Project Report On

SAFTEY TESTING OF ELECTRICAL AND ELECTRONICS

INSTRUMENTS

Submitted by
PARUSHNI SINGH
VIII Semester
Id – BTBTL14575
Banasthali University, Rajasthan

For the award of the degree of

B. Tech
(Electrical & Electronics)

Under Supervision of

External Guide: Internal Guide:

Ms. Deepika Gahlot Mrs. Shaily Sharma
Scientist ‘B’ Assistant Professor
Banasthali University

Department Of Electronics
Banasthali Vidyapith
Banasthali - 304022
Session: 2014-18
 ABOUT THE ORGANIZATION

Standardization Testing and Quality Certification (STQC) Directorate is an

attached office of the Ministry of Electronics and Information Technology,
Government of India, provides quality assurance services in the area of
Electronics and IT through countrywide network of laboratories and centres. The
services include Testing, Calibration, IT &e- Governance,
Training and Certification to public and private organizations. STQC
laboratories are having national/International accreditation and recognitions in
the area of testing and calibration. Besides testing and calibration STQC has
specialized institutions such as Indian Institute of Quality Management (IIQM)
for quality related training programs. Centre for Reliability (CFR) for reliability
related services and Centre for Electronics Test Engineering (CETEs) for skill
based trainings. In the area of IT & e-Governance, STQC provides assurance
services through its IT Centers for Software Quality testing, Information
Security and IT Service Management by conducting testing, training, audit and
certifications. STQC is responsible for maintaining e-Gov. standards. Based on
this concept a Conformity Assessment Framework (CAF) for e-Governance
project has also been developed and is in operation. Two IT test laboratories, at
Bangalore and Kolkata, have received accreditation from American Association
for Laboratory Accreditation (A2LA) being the first outside the USA.

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 CERTIFICATE

This is to certify that Ms. Parushni Singh has carried out the project work titled
“Saftey Testing Of Electrical And Electronics Instruments” from 1st January
2018 to 30th May 2018 for the award of the B.Tech ( Electrical and
Electronics ) from Safety Lab, STQC under my supervision. The thesis
embodies result of original work and studies carried out by Student herself and the
contents of the thesis do not form the basis for the award of any other degree to
the candidate or to anybody else.

Ms. Deepika Gahlot

Scientist ‘B’
Safety Lab, STQC

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 CERTIFICATE

This is to certify that Ms. Parushni Singh, ID- BTBTL14575 a student of

Bachelors Of Technology (Electrical & Electronics) 8th Semester of Banasthali
Vidyapith” has completed the Thesis titled “Safety Testing Of Electrical &
Electronics Instruments” at STQC, New Delhi of six months duration in partial
fulfilment of Bachelors Of Technology (Electrical & Electronics).

The project on evaluation fulfils all the stated criteria and the student’s findings
are her original work. I hereby certify her work good to the best of my knowledge
& wish her best of luck for her future.

Mrs. Shaily Sharma

Assistant Professor
Banasthali Vidyapith
Date:

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 ACKNOWLEDGEMENT

It gives me immense pleasure to express my gratitude towards my mentor

DEEPIKA GAHLOT, scientist’B’ for herguidance and invaluable advice
throughout the duration of my project at STQC. Her untiring presence and ever
encouraging attitude has been immensely valuable in keeping me motivated and
helping me surmount all obstacles in my work. The knowledge gained from her
was truly worthy.

I would also like to express my sincere thanks to DEEPIKA GAHLOT mam for
her support and for providing me with the required facilities to carry out my
project.

Parushni singh

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 ABSTRACT

Safety testing of various Electrical/Electronic appliances/equipment has become

of great importance specially in mission critical applications and safety critical
components. The product design for safety aspects of products shall be safe to
use in normal and abnormal condition i.e. it does not only provide the protection
of human beings against injuries or safeguard against health hazards but also the
protection of property and environment in connection with the operation of
equipment, installation and process. An electronic /electrical product must
provide protection against following safety hazards namely Electric shock,
Harmful radiation, Excessive Temperature, Implosion, Mechanical instability,
Fire etc.

The conformances to technical specifications, quality, reliability and

performance of electrical and electronics products is an important aspect for
consumers as well as equipment / products manufactures. The compliance to
various national and international standards / specifications is usually carried out
by testing and evaluations of such products.
STQC laboratories in houses safety testing facilities as per national &
international specifications.

