Electrical Endurance Test — IEC 61058-1 / IEC 60669-1 / IEC 60947

What Is Electrical Endurance?

The electrical endurance test is a test in which a switch, relay or contactor is subjected to a defined number of open–close cycles under its declared load, evaluating contact wear, arc damage and loss of function.

Purpose of Electrical Endurance

The purpose is to verify that the switching element meets its declared cycle life and remains safe at end of life.

Which Products Is Electrical Endurance Applied To?

Switches and buttons
Relays and contactors
Thermostats
Sockets and plugs
Switchgear

In Which Sectors Is Electrical Endurance Used?

ElectricalElectronicsMachineryMedical Device

Standards Related to Electrical Endurance

IEC 61058-1
IEC 60669-1
IEC 60947-4-1
IEC 61810-1

Electrical Endurance Conditions

Load type: Resistive, inductive or motor load; according to the rated value
Number of cycles: Defined in the product standard; typically 10,000 – 100,000 cycles
Cycle rate: Open–close frequency defined in the standard
Environment: Temperature defined in the standard

Equipment for Electrical Endurance

Automatic cycling test rig
Programmable load bank
Contact-resistance measurement
Temperature and fault monitoring

Sample Requirements for Electrical Endurance

The declared load and number of cycles must be documented
The number of specimens is defined in the standard
Initial contact resistance must be measured
The specimen may become unusable at the end of the test

Duration of Electrical Endurance

Depends on the number of cycles and rate; typically days to weeks.

Electrical Endurance Procedure

1The declared load and number of cycles are determined.
2The specimen is connected to the cycling rig.
3Open–close cycles are applied at the defined rate.
4Contact resistance and temperature are measured periodically.
5Dielectric and functional checks are performed at the end of the cycling.

Electrical Endurance Acceptance Criteria

The acceptance criterion is defined in the product standard: continuity of function at the end of the defined cycling, preservation of dielectric strength, and no hazardous fault occurring.

Evaluation of Results

The increase in contact resistance and arc erosion are evaluated. An end-of-cycling dielectric test is mandatory.

Electrical Endurance Report

Standard applied
Load type and rated values
Number and rate of cycles
Change in contact resistance
End-of-cycling dielectric and function results

Accreditation

EUROLAB holds internationally recognised accreditation obtained from accreditation bodies party to the IAF and ILAC multilateral recognition arrangements, under ISO/IEC 17025 for laboratory testing, ISO/IEC 17020 for inspection and surveillance, and ISO/IEC 17021-1 and ISO/IEC 17065 for system and product certification. This chain ensures the reports and certificates issued are accepted worldwide.

Whether this test can be offered within accredited scope depends on your product and the standard applied; since accreditation is method-based, the scope is confirmed in writing at the quotation stage.

Scope and authorisations

Related Regulations

LVD 2014/35/EU

Electrical Safety — What Does This Testing Field Cover?

The section below describes the field that the Electrical Endurance test belongs to; the conditions and acceptance criteria of this particular test are given in the sections above. The scope specific to your product is confirmed in writing at the quotation stage.

Electrical safety testing shows that a device poses no risk of electric shock, fire or injury to the user in normal use and under foreseeable fault conditions. This family is the test group most often requested when a product enters the market; almost every electrically operated product passes through this gate.

The logic of the field rests on a single assumption: FAULTS WILL HAPPEN. Insulation will age, a component will short, a cable will break, the user will misuse the device. Standards therefore test not only normal operation but also single fault conditions. The sentence "the device works correctly" is not evidence in this field; the evidence is that the device stays safe when it fails.

Assessment addresses three layers together. In the constructional layer, insulation distances (creepage and clearance), protective barriers, earthing continuity, enclosure strength and component selection are examined — this layer is largely a matter of inspection and measurement rather than testing. In the electrical layer, dielectric strength, leakage current, insulation resistance and behaviour under fault conditions are measured. In the thermal layer, temperature rise in normal and abnormal operation is monitored; an overheating component is both a fire risk and a risk of insulation breakdown.

