IEC 61810-10:2019

Electromechanical elementary relays - Part 10: Additional functional aspects and safety requirements for high-capacity relays

IEC 61810-10:2019, with functional and safety aspects, applies to electromechanical elementary relays (non-specified time all-or-nothing relays) with high capability requirements like breaking or short circuit capabilities and similar for incorporation into low-voltage equipment. These relays may have a specific design to extinguish the electric arc between contacts (e.g. by magnetic blow-out), or use an insulation coordination not covered by IEC 61810-1 (e.g. by gas filled contact chambers), or require safety assessments not covered by IEC 61810-1 (e.g. for higher loads).
It defines additional requirements for high-capacity relays with generic performance intended for use in applications in smart grids, electric vehicles and other applications where, for example, battery charge/discharge switching is used, such as:
• electrical energy storage (EES) systems,
• solar photovoltaic energy systems,
• electric road vehicles (EV) and electric industrial trucks,
• power electronic systems and equipment,
• secondary cells and batteries,
• road vehicles.
Compliance with the requirements of this standard is verified by the type tests indicated.

Relais électromécaniques élémentaires - Partie 10: Aspects fonctionnels et exigences de sécurité supplémentaires pour les relais à grande capacité

L'IEC 61810-10:2019, qui comporte des aspects fonctionnels et de sécurité, s'applique aux relais électromécaniques élémentaires (relais de tout ou rien à temps non spécifié) dont de grandes capacités sont exigées, telles qu'un pouvoir de coupure ou une capacité de court-circuit et des capacités analogues, destinés à être incorporés dans des matériels basse tension. Ces relais peuvent être conçus de manière spécifique afin d'éteindre les arcs électriques entre des contacts (par exemple, par soufflage magnétique) ou d'utiliser une coordination de l'isolement non couverte par l'IEC 61810-1 (par exemple, chambres de contact remplies de gaz), ou exiger des évaluations de sécurité non couvertes par l'IEC 61810-1 (par exemple, pour des charges supérieures).
Elle définit des exigences supplémentaires pour les relais à grande capacité à performances génériques destinés à être utilisés dans des applications dans les réseaux intelligents, dans les véhicules électriques et dans d'autres applications dans lesquelles, par exemple, la commutation charge/décharge de batterie est utilisée, telles que:
• systèmes de stockage d'énergie électrique (EES – electrical energy storage),
• systèmes d'énergie solaire photovoltaïque,
• véhicules électriques routiers (EV – electric vehicle) et chariots électriques de manutention,
• systèmes et matériels d'électronique de puissance,
• accumulateurs et batteries,
• véhicules routiers.
La conformité aux exigences de la présente norme est vérifiée par les essais de type indiqués.

General Information

• Status: Published
• Publication Date: 10-Jul-2019
• 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: 09-Aug-2019
• Completion Date: 11-Jul-2019

Overview

IEC 61810-10:2019 is an international standard published by the International Electrotechnical Commission (IEC) that specifies additional functional aspects and safety requirements for high-capacity electromechanical elementary relays. This standard supplements IEC 61810-1 and focuses on relays with high breaking capacities, short-circuit resistance, and specialized insulation designs used in low-voltage equipment. The relays covered are typically all-or-nothing, non-specified time relays, engineered for demanding applications requiring enhanced safety and performance features.

The standard addresses special design considerations such as magnetic blow-out mechanisms or gas-filled contact chambers to ensure electric arc extinction and insulation reliability. It also includes rigorous safety assessments beyond the scope of general relay standards.

Key Topics

• Scope and Application: IEC 61810-10 applies to high-capacity relays designed for applications involving significant current and voltage stresses requiring robust safety and functional performance.
• Functional Requirements: Defines operating characteristics, heating limits, dielectric strength, electrical and mechanical endurance, and contact performance under demanding load conditions.
• Safety Standards: Includes detailed assessments for insulation coordination, clearances, creepage distances, heat and fire resistance, sealing, and terminal robustness.
• Special Testing: Requires type testing procedures for verifying compliance with extreme operational scenarios such as short circuit endurance, special inductive and resistive loads, and environmental stresses.
• Documentation and Marking: Specifies necessary data for relay identification, performance ratings, and safety information for reliable integration into systems.
• Annexes: Provide normative and informative guidance on relay load testing, mechanical properties, sealing evaluations, risk assessment, and application-specific tests for photovoltaic systems and road vehicles.

