VDE 0620 0625 0626 插头连接器 插座工厂审查测试指导PM 375e 2014

Test Instruction for the Factory Surveillance of

Plugs, Couplers, Socket Outlets and Parts which are integral

with Flexible Cables and Cords according to

VDE 0620, -2-1, -101, VDE 0625-1,-2-1, -2-2, and VDE 0626 with

and without ENEC-Mark

PM 375 E

2014-07-08

References

DIN VDE 0620-1

Plugs and socket outlets for household and similar purposes

Part 1: General requirements on fixed socked-outlets

DIN EN 0620-2-1

Plugs and socket outlets for household and similar purposes

Part 2-1: General requirements on Plugs and portable socket-outlets

DIN EN 50075 - VDE 0620-101

Plugs and socket outlets up to 400 V, 25 A

Flat non-rewirable two-pole plugs, 2,5 A 250 V, with cord, for the

connection of class-II-equipment for household and similar purposes

DIN EN 60320-1 - VDE 0625-1

Appliance couplers for household and similar general purposes

Part 1: General requirements

DIN EN 60320-2-1 - VDE 0625-2-1

Appliance couplers for household and similar general purposes

Part 2-1: Sewing machine couplers

DIN EN 60320-2-2 - VDE 0625-2-2

Appliance couplers for

household and similar general purposes

Part 2-2: Interconnection couplers for household and similar general purposes

DIN EN 60799 - VDE 0626

Cord sets and interconnection cord sets

ENEC-303, Annex W, Annex AI and Annex X

Requirements for manufacturers

1. General

Any plug, socket outlet and appliance coupler has to be subjected to the following tests, as

far as applicable:

Type of plug, socket outlet and appliance

coupler

two-pole

with more than two poles

Test to be performed according to clause

2.1.1, 2.3.2; 3.1, 4.1, 4.3

2.1.1, 2.2, 2.3.2, 3.1.2; 4.1, 4.2, 4.3

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Original bei IC/ original at IC

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The indicated tests are minimum requirements. The manufacturer shall perform additional

tests or checks if he considers it necessary for a special product.

The performance of the tests has to be confirmed in writing; the records shall contain the

main conditions. The test records have to contain the following information:

- Product type

- Date of test

- Place of manufacture (if manufactured at several places)

- Tested quantity

- Number of rejected products and measures, i. e. destroyed/repaired.

Prior to the use of the test equipment it has to be checked as to correct functioning. It has to

be calibrated at least once a year.

1.1 Evaluation of base material and components

The manufacturer shall introduce a suitable programme to guarantee that only materials and

components are used corresponding with the certified version. In any case this programme

has to take into consideration the safety-relevant components, e. g. the plug insert and cord.

The validity of VDE Certificates available for components has to be checked periodically.

1.2 Production line test (required on finished products at 100%)

The following tests have to be performed by the manufacturer on all manufactured products

with and without ENEC-Mark. Products which fail to pass the tests shall not be delivered.

They have to be segregated in appropriate ways.

The test equipment has to be checked prior to and after each use as well as in case of con-tinuous use every 24 h. The checks have to show that the test equipment indicates errors

when detected defect products are checked or reproduced errors have been used.

Products having been produced prior to the check of the test equipment are allowed to be

placed on the market only if the check has been satisfactory.

1.3 Periodic Tests

For products with and without ENEC Mark, additional random tests have to be performed.

The tests are performed by the manufacturer or on his behalf, at least at the frequency

indicated; the test records have to be kept at the place of manufacture for revision by the

inspector of the certification body.

In selecting samples for periodic tests preference should be given to products whose

characteristics are close to the limiting values and for which tests related to safety are

necessary according to regulation.

For periodic tests preferably those products should be selected, the values of which are

close to the limiting values and to tests for safety considerations according to the standard.

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2. Production line test 100%

2.1 Continuity test

2.1.1 Polarized systems; Phase (L) und Neutral Conductor (N) – correct connection

In polarized systems the test has to be performed by applying the Safety Extra Low Votage

(SELV) for not less than 2 s:

Note: For test equipment with an automatic time programme the time may be reduced from 2 s to not less than

1 s.

- for plugs, couplers, plugs and socket outlets between the external terminal of L and N of

the flexible cable and cord and the corresponding L and N pin or contact of the plug and

socket outlet.

- for extension cord sets, cord sets and interconnection cord sets between L and N pin on

one terminal and the corresponding L and N contact on the other terminal of the flexible

cable and cord.

