. or Con. or Con.
1,2 × 1,4
2,3 – 2,9 // // Mod. Mod. /
0,8 × 2,4
or Con. or Con.
NOTE – Mod. = modified wrapped connection.
Con. = conventional wrapped connection.
/ = wrapped connection is not possible or not permitted.
Blank = wrapped connection might be applied but the relevant combination of dimensions is neither
  recommended nor widely used.
1)
For the permitted maximum insulation diameter, see 6.3.6.
2)
The relevant tool (bit) shall be chosen by the user.
3)
This diagonal group refers to chamfered posts, i.e. two corners of the post are chamfered, the other two are
in accordance with 4.3.7.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 19 –
4.3.3 Tolerance on post sizes
The dimensions of the post shall be such that the limits of the diagonals given in table 1 are
met. The diagonals include the effect of corner radii and burrs. The tolerance on post sizes
shall comply with the relevant detail specification for the component.
NOTE – Because posts are accommodated by round holes in the wrapping bits, it is necessary that their
diagonals be within acceptable limits. Several cross-sections may fall into a diagonal range, but the tolerance
on the diagonal is more important than the width and the thickness, or the tolerances thereon.
4.3.4 Length
The length of the post shall be as specified in the relevant detail specification.
NOTE – It is considered desirable for the effective wrapping length of the post to be capable of accommodating
up to three wrapped connections (see 6.3.5).
4.3.5 Parallelism
All posts shall have corners which are parallel within 0,05 mm per 10 mm over the entire
effective wrapping length.
4.3.6 Straightness
The posts shall be free from bends and bows which might restrict the free entry of the post into
the hole of the wrapping bit.
4.3.7 Corner radii
At any part of the post at least two of the corners shall meet the requirements of table 2 after
application of the surface finish.
Table 2 – Corner radii
Diagonals Corner radii
(max.)
mm mm
<0,6 0,025
0,6 – 1,3 0,05
>1,3 0,08
4.3.7.1 Corner radius verification
The corner radii shall be verified by comparing a magnified shadowgraph of the post under test
with an optical gauge as defined by figure 4.
A cross-section shadowgraph of the post under test shall be prepared using a minimum
magnification of 50 times.
A glass master as defined by figure 4 shall be prepared as an optical gauge. The radius value r
shall be chosen in accordance with the dimensions of table 2.
NOTE – For the glass master, the radius r of table 2 is multiplied by the magnification factor of the shadow-
graph.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 21 –
The shadowgraph of the post under test shall be placed upon the optical gauge so that the
flattest side of the shadowgraph is located on the datum line and the other side of the corner to
be tested passes through the datum point.
Requirements:
a) the side passing through the datum point shall be within the angular limits (2);
b) the corner shall be within the area (1) defined by the optical gauge.
If the corner is located in area (3), the conditions of 4.3.8 shall be fulfilled additionally.
NOTE – An example of a good radius is given in figure 5.
IEC  1 022/97
Figure 4 – Glass master Figure 5 – Example of a good radius
4.3.8 Corner burrs
Burrs shall not exceed the following values after application of the surface finish (table 3).
Table 3 – Corner burrs
Diagonals Corner burrs
(max.)
mm mm
<0,6 0,02
0,6 – 1,3 0,02
>1,3 0,05
4.3.9 Shape of tip
The tip of the post shall be tapered or bevelled (see figure 6) to facilitate insertion into the
wrapping bit.
Where the post is intended to be used with automatic or semi-automatic wiring machines using
fixed tools, the following dimensions (table 4) shall apply in both axes.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 23 –
Table 4 – Shape of tip
Diagonals c
max. min.
mm mm mm
<0,6 rounded or pointed
0,6 – 1,3 0,25 0,05
>1,3 0,4 0,05
NOTE – For the length of the tip, see table 13.
IEC  1 023/97
Figure 6 – Shape of tip
4.3.10 Mounting
Posts shall be securely mounted so that they can withstand the force and torque likely to be
encountered during the wrapping action. The mounting of the post shall withstand the axial
force specified in table 5 in the direction in which the tool is applied. The mounting of the post
shall withstand the torque specified in table 5.
Table 5 – Mounting strength
Diagonals Axial force Torque
mm N Nm
<0,44 25 0,02
0,44 – 1,3 30 0,02
>1,3 40 0,06

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 25 –
Where the post is intended to be used with automatic or semi-automatic wiring machines using
fixed tools, the following conditions shall apply:
– the basis of all assembled posts within a panel shall be flat and straight within 0,3 mm;
– the mounting dimensions shown in table 6 shall be used.
IEC  1 024/97
Figure 7 – True position tolerance zone
Table 6 – Mounting tolerances
True position tolerance zone
1)
Diagonals z y
mm mm mm
<0,6
≤0,5
0,6 – 1,3 y = z
≤0,5
>1,3
≤0,8
1)
The position tolerance might be restricted by the detail specification
or in other applications, for example press-in terminations (see
IEC 60352-5).
4.4 Wrapping wires
Only single solid round wires in accordance with IEC 60979 shall be used as wrapping wires;
stranded conductors are not permissible. Stable connections can be made with a range of wire
materials and diameters and using appropriate tools.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 27 –
4.4.1 Conductor materials
The conductor shall be as specified in table 7.