Applications

IEC 61810-10:2019 is particularly relevant for industries and systems that rely on high-capacity electromechanical relays for switching and protection purposes, including:

• Smart Grids: Ensuring safe and reliable switching in advanced electric power networks.
• Electrical Energy Storage (EES) Systems: Managing charge and discharge switching with high current loads.
• Solar Photovoltaic Energy Systems: Protecting solar installations with reliable relay performance under variable conditions.
• Electric Vehicles (EV) and Industrial Electric Trucks: Providing robust relay operations in battery management and propulsion systems.
• Power Electronic Systems: Supporting high-capacity switching and safety in power conversion and control.
• Secondary Cells and Batteries: Ensuring safety in energy storage devices with high load capacity.
• Road Vehicles: Addressing specific requirements for relay operation under automotive electrical and environmental stresses.

Related Standards

• IEC 61810-1:2015 – Electromechanical elementary relays – Part 1: Generic definitions and requirements. IEC 61810-10 supplements this with additional requirements specific to high-capacity relay types.
• IEC 60068 Series – Environmental testing procedures relevant for assessing relay mechanical and climatic endurance.
• IEC 61984 – Connectors – Safety requirements and tests, relevant for relay terminal and connection assessments.
• ISO 16750 Series – Road vehicles – Environmental conditions and testing for electrical and electronic equipment, applicable for automotive relay applications.
• IEC 60335 Series – Safety standards for electrical appliances that may incorporate relays conforming to these criteria.

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Keywords: IEC 61810-10, high-capacity relays, electromechanical elementary relays, relay safety requirements, relay functional aspects, low-voltage equipment, smart grid relays, electric vehicle relays, photovoltaic system relays, electrical energy storage relays, relay type testing, breaking capacity, insulation coordination.

Standards Content (Sample)

IEC 61810-10 ®
Edition 1.0 2019-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electromechanical elementary relays –
Part 10: Additional functional aspects and safety requirements for high-capacity
relays
Relais électromécaniques élémentaires –
Partie 10: Aspects fonctionnels et exigences de sécurité supplémentaires pour
les relais à grande capacité
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IEC 61810-10 ®
Edition 1.0 2019-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electromechanical elementary relays –

Part 10: Additional functional aspects and safety requirements for high-capacity

relays
Relais électromécaniques élémentaires –

Partie 10: Aspects fonctionnels et exigences de sécurité supplémentaires pour

les relais à grande capacité
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.70 ISBN 978-2-8322-7148-3

– 2 – IEC 61810-10:2019 © IEC 2019
CONTENTS
FOREWORD . 4
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 7
4 Influence quantities . 8
5 Rated values . 8
6 General provisions for testing . 8
7 Documentation and marking . 9
8 Heating . 9
9 Basic operating function . 11
10 Dielectric strength . 12
11 Electrical endurance . 14
12 Mechanical endurance . 14
13 Clearances, creepage distances and solid insulation . 14
14 Terminations . 18
15 Sealing . 18
16 Heat and fire resistance . 19
17 Special tests . 19
Annex A (normative) Explanations regarding relays . 20
Annex B (informative) Inductive contact loads . 21
Annex C (normative) Test set-up . 24
Annex D (informative) Special loads . 25
Annex E (normative) Heating test arrangement . 26
Annex F (normative) Measurement of clearances and creepage distances . 27
Annex G (normative) Relation between rated impulse voltage, nominal voltage and
overvoltage category . 28
Annex H (normative) Pollution degrees . 30
Annex I (normative) Proof tracking test . 31
Annex J (informative) Schematic diagram of families of terminations . 32
Annex K (normative) Glow-wire test . 33
Annex L (normative) Ball pressure test . 34
Annex M (informative) Needle flame test . 35
Annex N (informative) Resistance for standard soldering processes . 36
Annex O (informative) Risk assessment . 37
Annex P (informative) Mechanical properties of terminals . 38
Annex Q (normative) Long-term stability of the sealing (leak rate evaluation) . 44
Annex R (informative) Short-circuit capacity . 46
Annex S (informative) Special tests for applications – Photovoltaic systems . 49
Annex T (informative) Special tests for applications – Road vehicles . 53
Bibliography . 62

