IEC 63522-11:2025

Electrical relays - Tests and measurements - Part 11: Enclosure protection and degree of protection

IEC 63522-11:2025 is used for testing electrical relay enclosures along with the appropriate severities and conditions for measurements and tests designed to assess the ability of DUTs to perform under expected conditions of transportation, storage and all aspects of operational use.
This document defines standard test methods for appropriate enclosure sealing testing.

Relais électriques - Essais et mesurages - Partie 11: Protection des enveloppes et degré de protection

IEC 63522-11:2025 traite des essais des enveloppes des relais électriques ainsi que des sévérités et conditions appropriées pour les mesurages et essais destinés à évaluer l'aptitude de DUT à fonctionner dans des conditions prévues de transport, de stockage, et de tous les aspects d'utilisation opérationnelle.
Le présent document définit des méthodes d'essai normalisées pour les essais appropriés d'étanchéité des enveloppés.

General Information

• Status: Published
• Publication Date: 06-Feb-2025
• ICS: 29.120.70 - Relays
• Technical Committee: TC 94 - Electrical relays
• Drafting Committee: WG 3 - TC 94/WG 3
• Current Stage: PPUB - Publication issued
• Start Date: 07-Feb-2025
• Completion Date: 28-Feb-2025

Standards Content (Sample)

IEC 63522-11 ®
Edition 1.0 2025-02
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electrical relays – Tests and measurements –
Part 11: Enclosure protection and degree of protection

Relais électriques – Essais et mesurages –
Partie 11: Protection des enveloppes et degré de protection
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IEC 63522-11 ®
Edition 1.0 2025-02
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electrical relays – Tests and measurements –

Part 11: Enclosure protection and degree of protection

Relais électriques – Essais et mesurages –

Partie 11: Protection des enveloppes et degré de protection

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.70  ISBN 978-2-8327-0154-6

– 2 – IEC 63522-11:2025 © IEC 2025
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Test procedure . 6
4.1 Purpose . 6
4.2 Procedure . 6
4.2.1 Enclosure protection . 6
4.2.2 Degree of protection (IP code) . 7
4.3 Conditions . 9
4.3.1 Conditions for RT I relays . 9
4.3.2 Conditions for RT II to V relays . 9
4.3.3 Conditions for degree of protection (IP code) . 9
5 Evaluation . 10
5.1 General . 10
5.1.1 RT I – Dust protection . 10
5.1.2 RT II – Sealing. 10
5.1.3 RT III to V – Sealing . 10
5.1.4 Degree of protection (IP code) . 11
5.2 Test report . 11
Annex A (normative) Procedure 2: Helium sniffer test. 12
Annex B (normative) Categories of environmental protection . 13
Bibliography . 14

Table 1 – Degree of protection against access to hazardous parts indicated by the first
characteristic numeral . 8
Table 2 – Degree of protection against access to hazardous parts indicated by the
second characteristic numeral. 8
Table B.1 – Categories of protection . 13

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTRICAL RELAYS – TESTS AND MEASUREMENTS –

Part 11: Enclosure protection and degree of protection

FOREWORD
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IEC 63522-11 has been prepared by IEC technical committee 94: Electrical relays. It is an
International Standard.
The text of this International Standard is based on the following documents:
Draft Report on voting
94/1058/FDIS 94/1109/RVD
Full information on the voting for its approval can be found in the report on voting indicated in
the above table.
The language used for the development of this International Standard is English.

– 4 – IEC 63522-11:2025 © IEC 2025
This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in
accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available
at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are
described in greater detail at www.iec.ch/publications.
A list of all parts in the IEC 63522 series, published under the general title Electrical relays –
Tests and measurements, can be found on the IEC website.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under webstore.iec.ch in the data related to the
specific document. At this date, the document will be
• reconfirmed,
• withdrawn, or
• revised.
ELECTRICAL RELAYS – TESTS AND MEASUREMENTS –

