How to Design-In Product Safety Compliance. I.Identify Requirements II.Construction Requirements III.Performance Testing Requirements IV.Production Testing

How to Design-In Product How to Design-In Product Safety ComplianceSafety Compliance

I. Identify Requirements

II. Construction Requirements

III.Performance Testing Requirements

IV.Production Testing Requirements

Identify RequirementsIdentify Requirements

• Identify the nature or scope of your productIdentify the nature or scope of your product

• What market will you distribute your product What market will you distribute your product (U.S.A., Canada, Europe, Far East, etc.)(U.S.A., Canada, Europe, Far East, etc.)

• What certification mark will you use for What certification mark will you use for compliancecompliance

• What local ordinances and standards are in place What local ordinances and standards are in place (NV Gaming Commission & NFPA 70)(NV Gaming Commission & NFPA 70)

• Have the compliance specification/standard on Have the compliance specification/standard on file for referencefile for reference

ConstructionConstruction

• Frame & EnclosureFrame & Enclosure

- - Should have the strength and rigidity Should have the strength and rigidity to resist the increase of electrical to resist the increase of electrical

shock, injury to person, or risk of fire shock, injury to person, or risk of fire under normal applicationsunder normal applications

ConstructionConstruction• External MaterialExternal Material

- - External material such as steel, wood, External material such as steel, wood, aluminum, glass, and composites can aluminum, glass, and composites can

be be used for the enclosure.used for the enclosure.

- - If any of these materials are If any of these materials are combustible combustible and have a surface area and have a surface area greater than 10 sq. greater than 10 sq. feet they are subject to feet they are subject to a flame index less a flame index less than 200 when tested than 200 when tested against the following against the following standardsstandards


• UL 723 (Surface Burning UL 723 (Surface Burning Characteristics of Building Material)Characteristics of Building Material)

• ASTM E162 (Surface Flammability of ASTM E162 (Surface Flammability of Materials Using a Radiant Heat Materials Using a Radiant Heat Energy Source)Energy Source)

ConstructionConstruction• Enclosure Bottom OpeningsEnclosure Bottom Openings

- - A barrier or pan of noncombustible A barrier or pan of noncombustible material material must be used to prevent a fire must be used to prevent a fire hazard in the hazard in the event of flaming particles, event of flaming particles, burning insulation, burning insulation, and molten metaland molten metal

- - The barrier would be commonly The barrier would be commonly placed placed under motors, wires, switches, under motors, wires, switches,

transformers, etc. that upon failure transformers, etc. that upon failure could pose a fire hazardcould pose a fire hazard

Blue = Minimum Barrier Area

Red = Area of the component

Yellow = Means of finding minimum area of blue. This is a 5 degree tangent from red area

ConstructionConstruction• Accessibility of Un-insulated live parts, Accessibility of Un-insulated live parts,

film-coated wire, moving partsfilm-coated wire, moving parts

- If and opening in an enclosure would If and opening in an enclosure would allow access to un-insulated live parts, allow access to un-insulated live parts, film-coated wire, moving parts the film-coated wire, moving parts the opening has specific dimensions.opening has specific dimensions.

- If < than 1 inch (articulate probe)If < than 1 inch (articulate probe)

- If > than 1 inch (non-articulate probe)If > than 1 inch (non-articulate probe)



Dimensions of OpeningDimensions of Opening Minimum Distance from Minimum Distance from Opening to PartOpening to Part

3/4 in3/4 in

1 in1 in

1-1/4 in1-1/4 in

1-7/8 in1-7/8 in

2-1/8 in2-1/8 in

4-1/2 in4-1/2 in

6-1/2 in6-1/2 in

7-1/2 in7-1/2 in

15-1/2 in15-1/2 in

17-1/2 in17-1/2 in

ConstructionConstruction• Supply ConnectionsSupply Connections

- Can be permanent or detachableCan be permanent or detachable

- Must be under 15 feet in lengthMust be under 15 feet in length

- Must have strain relief & bushingMust have strain relief & bushing

- Must comply to ANSI Plug TypesMust comply to ANSI Plug Types


Amperes, VoltsAmperes, Volts ANSI DesignationANSI Designation

15, 125 15, 125

20, 12520, 125

30, 12530, 125

15, 25015, 250

20, 25020, 250

30, 25030, 250

C73.11C73.11

C73.12C73.12

C73.45C73.45

C73.20C73.20

C73.51C73.51

C73.52C73.52


•Grounding & BondingGrounding & Bonding

- Grounding of all dead metal parts should Grounding of all dead metal parts should be available if they can become be available if they can become energized by a single fault conditionenergized by a single fault condition

