1. Electrical Safety Compliance Made Easy
A practical approach guide to what you need to know when submitting products for electrical safety testing

2. Who Am I? Name Mark Penton Title: Senior Consultant Employer:
TÜV Product Service Ltd
Experience:
20 Years experience in Electrical Safety
History:
Worked for Electrolux, TÜV Product Service, Underwriters Laboratories (UL) & Ericsson
Telephone:

3. Contents What is Electrical Safety? Preparing In advance
A brief overview of electrical safety testing
Preparing In advance
How to prepare in advance to ensure things run smoothly when submitting products
Selecting critical components and materials.
Guidance on selecting correct components and materials to use in your products
Hints and tips
Practical advice to help you avoid problems

4. What is Electrical Safety?

5. What is Electrical Safety
Electrical safety actually covers a range of issues aimed at ensuring the product is safe for the user and does not pose a hazard to the surrounding environment.
Considers the following-
The design and construction of the product
The product operation under normal operating conditions
What happens under fault conditions and component failures
Interconnection with other equipment and networks
Selection of materials and components
Despite the term “electrical safety” it actually covers a whole range of hazards.

6. Hazards Addressed by the Standards
Type of Hazard
What is addressed
Electric Shock
Voltages on accessible parts, insulation between circuits and parts, leakage current, protective earthing, safety interlocks
Energy
Energy on accessible parts, interconnection circuits, fault conditions
Fire
Overloads, component failures, insulation breakdown, selection of materials, fire enclosures, protective devices
Heat
Temperature limits, material properties, cooling & ventilation, operator accessible parts, fault conditions, material & component selection, flammable liquids.
Mechanical hazards
Operator access, safety interlocks, guarding, mechanical strength & stability
Radiation hazards
Laser (light) radiation, X-radiation, Radio Frequency
Ultraviolet (UV)
Chemical Hazards
Toxic vapours and smoke under fault conditions, dangerous liquids, chemical interaction between materials, warnings

7. Types of Safety Testing
There are 2 types of approach to safety testing
1. Type testing:
A one off test on a sample of the product.
A report or certificate relating to the product.
No production control or factory inspections.
No means of ensuring ongoing compliance.
A snapshot based on one sample does not guarantee future product quality.
Examples of applications for type testing:
To support CE Marking (for inclusion in technical file)
CB Scheme (as basis for obtaining international acceptance & certification)

8. Types of Safety Testing
2. 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.
Ongoing compliance maintained.
Assignment of a certification mark
Examples of the benefits of certification:
Market access
Consumer confidence
Ongoing production quality
Marketing advantage

9. The CB Scheme Internationally recognised
There are 46 formally participating countries
Recognised in many more countries (eg: South Africa)
And 61 National Certification Bodies - NCBs
With 225 Testing Laboratories – CBTLs
50,000 CB certificates issued each year
Over 400,000 CB Certificates currently in circulation
More than 15,000 manufacturers use the CB Scheme

10. Formal participating countries
Argentina
Australia
Austria
Belgium
Brazil
Canada
China
Czech Rep.
Denmark
Finland
France
Germany
Greece
Hungary
India
Indonesia
Ireland
Israel
Italy
Japan
Kenya
Rep. of Korea
Malaysia
Mexico
Netherlands
New Zealand
Norway
Poland
Portugal
Romania
Russia
Singapore
Slovakia
Slovenia
South Africa
Spain
Sweden
Switzerland
Thailand
Turkey
Ukraine
United Kingdom
United States
Serbia and Montenegro

