IEC 61003-2:2016

Industrial-process control systems - Instruments with analogue inputs and two- or multi-position outputs - Part 2: Guidance for inspection and routine testing

IEC 61003-2:2016 gives guidelines for inspection and routine testing of electrical and pneumatic instruments with two- or multi-position output, for instance, for acceptance tests or after repair. It is applicable to electrical and pneumatic industrial-process instruments, using measured values that are continuous signals. The set point value may be either a mechanical (position, force, etc.) or a standard signal. These instruments may be used as controllers or as switches for alarms and other similar purposes. This second edition cancels and replaces the first edition published in 2009. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
- use of the term "two- or multi-position output" instead of "two- or multi-state instrument" (see Scope);
- use of the term "differential gap" instead of "switching differential" (see Table 1 No 2);
- use of the term "dielectric strength" instead of "isolation test" (see Table 1 No 5).
This publication is to be read in conjunction with IEC 61003-1:2016, IEC 61298-2:2008 and IEC 61298-3:2008

Système de commande de processus industriels - Instruments avec entrées analogiques et sorties à deux ou plusieurs positions - Partie 2: Conseils pour les inspections et les essais individuels de série

L'IEC 61003-2:2016 donne des lignes directrices pour les inspections et les essais individuels de série des instruments électriques et pneumatiques à sorties à deux ou plusieurs positions, par exemple pour les essais de réception ou après réparation. Elle est applicable aux instruments électriques et pneumatiques des processus industriels, utilisant des valeurs mesurées qui sont des signaux continus. La valeur de consigne peut être soit un signal mécanique (position, force, etc.) soit un signal normalisé. Ces instruments peuvent être utilisés comme régulateurs ou comme interrupteurs pour systèmes d'alarme et autres usages similaires. Cette deuxième édition annule et remplace la première édition parue en 2009. Cette édition constitue une révision technique. Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
- utilisation du terme "sortie à deux ou plusieurs positions" au lieu de "instrument à deux ou plusieurs états" (voir Domaine d'application);
- utilisation du terme "recouvrement" au lieu de "différentiel de coupure" (voir Tableau 1, n° 2);
- utilisation du terme "rigidité diélectrique" au lieu d'"essai d'isolation" (voir Tableau 1 n° 5).
Cette publication doit être lue conjointement avec la IEC 61003-1:2016, IEC 61298-2:2008 et IEC 61298-3:2008.

General Information

• Status: Published
• Publication Date: 13-Jun-2016
• ICS: 01 - GENERALITIES. TERMINOLOGY. STANDARDIZATION. DOCUMENTATION
• ICS: 25.040.40 - Industrial process measurement and control
• Technical Committee: SC 65B - Measurement and control devices
• Drafting Committee: WG 6 - TC 65/SC 65B/WG 6
• Current Stage: PPUB - Publication issued
• Start Date: 14-Jun-2016
• Completion Date: 30-Jun-2016

Relations

• Revises: IEC 61003-2:2009 - Industrial-process control systems - Instruments with analogue inputs and two or multi-state outputs - Part 2: Guidance for inspection and routine testing
• Effective Date: 05-Sep-2023

IEC 61003-2:2016 Overview

IEC 61003-2:2016 is an international standard developed by the International Electrotechnical Commission (IEC) that provides comprehensive guidance for the inspection and routine testing of industrial-process control instruments. This second edition, published in 2016, supersedes the 2009 edition, introducing updated terminology and technical revisions to enhance clarity and operational relevance.

This standard specifically addresses electrical and pneumatic instruments with analogue inputs and two- or multi-position outputs. It covers testing methods used for acceptance testing, routine inspections, and post-repair qualifications. The instruments in question process continuous measured values and serve as controllers or switches, including applications such as alarms in industrial scenarios.

Key Topics and Terminology

IEC 61003-2:2016 lays out essential test procedures and environmental conditions with the aim to verify proper instrument performance under defined conditions. Notable improvements over the previous edition include:

• Use of the term "two- or multi-position output" instead of "two- or multi-state instrument" for accuracy in describing output characteristics.
• The term "differential gap" replaces "switching differential" to correctly reference the measurement in performance testing.
• Adoption of "dielectric strength" in place of "isolation test" to better describe electric insulation testing specifics.