- Un-insulated metal parts that are likely Un-insulated metal parts that are likely to become energized and provide a to become energized and provide a shock hazard in normal operation or shock hazard in normal operation or service must be bonded for groundingservice must be bonded for grounding


- A separate bonding conductor or strap A separate bonding conductor or strap must be usedmust be used

- Be protected from damage or located Be protected from damage or located within enclosurewithin enclosure

- Be secured by a bolt, clamp, rivet, etc. and Be secured by a bolt, clamp, rivet, etc. and be able withstand a temperature of 850be able withstand a temperature of 850ºº F F

ConstructionConstruction• Protection Against Shock, Fire, Personnel Protection Against Shock, Fire, Personnel

InjuryInjury

- - means should be designed into the means should be designed into the product to product to protect protect individualsindividuals

- - the degree of protection is based on the degree of protection is based on the the nature of the device, for examplenature of the device, for example

1. degree of exposure1. degree of exposure


2. Sharpness of moving parts2. Sharpness of moving parts

3. Risk of unintentional contact with moving 3. Risk of unintentional contact with moving partsparts

4. Speed and movement of moving parts4. Speed and movement of moving parts

5. Risk of fingers, hair, clothing, etc. being drawn5. Risk of fingers, hair, clothing, etc. being drawn

into moving parts.into moving parts.

ConstructionConstruction• ComponentsComponents

- Attachment Plugs & Receptacles (UL 498)- Attachment Plugs & Receptacles (UL 498)

- Filters, Electromagnetic Interference (UL - Filters, Electromagnetic Interference (UL 1283)1283)

- Motors, Electric (1004)- Motors, Electric (1004)

- Printed-Wiring Boards (UL 796)- Printed-Wiring Boards (UL 796)


- - Switches, Snaps, General-use (UL 20)Switches, Snaps, General-use (UL 20)

- - Wires & Cables, Thermal plastic-Wires & Cables, Thermal plastic-Insulated Insulated

(UL 83)(UL 83)

Performance TestsPerformance Tests

• General PowerGeneral Power

– Device should be powered at rated Device should be powered at rated voltage and normal operating Hzvoltage and normal operating Hz

– An IR test should be conducted at 250 An IR test should be conducted at 250 VDC with a resistance > 30 kohmsVDC with a resistance > 30 kohms

Performance TestsPerformance Tests

• Starting Current TestStarting Current Test

- - Device should be powered on 3 times Device should be powered on 3 times sequentially at rated voltage and sequentially at rated voltage and

current current without tripping fuse or over-without tripping fuse or over-current current protection devices.protection devices.

- - Device should be at room Device should be at room temperature for temperature for each test and the each test and the motor can come to a motor can come to a complete rest complete rest prior to the next testprior to the next test

Performance TestPerformance Test

• Leakage Current TestLeakage Current Test

- - measurement of leakage current that measurement of leakage current that are are present under normal and signal fault present under normal and signal fault

conditions on conductive surfaces or conditions on conductive surfaces or ground.ground.



- Leakage Current LimitsLeakage Current Limits

a) .75 mA when ground closed and S1 is closeda) .75 mA when ground closed and S1 is closed

b) 1.0 mA when ground opened and S1 is closedb) 1.0 mA when ground opened and S1 is closed

c) 2.0 mA when ground opened and S1 is c) 2.0 mA when ground opened and S1 is openedopened

Performance TestsPerformance Tests• Temperature TestsTemperature Tests

- - when device is tested at maximum when device is tested at maximum load the load the temperature should not reach a temperature should not reach a point to:point to:

- - cause risk of a firecause risk of a fire

- - damage materials within the devicedamage materials within the device

- - reach temperature in (table 33.1)reach temperature in (table 33.1)

