IEC 62368-1: A new ‘hazard-based’ standard approach Matthew Emery TÜV SÜD Product Service Who am I? Name Matthew Emery Title: Product Safety Specialist Employer: TÜV SÜD Product Service Experience: 8 years experience in Product Testing History: Worked for lighting manufacturer for 8 years Telephone: +44 (0)1489 558 128 E-mail: Matthew.emery@tuv-sud.co.uk TÜV SÜD 15-07-15 Customer Day 2015 Introduction TÜV SÜD 15-07-15 1 Existing Product Safety Standards 2 Introduction to IEC 62368-1 3 Injury Classification 4 Energy Sources 5 Safeguards 6 Models for Protection Customer Day 2015 ECMA - 287 Existing product safety standards: • Blurred borderline between different classes of products • Too diverse: safety requirements differed widely due to the evolution of “Multi-Media” products • Changed too frequently because: − design oriented rather than performance based − Maintenance cycles required for any technology evolution • Were lacking for some product families TÜV SÜD 15-07-15 Customer Day 2015 Standard ECMA-287:1999 Safety of electronic equipment Philosophy applied: To define hazard-based requirements using engineering principles and taking into account relevant IEC standards and pilot documents. Where technical discrepancies between standards emerged, conclusion was based on engineering principles. TÜV SÜD 15-07-15 Customer Day 2015 ECMA-287 - Facts • Technology independent safety standard • Scope is ICT and CE equipement rated less than 600Vrms • Covers products currently under the scope of IEC 60065 and IEC 60950x • New standard NOT simply a merger of IEC 60065 and IEC 60950) • ECMA International Technical Committee 12 draft, based on IEC basic safety publications and HBSE (Hazard Based Safety Engineering) principles • Free to download http://www.ecma-international.org/publications/standards/Ecma-287.htm • Contributed to IEC TC108 for further elaboration TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – What is it? • New safety standard (NOT a merger of IEC 60065 and 60950-1) • Covers products currently under the scopes of IEC 60065 and IEC 60950-x • Hazard based • Technology independent • Based on sound engineering principles, research and field data TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Objectives • Clearly identify the hazard being addressed • Clearly state principles upon which hazard is addressed • Follows of IEC pilot publication • Use of IEV definitions • Performance based (conformance based on tests rather than on construction) • Type test standard • Useful to designers • Suitable to assess conformance by suppliers, purchasers and certifiers (but NOT a certification document) • Meet above in a “user friendly” manner TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Structure The standard: • Covers all specified hazards • Each hazard will be in a separate section • Will include examples of accepted constructions • Include basics of three block model in “Principles of Safety” • Adjunct Documents − Interpretations (clarification of standard, newly identified accepted constructions, etc.) − Part 2 documents for a few very special cases TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Format For each hazard clause will be formatted as follows: • Clause − State objective of clause • Specify the energy source (as far as possible three (3) levels) and define the limits between the energy levels − Specify principal; supplemental and reinforced safeguards • Location of safeguard − Specify safeguard properties − Specify safeguard parameters (e.g. materials) • Specify safeguard tests/construction TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Definitions HAZARD, HAZARDOUS: An energy source that exceeds body susceptibility limits. ISO/IEC Guide 51: potential source of harm SAFE, SAFETY: Situation where at least one safeguard is interposed between the body and a hazardous energy source. ISO/IEC Guide 51: freedom from unacceptable risk TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Injury Classification Injury occurs ONLY when energy of sufficient magnitude and duration is imparted to a body part. Hazardous energy source (capable of causing pain or inquiry) Transfer mechanism Body Energy source Effect on the body Effect on combustible materials Class 1 Not painful, but may be detectable Ignition not likely Class 2 Painful, but not an injury Ignition possible, but limited growth and spread of fire Class 3 Injury Ignition likely, rapid growth and spread of fire TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Energy Sources • Electric shock energy source • Electrically caused fire energy source • Chemical energy source (e.g. chemicals (including batteries)) • Mechanical energy source (e.g. moving parts, sharp edges, physical stability) • Thermal energy source (e.g. skin burn) • Radiation energy source (e.g. ionizing, non-ionizing, acoustic) TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Body