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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 1
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)1789 731 155
E-mail:
alastair.mclaughlin@tuv-sud.co.uk
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 2
Contents
1
Submitting for Safety Testing
Selection of test standards
Requesting a quote
Safety critical components
Hints and tips to minimise failures
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 3
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
TÜV SÜD Product Service
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Customer Day 2015
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Submitting for Testing
• Regulations, directives and laws tell us products must be safe
• Technical standards give the means to prove safety
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IEC 60065 (AV equipment)
IEC 60335 (household appliances)
IEC 60950 (office and IT equipment)
IEC 61010 (lab and control equipment)
IEC 62368 (AV and IT equipment)
 etc (specialist standards for other safety requirements)
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 5
Submitting for Safety Testing
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:
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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:
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Market access
Consumer confidence
Ongoing production quality
Marketing advantage
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 6
Submitting for Safety Testing
Preparing in Advance: Design Stage
• Ensure design engineers are aware of safety requirements
• Seek advice from 3rd parties
– Enlist a consultant
– Consider a 3rd 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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 7
Submitting for Safety Testing
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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 8
Submitting for Safety Testing
• Requesting a Quotation
– Know your market
 Different test requirements for different markets
– Provide as much information as possible
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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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 9
Submitting for Safety Testing
• Collate documentation before submitting
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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
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Worst case normal load conditions
Prepare support equipment loads & cabling
Provide clear operating instructions
Write test software
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 10
Submitting for Safety Testing
• Find out how many samples are required
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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
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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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 11
Submitting for Safety Testing
Safety Critical Components & Materials
• Which Components are Safety Critical?
– Mains components:
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Mains plugs and cords
Appliance couplers
Fuse and fuseholders
Wiring
Power supplies
X and Y-capacitors
Transformers
– Other components:
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DC-DC converters
Fans
Enclosure materials
Connectors
PCB material
Thermistors and PTCs
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 12
Submitting for Safety Testing
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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 13
Submitting for Safety Testing
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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 14
Submitting for Safety Testing
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
TÜV SÜD Product Service
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Customer Day 2015
Slide 15
Submitting for Safety Testing
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 60695
– To assess the suitability of the materials, the following information is required:
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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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 16
Submitting for Safety Testing
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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 17
Submitting for Safety Testing
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
TÜV SÜD Product Service
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Customer Day 2015
Slide 18
Submitting for Safety Testing
• UL Power Supply Listing
Ratings
Model number
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 19
Submitting for Safety Testing
• Example of VDE listing
Model number
Ratings
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 20
Submitting for Safety Testing
• CB Certificates
– Test report forms part of certificate
Ratings
Model number
Test standard
Number of pages
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 21
Submitting for Safety Testing
• NRTL Certificates
Ratings
Model number
Test standard
Number of pages
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 22
Submitting for Safety Testing
On-Line Approvals Links
• TÜV SÜD Product Service
– https://www.tuev-sued.de/industry_and_consumer_products/certificates
– x
• ASTA and BEAB
– http://www.astabeab.com/buyers.htm
• CSA
– x
– http://directories.csa-international.org/
– x
• ENEC
– http://www.enec.com/dev/recherche.php?soc=ENEC&s=2
– x
• Intertek
– http://etlwhidirectory.etlsemko.com/WebClients/ITS/DLP/products.nsf/$$Search?OpenForm
– x
• ÖVE
– http://www.ove.at/puz/reg/form.php
– x
• UL
– http://database.ul.com/cgi-bin/XYV/template/LISEXT/1FRAME/index.htm
• VDE
– X
– http://www.vde.de/VDE_PI_en/Zertifizierungsregister/detailSearch
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 23
Submitting for Safety Testing
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
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 24
Summary
Submitting for Safety Testing
• Selection of test standards
• Requesting a quote
• Hints and tips to minimise failures
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 25
Thank you for
listening
Alastair McLaughlin
Product Safety Specialist
TÜV SÜD Product Service
Tel: +44 (0)1789 731155
alastair.mclaughlin@tuv-sud.co.uk
TÜV SÜD Product Service
15-07-15
Customer Day 2015
Slide 26