Part 11: Enclosure protection and degree of protection

1 Scope
This part of IEC 63522 is used for testing electrical relay enclosures along with the appropriate
severities and conditions for measurements and tests designed to assess the ability of DUTs to
perform under expected conditions of transportation, storage and all aspects of operational use.
This document defines standard test methods for appropriate enclosure sealing testing.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60068-2-17:2023, Environmental testing – Part 2-17: Tests – Test Q: Sealing
IEC 60068-2-68:1994, Environmental testing – Part 2-68: Tests – Test L: Dust and sand
IEC 60529:1989, Degrees of protection provided by enclosures (IP Code)
IEC 60529:1989/AMD1:1999
IEC 60529:1989/AMD2:2013
IEC 63522-0:— , Electrical relays – Tests and measurements – Part 0: General and guidance
IEC 63522-4:2024, Electrical relays – Tests and measurements – Part 4: Dielectric strength test
IEC 63522-7:2024, Electrical relays – Tests and measurements – Part 7: Functional tests
IEC 63522-15:2024, Electrical relays – Tests and measurements – Part 15: Robustness of
terminals
IEC 63522-19, Electrical relays – Tests and measurements – Part 19: Electrical endurance
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 63522-0 apply.
ISO and IEC maintain terminology databases for use in standardization at the following
addresses:
• IEC Electropedia: available at https://www.electropedia.org/
• ISO Online browsing platform: available at https://www.iso.org/obp
___________
Under preparation. Stage at the time of publication: IEC CCDV 63522-0:2024.

– 6 – IEC 63522-11:2025 © IEC 2025
3.1
relay technology category
RT
categories of relays, based upon levels of environmental protection
Note 1 to entry: Six categories are in use (RT0 to RTV).
4 Test procedure
4.1 Purpose
The purpose of the test procedure is to determine the effectiveness of the relay enclosure in
regard to either sealing or protection against ingress of dust and water.
Refer to Annex B for relay technology categories.
4.2 Procedure
4.2.1 Enclosure protection
4.2.1.1 Procedure for RT 0 relays
No test procedure applies.
4.2.1.2 Procedure for RT I relays – Dust protection
This test applies to relays according to the category relay technology I (RTI) only.
This test shall be carried out in accordance with test La2 of IEC 60068-2-68. The non-operated
relay shall be mounted with standard mounting position pin downwards if not otherwise specified
in the test chamber. The air pressure within the relay shall be that of the ambient air pressure
in the test chamber (category 2 enclosure). The relay shall be subjected to talc (hydrated
magnesium silicate) for 8 h. After a recovery period of 2 h under normal atmospheric conditions
and after cleaning (removal of external surface dust) the test samples shall be submitted to
visual and functional measurement.
4.2.1.3 RT II to V – Sealing
4.2.1.3.1 General
A suitable soldering process in accordance with the manufacturer's specification shall be
chosen from IEC 63522-16 and all DUTs shall go through the selected soldering process.
4.2.1.3.2 Procedure for RT II relays
The DUT shall be exposed to a specified flux process according to the product specification.
NOTE Typical flux processes are foam or spray processes.
4.2.1.3.3 Procedure for RT III relays
The sealing test shall be carried out by immersion of the RTIII relay in a liquid at a temperature
in accordance with test Qc, method 1 or 2 of IEC 60068-2-17. Immersion times shorter than
10 min may be specified by the manufacturer. Bubbles shall not exceed the limits given in
IEC 60068-2-17.
4.2.1.4 Procedure for RT IV and V for relays
4.2.1.4.1 Procedure – Sealing test method Qk
The helium detection test shall be carried out in accordance with test Qk, method 1 or 2 of
IEC 60068-2-17. Where method 2 is used and the existence of a gross leak cannot be ruled out,
it shall be followed by method 1.
Further requirements on the helium sniffer test are given in Annex A.
The helium leak rate is not equal to the leak rate of the gases normally used within sealed
relays.
If the time interval between sealing and testing has been more than 48 h, the relay shall be
exposed to an atmosphere of helium at high pressure.
The difference in pressure (inside DUT to surrounding ambient) and the duration of exposure
shall be as prescribed by the manufacturer.
After the exposure, the absorbed helium shall be cleaned from the surface as prescribed by the
manufacturer.
4.2.1.4.2 Procedure – Sealing test method Ql
This test applies for reed switches and high voltage vacuum reed switches as an alternative to
the Qk test.
The sealing test shall be in accordance with test Ql of IEC 60068-2-17:2023.
4.2.1.4.3 Procedure – Arc time duration test
This test applies for heavy duty reed switches only.
The test shall be performed as follows:
a) Arcing time less than
i) 60 ms for 3A types;
ii) 100 ms for 5A types;
b) Coil voltage: 150 % of must operate voltage;
c) Load voltage: 100 V DC to 110 V DC;
d) Load current: 0,5 A to 0,55 A;
e) Total number of operations: 3.
The test setup shall be in accordance with IEC 63522-19 and carried out in ambient
environmental conditions.
4.2.2 Degree of protection (IP code)
4.2.2.1 General
For relays, the first digit, i.e., the solid particle protection defined in IEC 60529, may apply and
can be tested as the component shall be used in the final application.
In any case, there is no direct linkage between the relay technology category and the degree
of protection (IP code) given as the RT categories are linked to the function and handling
process compared to the IP code which is linked to the avoidance of electrical shock.