Figure 1 – Test procedure of system evaluation . 18

Figure P.1 – Test equipment for flexion test . 42
Figure Q.1 – Temperature cycle . 44
Figure R.1 – Short-circuit capacity test circuit . 47
Figure T.1 – Short voltage drop for system with nominal voltages . 55
Figure T.2 – Supply voltage profile for the reset test . 56
Figure T.3 – PSD of acceleration versus frequency . 59
Figure T.4 – PSD of acceleration versus frequency . 60

Table 1 – Type testing . 9
Table 2 – Required relay data . 9
Table 3 – Test conductor for test current above 400 A and up to 800 A inclusive
dependent on the current carried by the terminal . 11
Table 4 – Test copper bars for test current above 400 A and up to 1 000 A inclusive

dependent on the current carried by the terminal . 11
Table 5 – Dielectric strength – AC. 12
Table 6 – Dielectric strength – DC . 13
Table 7 – Minimum clearances in air for insulation coordination . 15
Table B.1 – Verification of the making and breaking capacity (abnormal conditions) . 21
Table B.2 – Verification of the making and breaking capacity (normal conditions) . 22
Table B.3 – Electrical endurance test . 23
Table G.1 – Correspondence between the nominal voltage of the supply system and
the equipment rated impulse withstand voltage, in case of overvoltage protection by
surge-arresters according to IEC 61810-1 . 28
Table P.1 – Tightening torques for the verification of the mechanical strength of screw-
type terminals . 39
Table P.2 – Test values for flexion and pull-out tests for round copper conductors . 41
Table P.3 – Test values for pull-out test for flat copper conductors . 43
Table S.1 – Special tests for photovoltaic system . 50
Table S.2 – Number of operating cycles . 51
Table S.3 – Special tests . 52
Table T.1 – Special test for road vehicles . 53
Table T.2 – Supply voltage for U = 12 V system devices . 57
N
Table T.3 – Supply voltage for U = 24 V system devices . 57
N
Table T.4 – Values for PSD and frequency . 59
Table T.5 – Values for PSD and frequency . 60
Table T.6 – Values for PSD and frequency, additional test in case of natural
frequencies, f , of DUT below 30 Hz . 61
n
– 4 – IEC 61810-10:2019 © IEC 2019
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTROMECHANICAL ELEMENTARY RELAYS –

Part 10: Additional functional aspects and safety
requirements for high-capacity relays

FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
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indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
The International Standards of the IEC 61810 have been prepared by IEC technical committee
94: All-or-nothing electrical relays.
The text of this International Standard is based on the following documents:
FDIS Report on voting
94/453/FDIS 94/458/RVD
Full information on the voting for the approval of this International Standard can be found in
the report on voting indicated in the above table.
This document has been drafted in accordance with the ISO/IEC Directives, Part 2.

A list of all parts of IEC 61810 series, published under the general title Electromechanical
elementary relays, can be found on the IEC website.
This International Standard is to be used in conjunction with IEC 61810-1:2015.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to
the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – IEC 61810-10:2019 © IEC 2019
ELECTROMECHANICAL ELEMENTARY RELAYS –

Part 10: Additional functional aspects and safety
requirements for high-capacity relays

1 Scope
This part of IEC 61810, with functional and safety aspects, applies to electromechanical
elementary relays (non-specified time all-or-nothing relays) with high capability requirements
like breaking or short circuit capabilities and similar for incorporation into low-voltage
equipment. These relays may have a specific design to extinguish the electric arc between
contacts (e.g. by magnetic blow-out), or use an insulation coordination not covered by
IEC 61810-1 (e.g. by gas filled contact chambers), or require safety assessments not covered
by IEC 61810-1 (e.g. for higher loads).
It defines additional requirements for high-capacity relays with generic performance intended
for use in applications in smart grids, electric vehicles and other applications where, for
example, battery charge/discharge switching is used, such as:
• electrical energy storage (EES) systems,
• solar photovoltaic energy systems,
• electric road vehicles (EV) and electric industrial trucks,
• power electronic systems and equipment,
• secondary cells and batteries,
• road vehicles.
Compliance with the requirements of this standard is verified by the type tests indicated.
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 60028, International standard of resistance for copper
IEC 60060-1:2010, High-voltage test techniques – Part 1: General definitions and test
requirements
IEC 60068-2-14, Environmental testing – Part 2-14: Tests – Test N: Change of temperature
IEC 60068-2-17, Basic environmental testing procedures – Part 2-17: Tests – Test Q: Sealing
IEC 60068-2-27, Environmental testing – Part 2-27: Tests – Test Ea and guidance: Shock
IEC 60068-2-64:2008, Environmental testing – Part 2-64: Tests – Test Fh: Vibration,
broadband random and guidance
IEC 60270, High-voltage test techniques – Partial discharge measurements

