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Berri Remenick NARTE Certified Product Safety Engineer Product Safety Manager Washington Laboratories, Ltd.
September 14, 2007 Gaithersburg, MD
Washington Laboratories (301) 417-0220 web: www.wll.com 7560 Lindbergh Dr. Gaithersburg, MD 20879
Outline
Background Insulation
Component
Labeling
Selection
to Fire
US/Canada:
NRTL Listing (cULus, cTUVus, cCSAus) Legal requirement, customer requirement, or to limit liability
Europe:
CE Mark Legal requirement
Others:
CB Report To facilitate International Approvals.
Electric Shock Hazards: Accessible parts over 30Vrms, 42.4Pk, or 60VDC. Energy Hazards: Energy level over 240VA or 8A Fire Hazards: Materials, Enclosure, Abnormal conditions Mechanical Hazards: Moving parts, Sharp edges, Tipping, Handles
Design Requirements
Protection against electric shock and energy hazards:
The OPERATOR can not touch bare or inadequately insulated parts at hazardous voltage or energy levels. Hazardous Voltage Level is typically >30Vrms, 42.4Vpeak, or 60VDC. Hazardous energy is typically >240VA or 8A Protection may be provided via insulation, guarding or interlocking.
What is Insulation?
Physical barrier between two parts (tape, plastic shield, wire insulation, enclosure, etc)
Separation between two parts through air or along a surface (creepage or clearance distance)
Insulation Types
Functional / Operational Insulation (DC input to ground) Basic Insulation (Primary to Ground, TNV to Ground, TNV to SELV) Reinforced Insulation (Primary to Secondary)
Creepage / Clearance
Creepage / Clearance
Creepage
Creepage = distance between two points along the surface Creepage is measured on 1:1 artwork or on a blank board Locations of circuits determined by reviewing schematics
Clearance
Clearance = distance between two points through the air Clearance is measured on a populated sample
Component Selection
Safety Critical Components must have the appropriate approvals or additional evaluation will be required. Safety Critical Components:
Devices in the AC path (inlets, fuses, switches, power supplies, transformers, etc.) Motors, fans Power conversion components (AC-DC or DC-DC Converters) Any isolation component (Transformer, Bridging Capacitors, MOVs,) Wiring Batteries Others depending on their application.
Component Selection
For NRTL approvals, all components must be UL approved. For CE Mark approvals, all components must have a European approval such as CE, TUV, VDE, etc. (exception: fuses and wiring can be UL approved) For GS or CB Scheme approvals, all components must have a TUV, VDE, or other official European approval. CE Mark is not acceptable for these approvals. Approval certificates required (TUV or VDE Cert, CE Declaration of Conformity, UL File number, etc.)
Rated voltage, current or power, frequency Manufacturers name or registered trademark. Model or type number. Fuse replacement info (if applicable). IEC symbols wherever possible. Warnings and Cautions appropriate for the particular equipment.
User Instructions
Installation Instructions - information regarding mounting, connection to the supply, ventilation, input ratings, etc. All information regarding use, cleaning, maintenance (if necessary). All safety warnings and cautions. Rack Mount instructions. Safety-related information to be in appropriate language of the country you are exporting to. Some standards have entire sections of specific info that must be in manual.
PE conductor must be green/yellow or bare insulation conductor PE connections must be double secured so that both the wire and insulation are crimped IEC PE symbol shall be marked adjacent to PE stud PE conductor shall connect to chassis directly from input (inlet, terminal block, etc). PE conductor must be secured with washer and locknut. Additional PE conductors can be secured to PE stud with a second washer and locknut.
PE Stud Example
EMI FILTER
CHASSIS CONNECTION TO OTHER GROUNDS
MECHANICALLY SECURED GROUND: GREEN/YELLOW WIRE SAME GAUGE AS OR BIGGER THAN SUPPLY
All AC wires shall be double secured. Double securement can be met by:
Double crimp connector or Single crimp connector and cable tie or Single crimp connector and shrink sleeving.
AC wiring shall be rated for the maximum working voltage and current. AC wiring shall be isolated from low voltage wiring or low voltage parts, this can be accomplished by:
Shrink sleeving the AC conductors or By routing the AC conductors away from low voltage wires and securing with cable ties or By using UL1015 Reinforced Insulation wire.
Enclosures, components, and other parts shall be constructed such that propagation of fire is limited. Flammability of enclosure, internal, and external parts shall be adequate for the use of that part.
Flammability ratings
5VA Most fire resistant 5VB V0 V1 V2 HB40 HB75 - Least fire resistant Foamed materials: HF-1 HF-2 HBF
Requirement: There shall be no spread of fire outside the equipment in Normal or Single Fault Conditions.
Methods of Compliance: A: Testing in single fault conditions B: Reducing sources of ignition within the equipment C: Containing fire within the equipment should it occur
- Components in secondary circuits that are not supplied by LPS - Components in secondary circuits supplied by LPS but not on V-1 material - Components with unenclosed arcing parts - Insulated wiring
Movable equipment <18kg: V-1 or pass A.2 HWI test (if <13mm from high temp parts) Movable equipment >18kg or stationary equipment: 5VB or pass A.1 HWI test (if <13mm from high temp parts) Materials filling an opening in a fire enclosure: V-1 or pass A.2
Exceptions: Electronic components (ICs, optos, etc.) mounted on V-1. Wiring and connectors insulated with PVC, TFE, PTFE, FEP, neoprene, or polymide. Clamps, cable ties. Wire marked VW-1 or FT-1 or better. Others.
Material outside fire enclosure: HB75 if <3mm or HB40 if >3mm or HBF or Glow Wire test at 550C
Connectors: V-2 or pass A.2 or mounted on V-1 and be small or be in secondary circuit with max 15VA
Exceptions: Electronic components (ICs, optos, etc.) mounted on V-1. Wiring and connectors insulated with PVC, TFE, PTFE, FEP, neoprene, or polymide. Clamps, cable ties. Others.
Help you select the proper Directives and Standards to apply to your product. Evaluate and test your product to the appropriate Safety Standard and offer solutions for non-compliances. Provide product design assistance. Obtain cTUVus, cCSAus, cULus, GS Mark, and other approvals. WLL is a Partner Test Lab for TUV Rheinland for 60950-1, 61010-1, and 60065
Give us a call or send us info about your product were here to help!
Berri Remenick Product Safety Manager Phone: 301-473-1255 Fax: 301-473-1257 E-mail: berrir@wll.com