Which standard applies is determined by WHAT THE PRODUCT IS, and that decision affects the entire outcome. Household appliances fall under the IEC 60335 series, information technology and audio/video products under IEC 62368-1, measurement and laboratory equipment under IEC 61010-1, and medical devices under IEC 60601-1. A report obtained under the wrong standard is not accepted in the file even if the measurements it contains are correct.

Component conformity is often overlooked in this field. The safety of the device rests on the conformity of the transformer, optocoupler, fuse, switch and power supply it uses. The list of critical components and the certification status of each is part of the technical file; a change of component reopens the safety assessment.

Method groups in this field

Constructional examination
Insulation distances, barriers, earthing arrangement, accessibility and selection of critical components are examined. It comes before testing and many non-conformities are caught here.
Dielectric strength
It is verified that the insulation withstands the defined voltage. It must not be confused with the routine test on the production line; the type test is more severe.
Leakage current and earthing
The current that could reach the user is measured; the continuity and resistance of the protective earthing path are verified.
Heating tests
Temperatures of components, windings and accessible surfaces are measured in normal and abnormal operation.
Fault condition tests
Components are deliberately short-circuited or open-circuited; the appliance is expected not to cause a fire and not to make a hazardous part accessible.
Mechanical and enclosure tests
Impact, drop, strain relief, IP protection and the safety of moving parts are assessed.

Commonly confused in this field

A CB certificate is not a CE declaration. CB is the output of a mutual recognition arrangement that eases national certification; the CE declaration is made by the manufacturer under its own responsibility.
A part of IEC 60335 is not sufficient on its own; it is applied together with Part 1.
IEC 60950-1 and IEC 60065 have been withdrawn. Old certificates based on these codes cannot be used in a current file.
Separate certification of the adapter does not cover the conformity of the device; the device is assessed as the system it forms together with its power supply.
A change of critical component (transformer, fuse, optocoupler supplier) is not a silent change; it requires the safety file to be reviewed.

Which decisions these results support

CE declaration under the Low Voltage Directive
IECEE CB certificate and entry into national certification schemes
Assessing the safety impact of design changes
Establishing and maintaining the critical component list
Responding to market surveillance requests

Related Tests

Frequently Asked Questions About Electrical Endurance

According to which standard is Electrical Endurance made?

Electrical Endurance is executed in scope IEC 61058-1, IEC 60669-1, IEC 60947-4-1 and IEC 61810-1. The limit values and acceptance criteria to be applied are defined in the product standard; The version valid for your product is confirmed in writing at the offer stage.

Which products does Electrical Endurance apply to?

Mainly applied to Switches and buttons, Relays and contactors, Thermostats, Sockets and plugs and Switchgear. Whether your product is included in the scope is determined by examining its technical specifications and intended use.

Under what conditions is Electrical Endurance done?

The determining parameters are: Load type — Resistive, inductive or motor load; according to the rated value, Number of cycles — Defined in the product standard; typically 10,000 – 100,000 cycles and Cycle rate — Open–close frequency defined in the standard. The full terms are in the "Test Conditions" section on the page and vary depending on the product standard.

What kind of sample is needed for Electrical Endurance?

The declared load and number of cycles must be documented, The number of specimens is defined in the standard and Initial contact resistance must be measured. The number of samples is determined according to the product standard and the scope to be reported.

How long does Electrical Endurance take?

Depends on the number of cycles and rate; typically days to weeks. This duration belongs to the experiment itself; sample preparation, queuing and reporting are also evaluated. A realistic schedule for your product is given in the offer.

What is the Electrical Endurance result called "appropriate"?

The acceptance criterion is defined in the product standard: continuity of function at the end of the defined cycling, preservation of dielectric strength, and no hazardous fault occurring.