IEC 60664-1:2007, Insulation coordination for equipment within low-voltage systems – Part 1:
Principles, requirements and tests
IEC 60664-3:2016, Insulation coordination for equipment within low-voltage systems – Part 3:
Use of coating, potting or moulding for protection against pollution
IEC 60947-1:2007, Low-voltage switchgear and controlgear – Part 1: General rules
IEC 60999-1, Connecting devices – Electrical copper conductors – Safety requirements for
screw-type and screwless-type clamping units – Part 1: General requirements and particular
2 2
requirements for clamping units for conductors from 0,2 mm up to 35 mm (included)
IEC 60999-2, Connecting devices – Electrical copper conductors – Safety requirements for
screw-type and screwless-type clamping units – Part 2: Particular requirements for clamping
2 2
units for conductors above 35 mm up to 300 mm (included)
IEC 61810-1:2015, Electromechanical elementary relays – Part 1: General and safety
requirements
ISO 16750-1:2018, Road vehicles – Environmental conditions and testing for electrical and
electronic equipment – Part 1: General
ISO 16750-2:2012, Road vehicles – Environmental conditions and testing for electrical and
electronic equipment – Part 2: Electrical loads
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 61810-1 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
NOTE In the text of this document, the term "relay" is used instead of "elementary relay" to improve the
readability.
3.5 Terms and definitions related to contacts
Addition to IEC 61810-1:2015:
3.5.23
polarity of contact
indication of which terminal of a contact is to be connected to the positive supply and which to
the negative
3.5.24
arcing time
interval of time between the instant of the initiation of the arc in a pole or
a fuse and the instant of final arc extinction in that pole or that fuse
[SOURCE: IEC 60050-441:1984, 441-17-37]

– 8 – IEC 61810-10:2019 © IEC 2019
4 Influence quantities
Clause 4 of IEC 61810-1 is applicable.
5 Rated values
Clause 5 of IEC 61810-1 is applicable, except as follows.
5.6 Electrical endurance
Recommended number of cycles: 1; 2; 5; 10; 20; 50; 100; 200; 500; 1 000; 2 000; 3 000;
5 000; 6 000; 10 000; 20 000; 25 000; 30 000; 50 000;100 000; 200 000; 300 000; 500 000;
etc.
5.7 Frequency of operation
Recommended frequencies: 180/h; 360/h; 720/h; 900/h and multiples thereof.
0,05 Hz; 0,1 Hz; 0,2 Hz; 0,25 Hz and multiples thereof.
5.8 Contact loads
a) Resistive loads, recommended values
Current: 0,1 A; 0,5 A; 1 A; 2 A; 3 A; 5 A; 6 A; 8 A; 10 A; 12 A; 16 A; 20 A; 25 A; 30 A;
35 A; 60 A; 100 A, 120 A; 150 A; 200 A; 300 A; 400 A; 600 A; 800 A; 1 000 A (AC/DC).
Voltage: 4,5 V; 5 V; 12 V; 24 V; 36 V; 42 V; 48 V; 110 V; 125 V; 230 V; 250 V; 300 V;
380 V; 400 V; 480 V; 500 V; 575 V; 600 V; 690 V; 1 000 V (AC/DC); 1 200 V DC; 1 500 V
DC.
b) Recommended inductive loads: see Annex B.
c) Recommended capacitive loads: see Annex D of IEC 61810-1:2015.
6 General provisions for testing
Clause 6 of IEC 61810-1 is applicable, except as follows.
Deviating from IEC 61810-1, the specimens shall be grouped in 8 inspection lots, and the
related tests shall be taken from Table 1 of this document.
Table 1 of this document replaces Table 3 of IEC 61810-1:2015.