The polarity has to be correct.

Other suitable test can be used.

2.2 Protective earth conductor (E) connection

The test has to be performed at safety extra low voltage (SELV) which is applied for not less

than 2 s.

Note: For test equipment with an automatic time programme the time may be reduced from 2 s to not less than

1 s.

- for plugs, couplers and plugs and socket outlets between the external terminal of the

protective earth conductor of the flexible cable and cord and the earth conductor pin or

contact of the plug and socket outlet.

- for extension cord sets, cord sets and interconnection cord sets between the correspon-ding protective earth conductor or contact on each terminal of the extension cord.

It must be possible to measure the continuity.

Other suitable test can be used.

2.3 Dielectric strength test

2.3.1 Short circuit/wrong connection, connection and reduction of the creepage distances

and clearances Phase (L) or Neutral Conductor (N) connected to the protective earth

conductor (E)

The test is performed between L and N conductors and the protective earth conductor.

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An a. c. voltage of 50 or 60 Hz is applied for 2 s on the supply terminal, i. e. on the plug.

Note: For test equipment with an automatic time programme the time may be reduced from 2 s to not less than

1 s.

- 1250 V +/- 10% for products having arated voltage up to and including 130 V

- 2000 V +/- 10% for products having a rated voltage over 130 V

or

- through an impulse voltage test having a waveform 1,2/50 s, peak value 4 kV; three im-pulses with intervals not below 1 s are applied on each pole:

- between L and protective earth conductor

- between N and protective earth conductor

Note: L and N may be connected for this test.

A flashover shall not occur.

2.3.2 Contour check

It shall be checked that live parts, e. g. loose strands, are not accessible.

If this danger cannot be prevented by the construction itself and suitable manufacturing pro-cesses, the following test or a similar one (e. g. impulse voltage test) shall be performed:

The endangered parts of plug and socket outlet surfaces, except the engagement face of

plugs, are scanned by adjusted electrodes and a pressure force of 20 N, applying to live

parts of the plugs and socket outlets a voltage of AC 2000 V (r. m. s. value) for at least 1 s.

Neither a flash-over nor a breakdown shall occur.

Note: It is recommended to set the tripping device to 30mA or less. The high voltage transformer is to be capable

of maintaining the specified voltage untilthe tripping current ng of the current sensing device

(indicated by audible and/or visual means) is considered a breakdown.

3. Random tests (only for products with certification according to

DIN VDE 0620-1, 0620-2-1)

3.1 Tests to be performed during the production of plugs and couplings with crimp

connections

- A capability test of the tool used must be performed on at least 50 test objects.

At least the following must be documented:

- crimp height; or

- withdrawal force; or

- voltage drop in the crimp connection.

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It is recommended to perform the test following

DIN EN 60352-2 - Solderless connections – Crimp connections – General requirements, test

methods and instructions for use.

The values obtained in this test must not be worse than those laid down in the type test in

accordance with VDE 0620-1, 0620-2-1 Section 12.4.

Crimp connections in non-reconnectable plugs and connectors must possess adequate

electrical and mechanical properties. Photographic documentation must be drawn up of a

total of 3 points of contact from 3 sides, consisting of side view, top view and perspective

view. The values for crimp height, withdrawal force or voltage drop (lower and upper limit

values) are to be determined and documented by the manufacturer and are the basis for

continuous production inspections.

- The crimp height, withdrawal force and/or voltage drop in the crimp connection are to be

checked during production. The determined values must not be worse than those laid

down in the type test in accordance with VDE 0620-1, Section 12.4.

The test is to be performed on at least 3 test objects per product at the beginning and end of

the production of the batch, but at the latest after 8 hours.

The results must not be worse than those laid down in the type test in accordance with

VDE 0620-1, Section 12.4.

The results are to be documented by the manufacturer and archived for ten years.

4. Periodic tests

4.1 Periodic tests (only for products with certification according to DIN EN 50075 – with

ENEC-Mark)

4.1.1 Dimensions according to section 7

4.1.2 Dielectric strength test according to section11.2

4.1.3 Flexing test according to section 11.2

4.1.4 Torque test on the plug pins as prescribed in section 13.2

The test of 4.1.1, 4.1.2 and 4.1.3 have to be performed by the manufacturer, at least 2 times

per year, on 3 samples from each series/family (same construction) when in production.

