2 Pfg 1162/07.

2007
Requirements for
Junction Boxes for
Photovoltaic Systems
 2 Pfg 1162/07.2007

C ontent

1 S c o p e ................................................................................................................................................................................................... 4

2 Normative r e f e r e n c e s ...................................................................................................................................................................4

3 D efinitions.......................................................................................................................................................................................... 6

4 C la s s ific a tio n ....................................................................................................................................................................................9

5 Constructional requirements and p e r fo r m a n c e ................................................................................................................ 9

5.1 G e n e r a l ............................................................................................................................................................................................... 9

5 .2 Marking and identification........................................................................................................................................................... 9

5 .3 Protection a g a in s t electric s h o c k ...........................................................................................................................................10

5 .4 Terminations and con n ectio n m e t h o d s ............................................................................................................................. 10

5.5 C o n n e c t o r s ...................................................................................................................................................................................... 11

5 .6 C a b l e ..................................................................................................................................................................................................11

5 .7 R e s is ta n c e to a g e i n g ...................................................................................................................................................................II

5.8 G e n e r a l c o n s t r u c t io n .................................................................................................................................................................. 11

5 .9 D e g r e e o f protection ( I P ) .......................................................................................................................................................... 12

5 .1 0 Dielectric str en g th .........................................................................................................................................................................12

5.11 Cord a n c h o r a g e ............................................................................................................................................................................ 12

5 .1 2 M echanical s t r e n g t h ................................................................................................................................................................... 13

5 .13 C le a r a n c e s and c r e e p a g e d i s t a n c e s ................................................................................................................................... 13

5 .1 4 In su lation ..........................................................................................................................................................................................14

5 .15 Insulation p a r t s ..............................................................................................................................................................................14

5 .1 6 Current carrying parts and r esista n c e a g a in s t corro sion .............................................................................................. 15

5 .17 S e a l i n g ...............................................................................................................................................................................................15

5 .18 B y p a s s - d i o d e ..................................................................................................................................................................................15

5 .1 9 Knock-out inlets (outlets)intended to be re m o v e d by m ec h a n ic a l im p a c t .......................................................... 15

6 T e s t s .................................................................................................................................................................................................. 16

6.1 G e n e r a l ............................................................................................................................................................................................. 16

6 .2 Preparation o f s p e c i m e n s ......................................................................................................................................................... 16

6 .3 Perform ance o f t e s t s .................................................................................................................................................................. 17

6 .4 T e s t s c h e d u l e ................................................................................................................................................................................27

A nnex A (normative) Warning label „No d iscon n ection under load“.................................................................................. 34

A nnex B (normative) N u m b er o f s p e c i m e n .................................................................................................................................... 35

Figure 1 Therm al cycling t e s t .......................................................................................................................................................20

Figure 2 Humidity-freeze c y c l e ............................................................................................................................................................ 23

Figure 3 - Typical arran gem en t for the cable a n ch o ra g e pull t e s t ........................................................................................ 26

Figure 4 - Typical arrangem ent for torsion t e s t ............................................................................................................................27

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Tabic 1 - Rated impulse v o l t a g e ..........................................................................................................................................................13

Table 2 - V alu es o f torque for sere w-type clam ping units.........................................................................................................17

Table 3 - Pull forces for cord a n c h o r a g e ..........................................................................................................................................25

Table 4 - V alu es for torsion t e s t .......................................................................................................................................................... 27

Table 5 Group A Marking, information, d o c u m e n t a tio n ......................................................................................................... 27

Table 6 Group B Material te st (single t e s t s ) ............................................................................................................................... 29

Table 7 Group C Construction (single t e s t s ) ..............................................................................................................................30

Table 8 Group D M ech an ical te sts (single t e s t s ) .......................................................................................................................31

Table 9 Group E T e s t s e q u e n z 1 (T ests c o n s e q u e n t ly in this o r d e r )..............................................................................32

Table 10 Group F T e s t s e q u e n z 2 (T ests c o n s e q u e n t ly in thiso r d e r )........................................................................... 33

Table 11 Group G T e s t s e q u e n z 3 (T ests c o n s e q u e n t ly in this order).............................................................................. 33

Table 12 Group H B y p a s s - D i o d e - T e s t ........................................................................................................................................... 33

Table B .l N um ber o f s p e c i m e n ............................................................................................................................................................35

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1 Scope

T h is s t a n d a r d a p p l i e s to j u n c t i o n b o x e s u p to 15 0 0 V D C fo r u s e o n p h o t o v o l t a i c m o d u l e s a c c o r d i n g t o a p p l i c a t i o n
c la ss A o f E C 61730-1.

Note - For junction bo x e s a ccord ing to application c l a s s e s B a n d C o f IEC 6 1 7 3 0 in photovoltaic-systerns this st a n d a r d c a n be

u s e d a s guideline.

2 Normative references
The following normative d o c u m e n t s are n e c e ss a ry for application o f this d o c u m e n t s . For dated r e fe r e n c e s ,
s u b s e q u e n t a m e n d m e n ts to, or revisions of, a n y o f th e s e publications d o not apply. For und ated r e fe r e n c e s , the
latest edition o f the normative d o c u m e n t referred to applies.

IEC 60050-581, International Electrotechnical Vocabulary (IEV) - Chapter 581: Electromechanical components for
electronic equipment
IEC 60050-826, International Electrotechnical Vocabulary (IEV) - Chapter 826: Electrical installations o f buildings
IEC 60060-1:1989. High-voltage test techniques - Part 1: General definitions a nd test requirements
IEC 60068-1:1988. Environmental testing - Part 1: General and guidance

IEC 60068-2-14. Basic environmental testing procedures Part 2: Tests - Test N: Change o f temperature

IEC 60068-2-75. Environmental testing - Part 2: Tests - Test Eh: Hammer tests
IEC 60068-2-70:1995. Environmental testing - Part 2: Tests - Test Xb: Abrasion o f marking and letterings caused
by rubbing o f fingers and hands

IEC 60112:1979, M ethod fo r determining the comparative and p ro of tracking indices o f solid insulating materials
under m oist conditions
IEC 60352-2, Solderless connections - Part 2: Solderless crim ped connections - General requirements, test
methods and practical guidance
IEC 60352-3, Solderless connections - Part 3: Solderless accessible insulation displacement connections -G eneral
requirements, test methods and practical guidance
IEC 60352-4, Solderless connections - Part 4: Solderless non-accessible insulation displacement connections -
General requirements, test methods and practical guidance
IEC 60352-5, Solderless connections - Part 5: Solderless press-in connections - General requirements, test
methods and practical guidance
IEC 60364-4-41:1992, Electrical installations o f buildings - Part 4: Protection for safety - Chapter 41 P rotection
against electric shock
IEC 60364-5-51:2001, Electrical installations o f buildings - Part 5: Selection and erection o f electrical equipment -
Chapter 51 .Common rules

IEC 60364-7-712, Electrical installations o f buildings - Part 7-712: Requirements for special installations or locations
- Solar photovoltaic (PV) pow er supply systems
IEC 6 0 4 17 -2 :1998, Graphical symbols for use on equipment - Part 2: Sym bol originals
IEC 60423:1993. Conduits for electrical purposes - Outside diameters o f conduits for electrical installations and
threads fo r conduits and fittings.

IEC 6 0 5 12 (all parts). Electromechanical components fo r electronic equipment

4
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IEC 6 0 5 1 2 - 1 . Electromechanical components for electronic equipment - Basic testing procedures and measuring
methods - Part 1: General
IEC 6 0 5 1 2 - 1 1 - 7 : 1 9 9 6 , Electromechanical components for electronic equipment - Basic testing procedures and
measuring methods - Part 11: Climatic tests - Section 7: Test 11g: Flowing m ixed gas corrosion test
IEC 6 0 5 2 9 : 1 9 8 9 . Degrees o f protection provided by enclosures (IP Code)

IEC 6 0 6 6 4 - 1 : 1 9 9 2 , Insulation coordination for equipment within low voltage systems - Part 1: Principles,
requirements a nd tests Amendment 1 (2000)

IEC 6 0 6 9 5 - 2 - 10, Fire hazard testing - Part 2-10: Glowing/hot-wire based test methods - Glow-wire apparatus and
common test procedure
IEC 6 0 6 9 5 - 2 - 1 1 . Fire hazard testing - Part 2: Test methods - Section 11: Glow-wire end product test and guidance.

IEC 6 0 6 9 5 - 1 0 - 2 . Fire hazard testing - Part 10: Guidance and test m ethod for the minimization o f the effects o f
abnormal heat on electrotechnical products involved in fires - Section 2: M ethod for testing products made from
non-metallic materials for resistance to heat using the ball pressure test.
IEC 6 0 6 9 5 - 11 -10 , Fire hazard testing - Part 11-10: Test flames - 50 W horizontal and vertical flame test methods

IEC 6 0 6 9 5 -1 1 -20, Fire hazard testing - Part 11-20: Test flames - 500 W flame test methods

IEC 6 0 7 6 0 : 1 9 8 9 , Flat, quick-connect terminations

IEC 6 0 9 8 1 : 1989, Extra-heavy duty rigid steel conduits for electrical installations.

IEC 6 0 9 9 8 - 2 - 3 , Connecting devices for low-voltage circuits for household and sim ilar purposes - Part 2-3: Particular
requirements for connecting devices as separate entities with insulation-piercing clamping units
IEC 6 0 9 9 9 - 1 : 1999. Connecting devices - Electrical copper conductors - Safety requirements for screw-type and
screwless-type clamping units - Part 1: General requirements a nd particular requirements for clamping units for
conductors from 0,2 mm2 up to 35 mm2
IEC 6 0 9 9 9 - 2 : 1 9 9 5 . Connecting devices - Safety requirements for screw-type and screwless-type clamping units for
electrical copper conductors - Part 2: Particular requirements for conductors from 35 m m 2 up to 300 mm2
IEC 6 1 0 3 2 : 1 9 9 7 . Protection o f persons and equipment by enclosure - Probes for verification.

IEC 6 1 0 8 4 series: 1 9 9 1. Cable trunking a nd ducting systems for electrical installations.