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 TABLE OF CONTENTS

1. Introduction
1.1. Objective
1.2. Calibration
1.3. Durability and environmental testing
2. Hazard
2.1. Introduction
2.2. Hazardous voltage
2.3. Hazardous energy level
3. Important features during testing
3.1. General instructions
3.2. Marking
3.3. Selection of Electrical Test Instruments
4. Terminologies used
4.1. DC mains supply
4.2. AC mains supply
4.3. Mains supply
4.4. Rated voltage
4.5. Rated current
4.6. Rated frequency
4.7. Normal load
4.8. Rated operating time
4.9. Rated resting time
4.10. Classes of equipment
4.11. Primary circuit
4.12. Secondary circuit
4.13. ELV circuit
4.14. SELV circuit
4.15. Limited current voltage

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 4.16. TNV circuit
4.17. Working voltage
4.18. Functional earthing
4.19. Touch current
4.20. Power interface
4.21. Input current
4.22. Neutral conductor
5. Testing instrument review
5.1. High voltage test
5.2. Insulation Resistance Test
5.3. Earth continuity test
5.4. Leakage current test
5.5. Ball pressure test
5.6. Determine the Temperature of Winding under Short Circuit
5.7. Heat deflection test
5.8. Clearances, Creepage distance and Solid insulation
5.9. Dielectric Strength Tests
5.10. Leakage Current
5.11. TestsGlow Wire Test
5.12. Cables testing
6. Major work
6.1. Switching adapter
6.2. Test of cable
6.3. Printer
6.4. Electric fence
6.5. Control gear
7. Conclusion
8. Reference

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 TABLE OF FIGURES

Title of Figure

Figure 1 4.1 measurement of SELV circuit

1.
2. Figure 2 5.1 High voltage test

3. Figure 3 5.2 insulation resistance test

4. Figure 4 5.3 connection of metal on of DUT

5. Figure 5 5.4ball pressure test method

6. Figure 6 5.5 heat deflection test equipment

7. Figure 7 5.6 clearance

8. Figure 8 5.7 creepage

9. Figure 9 5.8 diaelectric strength test procedure

10. Figure 10 5.9 arcing graph

5.10 Current v/s time for minimum current test
Figure 11
11. pass and fail
12. Figure 12 5.11 glow wire test equipment

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 LIST OF TABLES
Title of table Pg No

1. Table 1 1.1 Harmonized Standards

2. Table 2 2.1 Electric shock harm and measures to reduce
3. Table 3 3.1 Marking symbols
4. Table 4 5.1 value of leakage current
5. Table 5 5.2 clearance voltage
6. Table 6 5.3 creepage voltage
7. Table 7 5.4 color scheme of cable
8. Table 8 5.5 cable tests procedure

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Chapter 1: Introduction

1.1 GENERAL

Safety testing is required at the point of manufacture, before the product is

available to the end user. Manufacturers of electrical and electronic products must
ensure that no hazardous voltages or currents are accessible to the user. They need
to test their products to determine if they meet shock hazards from each, the
minimum requirements for protecting the operator from high voltage and leakage
currents, and test methods that determine if the product’s insulation system meets
the minimum requirements. There also is the issue of design conformity and
liability of the manufacturer.

Agencies such as Underwriters Laboratories (UL), the Canadian Safety

Association (CSA) certify that electrical and electronic equipment is safe to
operate. Once these products are tested and proven to comply with the appropriate
standard, the agency will allow the manufacturer to place a label on the unit to
signify compliance or certification. These labels give consumers confidence in
their equipment and confirm that the manufacturer has certified and verified the
product for electrical safety.

The manufacturer must maintain accurate records to ensure it builds products with
the same materials and processes on a continuous basis. The manufacturer must
notify the safety agency of any changes to the material, design, or process used in
producing its product. If the manufacturer makes a change, safety agencies may
amend the safety certification; in some cases, the product may need to be
recertified .

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UL/IEC Harmonized Standards

STANDARD DISCRIPTION

UL 2279 Electrical Equipment for Use in Class I, Zone 0, 1, and 2

Hazardous (Classified) Locations

UL 2601-1 Medical Electrical Equipment; Part 1: General Requirements

UL 3101-1 Electrical Equipment for Laboratory Use; Part 1: General

Requirements

UL 3101-2-20 Electrical Equipment for Laboratory Use; Part 2: Laboratory

Centrifuges

UL 3111-1 Electrical Measuring and Test Equipment; Part 1: General

Requirements UL 6500 Audio/Video and Musical Instrument
Apparatus for Household, Commercial, and Similar General Use

UL 60335-1 Household & Similar Electrical Appliances, Part 1: General

Requirements

UL60335-2- Household & Similar Electrical Appliances, Part 2: Particular

34 Requirements for MotorCompressors

UL 60950 Instformation Technology Inument

(Table 1.1)

