IEC 63522-56:2025

Electrical relays - Tests and measurements - Part 56: Ball Pressure test

IEC 63522-56:2025 This part of IEC 63522 is used for testing along with the appropriate severities and conditions for measurements and tests designed to assess the ability of specimens to perform under expected conditions of transportation, storage and all aspects of operational use.
The object of this test is to define a standard test method for evaluation of appropriate materials to withstand mechanical pressure at elevated temperatures without undue deformation.

Relais électriques - Essais et mesurages - Part 56: Essai à la bille

IEC 73522-56:2025 La présente partie de l'IEC 63522 est utilisée pour les essais mettant en œuvre les sévérités et les conditions appropriées pour les mesurages et les essais, destinés à évaluer la capacité des éprouvettes à fonctionner dans des conditions prévues de transport et de stockage, ainsi que tous les aspects de l'utilisation opérationnelle. L'objet de cet essai est de définir une méthode d'essai normalisée pour évaluer la capacité des matériaux appropriés à résister à une pression mécanique à des températures élevées sans déformation excessive.

General Information

• Status: Published
• Publication Date: 22-Apr-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: 23-Apr-2025
• Completion Date: 07-Mar-2025

Overview

IEC 63522-56:2025 is an international standard published by the International Electrotechnical Commission (IEC) as part of the IEC 63522 series on electrical relays - tests and measurements. Part 56 of this series details the ball pressure test, a standard test method used to assess how well materials used in electrical relays can resist mechanical pressure under elevated temperature conditions. This evaluation is crucial for ensuring the quality, safety, and reliability of electrical relay components during transportation, storage, and normal operational environments.

The primary objective of the ball pressure test according to IEC 63522-56:2025 is to determine whether materials can withstand high temperature and mechanical pressure without undergoing unacceptable deformation. This standard thus provides a harmonized test method to support product compliance and performance verification across the electrical industry.

Key Topics

• Test Scope & Applicability:

  • Relevant for materials used in electrical relays except ceramics
  • Focuses on end product parts and test plaques made from identical materials

• Pre-conditioning Requirements:

  • Test specimens must be conditioned under controlled temperature and humidity for at least 24 hours before testing

• Test Methodology:

  • Specifies specimen preparation requirements, including minimum thickness and dimensions
  • Describes the use of a 5 mm steel ball pressed with a standardized force under specific temperature conditions

• Evaluation Criteria:

  • Measurements of deformation (indentation) on the material surface
  • Explicit pass/fail criteria based on the size of the impression and absence of surrounding deformations

• Test Reporting:

  • Detailed capture of specimen description, conditioning, test environments, observed results, and specific measurement points

Applications

The ball pressure test as defined by IEC 63522-56:2025 is essential in the following contexts:

• Product Qualification:

  • Manufacturers use this standard to validate the mechanical and thermal resistance of plastics and non-ceramic materials used in electrical relay components.

• Quality Assurance:

  • Routine compliance checks during production to maintain consistent product performance and safety.

• Material Selection:

  • Supports engineers and designers in choosing appropriate materials that meet expected environmental and operational stress profiles.

• Certification and Regulatory Compliance:

  • Helps organizations demonstrate conformity with global safety and durability requirements for electrical components.

• Failure Analysis:

  • Used during investigation of relay failures related to environmental or operational stress to understand material limitations and improve product design.

Related Standards

• IEC 63522-0: General guidance for electrical relays – tests and measurements (to be used in conjunction with Part 56)
• IEC 60695-10-2: Fire hazard testing – Abnormal heat – Ball pressure test method
• IEC 63522-10: Electrical relays – Tests and measurements – Part 10: Heating (for temperature determination)
• ISO 293, ISO 294, ISO 295: Methods for compression and injection moulding of thermoplastic and thermosetting materials for test specimens

Practical Value

Implementing the IEC 63522-56:2025 ball pressure test standard ensures reliable performance of electrical relays under real-world stress conditions. By adhering to these best practices, manufacturers, testing laboratories, and quality assurance teams can:

• Enhance product reliability and operational safety
• Reduce failure rates caused by material deformation
• Streamline global market access by demonstrating international compliance
• Optimize material selection for cost-effective and robust design

For organizations involved in the design, manufacturing, or certification of electrical relays, following IEC 63522-56:2025 is fundamental to achieving high standards of durability and safety.

Keywords: IEC 63522-56:2025, ball pressure test, electrical relays, mechanical pressure resistance, elevated temperature test, material evaluation, international standards, electrical component testing.

Standards Content (Sample)

IEC 63522-56 ®
Edition 1.0 2025-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electrical relays – Tests and measurements –
Part 56: Ball Pressure test
Relais électriques - Essais et mesurages -
Part 56: Essai à la bille
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IEC 63522-56 ®
Edition 1.0 2025-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electrical relays – Tests and measurements –
Part 56: Ball Pressure test
Relais électriques - Essais et mesurages -
Part 56: Essai à la bille
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.120.70 ISBN 978-2-8327-0351-9
– 2 – IEC 63522-56:2025 © IEC 2025
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Test procedure . 5
4.1 Purpose . 5
4.2 Procedure . 6
4.2.1 Pre-conditioning. 6
4.2.2 Test specimen . 6
4.2.3 Test process. 6
4.3 Conditions . 8
5 Evaluation . 8
5.1 General . 8
5.2 Test report . 8
Bibliography . 9

Figure 1 – Ball pressure test apparatus. 7
Figure 2 – Measurement points . 7

Table 1 – Measurement points . 7

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTRICAL RELAYS –
TESTS AND MEASUREMENTS –
Part 56: Ball pressure test
FOREWORD
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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
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shall not be held responsible for identifying any or all such patent rights.
IEC 63522-56 have 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
94/1067/FDIS 94/1117/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 63522-56:2025 © 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 of IEC 63522 series, published under the general title Electrical relays – Tests
and measurements, can be found on the IEC website.
This International Standard is to be used in conjunction with IEC 63522-0:– .
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.
___________
Under preparation. Stage at the time of publication: IEC CDV 63522-0:2024.