Core Testing Areas

• Inaccuracy of switching points – assessing deviation from set values.
• Inaccuracy of differential gap – verifying precision in output change points.
• Set point evaluation – checking adjustability and indication capability.
• Dielectric strength – testing the insulation to prevent electrical failure.
• Characteristics of multi-position outputs – ensuring reliable switching over multiple positions.
• Supply variations – evaluating device response under varying electrical voltage or pneumatic pressure.

Standardized Test Conditions

The testing environment adheres to well-defined parameters for accuracy and reproducibility:

• Ambient temperature between 15 °C and 25 °C.
• Relative humidity from 45% to 75%.
• Atmospheric pressure between 86 kPa and 106 kPa.
• Electrical supply stability with voltage and frequency variations within ±1%.
• Pneumatic supply maintained within ±3% of rated pressure.

Applications of IEC 61003-2

This standard is critical for manufacturers, users, and quality assurance professionals involved in industrial-process control systems. It supports:

• Acceptance testing – confirming newly manufactured instruments meet contractual specifications.
• Routine inspections – ongoing verification of operational performance during service.
• Post-repair validation – ensuring instruments maintain reliability after maintenance.

Typical applications include:

• Controllers in automated manufacturing.
• Switches for alarm signaling and safety systems.
• Pneumatic and electrical instruments used in process measurement and control industries.

Adhering to IEC 61003-2 helps minimize risks related to instrument failure, optimize maintenance schedules, and ensure operational safety and compliance with international industry standards.

Related Standards

IEC 61003-2 is to be used in conjunction with a series of complementary standards to provide a comprehensive performance evaluation framework:

• IEC 61003-1:2016 – Methods for evaluating performance of instruments with analogue inputs and two- or multi-position outputs.
• IEC 61298-2:2008 – Tests under reference conditions for process measurement and control devices.
• IEC 61298-3:2008 – Tests evaluating the effects of influence quantities on devices.
• IEC 61298-4 – Guidelines for evaluation report content ensuring thorough documentation.

Together, these standards ensure that industrial-process instruments meet rigorous international criteria for accuracy, reliability, and environmental resilience.

---

By following IEC 61003-2:2016, industries can maintain high-quality control systems that are essential for efficient, safe, and compliant industrial automation and process monitoring. This standard is indispensable for stakeholders seeking to implement robust inspection and testing routines for analogue input instruments with digital multi-position outputs.

Standards Content (Sample)

IEC 61003-2 ®
Edition 2.0 2016-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Industrial-process control systems – Instruments with analogue inputs and two
or multi-position outputs –
Part 2: Guidance for inspection and routine testing

Systèmes de commande de processus industriels – Instruments avec entrées
analogiques et sorties à deux ou plusieurs positions –
Partie 2: Conseils pour les inspections et les essais individuels de série

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IEC 61003-2 ®
Edition 2.0 2016-06
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Industrial-process control systems – Instruments with analogue inputs and two

or multi-position outputs –
Part 2: Guidance for inspection and routine testing

Systèmes de commande de processus industriels – Instruments avec entrées

analogiques et sorties à deux ou plusieurs positions –

Partie 2: Conseils pour les inspections et les essais individuels de série

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 25.040.40 ISBN 978-2-8322-3389-4

– 2 – IEC 61003-2:2016 © IEC 2016
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references. 5
3 Terms and definitions . 5
4 Sampling for test . 6
5 Performance tests . 6
5.1 General . 6
5.2 Test conditions . 6
5.2.1 Ambient conditions . 6
5.2.2 Supply conditions . 7
5.3 Tests under reference conditions . 7
5.3.1 General . 7
5.3.2 Set point . 7
5.4 Tests for the effects of influence quantities . 7
5.4.1 General . 7
5.4.2 Supply voltage variations . 8
5.4.3 Supply pressure variations . 8
6 Test report and documentation . 8
6.1 General . 8
6.2 Test report and general observations . 8

