Principle/Testing of IEC 60598-1/IEC 60598-2-1 Vicky Zhang Product Expert DEKRA Shanghai IECEE Workshop August 26 & 27 Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Content Why? What? How? IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Why to use IEC standards? IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya

Recalls by product categories - 2012, EU IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Recalls by type of risk - 2012, EU IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Product Risks IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya What is product safety? No hazards to environment No hazards to People Product Safety No hazards to other equipments IECEE Workshop August 26 & 27, Nairobi - Kenya

Provisions against Hazards B E C D A Mechanical hazards Electrical Hazards Heat related hazards Radiation hazards Fire hazards IECEE Workshop August 26 & 27, Nairobi - Kenya

Advantage of IEC standards Representing market needs IEC Standards Transparent process Wide adoption Bases of national standard or regulations Reducing risk, increasing quality, confidence IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Technical committees TC 34 Lamps and related equipments SC 34D Luminaires SC 34C Auxiliaries for lamps SC 34A Lamps SC 34B Lampcaps/ holders IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya What criterias are required in IEC 60598-1/60598-2-1? IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Standards IEC 60598-1 Luminaires – Part 1: General requirements and tests IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Standards IEC 60598-2-1 Luminaires – Part 2- Particular requirements for Fixed general purpose luminaires IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Scope Fixed general purpose luminaire Working voltage <= 1000 V Tungsten filament, tubular fluorescent and other discharge lamps IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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) IECEE Workshop August 26 & 27, Nairobi - Kenya

Conformity Assessment Type Test Carried out by laboratory To use standardized test method To check compliance of the design of a product Routine Test Carried out by manufacturers after production To ensure every luminaire conforms with the sample approved under type test IECEE Workshop August 26 & 27, Nairobi - Kenya

Conformity Assessment Type Test Carried out by laboratory To use standardized test method To check compliance of the design of a product Routine Test Carried out by manufacturers after production To ensure every luminaire conforms with the sample approved under type test IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Component Suitable for use in the Luminaire Correct Classification and Ratings In compliance with relevant IEC requirements To ensure safety of usage IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction - Lampholder Positioning test IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction - Lampholder Bending test IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction - Lampholder Torque test IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Terminal block Space Luminaire with connecting leads requires a terminal block to connect to fixed wiring Adequate space for terminal block IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Reliable terminals 8 mm conductor live conductor earth conductor IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Reliable terminals External cable & Internal wiring Retained by cord anchorage Clamped by spring terminal IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Reliable terminals Internal wiring Securely crimped Securely wrapped IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

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 means 2.Not be removed without being seriously damaged Humidity 48 hrs Insulation resistance & electric strength Thermal test T(wire)+20°C Aging T(wire)+20°C, 240 hrs, checked by electrical strength IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Construction – Screws Torque test No damage No creep IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Construction – Screws Torque test 0,5 Nm for screws on cord anchorage bearing directly on cable or cord IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Construction – Glands Torque test IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Impact test IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength All Suspended luminaires Loading test 4 x weight of luminaire 1 hrs No deformation on suspension system IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Rigid Suspension bracket (heavy duty) Loading 40 N, >=2,5 Nm, at free end 1 min No permanent displacement, deformation IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Rigid Suspension bracket (light duty) Loading 10 N, >=1,0 Nm, at free end 1 min No permanent displacement, deformation IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Track mounted luminaire Luminaire mass < max. load for track IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Adjusting device No twisting over 360 IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Mechanical Strength Flexing test Strands broken < 50% Insulation resistance & electric strength IECEE Workshop August 26 & 27, Nairobi - Kenya

Construction – Flammable Material Glow‑wire test 650 C Spacing  30 mm No fiercely burning material IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Supply connection Supply cable & Plug Adaptor for track Terminals IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Supply connection Connecting leads Appliance inlet IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Type of cable 0,75 mm2 for ordinary luminaires; 1,0 mm2 for other luminaires IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Type of connection - Type X attachment - Type Y attachment - Type Z attachment IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Cord anchorage IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya External Wiring Cord anchorage - Pull test (25 time, displacement <= 2mm) - Torque test IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 1,5 mm2 for through wiring -- IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

