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.
Open preview (PDF)Electrical relays - Tests and measurements - Part 1: Visual inspection and check of dimensions
