principle/testing of iec 60598-1/iec 60598-2-1
DESCRIPTION
Principle/Testing of IEC 60598-1/IEC 60598-2-1. Vicky Zhang Product Expert DEKRA Shanghai. IECEE Workshop August 26 & 27 Nairobi - Kenya. Content. Why? What? How?. Why to use IEC standards?. Recalls by product categories. - 2012, EU. Recalls by type of risk. - 2012, EU. - PowerPoint PPT PresentationTRANSCRIPT
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IEC SYSTEM OF CONFORMITY ASSESSMENT
SCHEMES FOR ELECTROTECHNICAL
EQUIPMENT AND COMPONENTS
Principle/Testing of IEC Principle/Testing of IEC 60598-1/IEC 60598-2-160598-1/IEC 60598-2-1
Vicky ZhangProduct ExpertDEKRA Shanghai
IECEE Workshop August 26 & 27Nairobi - Kenya
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IECEE Workshop August 26 & 27, Nairobi - Kenya2
Content
• Why?
• What?
• How?
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IECEE Workshop August 26 & 27, Nairobi - Kenya3
• Why to use IEC standards?
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IECEE Workshop August 26 & 27, Nairobi - Kenya4
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Recalls by product categories
- 2012, EU
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Recalls by type of risk
- 2012, EU
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Product Risks
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What is product safety?
Product Product SafetySafety
No hazards to People
No hazardsto environment
No hazards to other equipments
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Provisions against Hazards
ProvisionsProvisions
BB
EE
CC
DD
AAMechanical
hazards
Electrical Hazards
Heat related hazards
Radiation hazards
Fire hazards
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Advantage of IEC standards
IEC Standards
Reducing risk, increasing quality, confidence
Bases of national standard or regulations
Wide adoption
Transparent process
Representing market needs
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Technical committees
TC 34Lamps and
related equipments
SC 34DLuminaires
SC 34CAuxiliaries for lamps
SC 34ALamps
SC 34BLampcaps/
holders
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• What criterias are required in IEC 60598-1/60598-2-1?
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Standards
• IEC 60598-1
Luminaires –
Part 1: General requirements and tests
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Standards
• IEC 60598-2-1
Luminaires –
Part 2- Particular requirements for Fixed general purpose luminaires
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Scope
• Fixed general purpose luminaire
• Working voltage <= 1000 V
• Tungsten filament, tubular fluorescent and other discharge lamps
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Definition – Fixed luminaire
• Not easily be moved from one place to another
• A: only be removed with the aid of a tool
or
• B: for use out of arms reach
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Classification• Protection against electrical shock
• Class I luminaire:
basic insulation + protective earthing
• Class II luminaire:
basic + supplementary insulation or
reinforced insulation
• Class III luminaire:
SELV (safety extra-low voltage)
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Conformity Assessment
Type Type TestTestType Type TestTest
Carried out by laboratoryTo use standardized test methodTo check compliance of the design of a product
Routine Routine TestTestRoutine Routine TestTest
Carried out by manufacturers after productionTo ensure every luminaire conforms with the sample approved under type test
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Conformity Assessment
Type Type TestTestType Type TestTest
Carried out by laboratoryTo use standardized test methodTo check compliance of the design of a product
Routine Routine TestTestRoutine Routine TestTest
Carried out by manufacturers after productionTo ensure every luminaire conforms with the sample approved under type test
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Component
• Suitable for use in the Luminaire
• Correct Classification and Ratings• In compliance with relevant IEC
requirements To ensure
safety of usage
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Provision of Marking
• Marking on products
• Mounting Instructions
The height of letters and numerals ≥ 2 mm .