Table 1 – Type testing
Inspection Tests Clause Additional references
lot
1 Marking and documentation 7 IEC 60417
Heating (all coil voltages) 8 IEC 60085
Basic operating function (all coil voltages) 9
2 Dielectric strength 10
3 Electrical endurance (per contact load and contact material) 11
4 Mechanical endurance 12
5 Clearances, creepage distances and distances through solid 13 IEC 60664-1
insulation
6 Insulation coordination evaluation as a system (if applicable) 13.6 IEC 60060-1
Screw type terminals and screwless terminals (if applicable) 14.2 IEC 60999-1
Flat quick-connect terminations (if applicable) 14.3 IEC 61210
Solder terminals (if applicable) 14.4 IEC 60068-2-20
Sockets (if applicable) 14.5 IEC 61984
Alternative termination types (if applicable) 14.6
Sealing (if applicable) 15 IEC 60068-2-17
7 Heat and fire resistance 16 IEC 60695-2-10
8 Leaking test (sealed relay only) Annex Q IEC 60068-2-14
IEC 60068-2-17
NOTE The number of coil voltages in inspection lot 1 to be tested can be reduced under certain conditions
explained in Clauses 8 and 9.
Beside the defined minimum requirements, deviations of test conditions and procedures could be specified by the
manufacturer in the inspection lot 8.

7 Documentation and marking
Clause 7 of IEC 61810-1:2015 is applicable with the additions given in Table 2 of this
document.
Table 2 – Required relay data
N° Data Notes Place of indication
2d Coil polarity N/A in case of non-polarized coil Relay and/or catalogue or
instruction sheet
3h Classification of load and polarity Relay and/or catalogue or
For DC only use:+, -
of contacts instruction sheet
For AC/DC use: +/∼, -/∼, ∼
5l Limited short circuit capacity Specify the fuses or current Catalogue or instruction sheet
limiting device (if applicable)

8 Heating
Clause 8 of IEC 61810-1:2015 is applicable with the following changes/additions.

– 10 – IEC 61810-10:2019 © IEC 2019
8.4.4 Screw and screwless type terminals
The electrical interconnections between the relays are made with bare rigid conductors
(= default, however the usage of flexible conductors is allowed if defined from the
manufacturer; this shall be stated in the documentation and in the test report) in accordance
with Table 10 of IEC 61810-1:2015 with a maximum of 400 A, and in accordance with Table 3
with a maximum of 800 A. The connections of the relay to the voltage or current source(s) are
realized with flexible conductors in accordance with Table 10 of IEC 61810-1:2015 with a
maximum of 400 A, and in accordance with Table 3 with a maximum of 800 A. The electrical
interconnections between the relays are made with copper bars in accordance with Table 4
with a maximum of 1 000 A. Any fixture to hold the flexible-connected test samples in place is
not allowed to have any impact on the results.
The temperature rise at the terminals shall not exceed 45 K. This may be verified without the
temperature rise influence of the relay contacts and the coil (e.g. bridged or short-circuited or
soldered relay contacts).
8.4.5 Alternative termination types
The electrical interconnections between the relays are made with bare rigid conductors in
accordance with Table 10 of IEC 61810-1:2015 with a maximum of 400 A, and in accordance
with Table 3 with a maximum of 800 A. The connections of the relay to the voltage or current
source(s) are realized with flexible conductors in accordance with Table 10 of IEC 61810-
1:2015 with a maximum of 400 A, and in accordance with Table 3 with a maximum of 800 A.
The electrical interconnections between the relays are made with copper bars in accordance
with Table 4 with a maximum of 1 000 A.
The temperature rise at the terminals shall not exceed 45 K. This may be verified without the
temperature rise influence of the relay contacts and the coil (e.g. bridged or short-circuited or
soldered relay contacts).
8.4.6 Sockets
The maximum steady-state temperature limits permissible for the connections between relay
and socket as well as for the insulating materials of both relay and socket adjacent to the
connection shall not be exceeded.
The electrical interconnections between the sockets are made with conductors in accordance
with Table 10 of IEC 61810-1:2015 with a maximum of 400 A, and in accordance with Table 3
with a maximum of 800 A. The connections of the sockets to the voltage or current source(s)
are realized with flexible conductors in accordance with Table 10 of IEC 61810-1:2015 with a
maximum of 400 A, and in accordance with Table 3 with a maximum of 800 A.
The electrical interconnections between the sockets are made with copper bars in accordance
with Table 4 with a maximum of 1 000 A.
The mounting distance between sockets shall be specified by the manufacturer.