ComponentComponent Temperature in FTemperature in F

Motor Class 130Motor Class 130 180180ºº

Capacitors Capacitors ElectrolyticElectrolytic

7272ºº

FusesFuses 117117ºº

Insulated ConductorsInsulated Conductors 6363ºº

Electrical InsulationElectrical Insulation 117117ºº

Handles & KnobsHandles & Knobs 140140ºº

Other SurfacesOther Surfaces 158158ºº


• Dielectrical Withstand TestDielectrical Withstand Test

- - performed on primary and secondary performed on primary and secondary circuits circuits for 1 min. at 40-70 hz at 1 KVAC for 1 min. at 40-70 hz at 1 KVAC for no for no breakdownbreakdown

PerformancePerformance

Performance TestPerformance Test•Spill TestSpill Test

- - any device with a horizontal service any device with a horizontal service able to able to hold a glass of liquid must be hold a glass of liquid must be subjected to a subjected to a spill testspill test

- - 1 liter of water will be poured onto the 1 liter of water will be poured onto the enclosure at a rate of 1L/min.enclosure at a rate of 1L/min.

- - when the test is completed the device when the test is completed the device will be will be subjected to the dielectrical subjected to the dielectrical withstand testwithstand test

Performance TestPerformance Test• Physical Stability TestPhysical Stability Test

- - device should not tip over when it is device should not tip over when it is tilted at tilted at a 10 degree anglea 10 degree angle

- - a free standing device that is placed a free standing device that is placed on the on the floor and could be sit on or floor and could be sit on or stood on should stood on should not tip over when 180 not tip over when 180 lbf is placed on the lbf is placed on the devicedevice

Performance TestPerformance Test• Abnormal TestAbnormal Test

- - Under an abnormal test the device should not Under an abnormal test the device should not pose pose a risk of fire, electrical shock, or injury to a risk of fire, electrical shock, or injury to personnelpersonnel

- - Unacceptable conditions include Unacceptable conditions include

1. flame emitted from enclosure1. flame emitted from enclosure

2. single layer of cheesecloth or tissue paper 2. single layer of cheesecloth or tissue paper glowsglows

3. 3 amp fuse opens3. 3 amp fuse opens


- Samples of abnormal tests include; Samples of abnormal tests include; operating device with cooling fans operating device with cooling fans disconnected, overload of power supply, disconnected, overload of power supply, malfunction of components in primary malfunction of components in primary circuit (ex. Shorts), wrong voltage selectedcircuit (ex. Shorts), wrong voltage selected

- Test duration is typically conducted for 1 Test duration is typically conducted for 1 hourhour


• Stain ReliefStain Relief

- - The power cord should be detached The power cord should be detached and a and a 35 lb weight is attached to the 35 lb weight is attached to the cord for cord for

1 min.1 min.

Performance TestPerformance Test• Grounding Impedance TestGrounding Impedance Test

- - The ground impedance path will be The ground impedance path will be subjected to 25 subjected to 25 amps for 1 minute with a amps for 1 minute with a resistance not to exceed resistance not to exceed 100 mohms.100 mohms.

- - The voltage should be < 12 volts AC with The voltage should be < 12 volts AC with 60 Hz.60 Hz.

- - Test points are between input ground and Test points are between input ground and grounded grounded external partsexternal parts



• Impact TestImpact Test

- - Three representative samples of the Three representative samples of the device device must withstand an impact test must withstand an impact test without any without any signs of cracks or openings signs of cracks or openings after impactafter impact

- - A steel sphere weighing 1.18 lbs will A steel sphere weighing 1.18 lbs will be be dropped 51 inches or swung from a dropped 51 inches or swung from a

pendulum at 51 inchespendulum at 51 inches

Manufacturing TestManufacturing Test

• Production Dielectrical Withstand Production Dielectrical Withstand TestTest

– Each appliance will be subjected to the Each appliance will be subjected to the dielectrial withstand test without dielectrial withstand test without breakdownbreakdown

– Appliance must be fully assembledAppliance must be fully assembled

Manufacturing TestManufacturing Test• Production Grounding-Continuity TestProduction Grounding-Continuity Test

- - Every product that will be supplied with a Every product that will be supplied with a power power cord that is grounded will be cord that is grounded will be subjected to a subjected to a continuity test continuity test

- - the test is between input ground and the test is between input ground and chassis groundchassis ground

- - instrument used could be an ohmmeter, instrument used could be an ohmmeter, battery/buzzer device, or similar devicesbattery/buzzer device, or similar devices

Documents

How to Design-In Product Safety Compliance. I.Identify Requirements II.Construction Requirements III.Performance Testing Requirements IV.Production Testing