August 2026: New Impulse Voltage Testing Standard for Electrical Relays

The electrical engineering industry has seen a pivotal update this August 2026 with the publication of EN IEC 63522-46:2026, introducing rigorous requirements for impulse voltage testing of electrical relays. Developed and endorsed by CLC, this standard aims to bolster the reliability, safety, and compliance of relays across a range of applications. With only one new standard featured this cycle, organizations in the sector need to be aware of these changes and understand how implementing them will affect both product development and compliance strategies.

Overview

Electrical relays play a crucial role in controlling circuits, switching devices, and safeguarding systems across power distribution, industrial automation, and critical infrastructure. Given their importance, ensuring relay durability under transient overvoltages is vital for operational safety and continuity.

Standards like EN IEC 63522-46:2026 provide rigorous testing methodologies and criteria that manufacturers, quality managers, and engineers depend on to validate relay performance. This article details what’s new in this essential standard, why impulse voltage testing matters, and how professionals should approach compliance and certification.

Detailed Standards Coverage

EN IEC 63522-46:2026 – Impulse Voltage Test for Electrical Relays

Electrical relays – Tests and measurements – Part 46: Impulse voltage test

EN IEC 63522-46:2026 establishes the test procedures, requirements, and evaluation criteria for conducting impulse voltage tests on electrical relays. This process is designed to assess the resistive ability of relay insulation under simulated lightning surges or switching transients, emulating real-world electrical disturbances.

Scope and Applicability:

• Focuses on relays used in low- and medium-voltage applications
• Covers the method for generating impulse voltages with defined shape, amplitude, and duration (combination wave, typically 1.2/50 µs)
• Applicable to manufacturers, independent testing laboratories, and quality assurance professionals involved in relay design and validation

Key Requirements:

• Preconditioning: Before testing, relays may require defined preconditioning, ensuring consistency in results
• Test Procedure: Specifies the application of standardized impulse voltages across relay insulation or relevant test points, with test parameters taken from Table A.1 and figures in Annex A
• Pass Criteria: The insulation must demonstrate no breakdown during the test sequence. After test completion, final checks validate relay functionality and insulation integrity
• Documentation: A detailed test report, including configurations, applied voltages, observed results, and compliance statement, must be produced

Practical Implementation: Complying with this standard means updating test setups to follow the prescribed combination wave generator circuit (see Figure A.1) and time parameters (Figure A.2). Manufacturing and QA teams will need to ensure their test records meet the reporting detail required by the standard. For multi-site manufacturers, harmonizing procedures across locations is recommended for global compliance.

Notable References:

• Uses methodology harmonized with IEC 60060-1:2025 (High-voltage test techniques)
• Cross-references insulation coordination and dielectric strength standards (EN IEC 60664-1, EN IEC 63522-4)
• Supplements generic relay test guidance from EN IEC 63522-0:– (under preparation)

Key highlights:

• Defines test circuits and parameters for reliable, repeatable impulse voltage testing
• Details pass/fail and reporting criteria to ensure compliance and traceability
• Harmonizes with related insulation and high-voltage test standards for broad applicability

Access the full standard:View EN IEC 63522-46:2026 on iTeh Standards

Industry Impact & Compliance

The implementation of EN IEC 63522-46:2026 affects a broad array of stakeholders across the electrical engineering value chain:

• Manufacturers must adapt production line testing and product validation to conform to updated protocols
• Quality managers and compliance officers must revise audit procedures, ensuring conformity assessment aligns with new pass/fail criteria
• Engineers and R&D teams can leverage the standardized approach for improved relay insulation design and risk assessment
• Testing laboratories will need to update equipment, operator training, and report templates

Compliance Timeline:

• Latest date for national adoption: August 2027
• Withdrawal of conflicting standards: August 2029

Adoption Benefits:

• Enhanced credibility in global markets due to harmonized, recognized test methods
• Lower product liability and improved user safety
• Streamlined procurement through clear specification of compliant relays

Risks of Non-Compliance:

• Exposure to regulatory penalties or product recalls
• Increased failure rates in the field, leading to system downtime or safety incidents
• Loss of customer trust due to inconsistent relay performance

Technical Insights

Common Requirements:

• Use of defined impulse shapes (combination wave, e.g., 1.2/50 µs)
• Strict adherence to insulation coordination and dielectric test sequences
• Documentation of all test parameters, circuit setup, and post-test evaluation

Implementation Best Practices:

1. Review and align in-house test equipment capabilities with new circuit diagrams and time parameters
2. Train operators on preconditioning protocols and detailed reporting
3. Regularly calibrate combination wave generators to IEC/EN referenced requirements
4. Develop standardized templates for test plans and reports as per clause 5.2
5. Conduct periodic audits to verify ongoing compliance

Certification Considerations:

• Ensure third-party testing bodies are aware and accredited for EN IEC 63522-46:2026
• Reference the standard explicitly in procurement, supplier quality contracts, and technical datasheets

Conclusion & Next Steps

In summary, EN IEC 63522-46:2026 marks a robust evolution in electrical relay testing, with a sharpened focus on reproducible and internationally accepted impulse voltage methodologies. Professionals across manufacturing, engineering, and compliance functions should review and update their testing frameworks to meet these requirements promptly, ensuring market access and system reliability.

For organizations seeking to lead in product quality and regulatory alignment, early adoption is recommended. Stay connected to the latest standard developments by regularly visiting authoritative resources such as iTeh Standards.

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