The test of 4.1.4 has to be performed on at least 3 randomly selected samples of each

production lot. The test of 4.1.4 may also be performed in the incoming inspection on 3

randomly selected samples of each lot of received inserts.

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4.2 Periodic tests (only for products with certification according to DIN EN 60320 – with

ENEC-Mark)

4.2.1 Dielectric strength test

The dielectric strength test has to be performed according to:

- Part 1 Section 15

4.2.2 Mechanical strength test

The mechanical strength - tensile test has to be performed according to:

- Part 2-2, 2-3, 2-4 Section 23

4.2.3 Connection of conductors

The connection of conductors test has to be performed according to:

- Section 22 (of the relevant parts; exept twist test part 2-1)

4.2.4 Force to insert and withdraw connector

Force necessary to insert and withdraw the connector (Part 1, section 16).

The tests 4.2.1, 4.2.2 and 4.2.3 have to be performed on three selected samples of each

series/family (same construction) when in production at least two times per year.

The test 4.2.4 has to be performed on three randomly selected samples of each production

lot. This test may also be performed in the incoming inspection on 3 randomly selected

samples of each lot of received inserts

4.3 Periodic tests (only for products with certification according to DIN EN 60799 - with

ENEC-Mark)

The manufacturer has to guarantee by suitable periodic tests that the manufactured products

comply with the certified version. For this purpose he has to introduce a uitable working

instruction to ensure that only materials and components are used corresponding with the

certified version.

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4.4 Periodic tests (only for products VDE-Mark)

The manufacturer has to guarantee by suitable periodic tests that the manufactured products

comply with the certified version. The periodic tests have to be performed by the manufact-urer on each day of production for each production lot at least on one sample per produced

type.

Plugs and portable Euro plug

socket outlets

DIN VDE

(VDE

Clauses

8

22

24.2

9

Socket outlets

Appliance couplers

0620-1 DIN VDE 0620-101 Corresponding parts of

0620-1) (VDE 0620-101) standard DIN EN 60320

Clauses (VDE 0625) Clauses

6

-

13.2

7

8

16

-

9

4.1 Visual check and markings

4.2 Pull forces

4.3 Twist test on plug pins *)

4.4 Dimensions

Testing:

The periodic tests are performed by measurement and/or with gauges.

*) Remark:

24.2 The tumbling barrel test need not be performed.

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Informative

/ 附页

Test-Requirements for periodic Test, according clauses 4.4 for plugs and socket

outlets/ 4.4章节中插头插座的定期确认检验要求

The periodic tests are performed by measurement and/or with gauges.

 To ensure that the test-requirements for periodic test during mass production can be

fulfilled in compliance with the standards, the gauges/devices mentioned in

DIN VDE 0620-1, 0620-2-1, 0620-101 should be prepared for each manufacturer.

 All concerned gauges are listed for reference as bellows.

定期确认检验需通过测量及/或借助制具进行。

 为保证批量生产中的定期确认检验能满足相关标准要求，生产商应备有标准

DIN VDE 0620-1和DIN VDE 0620-2-1中列出的制具和设备。

 相关制具请参见下文。

1. Dimensions / 尺寸

1.1 Gauge for the size of the socket outlet’s insertion hole:

1.1 插座插孔开口大小的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 1 / 制具1

Gauge for the size of the socket outlet’s insertion hole:

Gauge with diameter 6.0 mm： for 16 A socket with cover material made of rubber or ceramic

Gauge with diameter 5.8 mm: for 16 A socket with cover material made of all except rubber/ ceramic

Gauge with diameter 5.0 mm for 2.5 A socket with cover made of any material

The weight of the gauges is not greater than 150 g. The applicable force is the gauge’s own weight.

插座插孔开口大小的测量制具：

直径6.0mm制具（德式插座）：16A的插孔，插座外壳材料为橡胶或陶瓷；

直径5.8mm制具（德式插座）：16A的插孔，插座外壳材料为除橡胶和陶瓷之外的材料；

直径5.0mm制具（欧洲头插座）：2.5A的插孔， 任意的插座外壳材料；

在应用这些制具的时候，要求在自身重量不大于150克时，制具不能垂直插入到插座的插孔中去；

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1.2. Gauge to test the distances of the contacts and minimum withdrawal force for

plug and socket outlet:

1.2. 插孔内金属片的最短接触距离和最小拔出力的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 2 / 制具2

2A 2B

Gauge to test the distances of the contacts

and minimum withdrawal force for plug and

socket outlet:

Gauge 2A：diameter 3.8 mm weight 200 g.