The height of symbol ≥ 5 mm • Durability and legiability
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Construction - Lampholder
• Positioning test
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Construction - Lampholder
• Bending test
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Construction - Lampholder
• Torque test
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Construction – Terminal block
• Space- Luminaire with connecting
leads requires a terminal block to connect to fixed wiring
- Adequate space for terminal block
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Construction – Reliable terminals
• 8 mm conductor• live conductor
• earth conductor
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Construction – Reliable terminals
• External cable & Internal wiring• Retained by cord anchorage
• Clamped by spring terminal
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Construction – Reliable terminals
• Internal wiring- Anchored to a tag
before soldering
- Twisted in a reliable manner
- Fasten by sleeve, tape
- Inserted into a hole of PCB, bend and soldered
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Construction – Reliable terminals
• Internal wiring- Securely crimped- Securely wrapped
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Construction – Double/Reinforced Insulation
• Metal encased class II luminaire- No contact between mounting surface
and part with basic insulation only
Double insulated wire
Terminal block with a cover
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Construction – Double/Reinforced Insulation
• Metal encased class II luminaire- No contact between accessible part and
basic insulation→ Double insulated wire→ Insulating lining, sleeve
Mechanical strength
Electrical strength
Thermal strength
1.Retained by positive means2.Not be removed without being seriously damaged
1. Humidity 48 hrs
2. Insulation resistance & electric strength
1. Thermal test
2. T(wire)+20°C
3. Aging T(wire)+20°C, 240 hrs, checked by electrical strength
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Construction – Screws
• Torque test
No damage
No creep
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Construction – Screws
• Torque test• 0,5 Nm for screws on cord anchorage
bearing directly on cable or cord
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Construction – Glands
• Torque test
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Construction – Mechanical Strength
• Impact test
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Construction – Mechanical Strength
• Impact test- Live part shall not be accessible
- Insulation shall not be impaired
- No reduction on IP protection and classification
- Removable/replaceable part can be removed/replaced without breakage
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Construction – Mechanical Strength
• Metal part enclosing live part- Pressure test by test finger- 30 N- Metal part shall not touch live part- No reduction on creepage distance and
clearance
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Construction – Mechanical Strength
• All Suspended luminaires- Loading test- 4 x weight of luminaire- 1 hrs- No deformation on suspension system
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Construction – Mechanical Strength
• Rigid Suspended luminaires- Torque test- 2,5 Nm, 1 min- Clockwise and anti-clockwise- No rotation more than one revolution in both
directions
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Construction – Mechanical Strength
• Rigid Suspension bracket (heavy duty)- Loading 40 N, >=2,5 Nm, at free end- 1 min- No permanent displacement, deformation
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Construction – Mechanical Strength
• Rigid Suspension bracket (light duty)- Loading 10 N, >=1,0 Nm, at free end- 1 min- No permanent displacement, deformation
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Construction – Mechanical Strength
• Track mounted luminaire- Luminaire mass < max. load for track
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Construction – Mechanical Strength
• Adjusting device- No twisting over 360
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Construction – Mechanical Strength
• Flexing test- Strands broken < 50%- Insulation resistance & electric strength
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Construction – Flammable Material
• Glow‑wire test 650 C
• Spacing 30 mm
• No fiercely burning material
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External Wiring
• Supply connection
Terminals
Adaptor for track
Supply cable & Plug
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External Wiring
• Supply connection
Appliance inlet
Connecting leads
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External Wiring
• Type of cable
• 0,75 mm2 for ordinary luminaires;
• 1,0 mm2 for other luminaires
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External Wiring
• Type of connection
- Type X attachment
- Type Y attachment
- Type Z attachment
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External Wiring
• Cord anchorage
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External Wiring
• Cord anchorage - Pull test (25 time, displacement <= 2mm)
- Torque test
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Internal Wiring
• Internal wiring directly connected to fixed wiring
Operating current >= 2 A Operating current < 2 A
min. 0,5 mm2 min. 0,4 mm2
Insulation thickness: min. 0,6 mm
(PVC or Rubber)
Insulation thickness: min. 0,5 mm
(PVC or Rubber)
1,5 mm2 for through wiring
--
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Internal Wiring
• Internal wiring connected to fixed wiring via current limiting device <= 2 A
If current-carrying capacity and the mechanical properties are adequate
- Cross-sectional area min. may be less than 0,4 mm2
- Insulation thickness may be less than 0,5 mm