IEC 6 1 1 4 0 : 1 9 9 7 . Protection against electric shock - Common aspects for installation and equipment

IEC 6 1 2 1 0 : 19 9 3 . Connecting devices - Flat quick-connect terminations for electrical copper conductors -S a fety
requirements
IEC 6 1 2 1 5 : 1 9 9 3 , Crystalline silicon terrestrial photovoltaic (PV) modules - Design qualification and type approval

IEC 6 1 6 4 6 , Thin-film terrestrial photovoltaic (PV) modules - Design qualification and type
approval

IEC 6 1 7 3 0 - 1 :20 04 , Photovoltaic (PV) module safety qualification - Part 1: Requirements for construction

IEC 6 1 7 3 0 - 2 : 2 0 0 4 , Photovoltaic (PV) module safety qualification - Part 2 : Requirements for testing

ISO 4 8 9 2 - 2 , Plastics - Methods o f exposure to laboratory light sources - Part 2: Xenon-arc sources

ISO 4 8 9 2 - 3 , Plastics - Methods o f exposure to laboratory light sources - Part 3: Fluorescent U V lamp

ISO 6 9 8 8 : 1 9 8 5 , Metallic a nd other non organic coatings - Sulfur dioxide test with general condensation o f moisture

EN 5 0 2 6 2 : 1 9 9 8 + A 1 : 2 0 0 1, Metric cable glands fo r electrical installations

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3 Definitions

For the p urpose o f this International Standard, definitions from IEC 6 0 0 5 0 - 5 8 1 , IEC 6 0 0 5 0 - 8 2 6 , IEC 6 0 6 6 4 - 1 , IEC
6 09 9 9 -1 and IEC 6 1 1 4 0 , tog eth er with the following, apply.

3.1
Ju nctio n box
combination o f parts, s u c h a s b o x e s , c o v e r s, co ver-p lates, lids, box e x t e n s io n s , a c c e s s o r i e s , etc., providing after
a s s e m b l y and installation at the photovoltaic-module a s in normal u s e , an appropriate protection ag a in st external
in fluences, and a defined protection ag a in st co n ta ct with e n c l o s e d live parts
from any a c c e s s ib le direction.

3.1.1
Box fo r re-opening
Junction box which can be o p e n e d at a n y time. It m a y co n ten t rewireable and non rewireable c o n n e c tio n s.

3.1.1.1
Ju nctio n box fo r fa c to ry w iring
P V -cab le s in the box and/or PV -con nectors integrated in the en closu re are c o n n e c te d in the e n d application under
controlled conditions, usually at manufacturer’s location.

3.1.1.2
Ju nctio n box fo r field w iring
Wiring c o n n e ctio n s are m ade in the field.

3 .1 .2
Box, not intended to be re-opened
Junction box which can not be o p e n e d after mounting in the e n d application. It m a y co n ten t rewireable and non
rewireable c o n n e c tio n s.

3 .2
cable gland
housing usually o f cylindrical, hollow form a se c o n d a r y m e m b e r usually th readed to c o m p r e s s the a s s o c ia t e d s e a l
around the cable p a s s in g through the gland. It m a y have additional fimctions like insulation, buckle protection, strain
re lie f o r combination o f them .

sealing
sealin g material which will be inserted b e tw e e n tw o surfaces o f the box and which will form a s e a l e d con n ection after
co m p r es sio n

3 .4
sp ou t (hub)
o p e n entry o f a box permitting the insertion and contain m en t o f a conduit

3 .5
cable an cho rag e
the ability to limit the d is p la ce m en t o f a fitted flexible cab le ag a in st pull and push forces and torques

3 .6
co n n ecto r (for pho to vo ltaic-system s)
c o m p o n e n t suitable for u s e in P V - s y s te m s which terminates conductors for the purpose o f providing co n n ection to
and disco n n ectio n from a suitable mating c o m p o n e n t. It Is sp ecially d e s i g n e d to be e n g a g e d or d i s e n g a g e d in
normal u s e w h en live but not under load.

3 .7
cable (fo r pho to vo ltaic-system s)
cable suitable for u s e a s co n n ectio n for P V -m o d ules a s a PV-string

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3 .8
intended use
application conditions o f junction b o x e s which are included within the permissible rated va lu es and environm ental
conditions and characteristics a s s ig n e d by the manufacturer

3 .9
K lem m stelle
part(s) o f the terminal n e c e s s a r y for the m e c h a n ic a l clamping and the electrical con n ectio n o f the c o n d u c t o r s ),
including the parts which are n e c e s s a r y to en su r e the correct co n ta ct p ressu re flEC 6 0 9 9 9 - 1 , Definition 3.1]

3 .1 0
clearance
the shortest d istan ce in air b e tw e e n tw o conductive parts [ E C 6 0 6 6 4 - 1 , definition 1.3.2]

3.11
creep ag e distance
sh ortest distan ce along the surface o f the insulating material b e tw e e n two conductive parts [IEC 6 0 6 6 4 - 1. definition
1.3.3]

3 .1 2
o vervo ltag e categ o ry
numeral defining a transient overvoltage condition [IEC 6 0 6 6 4 - 1 , definition 1.3.10]

3 .1 3
pollution
a n y addition o f foreign matter, solid, liquid, or g a s e o u s , that c a n result in a reduction o f electric strength or surface
resistivity o f the insulation [IEC 6 0 6 6 4 - 1, definition 1.3.11]

3 .1 4
pollution degree
numeral characterizing the e x p e c te d pollution o f the micro-environment

[IEC 6 0 6 6 4 - 1, definition 1.3.13]

3 .1 5
rated voltage
value o f voltage a s s i g n e d by the manufacturer to the junction box an d to which operation and perform ance
characteristics are referred. [IEC 6 0 6 6 4 - 1, definition 1.3 .9 modified]

The rated voltage o f junction box shall not be le s s than o p e n circuit voltage (U oc) o f the P V -sy stem

NOTE Rated Voltage is equivalent to the rated system voltage according to IEC 61730-1.

3 .1 6
rated insulation voltage
r.m.s. withstand voltage value a s s i g n e d by the manufacturer to the junction b ox, characterising the specified (long
term) withstand capability o f its insulation

N O T E T h e r a t e d i n s u la tio n v o lta g e is n o t n e c e s s a r i l y e q u a l to th e r a t e d v o l t a g e , w h ic h is p r im a r ily r e l a t e d to f u n c tio n a l

p e rfo rm a n c e .

[IEC 6 0 6 6 4 - 1, definition 1.3.9.1 modified]

3 .17
rated im pu lse voltage
impulse withstand voltage value a s s i g n e d by the manufacturer to the junction box, characterising the specified
withstand capability o f its insulation ag a in st transient o v er v o lta g e s [IEC 6 0 6 6 4 - 1 , definition l . 3 .9 .2 modified]

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3 .1 8
im pulse w ith stan d voltage
h igh est p ea k value o f impulse voltage, o f prescribed form and polarity which d o e s not c a u s e breakdow n o f the
insulation under specified conditions I1EC 6 0 6 6 4 - 1 , definition 1.3.8.1]

N O TE The impulse withstand voltage is e q u a l to or h ig h er than the ra te d impulse voltage.

3 .1 9
r.m .s. w ith stan d voltage (p o w er-freq u ency w ith stan d voltage)
h igh est r.m.s. value o f a voltage which d o e s not c a u s e breakdown o f the insulation under specified conditions

[ E C 6 0 6 6 4 - 1 . definition 1.3.8.2]

3 .2 0
m axim um w o rkin g voltage
voltage value a s s i g n e d by the manufacturer to the junction b ox, ch aracterising the specified (long term) withstand
capability o f its insulation at module sid e. The working voltage o f the junction b o x shall not be l e s s than the o p c n -
circuit-voltage o f the P V-module.

3.21
rated current
current value a s s i g n e d by the manufacturer, which the junction box can carry continuously (without interruption) and
sim ultan eou sly through all its con tacts and b y p a s s - d io d c s , if applicable, wired with the largest sp ecified conductor,
preferably at an am bient temperature o f 85 °C, without the upper limiting temperature being e x c e e d e d .

The rated current o f the junction b o x shall not be le s s than the maximum short-circuit-current (fee) o f the P V -sy stem .

3 .2 2
functional insulation
insulation b e tw e e n conductive parts which is n e c e s s a r y only for the proper functioning o f the equip m en t. [IEC
6 0 6 6 4 - 1, definition l . 3 . 17.1]

3 .2 3
basic insulation
insulation applied to live parts to provide basic protection a g a in st electric sh o c k

N O TE Basie insulation d o e s not n e c e s s a r ily include insulation u s e d exclusively for functional p u r p o s e s (s e e 3.10.1 o f IEC
61140).

3 .2 4
su pp lem en tary insulation
in d ep en d en t insulation applied in addition to b a sic insulation, in order to provide protection a g a in s t electric sh o c k in
the e v e n t o f a failure o f b asic insulation ( s e e 3 .1 0 .2 o f IEC 6 1 1 4 0 )

[IEC 6 0 6 6 4 - 1 , definition 1.3.17.3]

3 .2 5
d o u b le insulation
insulation comprising both b asic insulation and su p p lem en ta ry insulation ( s e e 3 .1 0 .3 o f IEC 6 1 1 4 0 ) [IEC 6 0 6 6 4 - 1 ,
definition 1.3.17.4]

3 .2 6
reinforced insulation
single insulation s y s te m applied to live parts, which provides a d e g r e e o f protection a g a in st electric s h o c k equivalent
to double insulation under the conditions specified in the relevant IEC standard ( s e e 3 .1 0 .4 o f IEC 61 140)

NOTE A single insulation s y s te m d o e s not imply that the insulation m u s t be a h o m o g e n e o u s piece. It m ay c o m p rise s e v e ra l
layers which c a n n o t be t e s te d singly a s b a sic or s u p p le m e n ta r y insulation.

[IEC 606 64-1, definition 1.3.17.5]

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3.27
U tilization categ o ry A according to IEC 61730
Junction b o x e s which are provided for using in this utilization c a te g o r y can be u s e d ins y s t e m s where free a c c e s s
are e x p e c t e d and rated values e x c e e d 5 0 V DC or 2 40 W .

Junction b o x e s which co m p ly with the requirements o f this standard and which are classified in this utilization
c a te g o r y are co n sid e r e d to m e e t the requirements o f protection c la s s II. [IEC 6 1 7 3 0 -1 ]

3.28
U tilization categ o ry B according to IEC 61730
Junction b o x e s which are provided for using in this utilization c a te g o r y m a y only be u s e d in s y s t e m s where free
a c c e s s are protected by f e n c e s , locality etc.

Junction b o x e s which are classified in this utilization c a te g o r y and which are protected by b asic insulation are
co n sid e r e d to m e e t the requirements o f protection c la s s 0. [IEC 6 17 30 -1 ]

3.29
U tilization categ o ry C according to IEC 61730
Junction b o x e s which are provided for using in this utilization c a te g o r y can be u s e d in s y s t e m s where free a c c e s s
are e x p e c t e d and rated values le s s than 50 V DC or 24 0 W .

