Principle/Testing of IEC 60598-1/IEC 60598-2-1

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Principle/Testing of IEC 60598-1/IEC 60598-2-1
Vicky ZhangProduct ExpertDEKRA Shanghai
IECEE Workshop August 26 27 Nairobi - Kenya
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Content

• Why?
• What?
• How?

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• Why to use IEC standards?

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(No Transcript)
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Recalls by product categories
- 2012, EU
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Recalls by type of risk
- 2012, EU
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Product Risks
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What is product safety?
No hazards to environment
Product Safety
No hazards to People
No hazards to other equipments
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Provisions against Hazards
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Advantage of IEC standards
Representing market needs
IEC Standards
Transparent process
Wide adoption
Bases of national standard or regulations
Reducing risk, increasing quality, confidence
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Technical committees
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• What criterias are required in IEC
  60598-1/60598-2-1?

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Standards

• IEC 60598-1
• Luminaires
• Part 1 General requirements and tests

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Standards

• IEC 60598-2-1
• Luminaires
• Part 2- Particular requirements for Fixed
  general purpose luminaires

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Scope

• Fixed general purpose luminaire
• Working voltage lt 1000 V
• Tungsten filament, tubular fluorescent and other
  discharge lamps

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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

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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)

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Conformity Assessment
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Conformity Assessment
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Component

• Suitable for use in the Luminaire
• Correct Classification and Ratings
• In compliance with relevant IEC requirements

To ensure safety of usage
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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

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Construction - Lampholder

• Positioning test

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Construction - Lampholder

• Bending test

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Construction - Lampholder

• Torque test

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Construction Terminal block

• Space
• Luminaire with connecting leads requires a
  terminal block to connect to fixed wiring
• Adequate space for terminal block

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Construction Reliable terminals

• 8 mm conductor
• live conductor
• earth conductor

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Construction Reliable terminals

• External cable Internal wiring
• Retained by cord anchorage
• Clamped by spring terminal

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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

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Construction Reliable terminals

• Internal wiring
• Securely crimped
• Securely wrapped

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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
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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

1. Humidity 48 hrs
2. Insulation resistance electric strength

1. Thermal test
2. T(wire)20C
3. Aging T(wire)20C, 240 hrs, checked by
   electrical strength

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Construction Screws

• Torque test
• No damage
• No creep

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Construction Screws

• Torque test
• 0,5 Nm for screws on cord anchorage bearing
  directly on cable or cord

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Construction Glands

• Torque test

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Construction Mechanical Strength

• Impact test

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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

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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

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Construction Mechanical Strength

• All Suspended luminaires
• Loading test
• 4 x weight of luminaire
• 1 hrs
• No deformation on suspension system

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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

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Construction Mechanical Strength

• Rigid Suspension bracket (heavy duty)
• Loading 40 N, gt2,5 Nm, at free end
• 1 min
• No permanent displacement, deformation

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Construction Mechanical Strength

• Rigid Suspension bracket (light duty)
• Loading 10 N, gt1,0 Nm, at free end
• 1 min
• No permanent displacement, deformation

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Construction Mechanical Strength

• Track mounted luminaire
• Luminaire mass lt max. load for track

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Construction Mechanical Strength

• Adjusting device
• No twisting over 360?

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Construction Mechanical Strength

• Flexing test
• Strands broken lt 50
• Insulation resistance electric strength

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Construction Flammable Material

• Glow-wire test 650 ?C
• Spacing ? 30 mm
• No fiercely burning material

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External Wiring

• Supply connection

Supply cable Plug
Adaptor for track
Terminals
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External Wiring

• Supply connection

Connecting leads
Appliance inlet
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External Wiring

• Type of cable
• 0,75 mm2 for ordinary luminaires
• 1,0 mm2 for other luminaires

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External Wiring

• Type of connection
• - Type X attachment
• - Type Y attachment
• - Type Z attachment