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External & Internal Wiring
• Soldering
Clamping terminal
Spring terminal
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External & Internal Wiring
• Soldering
Spring terminal
Clamping terminal
Cold flowBad electrical
connection
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Earthing
• Accessible metal part, basic insulated• Non-accessible metal part, basic
insulated, but in contact with supporting surface
- Reliably connected to earthing terminal or earthing contact
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Earthing
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Earthing
• Location of earthing terminal• Adjacent to mains terminal (type X, Y)
• Material of earthing terminal• Brass or non-rusting material
• Bare contact surface
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Earthing
• Cord for earthing• Green-yellow cord shall only be used
for earthing connection
• Earthing make contact first
• Earthing detached later
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Earthing
• Terminal blocks with integrated screwless earthing contacts
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Earthing
• Terminal blocks with integrated screwless earthing contacts• Pull test 20 N – terminal block shall be in
place• Pull test 50 N – applies only to earthing
contact – no damage, no loosen on earthing contact
• Earthing contact – supporting plate < 0,05 ohm
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Earthing
• Terminal blocks with integrated screwless earthing contacts• Voltage drop test• Resistance < 0,05 ohm
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Protection against electrical shock
• Live parts not accessible when luminaire installed and wired as in normal use or during lamp/starter replacement
- Wall-mounted luminaires: within arm reach, no access to basic insulated parts by means of a Ø 50 mm probe
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Protection against electrical shock
• Basis insulated parts of Class II luminaires to be regarded as live parts
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Protection against electrical shock
• No basic insulated components on outside of luminaire
• Luminaires incorporating a capacitor >0,5μF must be provided with a discharge device
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Resistance to dust and moisture
• Dust Test (IP#X)
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Resistance to dust and moisture
• Dust Test (IP#X)• Solid-object-
proof (IP2X)• Solid-object-
proof (IP3X or IP4X)
• Dust-proof (IP5X)
• Dust-tight proof (IP6X)
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Resistance to dust and moisture
• IP Test (IPX#)• Drip-proof (IPX1) • Drip-proof (IPX2)
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Resistance to dust and moisture• IP Test (IPX#)
• Rain-proof (IPX3) and splash-proof (IPX4)
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Resistance to dust and moisture
• IP Test (IPX#)• Jet-proof (IPX5) and powerful water jet-proof
(IPX6)IP X5
15 min / distance = 3 m / 12,5 l/min ± 5 % (30 kN/m2)
IP X6
3 min / distance = 3 m / 100 l/min ± 5 % (100 kN/m2)
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Resistance to dust and moisture
• IP Test (IPX#)• Watertight (IPX7)• 30 min in water / 150 mm of water above the top of
the speciment and the lowest portion is subjected to at least 1 m head of water
• Pressure watertight (IPX8)• 30 min in water / water pressure 1,3 x pressure
which corresponds to the rated maximum immersion depth
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Resistance to dust and moisture
• Humidity test• R.H. 91% to 95 %• 10 ºC – 30 ºC
• 48 hrs
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Insulation Resistance
• Class I luminaire: 2 Mohm
• Class II luminaire: • Basic/Supplementary insulation: 2 Mohm• Double/Reinforced insulation: 4 Mohm
• Class III luminaire: 1 Mohm
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Electric Strength
• Class I luminaire: 2U + 1000 V
• Class II luminaire:• Basic/Supplementary insulation: 2U + 1000 V• Double/Reinforced insulation: 4U + 2000 V
• Class III luminaire: 500 V
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Creepage distance & Clearances
• Live Parts of different polarity
• Live Parts Adjacent Metal Parts
• Live Parts Body or Housing
• Live Parts Mounting Surface
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Creepage distance & Clearances
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Endurance and Thermal test
• Endurance 7 or 10 Days• Thermal Test Normal operation• Thermal Test Abnormal operation• Thermal Test on luminaires classified
for mounting on normally flammable surfaces
• Thermal Test on thermalplastic luminaires
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Resistance to heat, fire and tracking
• Needle Flame Test
• Ball Pressure Test
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Resistance to heat, fire and tracking
• Glow-wire Test 650 ºC
• Tracking Test on IP>20 Luminaire
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Conformity Assessment
Type Type TestTestType Type TestTest
Carried out by laboratoryUse standardized test methodTo check compliance of the design of a product
Routine Routine TestTestRoutine Routine TestTest
Carried out by manufacturers after productionTo ensure every luminaire conforms with the sample approved under type test
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Routine test by Manufacturer
• Visual check• Function test• Earth continuity (earthing resistance:
0,05ohm)• Electric strength or insulation
resistance (for metal encased)• Polarity (for Class I luminaire)
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• How to build up a laboratory carrying out testing of IEC 60598-2-1?
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What is a laboratory?