Response/Property Damage Examples of body response or property damage related to energy sources (e.g. energized conductive parts) Examples of body response or property damage Pain, fibrillation, cardiac arrest, respiratory arrest, skin burn, internal organ burn (e.g. electrical ignition, spread of fire) Electrically caused fire leading to burn related pain or injury or property damage 6 Skin damage, organ damage, or poisoning 7 Laceration, puncture, abrasion, contusion, crush, amputation, or loss of a limb, eye, ear 8 Skin burn 9 Loss of sight, skin burn, or loss of hearing 10 Forms of energy Electrical energy = ES Thermal energy = PS Chemical reaction (e.g. electrolyte, poison) Kinetic energy = MS (e.g. moving parts of equipment, or a moving body part against an equipment part) Thermal energy = TS (for example, hot accessible parts) Radiated energy = RS (e.g. electromagnetic, optical, acoustic) TÜV SÜD 15-07-15 Customer Day 2015 Clause 5 IEC 62368-1 – Class 1 Energy Source Unless otherwise specified, a class 1 source is an energy source with levels not exceeding class 1 limits under: • normal operating conditions; and • abnormal operating conditions that do not lead to a single fault condition; and • single fault conditions that do not result in class 2 limits being exceeded. Under normal operating conditions and abnormal operating conditions, the energy in a class 1 source, in contact with a body part, may be detectable, but is not painful nor is it likely to cause an injury. For fire, the energy in a class 1 source is not likely to cause ignition. Under single fault conditions, a class 1 energy source, under contact with a body part, may be painful, but is not likely to cause injury. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Classes 2 & 3 Energy Source Class 2 energy source Unless otherwise specified, a class 2 source is an energy source with levels exceeding class 1 limits and not exceeding class 2 limits under normal operating conditions, abnormal operating conditions, or single fault conditions. The energy in a class 2 source, under contact with a body part, may be painful, but is not likely to cause an injury. For fire, the energy in a class 2 source can cause ignition under some conditions. Class 3 energy source A class 3 source is an energy source with levels exceeding class 2 limits under normal operating conditions, abnormal operating conditions, or single fault conditions, or any energy source declared to be a class 3 source. The energy in a class 3 source, under contact with a body part, is capable of causing injury. For fire, the energy in a class 3 source may cause ignition and the spread of flame where fuel is available. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Safeguards Hazardous energy sources Safeguard Body A safeguard is a device or scheme or system that: • Is interposed between an energy source capable of causing pain or injury and a body part, and • Reduces the likelihood of transfer of energy to a body part TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Non-hazardous Energy Source Injury does not occur when the energy source is non-hazardous. Non-hazardous energy source No safeguard necessary Body A non-hazardous energy source is: An energy source that is less than the body susceptibility to that energy TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Supplementary Safeguards A BASIC SAFEGUARD is: A safeguard that is effective under normal and abnormal operating conditions whenever hazardous energy is present Hazardous energy source Basic safeguard Supplementary safeguard A SUPPLEMENTARY SAFEGUARD is: A safeguard that is effective in the event of a single fault of any part, including a fault of the basic safeguard TÜV SÜD 15-07-15 Customer Day 2015 Body IEC 62368-1 – Reinforced Safeguard A REINFORCED SAFEGUARD is: A single, robust safeguard that is effective under normal operating conditions, abnormal operating conditions, and single fault condition. Hazardous energy source TÜV SÜD Reinforced safeguard 15-07-15 Customer Day 2015 Body IEC 62368-1 – Hierarchy of Safeguards Hierarchy of safeguards Safeguard I. Equipment safeguards are always useful, since they do not require any knowledge or actions by persons coming into contact with the equipment II. Installation safeguards are useful when a safety characteristic can only be provided after installation (e.g. equipment has to be bolted to the floor to provide stability) III. Behavioural safeguards are useful when the equipment requires an energy source to be accessible. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Equipment Safeguard Equipment safeguard: Physical part of an equipment Basic safeguard Supplementary safeguard Reinforced safeguard Effective under normal operating conditions Effective in the event of failure of the basic safeguard Effective under normal operating conditions and in the event of a single fault condition Example: Basic Insulation Example: Supplementary Insulation Example: Reinforced Insulation Example: Normal temperatures below ignition temperatures Example: fire enclosure Not applicable TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Installation Safeguard Installation safeguard: Physical part of a man-made installation Basic safeguard Supplementary safeguard Reinforced safeguard Effective under normal operating conditions Effective in the event of failure of an equipment basic safeguard Effective under normal operating conditions and in the event of a single fault condition elsewhere in the equipment Example: Wire size Example: Overcurrent protective device Example: Socket outlet TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Personal Safeguard Personal safeguard: Physical device worn on the body Basic safeguard Supplementary safeguard Reinforced safeguard In the absence of any equipment safeguard, effective under normal operating conditions Effective in the event of failure of an equipment basic safeguard In the absence of any equipment safeguard, effective under normal operating conditions and in the event of a single fault con-dition elsewhere in the equip-ment Example: Gloves Example: Insulating floor mat Example: Electrically-insulated glove for handling live conductors TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Instructional Safeguard Instructional safeguard: Voluntary or instructed behaviour Basic safeguard In the absence of any equipment safeguard, effective under normal operating conditions Supplementary safeguard Reinforced safeguard Effective in the event of failure Only effective on an exceptional of an equipment basic basis, when providing all safeguard appropriate safeguards would prevent the intended functioning of the equipment Example: Instructional safeguard to disconnect telecommunication cable before opening cover Example: After opening a door, an instructional safeguard warning against hot parts Example: Instructional safeguard warning of hot parts in a photocopier, or a continuous roll paper cutter on a commercial printer TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Accessibility to Energy Sources Accessibility to electrical energy sources and safeguard ES 3 source Equipment Enclosure Double Insulated ES2 source ES1 source Q: What are the requirements between these non-accessible sources? A: None, as the enclosure is double insulated, the sources are not accessible. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Accessibility to Energy Sources Accessibility to electrical energy sources and safeguard Now there is an accessbile connection ES 3 source ? Equipment Enclosure Double Insulated ES2 source ES1 source Accessible Part/Interface Q: What are the requirements between the sources in this case? A: 1. Basic insulation between ES1 & ES2 A: 2. Double or reinforced insulation between ES1 & ES3 A: 3. Insulation between ES2 & ES3 depends on the insulation between ES1 & ES2 TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Accessibility to Energy Sources Accessibility to electrical energy sources and safeguard Now there are two accessible connections from independent sources ES1 source Equipment Enclosure Double Insulated ES1 source Accessible Connection Q: What are the requirements between the sources in this case? A: 1. According to B.4 (single fault condition), the insulation or any components between the sources need to be shorted A: 2. If one of the two ES1 sources would reach ES2 levels - basic safeguard (Note that a source that exceeds ES1 levels is not an ES1, but an ES2 source!!!) A: 3. If both ES1 sources stay within ES1 limits - no safeguard (functional insulation) TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Behavioural Safeguards Ordinary person: all persons other than “instructed” and “skilled”. Includes users and persons who may have access to or be in the vicinity of the equipment. Under normal or abnormal operating conditions, should not be exposed to energy sources capable of causing pain or injury. Under a single fault condition should not be exposed to energy sources capable of causing injury. Instructed person: instructed and trained or supervised by a skilled person to identify energy sources that may cause pain and to take precautions to avoid unintentional contact or exposure. Under normal operating conditions, abnormal operating conditions or single fault conditions, should not be exposed to energy sources capable of causing injury. Skilled person: persons who have training or experience in the equipment technology, particularly knowing the various energies and magnitudes used. Expected to use their training and experience to recognize energy sources capable of causing pain or injury and to take action for protection. Should be protected against unintentional contact or exposure to sources capable of causing injury. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Behavioural Safeguards Person Ordinary Behavioural safeguards Instructional safeguard: means of providing information, describing the existence and location of an energy source capable of causing pain or injury Intended to invoke a specific behaviour to reduce the likelihood of transfer of energy to a body part. Instructional safeguards may be considered acceptable protection to bypass an equipment safeguard such that the person is made aware of how to avoid contact with a class 2 or class 3 energy source. Instructed Precautionary safeguard is the training and experience or supervision of an instructed person by a skilled person to use precautions to protect the person against class 2 energy sources. During equipment servicing, an instructed person may need to remove or defeat an equipment safeguard. In this case, an instructed person is expected to then apply precaution as a safeguard to avoid injury. Skilled Skill safeguard is the education, training, knowledge and experience of the skilled person that is used to protect that person against class 2 or class 3 energy sources. During equipment servicing, a skilled person may need to remove or defeat an equipment safeguard. In this case, a skilled person is expected to then apply skill as a safeguard to avoid injury TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Limit Values The limit values for determining whether or not an energy source is hazardous and the safeguard tests and parameters are based on IEC Basic and Group safety publications. IDENTIFY ENERGY SOURCE IS SOURCE HAZARDOUS? Yes IDENTIFY MEANS BY WHICH ENERGY CAN BE TRANSFERRED TO A BODY PART DESIGN SAFEGUARD WHICH WILL PREVENT ENERGY TRANSFER TO A BODY PART MEASURE SAFEGUARD EFFECTIVENESS No IS SAFEGUARD EFFECTIVE? Yes DONE TÜV SÜD 15-07-15 Customer Day 2015 No IEC 62368-1 – Limit Values 1. Identify the ES1, ES2 and ES3 parts and circuits and their respective safeguards (ES = Electrical energy) IDENTIFY ENERGY SOURCE IS SOURCE HAZARDOUS? 2. Identify the PS1, PS2, and PS3 circuits and the fire safeguard methods (PS = Thermal energy) Yes IDENTIFY MEANS BY WHICH ENERGY CAN BE TRANSFERRED TO A BODY PART 3. Identify the MS1, MS2, and MS3 parts and circuits and their respective safeguards (MS = Kinetic energy) DESIGN SAFEGUARD WHICH WILL PREVENT ENERGY TRANSFER TO A BODY PART 4. Identify the TS1, TS2, and TS3 parts and circuits and their respective safeguards (TS = Thermal energy) 5. Identify the RS1, RS2, and RS3 parts and circuits and their respective safeguards (RS = Radiated energy) MEASURE SAFEGUARD EFFECTIVENESS No IS SAFEGUARD EFFECTIVE? Yes DONE TÜV SÜD 15-07-15 Customer Day 2015 No IEC 62368-1 – Electric Shock TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Energy Source Classification Electrical energy source classification table General Information Energy Source Area of Contact X 50-60Hz - 240 - C2 C2 C1-C2 C3 C3 C3 C2-C3 C4 C4 C5 C5 C6 C6 C7 Normal Faut F10 Normal Normal Fault F11 Fault F12 Normal Normal Fault F13 Normal Fault F14 Normal Fault F15 Normal X X X X X DC DC 100kHz DC DC Hiccup 30kHz DC DC 60kHz/0.8nF 30kHz/0.8nF 1kHz DC Non-DC 580 8.6 69 2500 1000 35 - 25.2 28.6 456 5.2 5.4 45 3.4 3.5 24 120 28Vdc 40Vdc 28Vdc 40Vdc 40Vdc 65Vrms 28Vdc 40Vdc 5000Vpeak 5000Vpeak 42.4Vpeak 40Vrms 140Vrms TÜV SÜD - - X X X X X X X X 15-07-15 Determined Voltage V Peak V RMS - 27 33 - 30 35 - mA Peak Normal S - Peak/RMS C1 M mA RMS - Determined Current Operating Reference L Applicable Current Limit Peak/R MS - Applicable Voltage Limit Diagram Reference Frequency, Capacitance or Pulse Duration Result Customer Day 2015 Classification ES1 ES2 ES3 X X X X X X X X X X X X X X X IEC 62368-1 – Example Test Report TEST REPORT IEC 62368-1 Audio/video, information and communication technology equipment Part 1: Safety requirements Clause 5.2 Body Part (e.g. Ordinary) OVERVIEW OF EMPLOYED SAFEGUARDS Electrically-caused injury Energy Source Related Safeguards (ES3: Primary Filter clause Basic circuit) 6.2.2 Material part (e.g. mouse enclosure) 7.5 Body Part (e.g., skilled) 8.2 Body Part (e.g. Ordinary) Supplementary (e.g., 5.3.6.3, etc.) Electrically-caused fire Energy Source Related (PS2: 100 Watt circuit) clause (Enclosure) Safeguards Basic Chemically-caused injury Energy Source Related (e.g., hazardous clause Safeguards Basic material) (e.g. gloves) Mechanically-caused injury Energy Source Related (MS3:Imploding part) clause Supplementary Safeguards Basic Supplementary Reinforced Supplementary Reinforced (8.5.5.1) 9.3 Body Part Thermal Burn Energy Source (e.g., Ordinary) (TS2) 10.2 Body Part Radiation Energy Source (e.g., Ordinary) (Output from audio port) Supplementary Information: Reinforced (e.g., PTC) (6.4.3.1) (7.4) Reinforced (Enclosure) Related clause Safeguards Basic (e.g. (9.3.2.2) Instructional) Related clause Safeguards Basic (e.g., (10.4.2) Instructional) Supplementary Reinforced Supplementary Reinforced (1) A block diagram can be attached to further detail the identified safeguards. (2) “N” – Normal Condition; “A” – Abnormal Condition; “S” Short Circuit TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1 – Electrical Energy Transfer Electrical energy transfer occurs when there are two or more electrical contacts to the body: The first electrical contact is between a body part and a conductive part of the equipment; the second electrical contact is between another body part; and earth, or another conductive part of the equipment. Energy source Prospective touch voltage or touch current TÜV SÜD 15-07-15 Customer Day 2015 Energy transfer mechansm Two electrical contacts Body Body resistance IEC 62368-1 – Models for Protection Models for protection against electrically-caused pain or injury Protection against electrically-caused pain or injury requires that one or more safeguards be interposed between an electrical energy source capable of causing pain or injury and a body part. Energy source Prospective touch voltage and touch current TÜV SÜD 15-07-15 Safeguard Electric insulation Body Body resistance Customer Day 2015 IEC 62368-1– Models Models for electrically-caused fire Electrically caused fire is due to conversion of electrical energy to thermal energy, where the thermal energy heats a fuel material followed by ignition and combustion. Energy source Electrical energy conversion to thermal energy TÜV SÜD 15-07-15 Energy transfer mechansm Conduction, convection, radiation Fuel material Material exceeds ignition temperature Customer Day 2015 IEC 62368-1– Models for Protection Models for protection against electrically caused fire The basic safeguard against electrically caused fire is that the temperature of a material, under normal operating conditions and abnormal operating conditions, does not cause the material to ignite. The supplementary safeguard against electrically-caused fire reduces the likelihood of ignition or, in the case of ignition, reduces the likelihood of spread of fire. Energy source Electrical energy conversion to thermal energy Safeguard Thermal resistance Fuel material Material does not exceeds ignition temperature Energy source Electrical energy conversion to thermal energy TÜV SÜD 15-07-15 Customer Day 2015 Fuel material Fuel ignition Safeguard Enclosure contains the fire IEC 62368-1– Safeguards SAFEGUARDS against electrically caused fire TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1–Models for Chemical Injury TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1–Models for Chemical Injury TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1– Definitions MS = Kinetic energy MS1 - Mechanical energy source with levels not exceeding MS1 limits under normal operating conditions and abnormal operating conditions and not exceeding MS2 under single fault conditions. MS2 - Mechanical energy source with levels not exceeding MS2 limits under normal operating conditions, abnormal operating conditions, and single fault conditions, but is not MS1. MS3 - Mechanical energy source with levels exceeding MS2 limits under normal operating conditions, abnormal operating conditions or single fault conditions, or any mechanical energy source declared to be treated as MS3 by the manufacturer. TÜV SÜD 15-07-15 Customer Day 2015 IEC 62368-1– Models for Thermally-Caused Fire Models for thermally-caused injury Thermally caused injury may occur when thermal energy capable of causing injury is transferred to a body part . Energy source Energy source Temperature, Material, Mass, etc. TÜV SÜD Body part Energy transfer mechansm Body part touches hot part Body Body part thermal resistance 15-07-15 Energy source Temperature, Material, Mass, etc. Customer Day 2015 Safeguard Thermal insulation Body Body part thermal resistance IEC 62368-1– Definitions TS = Thermal energy TS1 - Thermal energy source with temperature levels not exceeding TS1 limits under normal operating conditions; and not exceeding TS2 limits under abnormal operating conditions; or single fault conditions. TS2 - Thermal energy source where the temperature exceeds the TS1 limits; and under normal operating conditions, abnormal operating conditions or single fault conditions the temperature does not exceed the TS2 limits. Where the malfunction of the equipment is evident, no limits apply. TS3 - Thermal energy source where the temperature exceeds the TS2 limits in Table 38 under normal operating conditions or under abnormal operating conditions, or under single fault conditions. TÜV SÜD 15-07-15 Customer Day 2015 Thank you for listening Matthew Emery Product Safety Specialist TÜV SÜD Product Service +44 (0)1489 558128 Matthew.emery@tuv-sud.co.uk TÜV SÜD Product Service 15-07-15 Customer Day 2015 Slide 46