Junction b o x e s which co m p ly with the requirements o f this standard and which are classified in this utilization
c a te g o r y are c o n sid er ed to m e e t the requirements o f protection c la s s III.

Hint: Protection c la s s are defined in IEC 6 1 1 4 0

4 Classification

In order to apply the relevant test requirem ents, junction b o x e s shall be classified by the manufacturer’s specification
according to their intended u se under consideration o f c l a s s e s A according to IEC 6 1 7 3 0 .

5 Constructional requirem ents and perform ance

5.1 General
For junction b o x e s according to the p resen t standard no v alu es have b e e n defined for electric rated characteristics
voltage and current. T h e s e v alues m ust be d eclared by the manufacturer.

Junction b o x e s m u s t be suitable for the durable u s e outside in an am bient temperature area from - 4 0 ^ to +85*C.

Junction b o x e s shall be s o d e s i g n e d and d im en sio n e d that they ca n withstand the electrical, m ech a n ical, thermal
and corrosive s t r e s s e s which occu r in their intended u s e and p r e se n t no d a n g e r to the u s e r or the environment.

C om pliance with th e s e requirements are verified by specified tests o f this standard.

5 .2 M arking and identification

5.2.1 Identification

Junction b o x e s shall be identified and characterised by the following markings:

a) manufacturer’s n a m e , trademark or mark o f origin;

b) type identification;
c) rated current in a m p e r e s (A);
d) rated vo lta ges or rated insulation voltages
e) rated im pulse voltage in kilovolts (kV), if specified;
f) Maximum working voltage;

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g) pollution d e g r e e ;
h) d eg ree o f protection by e n closu r e according to E C 6 0 5 2 9 ,
i) range o f temperature; (low est und upper am b ien t temperature), if differ from this standard
j) type o f terminals;
k) co n n ecta b le conductors;
1) reference to this standard, if applicable;
m) H in t,N o t c o n n ectin g or d iscon n ectin g under load“ or a d e q u a te sym bol, ( s e e A n n ex A);
n) Polarity o f c o n n ector, if applicable;
o) Type and num b er o f b y p a s s - d io d e s , if applicable.

N O TE for m) alternatively an a d e q u a t e warning notice c a n be found in particular national l a n g u a g e .

5.2.2 M arking

The marking shall be indelible and ea sily legible.

The minimum marking on the junction b o x e s shall be that o f item a), 1) and n) in 5 .2.1 .

If co n n ectio n o f junction box is perform ed by co n n e cto rs the warning notice listed in m) o f 5.2.1 m ust be on a label or
similar on or clo s e to connector.

If co n n ectio n o f junction box is perform ed by a fixed cable which h a s im plem ented a c o n n e c to r on its e n d the
warning notice listed in m) o f 5.2.1 m u st be on a label or similar on or c lo s e to co n n ecto r. A notice to attaching the
sticker m ust be sp ecified in technical docu m en tation . For con n ectors VDE 0 1 2 6 - 3 is applicable.

Markings a) and b) o f 5.2.1 shall b e found on the sm a lle s t unit o f packaging.

All other markings o f 5.2.1 and following information shall be given in the tech nical docu m en tation or c atalo gu e o f
the manufacturer:

Information regarding the co n n ecta b le ca b le, if applicable

Information regarding the c o n n e c to r (-sy stem ), if applicable

Information regarding mounting (e .g . b ack sh eet-m a teria l o f m od u le) and mounting material (e.g. sealin g
material), if ap p lica b le.

5.3 Protection against electric shock

5.3.1 A co n n e c to r shall be s o d e s i g n e d that, after mounting, its live parts are not a c c e s s ib le by the IEC te s t finger
in a c c o r d a n c e with IEC 6 0 5 2 9 .

This requirement m ust be fulfilled e v e n if there is a n y deformation o f the ho u sin g and/or c o v e r a s a result o f
m e ch a n ic and thermal s t r e s s , which can oc cu r during normal u se ; furthermore the d e g r e e o f protection o f the
h ou sin g m a y not be impaired by this p o ss ib le deformation.

5 .3 .2 The cover can only be detached with the aid of tools. Covers which arc attached without screws must have one or
several detectable facilities, e.g. recesses, which enable tools to be deployed in order to remove them. If the lid is removed
correctly the tools and instruments may not come into contact with the active parts.
5 .3 .3 Parts shall be prevented from lo o s en in g or turning con cernin g to the type o f mounting a s d e scr ib ed in
3 .1 .1 .2 if su ch lo o s en in g or turning m a y result in a risk o f fire, electric sh o c k , or injury to p e rso n s .

5.4 Term inations and connection m ethods

Note Following r e quire m e n ts are a lso applicable for cell-connections.

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5.4.1 Terminations shall be suitable for the type and range o f co n du ctor c r o s s -s e c ti o n a l are a s according to
manufacturer's information.
Not insulated terminals m ust be hekl in position su ch that a p o ssib le disposition which m a y result in a reduction o f
c le a r a n c e s and c r e e p a g e d is ta n c e s is prevented.
5 .4 .2 Terminals m ust m e e t following requirements:

Clamping units m ust fulfil the requirem ents o f IEC 60 9 9 9 -1 or IEC 6 0 9 9 9 - 2 under the conditions prevailing in the
junction box.

Other terminals shall meet:

IEC 6 0 9 9 8 - 2 - 1 , IEC 6 0 9 9 8 - 2 - 2 or IEC 6 0 9 4 7 -7 -1 under the conditions prevailing in the junction box.

Other type attach m ents and co n n ectin g m eth o d s m a y be u s e d if they fulfil a com p arab le lev el o f s a fe ty a s the ab o ve
m en tioned standards.

Furthermore c o n n e ctio n s by soldering, welding, crimping and p ressin g m a y be u s e d .

The c a b le s m ust be s o m ou nted or fixed that they are not hold in position o nly from the c o n n e c tio n s by soldering,
welding, crimping and p ressin g , u n less it is e n su r e d by construction that c le a r a n c e s and c r e e p a g e d is ta n ce s
according to c la u s e 5 .1 4 will not be red u ced in c a s e o f break o f cond u ctor at soldering- or w cld ing-con n ection or
slipping out o f crimping- or pr essu re-con n ec tio n .

NOTE In ge nera l, hooking-in before soldering is c o n s i d e re d to be a suitable m e a n s for retaining the c o n d u c t o r in position.

5 .4 .3 T e sts o c c u r to c la u s e 6 5 . 3 .2 0 if no certification o f a b o v e m en tioned standards are existent.

Electrical and thermal tests on terminations shall be carried out in conjunction with the test on the junction box.

5 .4 .4 Electrical c o n n e ctio n s shall be s o d e s i g n e d that the co n ta ct pressure is not transmitted through insulating
material other than ceram ic, pure mica or other material with characteristics not le s s suitable, u n le s s there is
sufficient resiliency in the metallic parts to c o m p e n s a t e for a n y shrinkage or yielding o f the insulating material (s e e
c la u s e 7 o f IEC 6 0 9 9 9 -1 or IEC 6 0 9 9 9 -2 ) .

5.5 Connectors

P V -co n nectors which are part o f the junction box and P V -co n nectors c o n n e c t e d via a cable with the junction box
shall com p ly with the requirements o f VDE 0 1 2 6 - 3 . The va lu es o f the rated current and the rated voltage m ust
minimum correlate with the rated va lues o f the junction box.

5.6 Cable

C ab le s c o n n e c te d at the junction b o x m u st be suitable for u se in P V - s y s te m s . The values o f the rated current and
the rated voltage m u st minimum correlate with the rated va lu es o f the junction box.

5.7 Resistance to ageing

Parts which, due to a g e in g , might impair s a fe ty shall b e s o resistant that the specified characteristics will be provided
by testing o f test program.

5.8 General construction

Junction b o x e s shall be s o d e s i g n e d and d im en sio n e d that th ey provide sufficient protection for ca b le s and
terminations a g a in s t electrical, m ech a n ic a l, and environm ental s t r e s s e s which occu r in normal u s e .

5.8.1 Fixing m e a n s , actua ted in the mounting and in the con n ection o f junction b o x e s , shall not b e u s e d to fix live
parts, where a s a result o f their c h a n g e o f position their efficiency might be impaired and c r e e p a g e d is ta n c e s and
c le a r a n c e s be red uced.

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 2 Pfg 1162/07.2007

5.8.2 The thickness o f outer walls o f the junction box shall not be l e s s than 3 ,0 m m , u n les s the (finished) box
m e e t the end-product flammability test according to IEC 6 0 6 9 5 - 1 1 - 2 0 , c a te g o r y 5-V.

5.8.3 Junction b o x e s shall be s o d e s i g n e d that con n ection o f conductors o f the type and c r o s s -s e c ti o n a l are a s as
specified by the manufacturer shall be p o ss ib le . B e s id e s the termination o f the conductor, precautions shall be taken
that no d a m a g e o f the insulation is p o ss ib le , e .g . by avoiding o f sharp e d g e s .

5.8.4 All op en in g s shall be provided with appropriate coverings (such a s lids, plugs, etc.), w h o se functions
co m p ly with the requirem ents o f 6 . 3 . 1 6 . T h ey should only be able to be rem o v e d by the u se o f a tool.

T h e s e requirements are a lso applicable for knock-outs.

5.8.5 A barrier o f polymeric insulating material providing the so le insulation b e tw e e n a live part and an a c c e s s ib le
metal part or b e tw e e n uninsulated live parts not o f the s a m e potential shall be o f ad e q u a te thickn ess and o f a
material appropriate for the application. The barrier or liner shall be held in place and shall not be a d v e r se ly affected
to the exten t that its n e c e s s a r y properties fall b elo w the minimum a cc ep ta b le v alu es tor the application

5.8.6 Junction b o x e s for reop en in g according to 3.1.1 with rewireable c o n n ectio n s shall be d e s i g n e d su ch that

• precautions are taken that the con d u ctor is the wires is protected a g a in s t s h e a r and tensile stre ss at
the termination and be s e c u r e d to prevent twisting;

• the m ounted conductor is verified with rated va lu es o f the con n ectors and suitable for the u se in
photovoltaic s y s t e m s o r a n assig n atio n for using o f suitable c a b le s is given in the manufacturer’s
specification;

• the clamping units fulfill the requirements o f 5.4.2;

• th e r e ’s sufficient volum e for con necting the conductor.

