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2Underwriters Laboratories
Overview
Underwriters Laboratories (UL)
The “LISTING” process.
UL Standards FCI Lists to.
General product “LIST” requirements.
UL Follow-Up Services.
UL486A for copper SERVITs
UL486B for aluminum SERVITs and UNITAP
3Underwriters Laboratories
UL - Who are they?
Independent, Not-for-profit Product Testing & Certification Organization
Established in 1874
Primary founders were Insurers
Product/Consumer safety orientation
NOT restricted to electrical industry!
Marine
Fire equipment
Environmental and Public Health
& Electrical and Electronics products/services
4Underwriters Laboratories
UL Activities - 1999
Estimated UL Marks appearing on new products 16,1 billion
Product evaluations 94 396
Follow-up Service visits to audit compliance 509 442
Consumers UL reached in the U.S. and Canada 110 million
Total number of current UL Standards 748
Countries with UL customers 89
UL Staff 5 644
UL Inspection Centers 193 in 71 countries
Laboratory testing and certification facilities 46
Number of product types UL evaluates 18 059
Total number of facilities registered by UL 4 089
Number of manufacturers producing UL certified products 58 684
5Underwriters Laboratories
UL “Listing”
The Listing defined:
A UL Listing allows a manufacturer to apply the UL symbol
to all products that have successfully been sample tested
to the appropriate standard (primarily a UL standard) for the product category. Product with the UL mark implies
continued compliance with Follow-Up inspections.
6Underwriters Laboratories
UL Listing Process (simplified)
Initial Request (IR)
Approval & Project #
Testing
Listing
The IR proposes a List program of testing.
UL reviews the IR, approves with changes,
estimates cost, and assigns project #.
Testing conducted in certified lab to UL
approved test program.
UL issues the product file listing all Listed
products reviewed. Manufacturer can
apply the UL mark to the products.
Follow-Up
7Underwriters Laboratories
UL Certified Labs
UL Labs
Northbrook, IL
Melville, NY
Camas, WA
Santa Clara, CA
Research Triangle Park, NC
UL Certified Labs - Many
FCI Manchester is one
8Underwriters Laboratories
UL Standards
FCI Manchester - Certified for:
UL 486 A - Cu Connectors
UL 486 B - AL to AL and Al to Cu
UL 486 C - Small disconnects
UL 486 D - Insulated connectors
UL 467 - Grounding
9Underwriters Laboratories
General Product List Requirements
Performance
Usually (but not restricted to) testing to UL Standard
Construction
List File contains product details
Product must remain as tested
Product changes must be reevaluated
10Underwriters Laboratories
Product List Requirements
Marking
Connector Product marking
Catalog Number
Company Identifier
Smallest unit packaging
Conductor
Tools
Dies
Stuffer sheet
Installation Instructions
11Underwriters Laboratories
Follow-Up Services
Follow-Up Services defined:
Follow-Up Services performs conformance audits to the
Manufacturers Report, ensuring proper use of UL Marking.
12Underwriters Laboratories
Follow-Up Services
Manufacturers File
The Manufacturers File contains the product description details. Auditors will use the file to inspect product at the manufacturing location to ensure products being shipped with the UL Mark conform to the File requirements.
14Underwriters Laboratories
UL486A – Standard Scope
Scope
Terminal wire connectors and splices for #30 to #4 AWG or largercopper conductors with currents not exceeding the capacity of the insulated conductors.
Insulated connectors, insulating caps and covers intended for use at 600 Volts or less.
Exception: Uninsulated pressure wire connectors that are
compression tool applied may be used in circuits rated 35,000 Volts or less.
15Underwriters Laboratories
UL486A - Application
Areas of application:
UL 486A Listed products are appropriate for National Electric Code (NEC) applications.
NEC generally applies from the service entrance to throughout a facility.
UL 486A Listing NOT appropriate for distribution, transmission, or generation except for those facilities where the NEC applies by local law.
16Underwriters Laboratories
UL486A - Construction Requirements
All strands of conductor are contained.