– 8 – IEC 63522-11:2025 © IEC 2025
The first digit indicates the level of protection that the enclosure provides against access to
hazardous parts (e.g., electrical conductors, moving parts) and the ingress of solid foreign
objects.
See Table 1 for the degree of protection against access to hazardous parts parts indicated by
the first characteristic numeral.
Table 1 – Degree of protection against access to hazardous
parts indicated by the first characteristic numeral
Level sized Effective against Description
X — X means there is no data available to specify a protection rating with
regard to this criterion.
0 Non-protected No protection against contact and ingress of objects
1 > 50 mm Any large surface of the body, such as the back of a hand, but no
2,0 in protection against deliberate contact with a body part
2 > 12,5 mm Fingers or similar objects
0,49 in
3 > 2,5 mm Tools, thick wires, etc.
0,098 in
4 > 1 mm Most wires, slender screws, large ants, etc.
0,039 in
5 Dust protected Ingress of dust is not entirely prevented, but it must not enter in sufficient
quantity to interfere with the satisfactory operation of the equipment.
6 Dust-tight No ingress of dust; complete protection against contact (dust-tight). A
vacuum must be applied. Test duration of up to 8 h based on airflow.

The second characteristic numeral indicates the degree of protection provided by enclosures
with respect to harmful effects on the equipment due to the ingress of water.
See Table 2 for the degree of protection against ingress of water indicated by the second
characteristic numeral.
Table 2 – Degree of protection against access to hazardous parts indicated by
the second characteristic numeral
Second Effective against Description
characteristic
numeral
X — X means there is no data available to specify a protection rating with
regard to this criterion.
0 Non-protected No protection against contact and ingress of objects
1 Protected against Vertically falling drops shall have no harmful effects
vertically falling water
drops
2 Protected against Vertically falling drops shall have no harmful effects when the
vertically falling water enclosure is tilted at any angle up to 15° on either side of the vertical
drops when enclosure
tilted up to 15°
3 Protected against Water sprayed at an angle up to 60° on either side of the vertical
spraying water shall have no harmful effects
4 Protected against Water splashed against the enclosure from any direction shall have
splashing water no harmful effects
5 Protected against Water projected in jets against the enclosure from any direction shall
water jets have no harmful effects
6 Protected against Water projected in powerful jets against the enclosure from any
powerful water jets direction shall have no harmful effects

Second Effective against Description
characteristic
numeral
7 Protected against the Ingress of water in quantities causing harmful effects shall not be
effects of temporary possible when the enclosure is temporarily immersed in water under
immersion in water standardized conditions of pressure and time.
8 Protected against the Ingress of water in quantities causing harmful effects shall not be
effects of continuous possible when the enclosure is continuously immersed in water
immersion in water under conditions which shall be agreed between manufacturer and
user but which are more severe than for numeral 7.
9 Protected against high Protected against high pressure and temperature water jets
pressure and
temperature water jets
4.2.2.2 Procedure
Tests shall be performed according to IEC 60529:1989, Clause 5 and Clause 6,
IEC 60529:1989/AMD1:1999, Clause 5 and IEC 60529:1989/AMD2:2013, Clause 5 and
Clause 6.
4.3 Conditions
4.3.1 Conditions for RT I relays
The conditions to be specified are the following:
a) pressure reduction inside the relay, if required;
b) position of the relay, if other than normal operating position.
4.3.2 Conditions for RT II to V relays
The conditions to be specified are the following:
a) procedure or sequence of procedures, and methods used within them;
b) procedure 1: immersion time if different from 10 min;
c) procedure 2:
i) severity, if different from 1 000 h;
ii) absolute immersion pressure, if required;
iii) free internal volume V (cm );
iv) maximum leak rate, or time constant.
4.3.3 Conditions for degree of protection (IP code)
The test conditions to be specified are the following:
a) the IP level,
b) any preparation of the sample,
c) in kind of IP5X (dust protected): Definition of mandatory dust-free areas inside the relay.

