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

IEC SYSTEM OF CONFORMITY ASSESSMENT

SCHEMES FOR ELECTROTECHNICAL

EQUIPMENT AND COMPONENTS

Principle/Testing of IEC Principle/Testing of IEC 60598-1/IEC 60598-2-160598-1/IEC 60598-2-1

Vicky ZhangProduct ExpertDEKRA Shanghai

IECEE Workshop August 26 & 27Nairobi - Kenya

IECEE Workshop August 26 & 27, Nairobi - Kenya2

Content

• Why?

• What?

• How?


• Why to use IEC standards?



Recalls by product categories

- 2012, EU


Recalls by type of risk

- 2012, EU


Product Risks


What is product safety?

Product Product SafetySafety

No hazards to People

No hazardsto environment

No hazards to other equipments


Provisions against Hazards

ProvisionsProvisions

BB

EE

CC

DD

AAMechanical

hazards

Electrical Hazards

Heat related hazards

Radiation hazards

Fire hazards


Advantage of IEC standards

IEC Standards

Reducing risk, increasing quality, confidence

Bases of national standard or regulations

Wide adoption

Transparent process

Representing market needs


Technical committees

TC 34Lamps and

related equipments

SC 34DLuminaires

SC 34CAuxiliaries for lamps

SC 34ALamps

SC 34BLampcaps/

holders


• What criterias are required in IEC 60598-1/60598-2-1?


Standards

• IEC 60598-1

Luminaires –

Part 1: General requirements and tests


Standards

• IEC 60598-2-1

Luminaires –

Part 2- Particular requirements for Fixed general purpose luminaires


Scope

• Fixed general purpose luminaire

• Working voltage <= 1000 V

• Tungsten filament, tubular fluorescent and other discharge lamps


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


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)


Conformity Assessment

Type Type TestTestType Type TestTest

Carried out by laboratoryTo use standardized test methodTo check compliance of the design of a product

Routine Routine TestTestRoutine Routine TestTest

Carried out by manufacturers after productionTo ensure every luminaire conforms with the sample approved under type test




Carried out by laboratoryTo use standardized test methodTo check compliance of the design of a product




Component

• Suitable for use in the Luminaire

• Correct Classification and Ratings• In compliance with relevant IEC

requirements To ensure

safety of usage


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


Construction - Lampholder

• Positioning test



• Bending test



• Torque test


Construction – Terminal block

• Space- Luminaire with connecting

leads requires a terminal block to connect to fixed wiring

- Adequate space for terminal block


Construction – Reliable terminals

• 8 mm conductor• live conductor

• earth conductor



• External cable & Internal wiring• Retained by cord anchorage

• Clamped by spring terminal



• 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



• Internal wiring- Securely crimped- Securely wrapped


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


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 means2.Not be removed without being seriously damaged

1. Humidity 48 hrs

2. Insulation resistance & electric strength

1. Thermal test

2. T(wire)+20°C

3. Aging T(wire)+20°C, 240 hrs, checked by electrical strength


Construction – Screws

• Torque test

No damage

No creep


Construction – Screws

• Torque test• 0,5 Nm for screws on cord anchorage

bearing directly on cable or cord


Construction – Glands

• Torque test


Construction – Mechanical Strength

• Impact test



• 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



• 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



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



• Rigid Suspended luminaires- Torque test- 2,5 Nm, 1 min- Clockwise and anti-clockwise- No rotation more than one revolution in both

directions



• Rigid Suspension bracket (heavy duty)- Loading 40 N, >=2,5 Nm, at free end- 1 min- No permanent displacement, deformation



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



• Track mounted luminaire- Luminaire mass < max. load for track



• Adjusting device- No twisting over 360



• Flexing test- Strands broken < 50%- Insulation resistance & electric strength


Construction – Flammable Material

• Glow‑wire test 650 C

• Spacing 30 mm

• No fiercely burning material


External Wiring

• Supply connection

Terminals

Adaptor for track

Supply cable & Plug


External Wiring

• Supply connection

Appliance inlet

Connecting leads


External Wiring

• Type of cable

• 0,75 mm2 for ordinary luminaires;

