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How to Design-In Product Safety Compliance

How to Design-In Product Safety Compliance. Identify Requirements Construction Requirements Performance Testing Requirements Production Testing Requirements. Identify Requirements. Identify the nature or scope of your product

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How to Design-In Product Safety Compliance

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  1. How to Design-In Product Safety Compliance

  2. Identify Requirements • Construction Requirements • Performance Testing Requirements • Production Testing Requirements

  3. Identify Requirements • Identify the nature or scope of your product • What market will you distribute your product (U.S.A., Canada, Europe, Far East, etc.) • What certification mark will you use for compliance • What local ordinances and standards are in place (NV Gaming Commission & NFPA 70) • Have the compliance specification/standard on file for reference

  4. Construction • Frame & Enclosure - Should have the strength and rigidity to resist the increase of electrical shock, injury to person, or risk of fire under normal applications

  5. Construction • External Material - External material such as steel, wood, aluminum, glass, and composites can be used for the enclosure. - If any of these materials are combustible and have a surface area greater than 10 sq. feet they are subject to a flame index less than 200 when tested against the following standards

  6. Construction • UL 723 (Surface Burning Characteristics of Building Material) • ASTM E162 (Surface Flammability of Materials Using a Radiant Heat Energy Source)

  7. Construction • Enclosure Bottom Openings - A barrier or pan of noncombustible material must be used to prevent a fire hazard in the event of flaming particles, burning insulation, and molten metal - The barrier would be commonly placed under motors, wires, switches, transformers, etc. that upon failure could pose a fire hazard

  8. 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

  9. Construction • Accessibility of Un-insulated live parts, film-coated wire, moving parts • If and opening in an enclosure would allow access to un-insulated live parts, film-coated wire, moving parts the opening has specific dimensions. • If < than 1 inch (articulate probe) • If > than 1 inch (non-articulate probe)

  10. Construction

  11. Construction

  12. Construction • Supply Connections • Can be permanent or detachable • Must be under 15 feet in length • Must have strain relief & bushing • Must comply to ANSI Plug Types

  13. Construction

  14. Construction • Grounding & Bonding • Grounding of all dead metal parts should be available if they can become energized by a single fault condition • Un-insulated metal parts that are likely to become energized and provide a shock hazard in normal operation or service must be bonded for grounding

  15. Construction • A separate bonding conductor or strap must be used • Be protected from damage or located within enclosure • Be secured by a bolt, clamp, rivet, etc. and be able withstand a temperature of 850º F

  16. Construction • Protection Against Shock, Fire, Personnel Injury - means should be designed into the product to protect individuals - the degree of protection is based on the nature of the device, for example 1. degree of exposure

  17. Construction 2. Sharpness of moving parts 3. Risk of unintentional contact with moving parts 4. Speed and movement of moving parts 5. Risk of fingers, hair, clothing, etc. being drawn into moving parts.

  18. Construction • Components - Attachment Plugs & Receptacles (UL 498) - Filters, Electromagnetic Interference (UL 1283) - Motors, Electric (1004) - Printed-Wiring Boards (UL 796)

  19. Construction - Switches, Snaps, General-use (UL 20) - Wires & Cables, Thermal plastic-Insulated (UL 83)

  20. Performance Tests • General Power • Device should be powered at rated voltage and normal operating Hz • An IR test should be conducted at 250 VDC with a resistance > 30 kohms

  21. Performance Tests • Starting Current Test - Device should be powered on 3 times sequentially at rated voltage and current without tripping fuse or over-current protection devices. - Device should be at room temperature for each test and the motor can come to a complete rest prior to the next test

  22. Performance Test • Leakage Current Test - measurement of leakage current that are present under normal and signal fault conditions on conductive surfaces or ground.

  23. Performance Test

  24. Performance Test • Leakage Current Limits a) .75 mA when ground closed and S1 is closed b) 1.0 mA when ground opened and S1 is closed c) 2.0 mA when ground opened and S1 is opened

  25. Performance Tests • Temperature Tests - when device is tested at maximum load the temperature should not reach a point to: - cause risk of a fire - damage materials within the device - reach temperature in (table 33.1)

  26. Performance Test • Dielectrical Withstand Test - performed on primary and secondary circuits for 1 min. at 40-70 hz at 1 KVAC for no breakdown

  27. Performance

  28. Performance Test • Spill Test - any device with a horizontal service able to hold a glass of liquid must be subjected to a spill test - 1 liter of water will be poured onto the enclosure at a rate of 1L/min. - when the test is completed the device will be subjected to the dielectrical withstand test

  29. Performance Test • Physical Stability Test - device should not tip over when it is tilted at a 10 degree angle - a free standing device that is placed on the floor and could be sit on or stood on should not tip over when 180 lbf is placed on the device

  30. Performance Test • Abnormal Test - Under an abnormal test the device should not pose a risk of fire, electrical shock, or injury to personnel - Unacceptable conditions include 1. flame emitted from enclosure 2. single layer of cheesecloth or tissue paper glows 3. 3 amp fuse opens

  31. Performance Test • Samples of abnormal tests include; operating device with cooling fans disconnected, overload of power supply, malfunction of components in primary circuit (ex. Shorts), wrong voltage selected • Test duration is typically conducted for 1 hour

  32. Performance Test • Stain Relief - The power cord should be detached and a 35 lb weight is attached to the cord for 1 min.

  33. Performance Test • Grounding Impedance Test - The ground impedance path will be subjected to 25 amps for 1 minute with a resistance not to exceed 100 mohms. - The voltage should be < 12 volts AC with 60 Hz. - Test points are between input ground and grounded external parts

  34. Performance Test

  35. Performance Test • Impact Test - Three representative samples of the device must withstand an impact test without any signs of cracks or openings after impact - A steel sphere weighing 1.18 lbs will be dropped 51 inches or swung from a pendulum at 51 inches

  36. Manufacturing Test • Production Dielectrical Withstand Test • Each appliance will be subjected to the dielectrial withstand test without breakdown • Appliance must be fully assembled

  37. Manufacturing Test • Production Grounding-Continuity Test - Every product that will be supplied with a power cord that is grounded will be subjected to a continuity test - the test is between input ground and chassis ground - instrument used could be an ohmmeter, battery/buzzer device, or similar devices

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