Table 3 – Test conductor for test current above 400 A and up to 800 A
inclusive dependent on the current carried by the terminal
a b,c,d,e
Current carried by the terminal Conductor
A
Above Up to and including Number Size Number Size
mm kcmil
400 500 2 150 2 250
500 630 2 185 2 350
630 800 2 240 3 300
a
The value of test current shall be greater than the first value in the first column and less than or equal to the
second value in that column
b
For convenience of testing and with the manufacturer’s consent, smaller conductors than those given for a
stated test current may be used.
c
The tables give alternative sizes for conductors in the metric and AWG/kcmil system and for bars in
millimetres and inches. Comparison between AWG/kcmil and metric sizes is given in Table 1 of
IEC 60947-1:2007.
d
Either of the two conductors specified for a given test current range may be used.
e
When a dimension of a wire is not available, the next smallest available standard wire size shall be used.
f
Minimum conductor length for testing is 1 400 mm .
NOTE This table is based on Table 10 of IEC 60947-1:2007.

Table 4 – Test copper bars for test current above 400 A and up to 1 000 A
inclusive dependent on the current carried by the terminal
a b,c,d,e
Current carried by the terminal 2 set copper bars
A
Above Up to and including Number Dimension Dimension
mm inches
400 500 2 30 × 5 1 × 0,250
500 630 2 40 × 5 1,25 × 0,250
630 800 2 50 × 5 1,5 × 0,250
800 1 000 2 60 × 5 2 × 0,250
a
The value of test current shall be greater than the first value in the first column and less than or equal to the
second value in that column
b
For convenience of testing and with the manufacturer’s consent, smaller conductors than those given for a
stated test current may be used.
c
Either of the two conductors specified for a given test current range may be used.
d
Bars are assumed to be arranged with their long faces vertical. Arrangements with long faces horizontal may
be used if specified by the manufacturer.
e
Minimum conductor length for testing is 1 400 mm (including the length of flexible conductors).
f
The tables give alternative sizes for bars in millimetres and inches.
NOTE This table is based on Table 11 of IEC 60947-1:2007.

9 Basic operating function
Clause 9 of IEC 61810-1:2015 is applicable.

– 12 – IEC 61810-10:2019 © IEC 2019
10 Dielectric strength
Clause 10 of IEC 61810-1:2015 is applicable with the following changes/additions: Table 5
and Table 6 of this document replace Table 13 and Table 14 of IEC 61810-1:2015.
Table 5 – Dielectric strength – AC
a b
Test voltage depending on the rated voltage of the circuit (RMS values)
c
50 V to 100 V to 200 V 230 V / 400 V 400 V / 400/ > 480 V
Up to and
120 V
3 V
120 V to 240 V 277 V / 480 V
including
50 V
480 V / 480/
125 V to 250 V
3 V
e f
Insulation or
disconnection to
d
g
be tested
L L
L
L
L
E E
L N
L
E
L E
E
L – E L – E L – E L – L L – E L – L L – E L – L L – E
V V V V V
Functional 500 1 300 1 300 1 500 1 500 1 700 1 700 1 700 U + 1 200 V
n
h
insulation (rounded)
i
Basic insulation 500 1 300 1 300 --- 1 500 --- 1 700 --- U + 1 200 V
n
(rounded)
Basic insulation 500 1 000 + 2 times rated voltage
(Test procedure B)
Supplementary --- 1 300 1 300 --- 1 500 --- 1 700 --- U + 1 200 V
n
i
insulation (rounded)
Reinforced or 500 2 600 2 600 --- 3 000 --- 3 400 --- 2 ×
i
double insulation (U + 1 200 V)
n
(rounded)
Micro- 400 400 400 500 500 700 700 700 U + 250V
n
j
disconnection
Full-disconnection 500 1 300 1 300 1 500 1 500 1 700 1 700 1 700 U + 1 200 V
n
(rounded)
a
The high-voltage transformer used for the test shall be designed so that, when the output terminals are short-
circuited after the output voltage has been adjusted to the test voltage, the output current is at least 200 mA.
The overcurrent relay shall not trip when the output current is less than 3 mA. Care shall be taken to ensure
that the RMS value of the test voltage is measured within ±3 %.
b
For functional, basic and supplementary insulation as well as for full disconnection, the values are derived
from the formula U + 1 200 V (rounded). The reinforced level from 50 V up is consequently two times higher.
n
For micro-disconnection, the values are derived from the formula U + 250 V (rounded), with U being the
n n
nominal voltage of the supply system.
c
Up to and including 50 V: not to be connected direct to the supply mains. No temporary overvoltages in
accordance with IEC 60364-4-44 are expected to occur.
d
Single-phase system, mid-point earthed.
e
Three-phase system, mid-point earthed.
f
Three-phase system, one phase earthed.
g
Special components which might render the test impractical such as light emitting diodes, free-running
diodes, varistors are disconnected at one pole, or bridged, or removed, as appropriate to the insulation being
tested.
h
An example is the insulation between contacts necessary for proper function only.
i
For the test of basic, supplementary and reinforced insulation, all live parts are connected together and care
shall be taken to ensure that all moving parts are in the most unfavourable position.
j
Contact gap ensuring proper function of the contact (covers also micro-interruption).

