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TÜV Product Service Ltd 2006-05-10 1 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products for electrical safety testing
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TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

Dec 15, 2015

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Page 1: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd 2006-05-10 1

Electrical Safety Compliance Made Easy

A practical approach guide to what you need to know when submitting products for electrical safety testing

Page 2: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Who Am I?

2006-05-10 2

Name Mark Penton

Title: Senior Consultant

Employer: TÜV Product Service Ltd

Experience: 20 Years experience in Electrical Safety

History: Worked for Electrolux, TÜV Product Service, Underwriters Laboratories (UL) & Ericsson

Telephone: 01489 558214

E-mail: [email protected]

Page 3: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Contents

1. What is Electrical Safety?A brief overview of electrical safety testing

2. Preparing In advanceHow to prepare in advance to ensure things run smoothly when submitting products

3. Selecting critical components and materials.Guidance on selecting correct components and materials to use in your products

4. Hints and tipsPractical advice to help you avoid problems

2006-05-10 3

Page 4: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

What is Electrical Safety?

Page 5: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

What is Electrical Safety

Electrical safety actually covers a range of issues aimed at ensuring the product is safe for the user and does not pose a hazard to the surrounding environment.

Considers the following-

• The design and construction of the product• The product operation under normal operating conditions• What happens under fault conditions and component failures• Interconnection with other equipment and networks

• Selection of materials and components

Despite the term “electrical safety” it actually covers a whole range of hazards.

2006-05-10 5

Page 6: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Hazards Addressed by the Standards

Type of Hazard What is addressed

Electric Shock Voltages on accessible parts, insulation between circuits and parts, leakage current, protective earthing, safety interlocks

Energy Energy on accessible parts, interconnection circuits, fault conditions

Fire Overloads, component failures, insulation breakdown, selection of materials, fire enclosures, protective devices

Heat Temperature limits, material properties, cooling & ventilation, operator accessible parts, fault conditions, material & component selection, flammable liquids.

Mechanical hazards Operator access, safety interlocks, guarding, mechanical strength & stability

Radiation hazards Laser (light) radiation, X-radiation, Radio FrequencyUltraviolet (UV)

Chemical Hazards Toxic vapours and smoke under fault conditions, dangerous liquids, chemical interaction between materials, warnings

Page 7: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Types of Safety Testing

There are 2 types of approach to safety testing

1. Type testing: A one off test on a sample of the product. A report or certificate relating to the product. No production control or factory inspections. No means of ensuring ongoing compliance. A snapshot based on one sample does not guarantee future product

quality.

Examples of applications for type testing: To support CE Marking (for inclusion in technical file) CB Scheme (as basis for obtaining international acceptance &

certification)

Page 8: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Types of Safety Testing

2. Product certification: An ongoing partnership between manufacturer and certification body. Initial testing of product. Regular factory inspections where the product is made. Certification mark permitted on the product. Ongoing compliance maintained. Assignment of a certification mark

Examples of the benefits of certification: Market access Consumer confidence Ongoing production quality Marketing advantage

Page 9: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

The CB Scheme

Internationally recognised

There are 46 formally participating countries

Recognised in many more countries (eg: South Africa)

And 61 National Certification Bodies - NCBs

With 225 Testing Laboratories – CBTLs

50,000 CB certificates issued each year

Over 400,000 CB Certificates currently in circulation

More than 15,000 manufacturers use the CB Scheme

Page 10: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd 2006-05-10 10

Formal participating countriesArgentina

Australia

Austria

Belgium

Brazil

Canada

China

Czech Rep.

Denmark

Finland

France

Germany

Greece

Hungary

India

Indonesia

Ireland

Israel

Italy

Japan

Kenya

Rep. of Korea

Malaysia

Mexico

Netherlands

New Zealand

Norway

Poland

Portugal

Romania

Russia

Singapore

Slovakia

Slovenia

South Africa

Spain

Sweden

Switzerland

Thailand

Turkey

Ukraine

United Kingdom

United States

Serbia and Montenegro

Page 11: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd 2006-05-10 11

Scope of the CB Scheme

Designation Product Category Available IEC Standards

BATT Batteries 60086, 60099, 60254, 61809, 61960, 61982, 62133, 62259, 62281

CABL Cables and cords 60227, 60245, 60702, 60799

CAP Capacitors 60252, 60384, 60939, 61048, 61049

CONT Switches for appliances 60691, 60730, 60934, 61058, 61095, 61508, 61810

EMC Electromagnetic Compatibility CISPR 11, CISPR 12, CISPR 13, CISPR 14, CISPR 15, CISPR 16, CISPR 20, CISPR 22, CISPR 24, 60118, 60204, 60255, 60478, 60533, 60601, 60728, 60870, 60945, 60947, 60974, 61000, 61131, 61204, 61326, 61543, 61547, 61800, 61812, 62040, 62041, 62052, 62053, 62054, 62153, 62236

HOUS Household and similar equipment 60312, 60335, 60342, 60436, 60456, 60530, 60704, 60705, 60967, 61121, 61770, 61817

