Electrical Safety Compliance Made Easy A practical approach

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

Who Am I? 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: mpenton@tuvps. co. uk TÜV Product Service Ltd 2006 -05 -10 2

Contents 1. What is Electrical Safety? A brief overview of electrical safety testing 2. Preparing In advance How 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 tips Practical advice to help you avoid problems TÜV Product Service Ltd 2006 -05 -10 3

What is Electrical Safety? 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. TÜV Product Service Ltd 2006 -05 -10 5

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 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 Frequency Ultraviolet (UV) Chemical Hazards Toxic vapours and smoke under fault conditions, dangerous liquids, chemical interaction between materials, warnings TÜV Product Service Ltd

Types of Safety Testing There are 2 types of approach to safety testing 1. Type testing: Ø Ø Ø 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: Ø To support CE Marking (for inclusion in technical file) Ø CB Scheme (as basis for obtaining international acceptance & certification) TÜV Product Service Ltd

Types of Safety Testing 2. Product certification: Ø Ø Ø 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: Ø Ø Market access Consumer confidence Ongoing production quality Marketing advantage 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 TÜV Product Service Ltd

Formal participating countries Argentina India Romania Australia Indonesia Russia Austria Ireland Singapore Belgium Israel Slovakia Brazil Italy Slovenia Canada Japan South Africa China Kenya Spain Czech Rep. of Korea Sweden Denmark Malaysia Switzerland Finland Mexico Thailand France Netherlands Turkey Germany New Zealand Ukraine Greece Norway United Kingdom Hungary Poland United States Portugal Serbia and Montenegro TÜV Product Service Ltd 2006 -05 -10 10

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, 61009, 61643 PV Photovoltaics 60891, 60904 -1 to 10, 61194, 61215, 61345, 61646, 61702, 61721, 61829, 62093, PVRS 11 A 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 TÜV Product Service Ltd 2006 -05 -10 11

Why do we need the CB scheme? Because the world is getting smaller…! We trade in an international market. TÜV Product Service Ltd 2006 -05 -10 12

Preparing in advance 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 3 rd 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 TÜV Product Service Ltd 2006 -05 -10 14

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 TÜV Product Service Ltd 2006 -05 -10 15

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 TÜV Product Service Ltd 2006 -05 -10 16

Preparing to Submit for testing • 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 TÜV Product Service Ltd 2006 -05 -10 17

Preparing to Submit for testing • 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 TÜV Product Service Ltd 2006 -05 -10 18

Preparing to Submit for testing • 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 TÜV Product Service Ltd 2006 -05 -10 19

Safety Critical Components and materials TÜV Product Service Ltd 2006 -05 -10 20

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. TÜV Product Service Ltd 2006 -05 -10 21

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 TÜV Product Service Ltd 2006 -05 -10 22

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. TÜV Product Service Ltd 2006 -05 -10 23

IEC & EN Investigations Where Third Party Certification of your product is being sought self-declaration is not acceptable and 3 rd 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 2 nd 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 thermal classification of the winding in accordance with IEC 60085 (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 TÜV Product Service Ltd 2006 -05 -10 24

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) iii) iv) v) The name of the company that holds the UL approval (eg: GE Plastics, 3 M). The name and part number of the material (e. g. Lexan, LX 437). The UL file number (e. g. E 143678). The flammability rating (e. g. V-1, V-2, HB, HF 2). 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. TÜV Product Service Ltd 2006 -05 -10 25

Example of UL Flammability Listing TÜV Product Service Ltd 2006 -05 -10 26

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. E 143678). 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 an insulation Class higher than Class A is to be used the UL require a UL Recognised insulation system (OBJY 2) 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). TÜV Product Service Ltd 2006 -05 -10 27

UL Power Supply Listing TÜV Product Service Ltd 2006 -05 -10 28

Example of TÜV PS Certificate TÜV Product Service Ltd 2006 -05 -10 29

Example of VDE Certificate TÜV Product Service Ltd 2006 -05 -10 30

On-Line Approvals Links Certification Body Link Certification Body TÜV Product Service www. tuev-sued. de/product services/gblrenwwjohi. asp TÜV Rheinland VDE www. vde. de/VDE_PI_en/Zertifiz ierungsregister/detail. Search ÖVE directories. csa-international. org/ KEMA KEUR CSA Link www. tuvdotcom. com/pi/web/ by. Man. xml? str. Level=-1 www. ove. at/puz/reg/form. php www. kema. com/products_an d_processes/Certified_produ cts/Advanced_search/search. asp#0 FIMKO www. fimko. fi/certifiedproducts. ht CEBEC ml www. cebec. sgs. com/Certif/pr oducts. asp UL database. ul. com/cgi-bin/XYV/ template/LISEXT/1 FRAME/ index. htm etlwhidirectory. etlsemko. com /Web. Clients/ITS/DLP/produc ts. nsf/$$Search? Open. Form SEMKO IMQ TÜV Product Service Ltd ge. semko. se/semko/certified/ ETL ASTA BEAB www. beab. co. uk/buyers. htm www. imq. it/bgml/cat_prod. asp? l =inglese&if=&ia=&sett=&cat=&s ct 2006 -05 -10 31

Hints and Tips TÜV Product Service Ltd 2006 -05 -10 32

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 TÜV Product Service Ltd 2006 -05 -10 33

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 TÜV Product Service Ltd 2006 -05 -10 34

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 TÜV Product Service Ltd 2006 -05 -10 35

Summary 1. What is Electrical Safety? 2. Preparing In advance 3. Selecting critical components and materials. 4. Hints and tips TÜV Product Service Ltd 2006 -05 -10 36

Thanks for Listening Any Questions? TÜV Product Service Ltd