External & Internal Wiring Soldering Clamping terminal Spring terminal IECEE Workshop August 26 & 27, Nairobi - Kenya

External & Internal Wiring Soldering Spring terminal Cold flow Bad electrical connection Clamping terminal IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Earthing IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Earthing Location of earthing terminal Adjacent to mains terminal (type X, Y) Material of earthing terminal Brass or non-rusting material Bare contact surface IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Earthing Cord for earthing Green-yellow cord shall only be used for earthing connection Earthing make contact first Earthing detached later IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Earthing Terminal blocks with integrated screwless earthing contacts IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Earthing Terminal blocks with integrated screwless earthing contacts Voltage drop test Resistance < 0,05 ohm IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Protection against electrical shock Basis insulated parts of Class II luminaires to be regarded as live parts IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to dust and moisture Dust Test (IP#X) IECEE Workshop August 26 & 27, Nairobi - Kenya

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) IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to dust and moisture IP Test (IPX#) Drip-proof (IPX1) Drip-proof (IPX2) IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to dust and moisture IP Test (IPX#) Rain-proof (IPX3) and splash-proof (IPX4) IECEE Workshop August 26 & 27, Nairobi - Kenya

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) IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to dust and moisture Humidity test R.H. 91% to 95 % 10 ºC – 30 ºC 48 hrs IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Creepage distance & Clearances Live Parts of different polarity Live Parts  Adjacent Metal Parts Live Parts  Body or Housing Live Parts  Mounting Surface IECEE Workshop August 26 & 27, Nairobi - Kenya

Creepage distance & Clearances IECEE Workshop August 26 & 27, Nairobi - Kenya

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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to heat, fire and tracking Ball Pressure Test Needle Flame Test IECEE Workshop August 26 & 27, Nairobi - Kenya

Resistance to heat, fire and tracking Glow-wire Test 650 ºC Tracking Test on IP>20 Luminaire IECEE Workshop August 26 & 27, Nairobi - Kenya

Conformity Assessment Type Test Carried out by laboratory Use standardized test method To check compliance of the design of a product Routine Test Carried out by manufacturers after production To ensure every luminaire conforms with the sample approved under type test IECEE Workshop August 26 & 27, Nairobi - Kenya

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) IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya How to build up a laboratory carrying out testing of IEC 60598-2-1? IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya 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! IECEE Workshop August 26 & 27, Nairobi - Kenya

Conditions which can influence test results in your laboratory? Manpower Human factors Machines Environmental conditions Equipment Test methods/validation Measurement traceability Sampling Handling of test items Methods Means Consumable goods/ items IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Process model Manpower Machines Process Input Output Means Methods IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Manpower Input Process Output Manpower Machines Means Methods 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…) IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines (1) Machines Input Process Output Manpower Means Methods 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines Input Process Output Manpower Means Methods 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines Input Process Output Manpower Means Methods Machines (3) IECEE – CTL testing equipments under CB scheme http://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm IECEE-CTL Operational Procedures http://www.iecee.org/ctl/operational/Operational_procedures.htm 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines Input Process Output Manpower Means Methods 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 % IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines Input Process Output Manpower Means Methods Machines (5) Note: IEC 60598-1, cl. 12.4.1 e) ±1% (preferred ± 0.5%) voltage stability instead of ± 3%! IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines (6) Machines Input Process Output Manpower Means Methods IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines (7) Machines Input Process Output Manpower Means Methods IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines (8) Machines Input Process Output Manpower Means Methods IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Machines (9) Machines Input Process Output Manpower Means Methods IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Methods Machines 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Means Machines 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Input Machines 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Output Machines 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya Output Machines 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 IECEE Workshop August 26 & 27, Nairobi - Kenya

Vicky Zhang Product Expert DEKRA Shanghai IECEE Workshop August 26 & 27 Nairobi - Kenya