• Area where tests are conducted(electrical, chemical, physical, mechanical etc.)
Why are tests conducted in a laboratory?
• External influences on the test results are ruled out!
• Conditions for testing are controlled!
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Consumable goods/ items
Test methods/validationMeasurement traceabilitySamplingHandling of test items
Environmental conditionsEquipment
Conditions which can influence test results in your laboratory?
Manpower
Machines
Methods
Means
Human factors
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Process model
Input Process Output
Manpower Machines
Means Methods
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Manpower
• Competent staff• Staff in training (adequate supervision needed)• Personnel competent and qualified• Goals and policy / procedures for training and
qualification requirements• Job descriptions (management, technical and
supporting)• Records of all personnel maintained, readily
available (authorizations, competences, qualifications, training, skills, experience…)
Input Process Output
Manpower Machines
Means Methods
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Machines (1)
• Facilitate correct performance of tests• Technical requirements that can effect the
results documented• Monitor, control, record environmental
conditions and stop testing when environmental conditions jeopardize results
• Effective separation of incompatible areas• Access and use shall be defined and
controlled
Machines
Input Process Output
Manpower
Means Methods
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Machines (2)
• Lab with all equipments required for the correct
performance of tests• Equipment capable of achieving accuracy
needed• Authorized personnel; up to date instructions• Unique identification• List of records for each piece of equipment
Machines
Input Process Output
Manpower
Means Methods
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Machines (3)
• IECEE – CTL testing equipments under CB schemehttp://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm
• IECEE-CTL Operational Procedures
• http://www.iecee.org/ctl/operational/Operational_procedures.htm
Machines
Input Process Output
Manpower
Means Methods
CTL-OP 108 Use of thermocouples
CTL-OP 109 Acceptance of thermocouples
CTL-OP 110 Procedure for measuring power source characteristic
CTL-OP 111 Traceability of calibrations and calibration intervals
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Machines (4)
• Refer to CTL-OP 110 “Procedure for Measuring Laboratory Power Source Characteristics”
8.1 When not otherwise specified in the testing standard, the power source used for testing shall meet the following requirements:
A. Voltage stability: ± 3 % maximum
B. Frequency stability: ± 2 % maximum
C. Total harmonic distortion (THD): maximum 5 %
Machines
Input Process Output
Manpower
Means Methods
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Machines (5)
• Note:
IEC 60598-1, cl. 12.4.1 e) ±1% (preferred ± 0.5%)
voltage stability instead of ± 3%!
Machines
Input Process Output
Manpower
Means Methods
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Machines (6)Machines
Input Process Output
Manpower
Means Methods
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Machines (7)Machines
Input Process Output
Manpower
Means Methods
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Machines (8)Machines
Input Process Output
Manpower
Means Methods
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Machines (9)Machines
Input Process Output
Manpower
Means Methods
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MethodsMachines
Input Process Output
Manpower
Means Methods
• Appropriate methods for all tests within scope• Instructions for all equipment• Up to date and readily available to personnel• Methods must meet the requirements of
standards• Latest valid editions of standards to be used
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MeansMachines
Input Process Output
Manpower
Means Methods
• Policy and procedures for selection & purchase of services and supplies, when relevant for tests
• Procedures for inspecting supplies prior to use• Purchasing documents reviewed and approved
for technical content prior to release
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InputMachines
Input Process Output
Manpower
Means Methods
• Review of requests, tenders and contracts• Methods adequately defined
• Posses capability and resources
• Differences resolved before work begins
• Record of reviews maintained, including discussion with clients
• Any subcontracted work
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OutputMachines
Input Process Output
Manpower
Means Methods
• Reporting results• Shall include all information requested by the client
and all information required by the method used
• Subcontracted results clearly identified
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OutputMachines
Input Process Output
Manpower
Means Methods
• IECEE – TRF (test report form)
http://members.iecee.org/
• IECEE – TRF guide
• OD-2020
• http://www.iecee.org/Operational_documents/od-cb_index.html
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IEC SYSTEM OF CONFORMITY ASSESSMENT
SCHEMES FOR ELECTROTECHNICAL
EQUIPMENT AND COMPONENTS
Vicky ZhangProduct ExpertDEKRA Shanghai
IECEE Workshop August 26 & 27Nairobi - Kenya