5.9 Degree of protection (IP)

A junction b o x shall h av e a d e g r e e o f protection o f IP55, c a te g o r y 1 according to DEC 6 0 5 2 9 .

5.10 D ielectric strength

A junction box shall withstand the sp ecified te st voltage, preferably the im pulse withstand voltage (1 ,2 /5 0 jxs) and
r.m.s. withstand voltage d e p en d in g on its rated voltage.

5.11 Cord anchorage

The cord a n c h o ra ge shall be suitable for the cable to be c o n n e c te d . The range o f a c cep ta b le cable diam eters shall
be specified in the manufacturer’s specification. T ensile and torsion requirements shall be a s sp ecified a s in 6 .3 .2 3 .

L oo se parts inserted to obtain clamping o f the cable are permissible if th ey are fixed in the junction box in the
a s s e m b l e d state.

The cord a n ch o r a g e can be made o f insulating material or metal. If it c o n s is ts o f metal, it shall m e e t on e o f the
following requirem ents:

a) be provided with a covering o f insulating material to prevent a n y a c c e s s ib le m etal part b e c o m in g live in c a s e o f a

fault;

b) no con tact shall be p ossib le with the test finger according to IEC 6 0 5 2 9 ;

C om plian ce is c h e c k e d by the tests o f 6 .3 .2 3 .

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5.12 M echanical strength

5.12.1 A junction b o x shall s h o w no d a m a g e likely to impair s a fe ty after e x p o su r e to m e c h a n ica l stress according

to the test program.

5.12.2 In a junction box a s s e m b l e d for final u s e , the contacts shall be se c u r e ly retained in the contact insert.

5.12.3 After ex p o su r e to the s t r e s s e s according to the test sc h e d u le , the internal insulation shall s h o w no d a m a g e
which could impair normal u se.

5.13 Clearances and creepage distances

C le a r a n c e s and c r e e p a g e d is ta n c e s shall be d im e n sio n e d according to the following specifications.

5.13.1 C learan ces

C le a r a n c e s b e tw e e n live parts and a c c e s s ib le su rface s shall be d im e n sio n e d according to IEC 60 6 6 4 -1 b a s e d on

the rated im pulse voltage derived from table 1 o f this standard.

C le a r a n c e s through slots and o p en in g s in e n c lo s u r e s o f insulating material shall m e e t the v alu es o f c a s e A o f table 2

o f IEC 6 0 6 6 4 -1 .

Rewireable junction b o x e s shall m e e t the requirements o f reinforced or double insulation b e t w e e n clamping units for
the terminals for flexible cords relating on the rated voltage.

All other c le a r a n c e s within the junction box shall m e e t the requirements o f b a sic insulation relating on the maximum
working voltage sp ecified by the manufacturer.

5.13.1.1 Rated im pu lse voltage

The rated im pulse voltage shall be s e l e c t e d according to table I and the rated voltage o f the junction box.

5.13.1.2 O vervoltag e category

The a s s ig n m e n t o f junction box shall carried out according to the rules a s given in IEC 6 0 6 6 4 -1 for overvoltage
categorie ID.

T able 1 - Rated im pulse voltage

Rated voltage V V alues fo r the rated im pulse

voltage in kV (1,2/50jis)

100 1,5

150 2,5

300 4,0

600 6,0

1000 8,0

5.13.2 C reep age distances

C r e e p a g e d is ta n c e s shall be d im e n sio n e d according to the rated v olta ge, the pollution d e g r e e 3 and the insulating
material a s sp ecified in DEC 6 0 6 6 4 - 1.

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For the relationship b e tw e e n c r e e p a g e d is ta n c e s and c le a r a n c e s s e e 3 .2 .1 .5 o f l E C 60 6 6 4 -1

Rewireable junction b o x e s shall m e e t the requirements o f reinforced or double insulation according to E C 60 66 4-1
b e tw e e n clamping units o f the terminals for flexible cords relating on the rated voltage.

All other c r e e p a g e d is ta n c e s within the junction box shall m e e t the requirements o f basic insulation according to E C
6 06 6 4 -1 relating on the maximum working voltage specified by the manufacturer.

The sufficient insulation o f splice b e tw e e n module and junction box will be a pproved by tests o f te st s e q u e n c e E and
F o f 6.4.

5.13.2.1 Pollution degree

For a junction box complying with this standard, isolating parts (c le a r a n c e s and c r e e p a g e d is ta n c e s ) inside o f the
en closu re shall be d im e n sio n e d for pollution d e g r e e 2.

5.13.2.2 S hape of insulating surfaces

For insulating su rfa ces determ inations o f E C 6 0 6 6 4 -1 are applicable.

5.14 Insulation

5.14.1 Functional and basic insulation

Functional and basic insulation shall be su ch that it withstands the impulse withstand voltage or the r.m.s. withstand
voltage a s specified in the m an ufactu rers specification, a s derived from the rated insulation voltage o f the junction
box.

5.14.2 S u p p lem entary insulation

For the su p p lem en ta ry insulation, the s a m e requirements are valid a s for the b a sic insulation.

5.14.3 D ouble insulation

Double insulation shall be s o d e s i g n e d that the breakdow n o f on e part (b asic or su pp lem entary insulation) d o e s not
impair the protective function o f the other part. It shall not be p ossib le to rem ove the su p p lem en ta ry insulation
without using a tool.

For double insulation, where b a sic and su p p lem en tary insulation ca n n ot be te s te d sep ara tely, the insulation s y s te m
shall be co n sid e r e d a s reinforced insulation.

5.14.4 Reinforced insulation

For the a s s e s s m e n t o f c le a r a n c e s for reinforced insulation, the rated impulse voltage shall be s e l e c t e d from table I.

The c r e e p a g e d istan ce s shall be d oubled in c om parison with the basic insulation.

5.15 Insulation parts

5.15.1 G eneral requirem ents

Insulation parts shall be s o d e s i g n e d that they withstand the e x p e c t e d thermal requirements.

C om p lian ce is c h e c k e d by the test o f test group B o f 6.4.

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5.15.2 O u ter accessib le parts

Outer a c c e s s ib le parts con sistin g o f isolating material w h o se deterioration could impair the sa fety o f t h e junction box
shall m e e t following requirements:

a) C a tego ry o f the vertical burning HB, V-2, V - l , or V-0 according to IEC 6 0 6 9 5 - I I -10. This shall be proved by
a data s h e e t o f t h e material supplier or a t e s t i n the end-product.

NOTE: IEC 6 1 7 3 0 requires c a t e g o ry 5V

b) W e a th er resista n ce according to ISO 4 8 9 2 - 2 m ethod A or ISO 4 8 9 2 - 3 with total duration o f 5 0 0 h on parts

which are provided direct sunlight in normal u s e . Alter te st the glow wire test according to 6 .3 .1 5 a) m u s t be
passed.

c) Temperature resistan c e at ball p ressure test o f 6 .3 .1 4 a )

5.15.3 Inner parts

Inner parts con sistin g o f Isolating material w h o se k e e p active parts in a position shall m e e t following requirem ents:

a) C ateg ory o f t h e vertical burning HB, V-2, V - l , or V-0 according to IEC 60 6 9 5 -1 1-10. This shall be proved by
a data s h e e t o f t h e material supplier or a t e s t i n the final product..

b) Isolating material m ust have a CTI-value complying to the rated values o f this standard according to IEC
60664.

c) Glow wire test with 7 5 0 ^ according to 6 .3 .1 5 b ).

d) Temperature resista n ce at ball p ressure test o f 6 .3 .1 4 b )

5.16 Current carrying parts and resistance against corrosion

5.16.1 All current carrying parts m ust be o f m etal and shall be so d e s i g n e d that corrosion shall not impair safe ty
with regard to electrical and m e ch a n ica l characteristics.

During the normal function und er the occurring conditions a sufficient m ec h a n ic a l strength, electrical conductivity
and corrosion r esista n ce is given.

5.16.2 U nder w et am b ien t conditions all metal parts m ay not be in con tact with e a c h other which h a ve a difference
o f their elec tro ch em ica l potentials from > 35 0 m V according to IEC 6 0 9 4 3 .

5.17 Sealing
G a s k e ts and s e a l s shall not deteriorate b e y o n d limits during a cc e le r a te d a g e in g o f 6 .3 .1 6 .

5.18 Bypass-diode
The b y p a ss -d io d e and the a d e q u a c y o f t h e thermal d esig n and relative long-term reliability u s e d to limit the
detrimental effects o f module hot-spot susceptibility m ust be sufficient.

5.19 Knock-out inlets (outlets)intended to be rem oved by m echanical im pact

It shall be p o ssib le to rem ove knock-out inlets (outlets) intended to be rem o v ed by m e c h a n ica l impact without
d a m ag in g the box.

For knock-out inlets (outlets) for c a b le s , chips or burrs are not a c c e p te d .

For knock-out inlets (outlets) for conduits and/or for u s e with a grom m et or a m em b ra n e, chips and burrs are
disregarded.

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6 Tests

6.1 General

6.1.1 The tcst-program c o n sist both o f safety-tests and o f qualification-tests according to the rules o f valid
standards for c o m p o n e n t s and for P V -m od u les and - s y s t e m s .

6.1.2 The tests shall be carried out in the s e q u e n c e sp ecified for e a c h te st group using the num b er o f s p e c i m e n s
a s given in a n n e x B. For e a c h te s t group a sep a r a te s e t o f n e w s p e c i m e n s shall be u sed .

6.1.3 The tests shall be m ad e under the standard atm ospheric conditions o f IEC 6 0 0 6 8 - I , u n les s otherwise
specified in the test sc h e d u le .

6.1.4 The tests on the terminations shall be m ad e on three terminations per sp e c i m e n , ifavailable.

6.1.5 The s p e c i m e n is d e e m e d not to co m p ly with this standard if the sp e c im e n fails in more than one o f the tests
o f a n y test group. If the sp e c im e n fails in on e o f the te s ts, this te s t and the preceding tests which have affected its
result shall be r e p ea ted on a n ew s p e c i m e n , which shall then p a s s the r ep ea ted tests.

6.1.6 All visual examination tests should be perform ed with the n a ked e y e , u n les s otherwise specified.

6.2 Preparation of specim ens

6.2.1 S p e c im e n s shall be pre-conditioned under standard conditions for testing, for a period o f 24 h, in
a cc o r d a n c e with IEC 6 0 5 1 2 - 1 .