• 1,0 mm2 for other luminaires


External Wiring

• Type of connection

- Type X attachment

- Type Y attachment

- Type Z attachment


External Wiring

• Cord anchorage


External Wiring

• Cord anchorage - Pull test (25 time, displacement <= 2mm)

- Torque test


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

(PVC or Rubber)

1,5 mm2 for through wiring

--


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


External & Internal Wiring

• Soldering

Clamping terminal

Spring terminal


External & Internal Wiring

• Soldering

Spring terminal

Clamping terminal

Cold flowBad electrical

connection


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


Earthing


Earthing

• Location of earthing terminal• Adjacent to mains terminal (type X, Y)

• Material of earthing terminal• Brass or non-rusting material

• Bare contact surface


Earthing

• Cord for earthing• Green-yellow cord shall only be used

for earthing connection

• Earthing make contact first

• Earthing detached later


Earthing

• Terminal blocks with integrated screwless earthing contacts


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


Earthing

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


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



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



• No basic insulated components on outside of luminaire

• Luminaires incorporating a capacitor >0,5μF must be provided with a discharge device


Resistance to dust and moisture

• Dust Test (IP#X)



• Dust Test (IP#X)• Solid-object-

proof (IP2X)• Solid-object-

proof (IP3X or IP4X)

• Dust-proof (IP5X)

• Dust-tight proof (IP6X)



• IP Test (IPX#)• Drip-proof (IPX1) • Drip-proof (IPX2)


Resistance to dust and moisture• IP Test (IPX#)

• Rain-proof (IPX3) and splash-proof (IPX4)



• 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)



• 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



• Humidity test• R.H. 91% to 95 %• 10 ºC – 30 ºC

• 48 hrs


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


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


Creepage distance & Clearances

• Live Parts of different polarity

• Live Parts Adjacent Metal Parts

• Live Parts Body or Housing

• Live Parts Mounting Surface


Creepage distance & Clearances


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


Resistance to heat, fire and tracking

• Needle Flame Test

• Ball Pressure Test


Resistance to heat, fire and tracking

• Glow-wire Test 650 ºC

• Tracking Test on IP>20 Luminaire




Carried out by laboratoryUse standardized test methodTo check compliance of the design of a product




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)


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


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!


Consumable goods/ items

Test methods/validationMeasurement traceabilitySamplingHandling of test items

Environmental conditionsEquipment

Conditions which can influence test results in your laboratory?

Manpower

Machines

Methods

Means

Human factors


Process model

Input Process Output

Manpower Machines

Means Methods


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…)


Manpower Machines

Means Methods


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

Machines


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

Machines


Manpower

Means Methods


Machines (3)

• IECEE – CTL testing equipments under CB schemehttp://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm

• IECEE-CTL Operational Procedures

• http://www.iecee.org/ctl/operational/Operational_procedures.htm

Machines


Manpower

Means Methods

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

http://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm

http://www.iecee.org/ctl/operational/Operational_procedures.htm

http://www.iecee.org/ctl/operational/Operational_procedures.htm


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 %

Machines


Manpower

Means Methods


Machines (5)

• Note:

IEC 60598-1, cl. 12.4.1 e) ±1% (preferred ± 0.5%)

voltage stability instead of ± 3%!

Machines


Manpower

Means Methods


Machines (6)Machines


Manpower

Means Methods




Manpower

Means Methods




Manpower

Means Methods




Manpower

Means Methods


MethodsMachines


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


MeansMachines


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


InputMachines


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


OutputMachines


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


OutputMachines


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

http://members.iecee.org/

http://www.iecee.org/Operational_documents/od-cb_index.html

http://www.iecee.org/Operational_documents/od-cb_index.html

IEC SYSTEM OF CONFORMITY ASSESSMENT

SCHEMES FOR ELECTROTECHNICAL

EQUIPMENT AND COMPONENTS

Vicky ZhangProduct ExpertDEKRA Shanghai

IECEE Workshop August 26 & 27Nairobi - Kenya

Documents

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