INST Installation accessories and connection devices 60083, 60309, 60320, 60423, 60439, 60614, 60669, 60670, 60684, 60807, 60884, 60974, 60998, 60999, 61011, 61076, 61084, 61210, 61238, 61242, 61316, 61800, 61984, 62094, 62208

LITE Lighting 60064, 60155, 60238, 60360, 60400, 60432, 60570, 60598, 60838, 60901, 60920, 60921, 60922, 60924, 60926, 60927, 60928, 60929, 60968, 60969, 61046, 61047, 61050, 61184, 61195, 61199, 61231, 61347, 62035

MEAS Measuring instruments 60414, 61010, 61557

MED Electrical equipment for medical use 60580, 60601, 60976, 61676

MISC Miscellaneous 60747, 60900, 60938

OFF IT and office equipment 60825, 60950, 62040

POW Low voltage, high power switching equipment 60158, 60947, 62026, 62271

PROT Installation protective equipment 60127, 60257, 60269, 60282, 60529, 60755, 60898, 61008, 61009, 61643

PV Photovoltaics 60891, 60904-1 to 10, 61194, 61215, 61345, 61646, 61702, 61721, 61829, 62093, PVRS11, PVRS11A

SAFE Safety transformers and similar equipment 60044, 60742, 61558

TOOL Portable tools 60745, 61029, 61939

TOYS Electric toys 62115

TRON Electronics / Entertainment 60065, 60491, 61965

Page 12: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd 2006-05-10 12

Why do we need the CB scheme?

Because the world is getting smaller…!

We trade in an international market.

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TÜV Product Service Ltd

Preparing in advance

Page 14: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

At the Design Stage

• Ensure design engineers are aware of safety requirements.– Provide training– Ensure they have access to the standards– Seek advice from 3rd parties– Enlist a consultant

• Consider getting a compliance review at an early stage of development– Highlight any issues with the design– Avoid re-design at a later stage– Advice on component and material selection

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TÜV Product Service Ltd

At the Design Stage

• Select already approved components and materials.– Know your target markets– Reduce testing requirements– Avoid potential failures– Avoid having to change / re-source components

• Don’t design power supplies unless you really need to.– They involve extensive testing– Can cost more to test than the end product– Critical to safety of the product

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Page 16: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Requesting a Quotation

• Know your market• Where do you want to sell the product?• Is CE marking sufficient?• Are international approvals / Certifications required?• Ensure that these requirements are defined when requesting quotations

• Provide as much information as possible• Target markets• Product description / Brochures • Photos / drawings• Define power requirements• Specify other facilities required (water, drainage, compressed air etc..)• Fan speed control or air conditioning incorporated in the product• Timescales required• Budget constraints

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Page 17: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

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Preparing to Submit for testing

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• Collate documentation before submitting– Circuit Diagrams & Schematics

– Parts Listings

– Mechanical & Exploded drawings

– Critical Component Approvals information

– User and service manuals

– Rating label drawings

– List all accessories and parts required to be included with the product

– Define product families

– List all production facilities

Page 18: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Preparing to Submit for testing

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• Ensure that the equipment is suitably configured for testing – Worst case normal load conditions

– Provide worst case configuration

– Prepare support equipment loads & cabling

– Provide clear operating instructions

– Write test software

Page 19: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Preparing to Submit for testing

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• Find out how many samples are required– Complete product

– Power supplies

– Fuses, thermal cut-outs and other components

– Plastic parts

• In-Situ testing at your site can often be the most effective way of testing. – 100% of our engineers attention

– All support facilities available

– Issues can be resolved face to face

– Fix your problems and clear non compliances on-line with the testing

Page 20: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Safety Critical Components and materials

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Page 21: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Safety Critical Components & Materials

These guidance notes are intended to explain what information is required to show that a safety critical component holds suitable approval.

This will assist you in preparing the correct information in advance of submitting your product for testing.

 

 

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Page 22: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Which Components are Safety Critical

Mains Components Other components

Mains plugs and cords DC/DC converters

Appliance couplers, EMC filters Fans

Fuses and fuseholders Enclosure materials

Wiring Connectors

Power supplies PCB’s

Capacitors (Class X, Class Y) Thermistors, PTC’s

Transformers

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Page 23: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

IEC & EN Investigations

Component approvals should be in the form of a current test certificate / report to a relevant IEC / EN standard.

The documents should be in English from a CB, CCA or LVD accredited test laboratory (e.g. TÜV Product Service, VDE). The test certificate must be current (some have expiry dates) and must detail all relevant information i.e. some certificates are made up of many pages, all should be supplied.

If the test certificate does not give all of the required details then a copy of the test report may be required. This is generally the case, for example, with power supply units where more detailed information is required i.e. maximum rated ambient, classification of outputs, method of mains isolation.

Self-declaration in the form of a Certificate of Conformity, component marking, manufacturer’s declaration etc. may also be accepted in some cases. However, the responsibility that the component is suitably approved remains with you (this would be stated in any test report issued).