6.2.2 The tests shall be carried out with c o p p e r conductors u n les s otherw ise specified by the manufacturer and
with the type o f cond u ctor specified for the con n ector. If terminations are provided for all types o f con du ctors, solid,
stranded and flexible, the tests shall be carried out with conductors which rep re se n t the worst c a s e .

6.2.3 For the cell-con n ection s conductors specified from the manufacturer representing the worst c a s e m ust be
c o n n e c te d . For s o m e tests it is n e c e s s a r y to c o n n e c t t h e s e cell c o n n ec tio n s.

6.2.4 Screw -typ e clamping units shall be tightened with the value o f the torque stipulated in table 2 according to
IEC 60 9 9 9 -1 and IEC 6 0 9 9 9 - 2 u n les s otherwise sp ecified by the manufacturer.

6.2.5 U n le ss otherw ise specified in the test sc h e d u le , all tests shall be m a d e on the s p e c i m e n co m p letely
a s s e m b l e d according to the manufacturer’s instructions.

A sufficient num b er o f s p e c i m e n m u st be glued on a mounting surface a s in normal u s e . The mounting surface m ust
c o n s is t o f the s a m e material like the b a c k - s h e e t material o f the m od u le, the box is intended to be fixed. If the box is
intended to be fixed with s e v e r a l a d h e siv e on s e b e r a l b a c k s h e e t materials a sufficient n u m b er o f sp e c im e n for e a c h
material m u st be te sted .

The c e ll - c o n n e c t io n s will be bent down and fixed su ch that th ey h av e a conductive co n n ectio n to mounting surtace.
For s o m e tests it is n e c e s s a r y to c o n n e c t the cell co n n e ctio n s.

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Table 2 - Values of torque for screw-type clamping units

Gewinde-Nenndurchmesser Drehmoment fur metallische und nichtmetalllsche Schrauben

mm Nm

1 II III IV

bis einschlieBlich 2.8 0,20 0.40 0.40 0,70

über 2.8 bis einschlieBlich 3.0 0,25 0,50 0,50 0.90

über 3.0 bis einschlieBlich 3.2 0,30 0.60 0.60 1.10

über 3.2 bis einschlieBlich 3.6 0.40 0.80 0.80 1.40

über 3.6 bis einschlieBlich 4.1 0,70 1.20 1,20 1.80

über 4.1 bis einschlieBlich 4.7 0,80 1.80 1.80 2.30

über 4.7 bis einschlieBlich 5.3 0,80 2.00 2.00 4.00

über 5.3 bis einschlieBlich 6.0 1,20 2,50 3.00 4.40

über 6.0 bis einschlieBlich 8.0 2,50 3,50 6.00 4.70

über 8.0 3.00 a 4.00 10,00 5.00

0 Oder durch den Hersteller festzulegen

Column I applies to screws without heads if the screw, when tightened[ does not protrude from the screw hole
and to other screws which cannot be tightened by means o f a screwdriver with a blade wider than the
diameter o f the screw.

Column II applies to nuts o f mantle clamping units which are tightened by means o f a screwdriver.

Column III applies to screws and nuts, other than nuts o f mantle clamping units, which are tightened by means
other than a screwdriver

Column IV applies to screws tightened by means o f a cross-slotted screwdriver.

6.3 Perform ance of tests

6.3.1 General

In a c c o r d a n ce with the te s t sc h e d u le given in 6 .4, the g e n e r a l test m eth od s specified in tables 5 to 12 shall be
applied.

6.3.2 Durability of marking

The test o f the durability o f marking shall be don e a s a wet te st according to test Xb (abrasion o f marking) o f IEC
6 0 0 6 8 - 2 - 7 0 . For the test piston, size 1 shall be u s e d and the test liquid shall be water. A force o f 5 N shall be applied
for a duration o f 10 c y c le s .

Alter test the marking shall still be legible.

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 2 Pfg 1162/07.2007

This le s t shall be a ls o carried out at an additional sticker (if applicable) with specified warning indication listed under
m) from 5 .2 .1 , if applicable.

The test will not b e carried out with imprinted markings.

6.3.3 Fixing of lid at rew ireable ju n ction box

T e sts according to 6.3.3.1 and 6 .3 .3 .2 will be perform ed at s p e c i m e n which p a s s e d through test s e q u e n c e s o f test
group E an d F.

6.3.3.1 I .id with fixing o f screw s

S c r e w s o f the lid are tightended and lo o s e n e d :

- 10-tim es fo ra s c r e w in e n g a g e m e n t with a thread o f insulating material;

- 5 -times for other s c r e w s .

S c r e w s and nuts in e n g a g e m e n t with a thread o f insulating material and s c r e w s o f insulating material are com p letely
rem o v ed and reinserted e a c h time. The test is made by using a suitable screwdriver or an appropriate tool applying
a torque a s indicated in table 2. G reater va lu es o f torque m a y be u s e d if s o stated by the manufacturer, w h en the
relevant information is provided.

During the test, there shall be no d a m a g e , su ch as b r eak a ge o f s c r e w or d a m a g e to the h e a d slot (rendering the u s e
o f the appropriate screwdriver im p ossib le) or to the threads or to the e n clo s u re impairing the further u s e o f the fixing
m e a n s . The s c r e w s shall not be tightened in jerks.

6.3.3.2 Sere w le s s fixing o f lid

E n clo sures shall be te sted with the test probe 11 according to IEC 6 1 0 3 2 applied with a force o f 7 5 N for one minute
to all points where this could c a u s e a lo o s en in g o f the lid. During test the lid shall not c o m e off.

H ow e ver the lid m ust c o m e off without a n y d a m a g e w h en using a suitable tool a s d escrib ed in manufacturers
specification.

6.3.4 Protection against electric shock

6.3.4.1 C on n ecto rs shall be te sted by the IEC test finger in a cc o r d a n c e with c la u s e 5 o f EEC 6 0 5 2 9 using a te st
force o f 2 0 N.

For the le s t all co v ers and ho u sin g parts shall be rem o v e d which are d eta ch ab le withoul a tool.

6.3.4.2 The relevant tests for the specified IP-Code according to DEC 6 0 5 2 9 arc perform ed at s p e c i m e n describ ed
in 6 .2 .5 with c o n n e c te d c a b le s and/or m ated plugs and c o n n e c te d cell-c on n ec tio n s. G a s k e ts m ust be a g e d
according to 6 .3 .1 6 .

6.3.5 M echanical strength of adhesive

T e sts according to 6.3.5.1 and 6 .3 .5 .2 will be perform ed at s p e c i m e n which p a s s e d through test s e q u e n c e s o f test
group E and F. During test there should be no deposition o f the box at the mounting surface which impairs isolating
characteristics.

The test is performed under consideration o f requirements o f 6.2.5.

6.3.5.1 A force o f 4 0 N is gradually applied for 3 0 min in e a c h direction parallel to the mounting surface.

6.3.5.2 A force o f 4 0 N is gradually applied for 30 min without jerks, in a direction perpendicular to the mounting
su rfaces.

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6.3.6 M easu rem en t of clearances and creep ag e distances

C le a r a n c e s and c r e e p a g e d is ta n c e s shall be m e a s u r e d according to IEC 6 0 6 6 4 - 1 .

6.3.7 D ielectric strength

For c h e c k o f the insulation following tests are applicable:

a) Impulse withstand test

The im pulse withstand test shall be carried out with a voltage having a 1,2/50 fis w aveform according to IEC 6 0 0 6 0 -
1 with three im p u lses o f e a c h polarity and an interval o f at le a s t 1 s b e tw e e n p u ls e s . The output im p ed a n ce o f the
impulse g en era to r should not be higher than 5 0 0 H. The te st voltage shall com ply with the rated impulse voltage
under consideration o f IEC 6 0 6 6 4 -1 .

b) r.m.s. withstand voltage test

The voltage p roo f test shall be performed by applying a r.m.s. withstand voltage ( 5 0 /6 0 Hz) with a rms-value o f
2 0 0 0 V + 4 times rated voltage. The te st duration shall be 1 min.

6.3.8 R esistance to corrosion

Ferrous parts o f b o x e s and e n c lo s u r e s shall be a d e q u a te ly protected aga inst rusting.

C om pliance is c h e c k e d by the following test:

All g r e a s e is rem o v ed from the parts to be te s te d , by im mersion in a d e g r e a s i n g a g e n t for (10 ± 1 ) min. The parts are
then im m ersed for (10 ±1) min in a 10% solution o f a m m oniu m chloride in water at a temperature o f (2 0 ± 5) XI.

Without drying, but after shaking o ff any drops, the parts, are p laced for (1 0 ± 1 ) min in a box containing air saturated
with moisture to a level o f 91% to 95 % at a temperature o f (20 ± 5) V .

After the parts have b e e n dried for (1 0 ±1) min in a heating cabin et at a temperature o f (1 0 0 ± 5) “€ , their surface
shall s h o w no sign o f rust.

NOTE T r a c e s o f rust on s h a r p e d g e s a n d a n y yellowish film re m ov a ble by rubbing are ignored.

6.3.9 M echanical strength at lo w e r tem peratu res

Before the tests the s p e c i m e n s and test apparatus are stored for 5 h by a temperature o f -40*C on a 2 0 mm thick
s t e e l plate. The tests arc carried out im mediately after the end o f the stora ge duration in the cold cham ber.

An e n e r g y o f I joule by m e a n s o f a suitable impact test facility according to IEC 6 0 0 6 8 - 2 - 7 5 shall be occurred. Per
o n e impact at four o f the circum ference sp rea d p la c es .

The test is co n sid e r e d to be p a s s e d if no l o s s e s h a ve a p p e a r e d which impair the usability o f the co n n ectors.

6.3.10 Therm al c ycle test ( IEC 60068-2-14 Test Nb)

The test is performed at s p e c i m e n d escrib ed in 6.2.5 with c o n n e c te d and short circuited cell-co n n ectio n s.

The s p e c i m e n s are inserted in a climatic c h a m b e r without pre-treatment. Afterwards a therm al cycle with
tem peratures b e tw e e n ( - 4 0 + 2) V and (+85 + 2) *C according to the profile o f figure I is to b e applied.

The transfer duration b e tw e e n upper and lower temperature shall not e x c e e d lOO'C/h and the temperature at the
limit v alu es m ust be co n stan t for minimum 10 min.