Insert into the contact of the socket outlet

vertically, it will not slip out within 30 s;

Gauge 2B：diameter 4.6 mm weight 200 g.

Insert into the earthing contact of the plug

vertically, it will not slip out within 30 s;

插孔内金属片的最短接触距离和最小拔出力的测量制具，常用

2A制具：3.8 mm的直径，自重200克，

测量插座插孔内的金属片的最小拔出力。

垂直插入插座插孔，要求在30秒内不从孔内滑脱；

2B制具：4.6 mm的直径，自重200克，

测量插头接地孔内的金属片的最小拔出力。

垂直插入插座插孔，要求在30秒内不从孔内滑脱；

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1.3. Gauge for two-pole plug’s insertability:

1.3. 插座插孔（两极）开孔间距的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed by measurement and/or with gauges.

该测试可通过测量及/或借助相关制具进行.

Gauge 3 / 制具3

Gauge for two-pole plug’s insertability:

Both sides’ pin of the gauge can be

introduced freely and fully into the socket outlet.

插座插孔（两极）开孔间距的测量制具：

该制具两侧的插针，都应该可以自由地插入到插座

孔内。

1.4. Gauge to check the socket’s insertion capability for plugs with side earthing

contacts:

1.4. 德式插座（两芯带接地）插孔的可插入性的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed by measurement and/or with gauges.

该测试可通过测量及/或借助相关制具进行.

Gauge 4 / 制具4

德式插座（两芯带接地）插孔的可插入性的测量制具:

Gauge to check the socket’s insertion

capability for plugs with side earthing

contacts:

The pins of the gauge can be introduced

freely and fully into the socket-outlet.

制具4可以轻松的插入到德式插座的插孔中去。

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1.5. Gauge to test the distance between the cover and the contacts of the socket:

1.5 插座插孔表面与内部载流金属片间隙的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 5 / 制具5

Gauge to test the distance between the cover and

the contacts of the socket:

插座插孔表面与内部载流金属片间隙的测量制具：

When inserting the short side of the gauge (6.95 mm) it

要求这些制具短的插针（6.95 mm）插入插孔时

shall not touch the contacts;

不能碰到插孔内的金属片；

When inserting the long side of the gauge (9 mm)

要求这些制具长的插针（9 mm）插入插孔时，

it shall touch the contacts;

能够碰到到插孔内的金属片。

1.6. Gauges for the plug pin’s diameter:

1.6 插头插针直径的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 6/ 制具6

Gauges for the plug pin’s diameter:

For gauge 6A: the plug’s pin can insert

through the inner hole of the gauges;

For gauge 6B: the plug’s pin cannot

pass through the slot of the gauges;

插头插针直径的测量制具：

对于6A制具， 要求插头的插针可以插入制具的开孔；

对于6B制具， 要求插头的插针不能推入制具圆孔的缺口；

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1.7 Gauge to test the pin spacing for plugs (2P + earth)/ (2P) AC 16 A:

1.7 交流16A的插头(2P+earth)/ (2P)插针之间的内间隙和外间隙的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed by measurement and/or with gauges.

该测试可通过测量及/或借助相关制具进行.

Gauge 7 / 制具7

Gauge to test the pin spacing for plugs (2P +

earth)/ (2P) AC 16 A:

Gauge 7A slot can pass over the two pins;

Gauge 7B can pass through the inner space between

two pins.

交流16A的插头(2P+earth)/ (2P)插针之间的内间隙和外间隙的测量制具:

制具7A要能够通过两插针的最大的外侧间距；

制具7B要能够穿过两插针的内侧间距。

1.8. Gauge to test the largest opening insertion of contact tubes:

1.8 插座的载流金属片插入强度的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed by measurement and/or with gauges.

该测试可通过测量及/或借助相关制具进行.

Gauge 8 / 制具8

Gauge to test the largest opening insertion of

contact tubes:

The gauge can be introduced into the contact tubes

without excessive undue force.

插座的载流金属片插入强度的测量制具:

要求制具无需用很大的力就能够轻易的

插入到插座插孔的载流金属片里面。

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1.9 Gauges for plug’s exchangeability:

1.9 插头互换性的测量制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 9/ 制具9

Gauges for plug’s exchangeability:

The plug with side protective earthing contact can be

easily inserted into the gauge without excessive undue

force.