11. Scope of the CB Scheme Designation Product Category
Available IEC Standards
BATT
Batteries
60086, 60099, 60254, 61809, 61960, 61982, 62133, 62259, 62281
CABL
Cables and cords
60227, 60245, 60702, 60799
CAP
Capacitors
60252, 60384, 60939, 61048, 61049
CONT
Switches for appliances
60691, 60730, 60934, 61058, 61095, 61508, 61810
EMC
Electromagnetic Compatibility
CISPR 11, CISPR 12, CISPR 13, CISPR 14, CISPR 15, CISPR 16, CISPR 20, CISPR 22, CISPR 24, 60118, 60204, 60255, 60478, 60533, 60601, 60728, 60870, 60945, 60947, 60974, 61000, 61131, 61204, 61326, 61543, 61547, 61800, 61812, 62040, 62041, 62052, 62053, 62054, 62153, 62236
HOUS
Household and similar equipment
60312, 60335, 60342, 60436, 60456, 60530, 60704, 60705, 60967, 61121, 61770, 61817
INST
Installation accessories and connection devices
60083, 60309, 60320, 60423, 60439, 60614, 60669, 60670, 60684, 60807, 60884, 60974, 60998, 60999, 61011, 61076, 61084, 61210, 61238, 61242, 61316, 61800, 61984, 62094, 62208
LITE
Lighting
60064, 60155, 60238, 60360, 60400, 60432, 60570, 60598, 60838, 60901, 60920, 60921, 60922, 60924, 60926, 60927, 60928, 60929, 60968, 60969, 61046, 61047, 61050, 61184, 61195, 61199, 61231, 61347, 62035
MEAS
Measuring instruments
60414, 61010, 61557
MED
Electrical equipment for medical use
60580, 60601, 60976, 61676
MISC
Miscellaneous
60747, 60900, 60938
OFF
IT and office equipment
60825, 60950, 62040
POW
Low voltage, high power switching equipment
60158, 60947, 62026, 62271
PROT
Installation protective equipment
60127, 60257, 60269, 60282, 60529, 60755, 60898, 61008, 61009, 61643 PV
Photovoltaics
60891, to 10, 61194, 61215, 61345, 61646, 61702, 61721, 61829, 62093, PVRS11, PVRS11A
SAFE
Safety transformers and similar equipment
60044, 60742, 61558
TOOL
Portable tools
60745, 61029, 61939
TOYS
Electric toys
62115
TRON
Electronics / Entertainment
60065, 60491, 61965

12. Why do we need the CB scheme?
Because the world is getting smaller…!
We trade in an international market.

13. Preparing in advance

14. At the Design Stage
Ensure design engineers are aware of safety requirements.
Provide training
Ensure they have access to the standards
Seek advice from 3rd parties
Enlist a consultant
Consider getting a compliance 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

15. At the Design Stage Select already approved components and materials.
Know your target markets
Reduce testing requirements
Avoid potential failures
Avoid having to change / re-source components
Don’t design power supplies unless you really need to.
They involve extensive testing
Can cost more to test than the end product
Critical to safety of the product

16. Requesting a Quotation
Know your market
Where do you want to sell the product?
Is CE marking sufficient?
Are international approvals / Certifications required?
Ensure that these requirements are defined when requesting quotations
Provide as much information as possible
Target markets
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

17. Preparing to Submit for testing
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

18. Preparing to Submit for testing
Ensure that the equipment is suitably configured for testing
Worst case normal load conditions
Provide worst case configuration
Prepare support equipment loads & cabling
Provide clear operating instructions
Write test software

19. Preparing to Submit for testing
Find out how many samples are required
Complete product
Power supplies
Fuses, thermal cut-outs and other components
Plastic parts
In-Situ testing at your site can often be the most effective way of testing.
100% of our engineers attention
All support facilities available
Issues can be resolved face to face
Fix your problems and clear non compliances on-line with the testing

20. Safety Critical Components and materials

21. Safety Critical Components & Materials
These guidance notes are intended to explain what information is required to show that a safety critical component holds suitable approval.
This will assist you in preparing the correct information in advance of submitting your product for testing.

22. Which Components are Safety Critical
Mains Components
Other components
Mains plugs and cords
DC/DC converters
Appliance couplers, EMC filters
Fans
Fuses and fuseholders
Enclosure materials
Wiring
Connectors
Power supplies
PCB’s
Capacitors (Class X, Class Y)
Thermistors, PTC’s
Transformers

23. IEC & EN Investigations
Component approvals should be in the form of a current test certificate / report to a relevant IEC / EN standard.
The documents should be in English from a CB, CCA or LVD accredited test laboratory (e.g. TÜV Product Service, VDE). The test certificate must be current (some have expiry dates) and must detail all relevant information i.e. 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. This is generally the case, for example, with power supply units where more detailed information is required i.e. maximum rated ambient, classification of outputs, method of mains isolation.
Self-declaration in the form of a Certificate of Conformity, component marking, manufacturer’s declaration etc. may also be accepted in some cases. However, the responsibility that the component is suitably approved remains with you (this would be stated in any test report issued).
Note: statements like “designed to meet” or “complies with ENxxxx” are not evidence of suitable component approvals.