19
 2 Pfg 1162/07.2007

Figure 1 Therm al cycling test

6.3.10.1 The num b er o f c y c le s for test s e q u e n c e E is 20 0

6.3.10.2 The num b er o f c y c le s for te st s e q u e n c e F is 50

6.3.11 D am p heat test (see clause 10.13 of IEC 61215)

The test shall be carried out according to IEC 6 0 0 6 8 - 2 - 7 8 at sp e c im e n d e scrib e d in 6 .2.5 with c o n n e c t e d and short
circuited c e 11-connections under the following te st conditions:

T e st tem perature:+85 *C ± 2*C

Relative humidity:+85 % ± 5%
T e st duration: 1000 h

6.3.12 W eath er resistan ce test

The w e a th e r resistan c e test is perform ed according to the requirements o f ISO 4 8 9 2 - 2 or ISO 4 8 9 2 - 3 under
following conditions:

Irradiance: min. 6 0 W /m 2

W ave band: 3 0 0 -4 0 0 n m

Blackstandardtemperaturc: 65*C

Rel. Humidity: 65%

Cykles: 18 min spraying, 10 2 min drying with X eno n la m p or eq uivalent lamp

Duration: 500h

6.3.13 C lass of flam m ab ility

6.3.13.1 The te sts are performed according the flammability c la s s HB, V-0, V - l , or V-2 o f IEC 60 6 9 5 -1 1-10 at an
relevant materia 1-probe.

6.3.13.2 The tests are perform ed according the flammability c la s s 5V o f IEC 6 0 6 9 5 - I I-2 0 at an end-product. The
result is a s s e s s e d for flammability c la s s 5VB.

20
 2 Pfg 1162/07.2007

6.3.14 B allp ressu re test

The ballpressure test is performed according to IEC 6 0 6 9 5 - 1 0 - 2 . The test temperature is:

a) 90*C for outer materials providing protection ag ainst electric sh o ck .

b) 1 2 5 ^ , for materials n e c e s s a r y to retain current carrying parts in position.

6.3.15 G lo w w ire te s t

The glowwire test is perform ed according to IEC 6 0 6 9 5 -2 -1 l. The test temperature is:

a) 650*C for outer materials providing protection a gain st electric sh o ck.

b) 750*C, for materials n e c e s s a r y to retain current carrying parts in position and for potting material, if
applicable.

6.3.16 R esistance against ageing

Before testing the IP-code in a c c o r d a n c e with DIN EN 6 0 5 2 9 , the g a sk e t , e .g . sep a ra te sea lin g rings, are to be
stored in a heating ca b in et for 2 4 0 hrs at ( 1 0 0 + 2 ) “C and s u b s e q u e n t ly c o o le d d ow n for 16 hrs at a m b i e n t
temperature.

After test the characteristic con cern in g the sea lin g should not be impaired.

G a s k e ts which c o u ld n ’t be l o o s e n e d from the b o x or the lid are tested with lid or box.

6.3.17 W et leakage current test (clause 10.15 of IE C 61215)

The test is carried out at sp e c im e n describ ed in 6 .2 .5 with c o n n e c te d and short circuited c e 11-connections under the
following test conditions:

6.3.17.1 A pparatus

a) A shallow trough or tank o f sufficient size to e n ab le the module with frame to be p lace d in the solution in a flat,
horizontal position. It shall contain a water/wetting a g e n t solution m eetin g the following requirem ents:

Resistivity: 3 5 0 0 Q cm or less

Surface tension: 0 ,0 3 N -m -1 or less

Temperature: 22 T ± 3 *€

The depth o f the solution shall be sufficient to c o v e r all su r fa ces b e tw e e n mounting surface and box.

b) Spray eq u ip m en t containing the s a m e solution.

c) DC voltage so u r c e , with current limitation, ca p ab le o f applying 5 0 0 V.

d) Instrument to m ea su re insulation r e sista n c e .

6.3.17.2 P rocedure

All c o n n ectio n s shall be representative o f the r e c o m m e n d e d field wiring installation and precautions shall be taken to
en su re that leak a ge currents do not originate from the instrumentation wiring atta ch ed to the module.

21
 2 Pfg 1162/07.2007

a) Im merse the s p e c i m e n in the tank o f the required solution to a depth sufficient to c o v e r a l l su rfaces b e tw e e n
mounting surface and box. The cable entries shall be thoroughly sp ray ed with solution. If the s p e c i m e n is provided
with a mating co n n ecto r, the c o n n e c to r should be im m ersed during the test.

b) C o n n e c t the shorted output terminals o f the module to the positive terminal o f the test equipm en t. C o n n e c t the
liquid test solution to the negative terminal o f the test eq u ip m en t using a suitable metallic conductor.

c ) Increase the voltage applied by the test eq u ip m en t at a rate not to e x c e e d 5 0 0 V s - 1 to 5 0 0 V. Maintain the
voltage at this lev el for 2 min. Then determine the insulation re sistan c e.

d) R e d u c e the applied voltage to zero and short-circuit the terminals o f the te st eq u ip m en t to disch arge the voltage
build-up on the module.

6.3.17.3 R equirem ents

The insulation r esista n c e shall be not le s s 4 0 0 MÜ.

6.3.18 H um id ity-freeze-test

The test is carried out at s p e c i m e n d e sc rib ed in 6.2 .5 with c o n n e c te d and short circuited cell-con n ection s under the
following test conditions:

6.3.18.1 A pparatus

a) A climatic ch a m b e r with automatic temperature and humidity control, c ap a b le o f subjecting o n e or more sp e c im e n

to the humidity-freeze cycle specified in Figure 2.

b) M ea n s for mounting or supporting the m o d u le (s) in the ch am b er, s o a s to allow free circulation o f the surrounding
air. The thermal conduction o f the mount or support shall be low, s o that, for practical p u r p o se s , the m o d u le (s) is
(are) thermally isolated.

6.3.18.2 P rocedure

a ) A t t a c h a s u i t a b l e t e m p e r a t u r e s e n s o r to t h e f r o n t o r b a c k s u r f a c e o f t h e s p e c i m e n ( s ) n e a r t h e m i d d l e .

b ) I n s t a ll t h e s p e c i m e n ( s ) a t r o o m t e m p e r a t u r e in t h e c lim a tic c h a m b e r .

c) After closing the c h a m b er, subject the s p e c i m e n ( s ) to 10 c om plete c y c le s in a c c o r d a n c e with the profile in Figure
2. The maximum and minimum tem peratures shall be within ±2 V o f the specified levels and the relative humidity
shall be maintained within ±5 % o f the sp ecified value at all tem peratures a b o v e room temperature.

d) Throughout the test, record the module temperature.

e ) Then the s p e c i m e n (s ) are stored for a reco very time b e t w e e n 2 h and 4 h at room temperature.

6.3.18.3 Final m easu rem en ts

A v i s u a l c h e c k a n d th e r . m . s . w i t h s t a n d v o l t a g e t e s t a c c o r d i n g to 6 . 3 . 7 b ) a r e p e r f o r m e d . F o r this w r a p a c o n d u c t i v e
foil a r o u n d t h e e d g e s o f s p e c i m e n ( s )

6.3.18.4 R equirem ents

The requirements are a s follows:

a) N o e v id e n c e o f major visual defe cts;

b) N o flash over or breakdown o f test voltage

22
 2 Ffg 1162/07.2007

KcRH Continue far tccai

control 3' 1DCV2M
t l % a 5 S **

20 n mm 4 r max.

TJ-ne n

Figure 2 H um id ity-freeze cycle

6.3.19 B ypass diode th erm al te s t (clause 10.18 of IE C 61215)

The test is carried out at sp e c im e n d escrib ed in 6.2.5.

6.3.19.1 A pparatus

a) M ea n s for heating the s p e c i m e n to a temperature o f 7 5 V ± 5 XI.

b) M e a n s for m easu ring and recording the temperature o f the s p e c i m e n ( s ) to an a c c u r a c y o f ± l XI.

c) M ean s for m easuring the temperature o f any b y p a s s dio d es provided with the junction box. Care should be taken
to minimize a n y alteration o f the properties o f the diode or its h e a t transfer path.

d) M ea n s for applying a current e q u a l to 1,25 times the rated current o f the junction box under te s t and m e a n s for
monitoring the flow o f current through the s p e c i m e n throughout the test.

6.3.19.2 P rocedure

a) Operation o f d io d es in direction o f current-flow.

b) C o n n e c t wires o f the m anufacturer’s minimum r e c o m m e n d e d wire g a u g e to the output terminals o f the junction
box.

NOTE S o m e b o x e s h a v e overla ppin g b y p a s s diode circuits. In this c a s e it m a y be n e c e s s a r y to install a ju m p e r cable to a s s u r e

that all o f the curren t is flowing through one b y p a s s diode.

c) Heat the s p e c i m e n to 75 *C ± 5 “C. Apply a curre nt to the s p e c i m e n e q u a l to the rated current ± 2 % o f the
junction box. After 1 h m e a s u r e the temperature o f e a c h b y p a s s diode. Using the information provided by the diode
manufacturer calculate the junction temperature from the m e a s u r e d c a s e temperature and the p o w e r d issipated in
the diode using the following formula.

7j=7ca s e+/? thjc•t^DTD

where

7) is the diode junction temperature;

7casc is the m e a s u r e diode c a s e temperature;

RTHjc is the manufacturer’s value relating junction temperature to c a s e temperature;

23
 2 Pfg 1162/07.2007

Ud is the diode voltage;

/D is t h e d i o d e c u r r e n t .

NOTR If the m a n u f a c tu r e r o f diode h a s specified a n o th e r R th as Rinje this value is to be in se rte d in the formula a n d the th erm al
s e n s o r shall be fixed at specified position.

f) Increase the applied current to 1,25 times the rated current o f the junction box while maintaining the box
temperature at 7 5 XI ± 5 *C. Maintain the current f low for 1 h.

g) Verify that the diode is still operational.

6.3.19.3 R equirem ents

The requirements are a s follows:

- the diode junction temperature a s d eterm ined in 6 .3 .1 9 .2 c ) shall not e x c e e d the diode m anufacturer’s maximum
junction temperature rating;

- no e v id e n c e o f major visual d efects

- the diode shall still function a s a diode after the con clu sio n o f the test.

6.3.20 T est of term in ation s and connection m ethods

a) For crimped c o n n e c tio n s,

visual and d im en sio n al tests on the crimp barrel and tensile strength te st o f the crimp con n ection a s specified in
IEC 6 0 3 5 2 -2 .

b) For the sc r e w le s s-ty p e clamping unit.

m e ch a n ica l tests on the co nd u cto r co n n ectio n a s specified in EEC 6 09 9 9 -1 or IEC 6 0 9 9 9 -2 .

c) For the screw -type clamping unit,

m ec h an ic al tests on the co nd u cto r co n n ectio n a s sp ecified in IEC 6 09 9 9 -1 or IEC 6 0 9 9 9 -2 .

