IEC 63522-1:2025

Overview

IEC 63522-1:2025 - Electrical relays: Tests and measurements - Part 1: Visual inspection and check of dimensions defines a standardized, reproducible method for visually inspecting relays and verifying their key dimensions. Published by the IEC in 2025, this part of the IEC 63522 series is intended to assess a relay’s mechanical integrity, marking and dimensional conformity under expected conditions of transportation, storage and operational use. It is primarily a non-destructive testing procedure unless the product standard requires internal inspection.

Key topics and requirements

• Scope & purpose
  • Ensure relay marking, terminal identification and dimensions conform to product specifications.
  • Detect visible mechanical defects and document findings.
• Inspection levels
  • Initial inspection: marking, terminal ID, housing (colour) and mechanical defects.
  • Visual inspection: outside-only checks for deformation, abrasion or other defects.
  • Detailed inspection: internal examination when required by the product standard (may involve careful opening).
• Dimensional checks
  • Outline dimensions: conformity with drawings and detail specifications.
  • Clearance and creepage: verified per relay specification and IEC 63522-41 (insulation coordination); includes contact gap and barrier thickness where applicable.
  • Detailed dimensions & gauging: component-level checks and use of gauges when specified.
• Measurement methods & equipment
  • Acceptable tools include vernier gauges, micrometres, callipers, measuring projectors, microscopes, CT/X‑ray scanning and CAD evaluation combined with CT data for complex insulation geometry.
• Conditions to specify
  • Optical method, ambient lighting and special devices (e.g., polarized light), measurement magnification, gauging details and any deviations from standard methods.
• Reporting
  • Test report should enable reproducibility and record specimen description, methods, visual observations and dimensional results.

Applications and users

IEC 63522-1:2025 is used by:

• Relay manufacturers for production and final inspections
• Third‑party test laboratories and certification bodies
• OEMs and system integrators for incoming inspection and design verification
• Quality, compliance and procurement teams for supplier audits and acceptance testing
• R&D and failure‑analysis engineers for mechanical diagnosis and validation

Typical applications include routine production checks, pre‑shipment inspections, design verification (clearance/creepage checks) and documentation for conformity assessment.

Related standards

• IEC 63522-0: General and guidance for relay tests
• IEC 63522-41: Insulation coordination - reference for clearance and creepage requirements
• EN 13018: Guidance on visual testing (non‑destructive testing)

Keywords: IEC 63522-1:2025, electrical relays tests, visual inspection, check of dimensions, non-destructive testing, clearance and creepage, relay marking, dimensional inspection.