24. IEC & EN Investigations
Where Third Party Certification of your product is being sought self-declaration is not acceptable and 3rd approved components should be used (e.g. TÜV PS, UL, CB, VDE). X and Y class capacitors (including discrete components or within filters) - must comply with IEC nd Ed. Mains switches / circuit breakers – the approval documentation must clearly state the voltage and current ratings. Where transformers or motors are to be assessed then we require details of the thermal classification of the winding in accordance with IEC60085 (this also apply to the windings of inductors). The thermal classification of winding insulation is as follows: Class:- A 100ºC; E 115ºC; B 120ºC; F 140ºC; H 165ºC

25. Flammability of Materials
This refers to plastic or non-metallic materials used in the construction of the unit. Compliance may be based on self-declaration, and/or suitable documentary evidence of compliance with the relevant standard for flammability.
This will most commonly be to UL 94.
In order for the suitability of the materials used to be assessed the following information is required:- 
i) The name of the company that holds the UL approval (eg: GE Plastics, 3M).
ii) The name and part number of the material (e.g. Lexan, LX437).
iii) The UL file number (e.g. E143678).
The flammability rating (e.g. V-1, V-2, HB, HF2).
Thickness of material used
The name of the approval holder and material is the most important information required in order for us to confirm compliance. 
The easiest method of obtaining the information is to obtain a copy of the UL Listing (Yellow) Card, which can be obtained from the approval holder, the manufacturer of the material, or from UL’s website.

26. Example of UL Flammability Listing

27. US / Canadian Investigations
All safety critical components and materials must have current UL or CSA Recognition and in order to verify this the following information is required:- i) The name of the company that holds the UL or CSA approval ii) The type or model number of the component. iii) The UL file number (e.g. E143678). The easiest method of obtaining the information is to obtain a copy of the UL Listing (Yellow) Card, which can be obtained from the approval holder, the manufacturer of the component/part, or from UL’s website. Where transformers are to be assessed and an insulation Class higher than Class A is to be used the UL require a UL 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).

28. UL Power Supply Listing

29. Example of TÜV PS Certificate

30. Example of VDE Certificate

31. On-Line Approvals Links
Certification Body
Link
TÜV Product Service
services/services/gblrenwwjohi.asp
TÜV Rheinland
VDE
ÖVE
CSA
directories.csa-international.org/
KEMA KEUR
FIMKO
CEBEC UL
database.ul.com/cgi-bin/XYV/ template/LISEXT/1FRAME/ index.htm
ETL
etlwhidirectory.etlsemko.com/WebClients/ITS/DLP/products.nsf/$$Search?OpenForm
SEMKO
ge.semko.se/semko/certified/
ASTA BEAB
IMQ

32. Hints and Tips

33. Hints and Tips Know your target markets
Provide as much info as possible at the quotation stage
Get a copy of the applicable standard
Select already approved components
Get a compliance review at an early stage of development
Don’t rely on datasheets as evidence of component approvals (“designed to meet” “in accordance with”)
Don’t design your own power supplies unless you really need to
Consider In-Situ testing if its practical
Collate all documentation before submitting for test

34. Hints and Tips
Ensure that the equipment is suitably configured for testing (worst case normal load conditions)
Find out how many samples are required
List all accessories and parts required to be included with the product
Define product families
Check the thickness of plastic parts when determining flammability ratings
Supply equipment fully ready for testing
loads cables
support equipment
test software
Specify all manufacturing locations

35. 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

36. Summary What is Electrical Safety? Preparing In advance
Selecting critical components and materials.
Hints and tips

37. Thanks for Listening
Any Questions?