NOTE F o r p r e p a r e d co n d u cto rs the specific st a n d a r d for the pre para tion applies.

d) S o ld ered c o n n e c tio n s,

The test for so ld ered c o n n e c tio n s shall be carried out according to IEC 6 0 5 1 2 , le s t 12a or 12b.

6.3.21 K nock-out inlets (o u tlets)in ten d ed to be rem oved by m echanical im pact

6.3.21.1 K nock-out retention

For b o x e s and e n c lo s u r e s having knock-outs a c c e s s ib le after installation, a force o f (45 ± 1)N shall be applied to a
knock-out for (15 ± 1) s by m e a n s o f a 6 m m d ia m eter mandrel with a flat en d . The force is to be applied without a
blow in a direction perpendicular to the plane o f the knock-out and at a point m o st likely to c a u s e m ov em en t.

The knock-out shall remain in place and the d e g r e e o f protection o f the en c losu re shall be u n c h a n g e d when
m e a s u r e d 1 h after the force has b e e n rem o ved .

6.3.21.2 K nock-out rem oval

The knock-outs shall be rem o v e d by m e a n s o f a tool, a s stated by the manufacturer. The side e d g e o f a screwdriver
m a y be run along the e d g e o f the knock-out op en in g o n c e to rem ov e a n y fragile tabs remaining along the e d g e .

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 2 Ffg 1162/07.2007

The test is r ep e a ted with on e box or en closu r e which h as b e e n conditioned for 5 h ± 10 min in air maintained at the
temperature ( - 2 0 ± 2 ) ^ . Immediately following this conditioning, the knock-out is to be r e m o v e d a s a b o v e . For a
b o x and an en clo su re em ploying multi-stage knock-outs, there shall be no d is p la c e m e n t o f a larger sta g e w h en a
sm aller st a g e Is rem o ved .

After the te st there shall be no sharp e d g e s e x c e p t for knock-out inlets (outlets) for conduits and/or for u s e with a
g rom m et or a m em b ran e and the box and en c losu re shall not be d a m a g e d .

6.3.22 T est of cord an cho rag e

6.3.22.1 For junction box with cab le sp ecified by manufacturer the tests h a v e to be performed with the conductors
a s stated by the manufacturer.

The cable is marked when u n loa ded s o that a n y d is p la ce m en t relative to the gland ca n be ea sily d etected .

The cab le is pulled for a duration o f l s, 5 0 tim es, without jerks in the direction o f the axis with the relevant force
specified in table 3

At the e n d o f this period the d is p la c e m e n t shall not e x c e e d 2 mm. This m e a s u r e m e n t is to be carried out after
unloading the force from the test mandrel.

Following the s p e c i m e n is m ou nted in the test apparatus for torque test.

The cable is marked w hen u n loa ded s o that a n y torsion relative to the gland ca n be ea sily d e te c t e d , and then a
torque specified in table 4 is applied tor 1 min.

During test the torsion shall not e x c e e d 45°.

6.3.22.2 For other junction b o x e s the le s t is to be perform ed a s followed:

A test mandrel eq u ivalen t to the minimum value o f the a n c h o ra g e range o f the cable gland a s declared by the
manufacturer or supplier, with a s l e e v e thickness as specified in table 3 is fixed to the sa m p le.

The test mandrel is marked w hen un loaded s o that a n y d is p la c e m e n t relative to the gland can be ea sily d e te c te d .

The test mandrel is pulled for a duration o f 1 s, 5 0 tim es, without jerks in the direction o f the axis with the relevant
force specified in table 3

At the e n d o f this period the d is p la c e m e n t shall not e x c e e d 2 mm. This m e a s u r e m e n t Is to be carried out after
unloading the force from the test mandrel.

U n le ss otherwise specified te st mandrels shall c o n s i s t o f a metallic rod with an elastom eric s le e v in g having a
h a rd n e ss o f 7 0 Shore D ± 10 points in a cco rd a n ce with ISO 8 6 8 , a s l e e v e thickn ess a s specified in table 3 or table
4. The com p lete te st mandrel shall have a tolerance o f + 0 ,2 m m for mandrels up to and including 16 mm diam eter
and ± 0 ,3 mm for mandrels larger than 16 mm diameter. The s h a p e shall be circular or a profile simulating the outer
d im ension o f the cable a s d eclared by the m anufacturer or supplier.

T able 3 - Pull fo rces fo r cord anchorage

C able d iam eter Pull fo rce M inim um sleeve

th ickn ess of test
m andrel

mm N mm

Up to 4 - I *)
> 4 to 8 30 1

> 8 to 11 42 2

25
 2 Pfg 1162/07.2007

C able d iam eter Pull force M inim um sleeve

th ickn ess of test
m andrel

mm N mm

> 11 to 16 55 2

> 16 to 23 70 2

> 2 3 to 31 80 2

> 3 1 to 4 3 90 2

> 4 3 to 55 1 00 2

>55 1 15 2

5 Fo r cable d ia m e te r s up to 4 m m , a suitable non-metallic m a n d re l m ay

be u s e d ..

A typical a rra ng em en t for pull test is sh o w n in figure 3.

O ff C e n t r e
P u lle y

Figure 3 - T ypical arrang em en t for the cab le anchorage pull test

Following the s p e c i m e n is m ounted in the test apparatus for torque test.

The cable is marked w h en u nloaded s o that a n y torsion relative to the gland ca n be ea sily d e te c t e d , and then a
torque specified in table 4 is applied for I min.

D u r i n g t e s t t h e t o r s i o n s h a l l n o t e x c e e d 45°.

26
 2 Pfg 1162/07.2007

The torsion t e s t i s performed by a te s t mandrel eq u ivalen t to the m axim um value o f the a n ch o rag e range o f the
cable gland a s decla red by the manufacturer or supplier, with a torque for the appropriate maxim um cable dia m eter
a s specified in table 4.

A typical arran g em en t for torsion te st is sh o w n in figure 4.

T able 4 - V alu es for to rsion test

C able d iam etre torque M inim um sleeve th ic k n e s s of

test m andrel

mm Nm mm

> 4 to 8 0 ,1 0 1

> 8 to 1 1 0,15 2

> 1 1 to 16 0,35 2

> 16 to 23 0 ,6 0 2

> 2 3 to 31 0 ,8 0 2

> 31 to 43 0 ,9 0 2

> 43 to 55 1,00 2

>55 1,20 2

Vgrkoftrung zu i S*chonjng d ea Prfltoom s

Figure 4 - T ypical arrang em en t for torsion test

6.4 Test schedule

T able 5 G roup A M arking, inform ation, docu m en tatio n

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o r d i n g to S p e c im e n M e a s u re m e n ts, R e q u i r e m e n ts

p h ase d e s ig n a tio n

27
 2 Pfg 1162/07.2007

Al C h e c k o f K e n n z e ic h n u n g 5.2.1 Isabel, stic k e r(o r V isual c h e c k M arking a c c . to 5.2

sim ilar) with w arning
indication.

A2 C h e c k o f te c h n ic a l 5 .2 .2 M ounting instruction, V is u a lc h e c k Inform ation a c c o rd in g to 5 .2 .2

d o c u m e n ta tio n w arning indication, a n d a d d itio n a l inform ation
m a n u a l o r sim ilar

A3 C h e e k o f a p p ro v a ls o f A p p ro v a l by d a ta V is u a lc h c c k 5 .4 . 5 .5 . 5 .6 .
c o m p o n e n ts s h e e ts o r c e rtific a te s
fo r c a b le , c o n n e c to r s , C o m p o n e n ts m u s t c o m p ly with
c a b le g la n d s e tc . th e ir re le v a n t s ta n d a rd s .

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 2 Ffg 1162/07.2007

Table 6 Group B Material test (single tests)

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o rd in g S p e c im e n M e a su re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

Bl D urability o f m arking 6 .3 .2 Isabel, stic k er(o r W et te s t M arking e a s ily legible

sim ilar) with w arning
in dication.

B2 C o rro sio n te st 6 .3 .8 M etal parts C h e m ic a l te s t No c o rro sio n a t su rfa c e

B3 F lam m ab ility te s t 6 .3 .13.1 P la te s for p o ly m ers F lam m ability t e s t o r R e q u ire m e n ts a c c o rd in g to HB,

s e rv in g a s a n a p p ro v a l o f m a n u fa c tu re r V -2, V -1. V-0 o f E C 6 0 6 9 5 -1 1 -
e n c lo s u re a n d for o f m a te ria l 10
p o ly m ers s e rv in g a s
a s u p p o rt for live
m e ta l parts

B4 W e a th e r re s is ta n c e 6 .3 .1 2 p o ly m ers s e rv in g a s W e a th e r re s is ta n c e te s t No c ra c k s , following te s t o f B5
a n e n c lo s u re . a c c . to IS O 4 8 9 2 -
s ta n d a rd s

B5 G low wire te s t 6 .3 .1 5 a ) S p e c im e n from B4 G low wire te s t with 6 5 0 ^ No ignition o f m a te ria l o r

s u p p o rt, o r selfex tin g u L sh in g
within 30 s

B6 G low wire te s t 6 .3 .1 5 b) p o ly m ers s e rv in g a s G low wire t e s t with 7 5 0 “C No ignition o f m a te ria l o r

a s u p p o rt for live s u p p o rt, o r s e lf e x tin g u ish in g
m e ta l p a rts a n d within 30 s
p o tting m a te ria l
(T e s t-p la te )

B7 T h e rm a l re s is ta n c e 6 .3 .1 4 a ) p o ly m ers s e rv in g a s B a llp re ss u re te s t with Im p re s s io n < 2 ,0 m m

a n e n c lo s u re 9or

B8 T h e rm a l re s is ta n c e 6 .3 .1 4 b) p o ly m ers s e rv in g a s B a llp re ss u re te s t with Im p rte ssio n < 2.0m m

a s u p p o rt for live 125C
m e ta l parts

B9 R e s is ta n c e a g a in s t a g e in g 6 .3 .1 6 g a s k e ts A c c e le ra te d a g e in g in No c h a n g e o f s e a lin g
ov en c h a ra c te ris tic .