插头互换性的测量制具：

要求两芯带接地的插头可以不费力气就插入到该制具中。

1.10 Gauges for non insertion of the two-pole plug without side earthing protective

contact:

1.10 插座插孔的插入性测量制具（两芯不带接地插头）：

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行

Gauge 11/ 制具11

Gauges for non insertion of the two-pole

Plug without side earthing protective

Contact

It shall not be possible to introduce the gauge into the

socket outlet.

插座插孔的插入性测量制具（两芯不带接地插头）：

要求该制具不能插入到插座的插孔内。

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1.11 Gauge to test the withdrawal force of the earthing contact of the plug DIN 49441,

form R2:

1.11 DIN 49441-R2类型插头的接地孔最大拔出力制具

DIN VDE 0620-2-1, clause 9/ DIN VDE 0620-2-1, 第9章

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 16e/ 制具16e

Gauge to test the withdrawal force of the earthing

contact of the plug DIN 49441, form R2:

The gauge 16e is inserted vertically into the elastic

earthing contact of the plug.

The gauge will be 10 times inserted in the earthing

contact and detracted.

The gauge will be inserted again and shall not be stuck

to the contact.

DIN 49441-R2类型插头的接地孔最大拔出力制具:

18N制具16e应垂直插入到 DIN 49441-R2类型的插头的接地孔。

反复将该制具插入拔出接地孔10次。

再次将该制具插入接地孔，该制具不应留在接地孔内，应滑脱。

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1.12 Gauge for the interchangeability of the European plug:

1.12欧式插头的互换性的测试制具

EN 50 075, - DIN VDE 0620-101, clauses 7/ EN 50 075, - DIN EN 0620-101,

The test is performed with gauges.

该测试需借助相关制具进行.

Gauge 2/Figure 2 制具2

Gauge for the interchangeability of the European

plug:

It shall be possible to insert the European plug into the

gauge without undue force so that the engagement face

comes into contact with the surface of the gauge.

欧式插头的互换性的测试制具：

无需用太大的力就可以将欧洲头插头

插入到该制具中，使得插头的端面与

制具的表面相贴合。

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2. Withdraw forces/ 拔出力

2.1 Gauges for the maximum withdrawal force of the socket outlet:

2.1 插座插孔的最大拔出力测量制具:

DIN VDE 0620-1; clause 22/ DIN VDE 0620-1; 第22章

DIN EN 60320-1; clause 16/ DIN EN 60320-1; 第16章

The test is performed with test devices and gauges.

该测试需借助检验设备和制具进行。

Figure 1/ 图1

Apparatus for testing of withdrawal forces

测量拔出力所用装置

Gauges for the maximum withdrawal force of the

socket outlet:

Fix the socket outlet vertically on device as shown in

Figure 1. The gauge with main and additional weight is

inserted in the socket outlet. Then let the additional

weight fall from a height of 50 mm on the main weight.

The gauge shall not remain in the socket outlet.

Gauges for the maximum withdrawal force of

the socket outlet:

测试连接器

插座插孔的最大拔出力测量制具:

将插座固定在图1的架子上, 插孔朝下,

然后针对德式以及欧式的插座插孔,

分别插入德式和欧式插头的制具,在对

应的的重量下, 要求制具要从插座的

插孔内滑脱。

Seite / page 16/17

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VDE Testing and

Certification Institute

PM 375 E – 2014-07-08

Q

3. Twist test for plug pin / 插头插针的扭矩测试

3.1 Torque test for plug pin:

3.1插头插针的扭矩测试

DIN VDE 0620-2-1, clause 24.2/ DIN VDE 0620-2-1, 第24.2章

DIN VDE 620-101, clause 13.2/ DIN VDE 620-101, 第13.2章

Torque test for plug pin

The pins must not rotate when a torque of 0.4 Nm is

applied, first for 1 minute in one direction then

1 minute in the other direction

插头插针的扭矩测试：

The plug’s pin shall not loose or rotate when

applying a torque of 0.4 Nm on the plug pin.

No part should be loosened.

(1 min in one direction and then 1 min in the other

direction)

针对插头的插针， 需要进行扭矩测试。

要求在不小于 0.4 Nm 的扭矩下，

插针不能松动或转动。

The relevant standards should be kept in the factory for the performance of the tests.

工厂应备有相关标准以保证检验的顺利进行。

The above-mentioned tests have to be specified by the manufacture in a testing or working

instruction and the performance has to be documented in writing.

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