Table 6 – Dielectric strength – DC
a b
Test voltage depending on the rated voltage of the circuit
c
Above 120 V to 250 V 240 V to 480 V > 480V
Up to and
50 V up
125 V to 250 V
including
to
50 V
including
120 V
Insulation or
disconnection
= = = = = =
d
to be tested
L L L L
L L
E E
E E
L – E L – E L – E L – L L – E L – L L – E
V V V
Functional 500 1 300 1 300 1 500 1 500 1 700 U + 1 200 V
n
e
insulation (rounded)
Basic 500 1 300 1 300 --- 1 500 --- U + 1 200 V
n
f
insulation (rounded)
Basic insulation 500 1 000 + 2 times rated voltage
(Test procedure
B)
Supplementary --- 1 300 1 300 --- 1 500 --- U + 1 200 V
n
f
insulation (rounded)
Reinforced or 500 2 600 2 600 --- 3 000 --- 2 × (U + 1 200 V)
n
double (rounded)
f
insulation
Micro- 400 400 400 500 500 700 U + 250 V
n
g
disconnection
Full- 500 1 300 1 300 1 500 1 500 1 700 U + 1 200 V
n
disconnection (rounded)
a
The high-voltage transformer used for the test shall be designed so that, when the output terminals are short-
circuited after the output voltage has been adjusted to the test voltage, the output current is at least 200 mA.
The overcurrent relay shall not trip when the output current is less than 3 mA. Care shall be taken that the
value of the test voltage is measured within ±3 %.
b
For functional, basic and supplementary insulation, as well as for full disconnection, the values are derived
from the formula U + 1 200 V (rounded). The reinforced level from 50 V up is consequently two times higher.
n
For micro-disconnection, the values are derived from the formula U + 250 V (rounded), with U being the
n
n
nominal voltage of the supply system.
c
Up to and including 50 V: Not to be connected direct to the supply mains. No temporary overvoltages
according to IEC 60364-4-44 are expected to occur.
d
Special components which might render the test impractical such as light emitting diodes, free-running diodes,
varistors are disconnected at one pole, or bridged, or removed, as appropriate to the insulation being tested.
e
An example is the insulation between contacts necessary for proper function only.
f
For the test of basic, supplementary and reinforced insulation, all live parts are connected together and care
shall be taken to ensure that all moving parts are in the most unfavourable position.
g
Contact gap ensuring proper function of the contact (covers also micro-interruption).

– 14 – IEC 61810-10:2019 © IEC 2019
11 Electrical endurance
Clause 11 of IEC 61810-1:2015 is applicable with the following changes/additions.
11.1 General
If the relay has a defined polarity of a contact, the manufacturer shall specify an appropriate
schematics for contact loading for the test, which may deviate from the schematics of Table
16 of IEC 61810-1:2015.
The heating test after the electrical endurance is mandatory if prescribed by the relevant
product application annex of this document (e.g. Annex S for photovoltaic systems), or by
application standards (e.g. IEC 60730-1 or IEC 60669-1).
11.2 Overload test
For the overload test, a number of cycles specified by the manufacturer is allowed.
11.3 Severity
The first detected temporary malfunction is defined as a failure (Severity A in accordance with
4.30.2 of IEC 61810-7:2006).
12 Mechanical endurance
Clause 12 of IEC 61810-1:2015 is applicable with Table 5 and Table 6.
13 Clearances, creepage distances and solid insulation
Clause 13 of IEC 61810-1:2015 is applicable with the following changes/additions.
13.1 General provisions
The first two sentences of this subclause of IEC 61810-1:2015 are deleted and replaced by:
The requirements and tests indicated in this clause are based on IEC 60664-1 and
additionally allow the evaluation of the insulation evaluation as a system based on
IEC 60060-1.
13.1.b) the third bullet point is changed as following:
– the partial discharge test under 5.8.5 of IEC 60664-3:2016 is required for peak
voltages above 700 V;
13.2 Clearances and creepage distances
Table 18 of IEC 61810-1:2015 is replaced by the following Table 7.