Note: statements like “designed to meet” or “complies with ENxxxx” are not evidence of suitable component approvals.

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Page 24: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Where Third Party Certification of your product is being sought self-declaration is not acceptable and 3rd approved components should be used (e.g. TÜV PS, UL, CB, VDE).

X and Y class capacitors (including discrete components or within filters) - must comply with IEC 60384-14 2nd Ed.

Mains switches / circuit breakers – the approval documentation must clearly state the voltage and current ratings.

Where transformers or motors are to be assessed then we require details of the thermal classification of the winding in accordance with IEC60085 (this also apply to the windings of inductors). The thermal classification of winding insulation is as follows:

Class:- A 100ºC; E 115ºC; B 120ºC; F 140ºC; H 165ºC

2006-05-10 24

IEC & EN Investigations

Page 25: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Flammability of Materials

This refers to plastic or non-metallic materials used in the construction of the unit. Compliance may be based on self-declaration, and/or suitable documentary evidence of compliance with the relevant standard for flammability.

This will most commonly be to UL 94.

In order for the suitability of the materials used to be assessed the following information is required:- 

i) The name of the company that holds the UL approval (eg: GE Plastics, 3M).ii) The name and part number of the material (e.g. Lexan, LX437).iii) The UL file number (e.g. E143678).iv) The flammability rating (e.g. V-1, V-2, HB, HF2).v) Thickness of material used

The name of the approval holder and material is the most important information required in order for us to confirm compliance. 

The easiest method of obtaining the information is to obtain a copy of the UL Listing (Yellow) Card, which can be obtained from the approval holder, the manufacturer of the material, or from UL’s website.

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Example of UL Flammability Listing

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Page 27: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

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US / Canadian Investigations

All safety critical components and materials must have current UL or CSA Recognition and in order to verify this the following information is required:-

 

i) The name of the company that holds the UL or CSA approval

ii) The type or model number of the component.

iii) The UL file number (e.g. E143678).

 

The easiest method of obtaining the information is to obtain a copy of the UL Listing (Yellow) Card, which can be obtained from the approval holder, the manufacturer of the component/part, or from UL’s website.

 

Where transformers are to be assessed and an insulation Class higher than Class A is to be used the UL require a UL Recognised insulation system (OBJY2) to be employed. (A recognised insulation system is a combination of materials that have been tested together for suitability of use in prolonged high temperature conditions).

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UL Power Supply Listing

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Example of TÜV PS Certificate

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Example of VDE Certificate

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Page 31: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

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On-Line Approvals Links

Certification Body

Link Certification Body Link

TÜV Product Service

www.tuev-sued.de/productservices/services/gblrenwwjohi.asp

TÜV Rheinland

www.tuvdotcom.com/pi/web/byMan.xml?strLevel=-1

VDE www.vde.de/VDE_PI_en/Zertifizierungsregister/detailSearch

ÖVEwww.ove.at/puz/reg/form.php

CSA

directories.csa-international.org/

KEMA KEUR

www.kema.com/products_and_processes/Certified_products/Advanced_search/search.asp#0

FIMKOwww.fimko.fi/certifiedproducts.html CEBEC

www.cebec.sgs.com/Certif/products.asp

UL

database.ul.com/cgi-bin/XYV/template/LISEXT/1FRAME/index.htm

ETL

etlwhidirectory.etlsemko.com/WebClients/ITS/DLP/products.nsf/$$Search?OpenForm

SEMKOge.semko.se/semko/certified/ ASTA

BEABwww.beab.co.uk/buyers.htm

IMQwww.imq.it/bgml/cat_prod.asp?l=inglese&if=&ia=&sett=&cat=&sct 2006-05-10 31

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Hints and Tips

Page 33: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Hints and Tips

• Know your target markets

• Provide as much info as possible at the quotation stage

• Get a copy of the applicable standard

• Select already approved components

• Get a compliance review at an early stage of development

• Don’t rely on datasheets as evidence of component approvals (“designed to meet” “in accordance with”)

• Don’t design your own power supplies unless you really need to

• Consider In-Situ testing if its practical

• Collate all documentation before submitting for test

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Page 34: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Hints and Tips

• Ensure that the equipment is suitably configured for testing (worst case normal load conditions)

• Find out how many samples are required

• List all accessories and parts required to be included with the product

• Define product families

• Check the thickness of plastic parts when determining flammability ratings

• Supply equipment fully ready for testing – loads cables– support equipment– test software

• Specify all manufacturing locations

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Page 35: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Hints and Tips

• Ensure support is available during testing

• Select a nominated technical contact

• Attend on first day to assist with set up

• Respond to non-compliances as a package

• Advise when you are going to send new samples

2006-05-10 35

Page 36: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Summary

1. What is Electrical Safety?

2. Preparing In advance

3. Selecting critical components and materials.

4. Hints and tips

2006-05-10 36

Page 37: TÜV Product Service Ltd 2006-05-101 Electrical Safety Compliance Made Easy A practical approach guide to what you need to know when submitting products.

TÜV Product Service Ltd

Thanks for Listening

Any Questions?