Table 7 – Conductor materials
Nominal conductor Material Elongation
diameter at break
mm %
Copper alloy
≤0,4 ≥7
Oxygen free copper (Cu – OF)
≤0,5 ≥15
according to ISO 1337
>0,5 Copper
≥20
When connections are to operate for long periods at temperatures exceeding 90 °C, the wrapping
wire shall be of a suitable material less susceptible than copper to stress relaxation at elevated
temperatures. The elongation characteristics of such wires may be different from those of fully
annealed copper wires.
4.4.2 Conductor finish
The conductor finish shall be silver, tin, tin alloy or unplated. Its surface shall be free of
contamination and corrosion.
4.4.3 Diameter
The diameter of the conductor shall be within the range of 0,16 mm to 1,0 mm nominal. For the
relation between conductor diameter and post sizes, see table 1.
4.4.4 Insulation
The insulation shall be capable of being readily stripped from the conductor without changing
the physical characteristic of the wire. For a modified wrapped connection, the insulation shall
have sufficient wall thickness (generally in excess of 40 % of the conductor diameter).
The producer of the wrapped connections shall establish the compatibility between the outside
diameter of the wire and the wrapping bit designed for wrapping modified wrapped connections.
4.5 Wrapped connections
4.5.1 General
a) The combination of tool, post and wire shall be compatible.
b) The wire turns shall be closely wound and shall not overlap one another. A possible gap
between adjacent turns shall be not more than one-half the nominal diameter of the
conductor. The sum of all gaps except those of the first and last turns shall not exceed one
diameter of the conductor (see figure 15, figure 16 and table 13).
c) A connection once made shall not be disturbed, and there shall be no attempt to tidy up
the ends, or "tighten" the connection with pliers, etc. If necessary, the end tail may be
closed in, but only using the wrapping tool.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 29 –
d) The wrapped connection shall be entirely on the effective wrapping length.
e) Adjacent connections made on the same post, wrapped in the same direction, may touch
each other but there shall be no overlapping between adjacent connections (see figure 15,
figure 16 and table 13).
NOTE – It is considered desirable for the effective wrapping length to be capable of accommodating up to three
wrapped connections.
4.5.2 Conventional wrapped connection
For conventional wrapped connections, the minimum number of turns shall be as specified in
table 8. The insulation shall start as close as possible to the post to avoid short circuits to
adjacent wrapped connections or conductors.
4.5.3 Modified wrapped connection
Modified wrapped connections shall always be used for conductor nominal diameters of
0,32 mm or less (see table 1).
The minimum number of turns of stripped wires shall be as specified in table 8. The part of the
wrapped wire with insulation shall envelop at least three corners of the post.
Table 8 – Minimum number of turns of stripped wires
Nominal conductor
Minimum number of turns of stripped wires
diameter
(see table 1)
mm Annealed copper Copper alloy or
equivalents
0,16 8 8
0,26 7 5
0,32 7 5
0,4 6 5
0,5 5 4
0,65 4 4
0,8 4 4
1,0 4 3
4.5.4 Rewrapping of connections
To disconnect a wrapped connection, the wrapped wire shall be carefully uncoiled by a suitable
tool and not stripped off, to preserve the corners of the post for a new wrapped connection.
NOTE – An example of a suitable tool is shown in figure 14.
The rewrapping of that portion of a conductor which has been previously wrapped on a post,
then unwrapped, is not permissible. However, it is permissible to wrap a new connection on a
post on which a connection has been previously wrapped, provided that the post and the
connection are capable of meeting the requirements specified herein.
NOTE – Posts with a diagonal up to and including 1,3 mm may be rewrapped at least five times and posts with a
diagonal above 1,3 mm may be rewrapped at least ten times.

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SIST EN 60352-1:2002
60352-1 © IEC:1997 – 31 –
4.5.5 Combinations of soldered connections and wrapped connections
Soldered and solderless wrapped connections on a common post should be avoided, but,
where unavoidable, they shall be as far apart from each other as possible and solder shall not
spread onto the wrapped connection.
Precautions shall be taken to avoid damage to adjacent wrapped connections during the
soldering process.
NOTE – It is advisable to solder all adjacent connections on a common post if one soldered connection is made.
5 Tests
5.1 Testing
5.1.1 General
As explained in the introduction, there are two test schedules which are applied according to
the following conditions:
– wrapped connections which conform to all the requirements of clause 4 shall be tested in
accordance with and meet the requirements of the basic test schedule, see 5.3.2;
– wrapped connections which conform to all the requirements of clause 4 except for the size
or material of the wrapping wire or the post shall be tested in accordance with and meet the
requirements of the full test schedule, see 5.3.3.
5.1.2 Standard conditions for testing
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 test results, the test shall be repeated at one of the referee conditions
of IEC 60068-1.
5.1.3 Preconditioning
Where specified, the connections shall be preconditioned under standard conditions for testing
for a period of 24 h, in accordance with IEC 60512-1.
5.1.4 Recovery
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.
5.1.5 Mounting of specimens
When mounting is required in a test, the specimens shall be mounted using the normal
mounting method, unless otherwise specified.
5.2 Type tests
5.2.1 General examination
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 approximately five times.
All wrapped connections shall be examined to ensure that the applicable requirements of
...