– 10 – IEC 63522-11:2025 © IEC 2025
5 Evaluation
5.1 General
5.1.1 RT I – Dust protection
For RT I, no dust shall be observed inside the relay within areas defined by the manufacturer
and the function of the relay shall not be impaired.
Final measurements:
• functional tests as specified in IEC 63522-7;
• dielectric test as specified in IEC 63522-4;
• any other measurement, if required.
The relay shall work within the manufacturer's specification.
5.1.2 RT II – Sealing
For RT II, no flux shall be observed inside the relay within areas defined by the manufacturer
and the function of the relay shall not be impaired.
Final measurements:
• functional tests as specified in IEC 63522-7;
• dielectric test as specified in IEC 63522-4;
• any other measurement, if required.
The relay shall work within the manufacturer's specification.
5.1.3 RT III to V – Sealing
RTIII: Bubbles or leakages shall not exceed the limits according to Qc, method 1 or 2
of IEC 60068-2-17
RTIV and V: The leak rate shall not exceed the value in accordance with IEC 60068-2-17 and
Table B.1 of this document.
Final measurements:
• functional tests as specified in IEC 63522-7;
• dielectric test as specified in IEC 63522-4;
• any other measurement, if required.
The relay shall work within the manufacturer's specification.
Any deviation from the standards shall be noted within the report.
4 6
For reed switches, the time constant shall be better than 2 × 10 s or 2 × 10 s in accordance
with IEC 60068-2-17.
For reed switches and high voltage vacuum reed switches where Ql is an alternative to the Qk
test, the DUT shall be evaluated according to the Qi limits of IEC 60068-2-17. The same final
measurements apply.
If the arc time duration test for heavy-duty reed switches was performed, arcing time shall be
less than 60 ms for 3 A types and less than 100 ms for 5 A types.

5.1.4 Degree of protection (IP code)
The evaluation shall be carried out in accordance with IEC 60529.
5.2 Test report
If this document is applied as a part of a test record of another standard, then the results shall
be reported as required in the other standard.
Otherwise, it is recommended to issue a dedicated test report in accordance with this document.
The test report shall contain all the information necessary to reproduce the test. In particular,
the following shall be recorded:
• description of DUT;
• parameter describing the test;
• severity level – if applicable;
• all measurement values;
• the result of the evaluation.

– 12 – IEC 63522-11:2025 © IEC 2025
Annex A
(normative)
Procedure 2: Helium sniffer test
The detailed description of the Helium sniffer test is as follows:
a) Cleaning of the sample with adequate liquids like isopropanol/acetone to avoid negative
effects in the helium detection.
b) The samples will be taken into the pressure chamber for a duration defined in Table 4 of
3 4
IEC 60068-2-17:2023 with helium (He or He or higher) being the gas used in the chamber
(example: 3 bar for 45 min).
The pressure used should not damage the samples.
c) According to the Qk method used, as described in IEC 60068-2-17, the time duration after
the "bombing" should not be longer than 30 min. This will avoid measurement faults by the
detection process in the helium sniffer because the helium can be situated on the outside
surface. The relay should be located according to the reference conditions given in
IEC 63522-0:— ,Table 2 during that time.
The time between the pressuring and the detection shall be evaluated by the manufacturer
because it is related to the surface and dimension.
d) The time constant (of leakage) for
1) RT IV (2 × 10 s) = severity 6 h and
2) RT V (2 × 10 s) = severity 600 h
defined in IEC 60068-2-17:2023, Table 3.
The combination of these values with the internal volume defines the maximum
measured leak rate.
NOTE The helium sniffer equipment often uses different units than those given in Table 3, such as mbar × l/s.
e) The leakage testing should be done on single samples.
f) Finally, the method QC2 from the IEC 60068-2-17 shall be used on the same DUT to ensure
no leaks (which could not be detected by the fine leak method (Qk)) are present.
___________
Under preparation. Stage at the time of publication: IEC CCDV 63522-0:2024.

Annex B
(normative)
Categories of environmental protection
The relay technology categories describing the degree of sealing of the relay case or its contact
unit are given in Table B.1.
...