Are you ready for Electrical Safety Testing?
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1 Are you ready for Electrical Safety Testing? A short guide to preparing for safety itesting of electrical and electronic products Alastair McLaughlin TÜV SÜD Product Service Slide 1
2 Who am I? Name Alastair McLaughlin Title: Product Safety Specialist Employer: TÜV SÜD Product Service Experience: Over 20 years experience in compliance management and product testing. Worked for retail suppliers, major children s product manufacturers and TÜV SÜD Product Service. Telephone: +44 (0) alastair.mclaughlin@tuv-sud.co.uk Slide 2
3 Contents 1 Submitting for Safety Testing Selection of test standards Requesting a quote Safety critical components Hints and tips to minimise failures Slide 3
4 Submitting for Testing Selection of standards IEC electrical safety standards EN standards for electrical safety are derived from IEC standard Similarly many UL standards are derived from IEC EN and UL standards include group and national differences Editions of the standard Harmonised standards in the EU give a presumption of conformity European Commission s Official Journal (OJ) lists the current harmonised standards IEC webstore gives latest editions and amendments of the IEC standards National differences Many European Standards impose Special National Conditions (SNCs) SNCs are mandatory when the product is supplied in those nations Slide 4
5 Submitting for Testing Regulations, directives and laws tell us products must be safe Technical standards give the means to prove safety IEC (AV equipment) IEC (household appliances) IEC (office and IT equipment) IEC (lab and control equipment) IEC (AV and IT equipment) etc (specialist standards for other safety requirements) Slide 5
6 Types of Safety Testing There are two approaches to safety testing Type testing: A one-off test on a sample of the product. Does not guarantee future product quality CE marking (for inclusion in technical file) CB Scheme (as basis for obtaining international acceptance & certification) 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 Benefits of certification: Market access Consumer confidence Ongoing production quality Marketing advantage Slide 6
7 Preparing in Advance: Design Stage Ensure design engineers are aware of safety requirements Seek advice from 3rd parties Enlist a consultant Consider a 3 rd party design 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 Slide 7
8 Preparing in Advance: Design Stage Select pre-approved components and materials Reduce testing requirements Avoid potential failures Avoid having to change / re-source components Know your target markets UL and EN standards required for US and EU respectively Slide 8
9 Requesting a Quotation Know your market Different test requirements for different markets Provide as much information as possible 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 Slide 9
10 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 Ensure that the equipment is suitably configured for testing Worst case normal load conditions Prepare support equipment loads & cabling Provide clear operating instructions Write test software Slide 10
11 Find out how many samples are required Complete product Power supplies Fuses, thermal cut-outs and other components Plastic parts On-site testing can often be the most efficient way of testing 100% of our engineers attention All your support facilities available Issues can be resolved face to face Fix your problems and clear non-compliances in parallel with the testing Slide 11
12 Safety Critical Components & Materials Which Components are Safety Critical? Mains components: Mains plugs and cords Appliance couplers Fuse and fuseholders Wiring Power supplies X and Y-capacitors Transformers Other components: DC-DC converters Fans Enclosure materials Connectors PCB material Thermistors and PTCs Slide 12
13 Selection of Materials and Components Must be selected and arranged to perform over the expected life of the equipment without creating any hazard Compatible with other materials or chemicals used Reliable construction and arrangement in normal operation and fault conditions Used within their specified ratings Approved to relevant component safety standards Slide 13
14 Safety Critical Components & Materials Component approvals IEC and EN investigations Current test certificate / report Note - some certificates have expiry dates Relevant IEC / EN standard In English From a CB, CCA or LVD accredited test laboratory (e.g. TÜV SÜD Product Service, VDE) Must include all relevant information 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 e.g.: power supply units more detailed information is required i.e. maximum rated ambient, classification of outputs, method of mains isolation Slide 14
15 Safety Critical Components & Materials Self-declaration may also be accepted A certificate of conformity (CofC), manufacturer s declaration You remain responsible that the component is suitably approved This will be stated in any test report issued For a Third Party Certification, self-declaration is NOT acceptable 3rd party approved components MUST be used (e.g. TÜV SÜD PS, UL, CB, VDE) Note: do not rely statements like designed to meet or complies with ENxxxx These are NOT evidence of suitable component approvals Slide 15
16 Safety Critical Components & Materials Flammability of Materials Plastic or non-metallic materials Compliance may be based on testing, and/or suitable documentary evidence Applicable standards: UL 94, IEC To assess the suitability of the materials, the following information is required: Manufacturer name (eg: GE Plastics, 3M) Name and part number of the material (e.g. Lexan, LX437) Approval body s file number (e.g. UL E12345) Flammability rating (e.g. V-1, V-2, HB, HF2) Thickness of material used Slide 16
17 US / Canadian Investigations All safety critical components and materials must have current NRTL (Nationally Recognized Test Laboratory) listing or recognition The following information is required: The name of the company that holds the NRTL approval The type or model number of the component The NRTL file number (e.g. UL E56789) Obtain a copy of the NRTL approval From the approval holder, or the manufacturer of the component/part or from the NRTL s website Slide 17
18 US / Canadian Investigations Transformers with an insulation Class higher than Class A NRTL certification requires a NRTL 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 Slide 18
19 UL Power Supply Listing Model number Ratings Slide 19
20 Example of VDE listing Model number Ratings Slide 20
21 CB Certificates Test report forms part of certificate Ratings Model number Test standard Number of pages Slide 21
22 NRTL Certificates Ratings Model number Test standard Number of pages Slide 22
23 On-Line Approvals Links TÜV SÜD Product Service x ASTA and BEAB x CSA x ENEC x Intertek x ÖVE x UL X VDE Slide 23
24 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 Slide 24
25 Summary Submitting for Safety Testing Selection of test standards Requesting a quote Hints and tips to minimise failures Slide 25
26 Thank you for listening Alastair McLaughlin Product Safety Specialist TÜV SÜD Product Service Tel: +44 (0) Slide 26
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