Table 7 – Minimum clearances in air for insulation coordination
c d
Minimum clearances up to 2 000 m above sea level
Impulse withstand
e
Pollution degree
a
voltage
1 2 3
kV mm mm mm
b c
0,33 0,01 0,2 0,8
c
0,40 0,02 0,2 0,8
b c
0,50 0,04 0,2 0,8
0,60 0,06 0,2 0,8
b
0,80 0,10 0,2 0,8
1,0 0,15 0,2 0,8
1,2 0,25 0,8
b
1,5 0,5 0,8
2,0 1,0
b
2,5 1,5
3,0 2,0
b
4,0 3,0
5,0 4,0
b
6,0 5,5
b
8,0 8,0
10 11
b
12 14
b
15 18
b
18 22
b
20 25
a
This voltage is
– for basic insulation directly exposed to or significantly influenced by transient overvoltages from the low-
voltage mains: the rated impulse voltage of the equipment;
– for other basic insulation: the highest impulse voltage that can occur in the circuit;
– for reinforced insulation, see footnotes a and b of Table 17 of IEC 61810-1:2015.
In special cases, intermediate values derived by interpolation may be used for the dimensioning of
clearances.
b
Preferred values for relating to the overvoltage category (see Annex G).
c
For printed wiring material, the values for pollution degree 1 apply except that the value shall not be less than
0,04 mm, as specified in Table 20 of IEC 61810-1:2015.
d
As the dimensions in Table 18 of IEC 61810-1:2015 are valid for altitudes up to and including 2 000 m above
sea level, clearances for altitudes above 2 000 m are to be multiplied by the altitude correction factor
specified in Table A.2 of IEC 60664-1:2007.
e
Details regarding pollution degrees are specified in Annex H of IEC 61810-1:2015.

– 16 – IEC 61810-10:2019 © IEC 2019
13.3 Solid insulation
13.3.1 General
Solid insulation shall be capable of durably withstanding electrical and mechanical stresses
as well as thermal and environmental influences that may occur during the anticipated life of
the relay.
The qualification of the solid insulation shall be verified by dielectric tests in accordance with
10.2 of IEC 61810-1:2015 based on the Tables 5 and 6, immediately after the preconditioning
of 10.1 of IEC 61810-1:2015.
There is no dimensional requirement for the thickness of functional and basic insulation.
The basic insulation is always directly adjacent to the hazardous potential.
The distances through insulation for supplementary and reinforced insulation shall not be
smaller than 1 mm.
NOTE The distance through insulation can however be reduced when the relevant IEC standard for specific
equipment into which the relay is to be incorporated allows this.
Alternative to the solid insulation requirements above, supplementary or reinforced insulation
could be realized with multilayer solutions and/or other minimum thicknesses as defined
within other valid IEC standards (e.g. IEC 60065, IEC 60335, IEC 60730) and shall be
described within the datasheet.
The requirement indicated above does not mean that the specified distance through insulation
has to be achieved only by solid insulation. The insulation may comprise solid material and
one or more air gaps.
This requirement, however, is not applicable where the insulation consists of thin layers,
except for mica and similar scaling material, and if
• for supplementary insulation, the insulation consists of at least two layers, provided that
each of the layers withstands the dielectric strength test of 10.2 of IEC 61810-1:2015 for
supplementary insulation;
• for reinforced insulation, the insulation consists of at least three layers, provided that any
two layers withstands the dielectric strength test of 10.2 of IEC 61810-1:2015 for
reinforced insulation.
13.3.2 Partial discharge
For components designed for more than 700 V peak the pa
...