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External Wiring

• Cord anchorage

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External Wiring

• Cord anchorage
• - Pull test (25 time, displacement lt 2mm)
• - Torque test

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Internal Wiring

• Internal wiring directly connected to fixed
  wiring

Operating current gt 2 A Operating current lt 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 (PVC or Rubber)
1,5 mm2 for through wiring --
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Internal Wiring

• Internal wiring connected to fixed wiring via
  current limiting device lt 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

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External Internal Wiring

• Soldering

Clamping terminal
Spring terminal
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External Internal Wiring

• Soldering

Spring terminal
Cold flow Bad electrical connection
Clamping terminal
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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

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Earthing
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Earthing

• Location of earthing terminal
• Adjacent to mains terminal (type X, Y)
• Material of earthing terminal
• Brass or non-rusting material
• Bare contact surface

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Earthing

• Cord for earthing
• Green-yellow cord shall only be used for earthing
  connection
• Earthing make contact first
• Earthing detached later

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Earthing

• Terminal blocks with integrated screwless
  earthing contacts

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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 lt 0,05 ohm

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Earthing

• Terminal blocks with integrated screwless
  earthing contacts
• Voltage drop test
• Resistance lt 0,05 ohm

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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

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Protection against electrical shock

• Basis insulated parts of Class II luminaires to
  be regarded as live parts

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Protection against electrical shock

• No basic insulated components on outside of
  luminaire
• Luminaires incorporating a capacitor gt0,5µF must
  be provided with a discharge device

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Resistance to dust and moisture

• Dust Test (IPX)

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Resistance to dust and moisture

• Dust Test (IPX)
• Solid-object-proof (IP2X)
• Solid-object-proof (IP3X or IP4X)
• Dust-proof (IP5X)
• Dust-tight proof (IP6X)

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Resistance to dust and moisture

• IP Test (IPX)
• Drip-proof (IPX1)

• Drip-proof (IPX2)

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Resistance to dust and moisture

• IP Test (IPX)
• Rain-proof (IPX3) and splash-proof (IPX4)

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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)

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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

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Resistance to dust and moisture

• Humidity test
• R.H. 91 to 95
• 10 ºC 30 ºC
• 48 hrs

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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

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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

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Creepage distance Clearances

• Live Parts of different polarity
• Live Parts ? Adjacent Metal Parts
• Live Parts ? Body or Housing
• Live Parts ? Mounting Surface

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Creepage distance Clearances
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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

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Resistance to heat, fire and tracking

• Ball Pressure Test

• Needle Flame Test

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Resistance to heat, fire and tracking

• Glow-wire Test 650 ºC

• Tracking Test on IPgt20 Luminaire

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Conformity Assessment
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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)

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• How to build up a laboratory carrying out testing
  of IEC 60598-2-1?

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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!

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Conditions which can influence test results in
your laboratory?
Human factors
Environmental conditions Equipment
Test methods/validation Measurement
traceability Sampling Handling of test items
Consumable goods/ items
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Process model
Manpower
Machines
Process
Input
Output
Means
Methods
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Manpower

• 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)

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Machines (1)

• 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

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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

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Machines (3)

• IECEE CTL testing equipments under CB scheme
• http//www.iecee.org/ctl/equipment/html/ctl_testi
  ng_lite.htm
• IECEE-CTL Operational Procedures
• http//www.iecee.org/ctl/operational/Operational_p
  rocedures.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
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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

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Machines (5)

• Note
• IEC 60598-1, cl. 12.4.1 e) 1 (preferred 0.5)
  
• voltage stability instead of 3!

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Machines (6)
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Machines (7)
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Machines (8)
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Machines (9)
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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

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Means

• 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

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Input

• 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

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Output

• Reporting results
• Shall include all information requested by the
  client
• and all information required by the method used
• Subcontracted results clearly identified

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Output

• IECEE TRF (test report form)
• http//members.iecee.org/
• IECEE TRF guide
• OD-2020
• http//www.iecee.org/Operational_documents/od-cb_i
  ndex.html

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Vicky ZhangProduct ExpertDEKRA Shanghai
IECEE Workshop August 26 27 Nairobi - Kenya