Table 1 – Test items . 6
Table 2 – Test report and general observations . 9

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
INDUSTRIAL-PROCESS CONTROL SYSTEMS –
INSTRUMENTS WITH ANALOGUE INPUTS AND
TWO OR MULTI-POSITION OUTPUTS –

Part 2: Guidance for inspection and routine testing

FOREWORD
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patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 61003-2 has been prepared by subcommittee 65B: Measurement
and control devices, of IEC technical committee TC 65: Industrial-process measurement,
control and automation.
This second edition cancels and replaces the first edition published in 2009. This edition
constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous
edition:
a) use of the term “two- or multi-position output” instead of “two- or multi-state instrument”
(see Scope);
b) use of the term “differential gap” instead of “switching differential” (see Table 1 No 2);
c) use of the term “dielectric strength” instead of “isolation test” (see Table 1 No 5).

– 4 – IEC 61003-2:2016 © IEC 2016
The text of this standard is based on the following documents:
FDIS Report on voting
65B/1039/FDIS 65B/1049/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
This International Standard is to be used in conjunction with IEC 61003-1:2016. IEC 61298-
2:2008 and IEC 61298-3:2008.
A list of all parts of the IEC 61003 series, published under the general title Industrial-process
control systems – Instruments with analogue inputs and two or multi-position outputs, can be
found on the IEC website.
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC website under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
INDUSTRIAL-PROCESS CONTROL SYSTEMS –
INSTRUMENTS WITH ANALOGUE INPUTS AND
TWO OR MULTI-POSITION OUTPUTS –

Part 2: Guidance for inspection and routine testing

1 Scope
This part of IEC 61003 gives guidelines for inspection and routine testing of electrical and
pneumatic instruments with two- or multi-position output, for instance, for acceptance tests or
after repair, and it is to be used in conjunction with IEC 61003-1:2016 IEC 61298-2:2008 and
IEC 61298-3:2008.
This part of IEC 61003 is applicable to electrical and pneumatic industrial-process instruments,
using measured values that are continuous signals. The set point value may be either a
mechanical (position, force, etc.) or a standard signal. These instruments may be used as
controllers or as switches for alarms and other similar purposes.
Quantitative criteria for acceptable performance should be established by agreement between
manufacturer and user, and the report on the tests clarifies which tests were carried out. The
requirements of this standard are effective when agreed by the manufacturer and the user.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and
are indispensable for its application. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 61003-1:2016 Industrial-process control systems – Instruments with analogue inputs and
two- or multi-position outputs – Part 1: Methods for evaluating performance
IEC 61298 (all parts), Process measurement and control devices – General methods and
procedures for evaluating performance
IEC 61298-2:2008, Process measurement and control devices – General methods and
procedures for evaluating performance – Part 2: Tests under reference conditions
IEC 61298-3:2008, Process measurement and control devices – General methods and
procedures for evaluating performance – Part 3: Tests for the effects of influence quantities
IEC 61298-4, Process measurement and control devices – General methods and procedures
for evaluating performance – Part 4: Evaluation report content
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 61003-1,
IEC 61298-2 and the following apply.

– 6 – IEC 61003-2:2016 © IEC 2016
3.1
acceptance test
contractual test to prove to the customer that the item meets certain conditions of its
specification
4 Sampling for test
Usually a routine test is applied to each instrument. If, agreed upon by the user and
manufacturer, the tests can be performed on a sample lot.
When sampling is used, instruments to be tested may be chosen by the user's inspector.
5 Performance tests
5.1 General
Test items for routine test and acceptance test are specified in Table 1. The sequence of the
tests shall be such that the results of a test are not affected by a previous test.
The following test conditions, test methods and test procedures are compatible with
IEC 61003-1 and IEC 61298.
Table 1 – Test items
Subclause of Subclause of
No. Designation
this standard IEC 61003-1:2016
1. Inaccuracy of switching points 6.1.1.2
2. Inaccuracy of differential gap 6.1.1.4
Set point adjustable and measurable or indicated 6.1.3.1
3. Set point adjustable but not indicated 6.1.3.2
Set point not adjustable 6.1.3.3
5.3
Indication of the measured value 6.3.2
4.
a
Dielectric strength 6.3.4
5.
Characteristics of the multi-position output 7.2.1
6.
Determination of switching range 7.2.3
7.
Supply voltage variations 6.2.8
8. 5.4
Supply pressure variations 6.2.11
a
For safety use only.
b
Routine tests do not test frequency variations.

