IEC 63522-39:2025

Overview

IEC 63522-39:2025 is an international standard published by the International Electrotechnical Commission (IEC) covering the testing of electrical relays, specifically focused on measuring the insertion and withdrawal force. This standard addresses the practical reliability and performance of relays under expected conditions such as transportation, storage, and operational use. It is applicable to all types of electromechanical elementary relays, including those with flat quick-connect terminations and eye lug connectors.

Adhering to IEC 63522-39:2025 ensures consistent testing methods, objective evaluation, and improved safety and reliability of electrical relay assemblies. This document is a critical resource for manufacturers, test engineers, and quality assurance professionals in the field of electrical engineering and electronic equipment.

Key Topics

The standard details the following key test methods and procedures:

• Measurement of insertion and withdrawal forces for mating relay and socket pairs
• Assessment of insertion and withdrawal forces on relays fitted with flat quick-connect terminations
• Verification of correct connection of flat terminals with eye lug connectors

Additional core points include:

• Visual examination and inspection techniques
• Conditions to be specified (cycle count, force limits, mounting position, speed of operation)
• Comprehensive reporting requirements for each tested relay configuration

Applications

IEC 63522-39:2025 serves as an essential reference across industries where electrical relays are critical components, such as:

• Manufacturing and quality control - Standardized measurement methods ensure repeatable, comparable results in relay production and incoming inspection processes
• Transportation and storage validation - Relays are tested for resilience under real-world handling to prevent failure due to excessive insertion/withdrawal forces
• Safety-critical systems - Consistent and validated relay connections minimize the risk of malfunction in mission-critical applications (industrial controls, automotive systems, telecommunications, etc.)
• Maintenance and field testing - Ensures interoperability and proper connection force in equipment upgrades, repairs, or retrofits

Related Standards

Implementing IEC 63522-39:2025 often involves familiarity with several related standards, including:

• IEC 61810-1: Electromechanical elementary relays - General and safety requirements
• IEC 61210: Connecting devices - Flat quick-connect terminations for electric copper conductors - Safety requirements
• IEC 61984: Connectors - Safety requirements and tests
• IEC 63522-0: Electrical relays - Tests and measurements - Part 0: Testing general (under preparation)
• IEC 63522-1: Electrical relays - Tests and measurements - Part 1: Visual inspection and check of dimensions (under preparation)
• IEC 60512-13-2: Connectors for electronic equipment - Insertion and withdrawal force tests

Reference to these standards assures comprehensive compliance and harmonization with globally recognized testing methods.

Practical Value

Compliance with IEC 63522-39:2025 provides multiple benefits:

• Objective benchmarking of insertion and withdrawal force for electrical relays, supporting product development and quality assurance
• Enhanced safety and performance, reducing the risk of connection failures due to too-tight or too-loose fits
• Improved interoperability between different relay and socket manufacturers
• Streamlined documentation with detailed reporting protocols fostering traceability in testing and certification

By following IEC 63522-39:2025, stakeholders demonstrate commitment to quality and reliability in relay-based systems, supporting broader compliance efforts and market acceptance for electrical products worldwide.