BIO F lam m ab ility te s t 6 .3 .1 3 .2 S p e c im e n from C 7 F lam m ability te s t R e q u ire m e n ts a c c . to 5-V B o f

IEC 6 0 6 9 5 -1 1 -2 0

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 2 Pfg 1162/07.2007

Table 7 Group C Construction (single tests)

1 2 3 4 5 6

T est D e s ig n a tio n T e st a c c o rd in g S p e c im e n M e a s u re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

Cl P ro tec tio n a g a in s t e lectric 5 .3 .3 C o m p le te s p e c im e n V isu al c h e c k No lo o se n in g o r d is p la c e m e n t

sh o ck a s d e s c rib e d in 6 .2 .5
C2 6 .3 .4 .1 T e s t with t e s t fin g e r 2 0N No live p a rt a re a c c e s s ib le

C3 G e ne ra I c o n s true tion 5 .8 .5 C o m p le te s p e c im e n V isual c h e c k a n d S ufficient wall th ic k n e ss a c c .

m e a s u re m e n t To IEC 6 1 1 4 0 a n d fixing

C4 5 .8 .3 C o m p le te s p e c im e n V isu al c h e c k No s h a r p e d g e s

C5 C o n n e c tio n s a n d tc rm ia n tio n s 5.4.1 a n d 5 .4 .4 C o m p le te s p e c im e n V isu al c h e c k Fix p o sitio n o f term in als

C6 C le a r a n c e s a n d c r e c p a g c 6 .3 .6 C o m p le te s p e c im e n , M e a s u re m e n t R e q u ire m e n ts o f 5 .1 4 m u s t be
d is ta n c e s te rm in a te d fulfilled

C7 W all th ic k n e ss 5 .8 .2 C o m p le te s p e c im e n M e a s u re m e n t W all th ic k n e ss m in. 3,0m m ,

o th e rw ise te s t a c c . to BIO

C8 Lid 5 .3 .2 C o m p le te s p e c im e n V isu al c h e c k R e q u ire m e n ts o f 5 .3 .2 m u s t be

fulfilled

30
 2 Ffg 1162/07.2007

Table 8 Group D Mechanical tests (single tests)

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o rd in g S p e c im e n M e a su re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

Dl C o n n e c tio n s a n d te rm in a tio n s 6 .3 .2 0 C o m p le te s p e c im e n M e c h a n ic a l te s t o f R e q u ire m e n ts o f re le v a n t

suitability o f term in als c la u s e s m u s t b e fulfilled
T est a n d c o n n e c tio n s

D2 C o v e rs o f o p e n in g s 6 .3 .2 1 4 c o m p le te s p e c im e n M e c h a n ic a l te s t No d a m a g e in s e n s e o f 6.3.21

D3 C o rd a n c h o r a g e 6 .3 .2 2 C o rd a n c h o r a g e Pull- a n d to rsio n te s t No e x c e s s iv e d is p la c e m e n t o f
c a b le

D4 M e c h a n ic a l s tre n g th a t low 6 .3 .9 C o m p le te s p e c im e n Im p a c t te s t No d a m a g e
te m p e ra tu re s

D5 Fixing o f lid 6 .3 .3 2 a g e d s p e c im e n M e c h a n ic a l te s t No d m a g e o f sc re w s o r th re a d s
from G ro u p E a n d F
No d a m a g e o f s c r c w le s s
fixation

D6 Fixing o f ju n c tio n b o x a t 6 .3 .5 2 a g e d s p e c im e n M e c h a n ic a l te s t N o lo o s e n in g o r d is p la c e m e n t
b a c k s h e e t m a te ria l from G ro u p E a n d F o f s p e c im e n

Follow ing te s t a c c . to 6 .3 .1 7

31
 2 Pfg 1162/07.2007

Table 9 G roup E T estseq u en z 1 (T ests co nseq u en tly in th is order)

1 2 3 4 5 6

T est D e s ig n a tio n T e st a c c o rd in g S p e c im e n M e a s u re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

El D e g re e o f p ro te c tio n 6 .3 .4 S p e c im e n d e s c rib e d IP -protection N o in g re s s o f d u s t a n d w ater.

in 6.2.5

E2 D ielcctrie s tre n g th 6 .3 .7 b) S a m p le s from E l r.m .s high v o ltage te s t No fla s h o v c r o r b re a k d o w n o f

voltage
2 0 0 0 V + (4x ra te d
v o lta g e )

E3 W e t le a k a g e c u rre n t te st 6 .3 .1 7 S a m p le s from E l Insu latio n re s is ta n c e Insulation r e s is ta n c e not le ss

th a n 4 0 0 M fl.

E4 T h e rm a l cy cle te s t 6 .3 .1 0 .1 S a m p le s from E l C ycle te s t 2 0 0 c y cles N o visible d a m a g e s

E5 D ielectric s tre n g th 6 .3 .7 b) S a m p le s from E l r.m .s high v o ltage te s t No fla s h o v c r o r b re a k d o w n o f

voltage
2 0 0 0 V + (4x ra te d
v o lta g e )

E6 D ielectric s tre n g th 6 .3 .7 a ) S a m p le s from E l Im pulse v o ltage te s t No fla s h o v e r o r b re a k d o w n o f

voltage

32
 2 Pfg 1162/07.2007

T able 10 G roup F T e s ts e q u e n z 2 (T ests co nseq u en tly in th is order)

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o rd in g S p e c im e n M e a su re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

FI W e i le a k a g e c u rre n t te s t 6 .3 .1 7 S p e c im e n d e s c rib e d Insulation re s is ta n c e Insu latio n r e s is ta n c e n o t le ss

in 6 .2 .5 th a n 4 0 0 M ft.

F2 D am p h e at 6 .3 .1 1 S a m p le s from F I A g eing tc stg N o visible d a m a g e s

F3 D iclcctric stre n g th 6 .3 .7 b) S a m p le s from F I r.m .s high v o h a g c te s t N o fla s h o v e r o r b re a k d o w n o f

v o lta g e
2 0 0 0 V + (4x ra te d
v o lta g e )

F4 W e t le a k a g e c u rre n t te s t 6 .3 .1 7 S a m p le s from FI Insulation re s is ta n c e Insu latio n r e s is ta n c e n o t le ss

th a n 4 0 0 M ft.

T able 11 G roup G T estseq u en z 3 (Tests co nseq u en tly in th is order)

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o rd in g S p e c im e n M e a su re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

Gl T h e rm a l cy cle te s t 6 .3 .1 0 .2 S p e c im e n d e s c rib e d C ycle te s t 5 0 c y cles N o visible d a m a g e s

in 6 .2 .5

G2 H u m id ity -freeze te s t 6 .3 .1 8 S a m p le s from G l A geing te s t N o visible d a m a g e s

G3 W et le a k a g e c u rre n t te st 6 .3 .1 7 S a m p le s from G l Insu latio n re s is ta n c e Insu latio n r e s is ta n c e n o t le ss

th a n 4 0 0 M O.

Table 12 G rou p H B ypass-D iod e-T est

1 2 3 4 5 6

T est D e s ig n a tio n T e s t a c c o rd in g S p e c im e n M e a s u re m e n ts, R e q u i r e m e n ts

p h ase to d e s ig n a tio n

HI T h e rm a l b y p a s s -d io d e -te s t 6 .3 .1 9 S p e c im e n d e s c rib e d H e atin g te s t No e x c e e d in g te m p e ra tu re s a t

in 6 .2 .5 b y p a s s -d io d e

H2 W et le a k a g e c u rre n t te st 6 .3 .1 7 S a m p le s from H I Insu latio n re s is ta n c e Insu latio n r e s is ta n c e n o t le ss

th a n 4 0 0 M i l

33
 2 Pfg 1162/07.2007

Annex A
(norm ative)

W arning label „No disconnection under load 11

 2 Pfg 1 162/07.2007

Annex B
(norm ative)

Num ber of specim en

The tests m ust be perform ed with following num b er o f s p e c i m e n and plates (material). If o n e s p e c i m e n fails the tests
a s d escrib ed in 6 .1 .5 a relevant num b er o f s p e c i m e n m ust be p r e se n te d according to table B.l

T able B.1 N um ber of specim en

T e st Description o f sp e c im e n N u m b er

Group A S ep a r a te s p e c i m e n , provided with all markings and c o m p o n en ts 1

Group B S ep a r a te s p e c i m e n , provided with all markings and c o m p o n e n ts 3

B3 T e st plates o f polym er materials serving as an e n c lo s u re and o f polym ers serving a s support 1

for live m e ta l parts, e a c h

B6 Additional test plate o f potting material, if applicable. 1

Group C S e p ara te s p e c i m e n , provided with all markings and c o m p o n e n ts I

Group D S ep a r a te s p e c i m e n , provided with all markings and c o m p o n en ts 5

,a,
Group E S p e c im e n m ounted on relevant b a c k s h e e t material with relevant a d h e s i v e , potted (if
applicable). Cell c o n n e c tio n s b e n d e d and c o n n e c t e d a s d e scrib e d in 6 .2 .3 . Intended cable
m ust be c o n n e c te d ..

l a>
Group F S p e c im e n m ounted on relevant b a c k s h e e t material with relevant a d h e s i v e , potted (if
applicable). Cell c o n n e c tio n s b e n d e d and c o n n e c te d a s d escrib ed in 6 .2.3 . Intended cable
m ust be c o n n e c te d .

,a>
Group G S p e c im e n m ou n ted on relevant b a c k s h e e t material with relevant a d h e s i v e , potted (if
applicable). Cell c o n n e ctio n s b e n d e d and c o n n e c t e d a s d e scrib e d in 6 .2.3 . Intended cable
m ust be c o n n e c te d .

1 a)b)c)
HI S p e c im e n m ou n ted on relevant b a c k s h e e t material with relevant a d h e s i v e , potted (if
applicable). Cell c o n n e ctio n s b en d e d and c o n n e c t e d a s d e scrib e d in 6 .2 .3 . Intended cable
m ust be c o n n e c te d .

a)If the junction box is intended to be m ounted at se v e r a l b a c k s h e e t materials and/or fixed with se v e r a l a d h esiv e
an/or potted with s e v e r a l potting materials the tests m ust be performed at all possible constellations with relevant
num b er o f sp e c im e n .

b) If the junction box is intended to be u s e d with se v e r a l types and/or com binations o f b y p a s s -d io d e s and/or se v e r a l
rated currents o f junction box the tests m ust be perform ed at all p o ssible constellations with relevant num b er o f
sp e c im e n .

c) Is the junction box intended to be potted su ch that the b y p a s s - d io d e s are not a c c e s s ib le the thermal co u p les
m ust be fixed before potting upon consultation with the testing body.

35