5.2 Test conditions
5.2.1 Ambient conditions
– Temperature from 15 °C to 25 °C;
– Relative humidity from 45 % to 75 %;
– Atmospheric pressure from 86 kPa to 106 kPa;
– Electromagnetic field value to be stated if relevant.
The maximum rate of change of ambient temperature permissible during any test shall be
1 °C in 10 min and less than 3 °C/h.

5.2.2 Supply conditions
Electrical supply:
– Rated voltage
±1 %;
– Rated frequency
±1 %;
– Harmonic distortion (a.c. supply) less than 5 %;
– Ripple (d.c. supply) less than 0,1 %.
Pneumatic supply:
– Rated pressure
±3 %;
– Supply air temperature ambient temperature ±2 °C;
dew point at least 10 °C below device’s body
– Supply air humidity
temperature;
−6
– Oil and dust content
oil: less than 1 × 10 by weight;
dust: absence of particles greater than 3 µm.
5.3 Tests under reference conditions
5.3.1 General
All tests given in 6.1 and 6.3 of IEC 61003-1:2016 should be carried out. Multi-position output
should supplement the tests given in Clause 7 of IEC 61003-1:2016. The detailed test
procedures are given in IEC 61298-2.
5.3.2 Set point
5.3.2.1 Set point adjustable and measurable or indicated
The set point shall be tested at value of 10 %, 50 % and 90 % at least, the 50 % value being
taken last. The measurement or indication accuracy shall be determined at five points
approximately evenly spaced over the range.
5.3.2.2 Set point adjustable but not indicated
The set point shall be tested for at least three values, approximately evenly spaced over the
effective range of adjustment.
5.3.2.3 Set point not adjustable
The set point shall be tested directly.
5.3.2.4 Multi-position output set point
Each position should be tested in accordance with 5.3.2.1, 5.3.2.2 and 5.3.2.3.
IEC 61003-1:2016, 7.2.2 gives the test method of mutual influence of pairs of switching points.
5.4 Tests for the effects of influence quantities
5.4.1 General
When testing the effects of influence quantities, the set point shall be not less than one. For
measurable or indicated instruments, indication of the measured value should be tested also.
For set point adjustable instruments, the value of 50 % should be included.
The effects on switching points of influence quantities should be tested in accordance with 6.2
of IEC 61003-1:2016 and with IEC 61298-3.

– 8 – IEC 61003-2:2016 © IEC 2016
5.4.2 Supply voltage variations
This test shall be performed on instruments with electrical power supply for internal
operations.
For two-wire instruments, fix the load resistance at nominal value or a convenient value, and
record this value.
Test the instruments with the power voltage set at the nominal value, maximum value and
minimum value successively.
5.4.3 Supply pressure variations
This test shall be performed on instruments with pressure supply.
The testing supply pressure should be nominal value, +10 % of the nominal value or the
manufacturer's limit, –15 % of the nominal value or the manufacturer's limit.
6 Test report and documentation
6.1 General
A test report of the evaluation shall be prepared in accordance with IEC 61298-4 after
completing all tests.
All the original documentation, related to the tests, shall be stored by the test laboratory for at
least two years, after the report is issued.
6.2 Test report and general observations
Table 2 gives an example of a summary of the test results information to be reported.

Table 2 – Test report and general observations
No. Designation Reference Unit Information to be reported
Values of points x and x and their
1 2
average shall be reported.
The differential gap (x – x ) shall be
1 2
noted for each cycle.
Inaccuracy of switching IEC 61298-2:2008,
1. %
poi
...