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TÜV Product Service Ltd 2006-05-10 1
Electrical Safety
Compliance Made EasyA practical approach guide to what you need to know when
submitting products for electrical safety testing
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]
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
TÜV Product Service Ltd
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.
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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 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:
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)
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
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 2006-05-10 10
Formal participating countries
Argentina
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
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
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.
TÜV Product Service Ltd
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 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
2006-05-10 14
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
2006-05-10 15
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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TÜV Product Service Ltd
Preparing to Submit for testing
2006-05-10 17
• 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
Preparing to Submit for testing
2006-05-10 18
• 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
Preparing to Submit for testing
2006-05-10 19
• 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
Safety Critical Components
and materials
2006-05-10 20
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.
2006-05-10 21
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
2006-05-10 22
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.
2006-05-10 23
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
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.
2006-05-10 25
TÜV Product Service Ltd
Example of UL Flammability Listing
2006-05-10 26
TÜV Product Service Ltd
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).
2006-05-10 27
TÜV Product Service Ltd
UL Power Supply Listing
2006-05-10 28
TÜV Product Service Ltd
Example of TÜV PS Certificate
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TÜV Product Service Ltd
Example of VDE Certificate
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TÜV Product Service Ltd
On-Line Approvals Links
Certification Body Link Certification Body Link
TÜV
Product
Service
www.tuev-sued.de/product
services/services/gblrenwwjohi.
asp
TÜV
Rheinland
www.tuvdotcom.com/pi/web/
byMan.xml?strLevel=-1
VDE www.vde.de/VDE_PI_en/Zertifizi
erungsregister/detailSearch ÖVEwww.ove.at/puz/reg/form.php
CSA
directories.csa-international.org/
KEMA
KEUR
www.kema.com/products_an
d_processes/Certified_produ
cts/Advanced_search/search
.asp#0
FIMKOwww.fimko.fi/certifiedproducts.ht
ml CEBECwww.cebec.sgs.com/Certif/pr
oducts.asp
UL
database.ul.com/cgi-bin/XYV/
template/LISEXT/1FRAME/
index.htm
ETL
etlwhidirectory.etlsemko.com
/WebClients/ITS/DLP/produc
ts.nsf/$$Search?OpenForm
SEMKOge.semko.se/semko/certified/ ASTA
BEAB
www.beab.co.uk/buyers.htm
IMQ
www.imq.it/bgml/cat_prod.asp?l
=inglese&if=&ia=&sett=&cat=&s
ct
2006-05-10 31
TÜV Product Service Ltd 2006-05-10 32
Hints and Tips
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
2006-05-10 33
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
2006-05-10 34
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
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
TÜV Product Service Ltd
Thanks for Listening
Any Questions?