ELECTRICAL RELAYS –
TESTS AND MEASUREMENTS –
Part 56: Ball pressure test
1 Scope
This part of IEC 63522 is used for testing along with the appropriate severities and conditions
for measurements and tests designed to assess the ability of specimens to perform under
expected conditions of transportation, storage and all aspects of operational use.
The object of this test is to define a standard test method for evaluation of appropriate materials
to withstand mechanical pressure at elevated temperatures without undue deformation.
NOTE The test is not made on parts of ceramic material.
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 63522-0:─ , Electrical relays – Tests and measurements – Part 0: General and guidance
ISO 293, Plastics – Compression moulding of test specimens of thermoplastic materials
ISO 294 (all parts), Plastics – Injection moulding of test specimens of thermoplastic materials
ISO 295, Plastics – Compression moulding of test specimens of thermosetting materials
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
4 Test procedure
4.1 Purpose
The purpose of the ball pressure test is to assess the ability of materials to withstand
mechanical pressure at elevated temperatures without undue deformation.
___________
Under preparation. Stage at the time of publication: IEC CDV 63522-0:2024.

– 6 – IEC 63522-56:2025 © IEC 2025
4.2 Procedure
4.2.1 Pre-conditioning
The parts to be tested are stored for 24 h in an atmosphere having a temperature between
15 °C and 35 °C and a relative humidity between 45 % and 75 %, before starting the test.
4.2.2 Test specimen
4.2.2.1 End product test method
A test specimen is cut from the end product in such a way that a piece at least 2,5 mm thick
with approximately parallel upper and lower surfaces is obtained. If necessary, the thickness
may be attained by stacking two or more sections so long as there is no noticeable movement
between the surfaces prior to testing. If it is not possible to cut a test specimen with parallel
surfaces, care shall be taken to support the area of the test specimen directly under the
pressure ball. The test specimen shall be a square with a minimum of 10 mm sides or a circle
with a diameter of at least 10 mm.
If it is impracticable to use a test specimen from the end product, then a plaque of identical
material may be used as the test specimen as described in 4.2.2.2.
NOTE Three test specimens can be necessary.
4.2.2.2 Material Test method
4.2.2.2.1 Test specimen – Preparation
Test specimens shall be fabricated using the appropriate ISO method, for example casting and
injection moulding in accordance with the ISO 294 series, compression moulding in accordance
with ISO 293 or ISO 295, or transfer moulding to the necessary shape.
4.2.2.2.2 Test specimen – Dimensions
The dimensions of the planar sections of the test specimens shall be at least 10 mm in length
and 10 mm in width, or a circle with a diameter of at least 10 mm and shall be provided in a
thickness of 3,0 mm ± 0,5 mm.
NOTE Fifteen test specimens can be necessary.
4.2.3 Test process
The following applies for this document (see also IEC 60695-10-2):
The test is made in a heating cabinet at a temperature of 20 °C ± 2 °C plus the value of the
maximum temperature determined during the heating tests of IEC 63522-10, or at
• 75 °C ± 2 °C for external parts,
• 125 °C ± 2 °C for parts that support active parts,
whichever is higher.
The support and the test apparatus shall be at the specified test temperature before the test is
started.
The test apparatus is shown in Figure 1.
The surface of the part to be tested is placed in the horizontal position supported on a 3 mm
thick steel plate.
The thickness of the specimen shall be not less than 2,5 mm; if necessary, two or more layers
of the part subjected to the test shall be used.
A steel ball of 5 mm diameter is pressed against the surface of the specimen by a force of
20 N ± 0,2 N. Care should be taken that the ball does not move during the test.
After 1 h, the ball is removed from the specimen which is then cooled down to approximately
room temperature by immersion for 10 s in water. The water shall have a temperature within
the reference ambient temperature.
The diameter of the impression caused by the ball is measured with an accuracy of 0,1 mm
within 3 min after removal of the specimen from the water.

Figure 1 – Ball pressure test apparatus
The measurement points according to the descriptions are listed in Table 1. The diagrams in
Figure 2 illustrate these indentation measurement points.
Table 1 – Measurement points
Measurement points
A Edges of a simple indent
B Inside face of raised (rounded) edges
C Outside perimeter of raised (rounded) edges
D Limit of the shoulder of a slight subsidence
E Edges of the direct ball indent within a slight subsidence
Other Other – if applicable – description needed e.g., irregular shaped indent

Figure 2 – Measurement points
– 8 – IEC 63522-56:2025 © IEC 2025
4.3 Conditions
• Pre-conditioning as defined
• Test temperature
...