The clamping action of a range taking connector shall not
require the permanent addition or removal of parts.
There shall be no sharp edges or corners that may damage
insulation that it may contact.
17Underwriters Laboratories
UL486A – Material Requirements
Main current carrying portion of the connector shall be copper
or a copper alloy.
Tin is an accepted coating. Others are acceptable upon
testing.
Brass shall be resistant to stress corrosion (>15% Zinc shall be tested to the Moist Ammonia-Air Stress Cracking Test).
18Underwriters Laboratories
UL486A – Performance Requirements
Two sets of sequential testing:
Set 1: Static Heating
Secureness
Static Heating
Pullout
Set 2: Mechanical
Secureness
Pullout
19Underwriters Laboratories
SET 1: Static Heating Sequence - Secureness
Set 1: Static Heating
Secureness
Static Heating
Pullout
20Underwriters Laboratories
SET 1: Static Heating Sequence - SH
Set 1: Static Heating
Secureness
Static Heating
Pullout
21Underwriters Laboratories
SET 1: Static Heating Sequence - Pullout
Set 1: Static Heating
Secureness
Static Heating
Pullout conductor
connector
Pullout
Force
24Underwriters Laboratories
UL486A - Marking Requirements
Connector
Manufacturer’s name/tm/other
Catalog number
Conductor range
Container
“CU”
Class B or C
“Solid” (if tested and acceptable)
25Underwriters Laboratories
UL486A - Marking Requirements
Instructions
Specific tool(s) required
Multiple crimping operations
Location of crimp points
Conductor strip length
Preliminary conductor preparation
27Underwriters Laboratories
UL486B – Standard Scope
Scope:Pressure wire connectors intended for use with aluminum or copper-clad aluminum conductor according to the National Electrical Code, NFPA 70. The connectors may be constructed so that they are also acceptable for use with copper conductor.
Terminal-type wire connectors intended for use with No. 12 AWG (3.3 mm 2 ) or larger aluminum or copper-clad aluminum conductor.
Splicing-type wire connectors intended for use with No. 4 AWG (21.2 mm 2 ) or larger conductors, with currents not exceeding the ampacity of insulated conductors rated 75°C or 90°C
Insulated connectors, insulating caps, and covers intended for use at 600 volts or less anduninsulated connectors for use in general-use circuits rated 2000 volts nominal or less.
Exception: Uninsulated pressure wire connectors that are compression tool applied may be used in circuits rated 35,000 volts or less.
29Underwriters Laboratories
UL486B – Construction Requirements
The main current-carrying part of a connector shall be of aluminum, an aluminum alloy, copper, a copper alloy, or other material investigated and found to be acceptable for the purpose.
A connector body of copper, copper alloy, aluminum, or aluminum alloy shall be coated with an electrically conductive coating that will inhibit oxidation and corrosion.
30Underwriters Laboratories
UL486B – Installation Note
Note:
Split-bolt torque is specified by the standard based on the maximum conductor size accommodated.
Set screw torque is specified by the standard based on the maximum conductor size accommodated.
Manufacturer may provide instructions for alternate torque, but must be clearly identified in published literature and with the connector when shipped.
31Underwriters Laboratories
UL486B – Performance Requirements
Static Heating, Secureness & Heat Cycle:
Set 3: Heat Cycling
•500 cycles
•All combinations of
conductor
•125 °C max
connector temp rise
Set 1: Static
Heating
Secureness
Static Heating
Pullout
Set 2:
Mechanical
Secureness
Pullout +
As in UL486A
32Underwriters Laboratories
UL486B – Heat Cycle
Set 3: Heat Cycling
•500 cycles
•All combinations
of conductor
•125 °C max
connector temp
rise
Fully
Automated,
Digital Data
Acquisition
System for
Heat Cycle
Testing
33Underwriters Laboratories
UL486B - Marking Requirements
Connector
Manufacturer’s name/tm/other
Catalog number
Conductor range
“ALCU” or “AL7CU” for 75 °C applications
“AL9CU” for 90 °C applications
Container
Class B or C
“Solid” (if tested and acceptable)