1.2 OBJECTIVE

1.2.1 Electrical safety testing is essential to ensure safe operating standards for
any product that uses electricity. Various governments and agencies have

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developed stringent requirements for electrical products that are sold world-wide.
In most markets it is mandatory for a product to conform to safety
standards promulgated by safety and standard agencies such as
UL, CE, VDE,CSA, BSIand so on. To conform to such standards, the product
must pass safety tests such as the high voltagetest (also called as Dielectric
voltage-withstand test or high potential test), Insulation Resistance Test, Ground
(Earth) Bond & Ground Continuity Test & Leakage Current Test (also called as
Line Leakage Test, Earth Leakage Current Test, Enclosure Leakage Current Test
or Patient Leakage Current Test).

In general, IEC 60335 is the most widely applied standard for electrical safety
testing, especially for domestic appliances. Many safety testing standards in the
world have been based on it. To safeguard workplace health and safety, many
sections of the Occupational Health and Safety Regulation provide guidelines on
electrical safety and the appropriate equipment required to work on low and high
voltage electrical appliances.

1.2.2When Is Safety Testing Required?

Making a product “safe” requires an understanding of the “hazards” that exist in

each electrical product. Certain potential hazards are inherent in all electrical
products because of the manner in which they are powered and how they perform
their intended functions. Even though a product requires an electrical power
source and uses electrical or electronic components, it should not present an
electrical shock hazard to the user. Four fundamental hazards must be evaluated as
part of any product safety evaluation:
• Electrical shock
• Mechanical/physical injury
• Low voltage/high energy
• Fire

1.3 CALIBRATION

Calibration of an instrument is the process of determining its accuracy. The

process involves obtaining a reading from the instrument and measuring its
variation from the reading obtained from a standard instrument. Calibration of an

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instrument also involves adjusting its precision and accuracy so that its readings
come in accordance with the established .

1.3.1What is Equipment Calibration?

Calibration of equipment needs to be carried out on a regular basis. This is

because instruments tend to deviate owing to hard operating conditions,
mechanical shocks or exposure to extreme temperature or pressure. Frequency of
calibration would depend on the tolerance level. When the objective of the
measurement is critical calibration would need to be carried out more frequently
and with great accuracy.

To assure accuracy in instrument calibration, it is vital to ensure that each

component of the measuring instrument is conforming to its specified standard.
Regular equipment calibration carried out in a set format helps you obtain valid
data and operate in a safe working environment.

1.3.2Types of Calibration

Instrument calibration can be carried out on different types of instruments across

sectors. Discussed here are some of most frequently performed types of
calibration services.

 Pressure Calibration :This is one of the most frequently performed types of

equipment calibration. Under pressure calibration service gas and hydraulic
pressure are typically measured across a variety of sectors. Various types of
pressure balances and calibrators along with a number of pressure gages are
used for carrying out pressure calibration. For the purpose of pressure
calibration, it is vital that national standards be adhered to when performing
pressure calibration. Pressure instruments that are frequently calibrated
include:

Analogue Pressure Gauges

 Barometers

 Digital Indicators

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  Digital Pressure Gauges

 Test Gauges

 Transmitters

 Temperature Calibration:Temperature calibration is carried out in all

processes where temperature readings play a critical role. Temperature
calibration is carried out in a controlled environment. State-of-the-art
electrical and mechanical thermometers are available that can help in the
process of temperature calibration. Temperature measuring equipments that
require calibration on a periodic basis include:

 Chambers

 Data Acquisition Systems

 Dial Thermometers

 Infrared Meters

 PRTs and Thermistors

 Thermal Cameras

 Thermometers/Thermocouples

 Weather Stations

 Electrical calibration

Electrical calibration is required for checking the veracity of electrical instruments

across a diverse range of industries. Under electrical calibration elements such as
current frequency, resistance and voltage are checked. Ensure that calibration
process has been carried out under standards as it is considered the most credible
way. Instruments that are frequently sent for electrical calibration include:

 Clamp Meters

 Data Loggers

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  Electrical meters

 Insulation Testers

 Multi-meters

 Oscilloscopes

 Mechanical calibration:Mechanical calibration services are invoked for a

range of mechanical instruments. Under this process a number of elements
such as mass, force, dimension, angle, volume, flatness, torque and vibration
are calibrated in a temperature controlled facility. Some of the most frequently
tested instruments for mechanical calibration include:

 Accelerometers

 Load Cells & Force Gauges

 Micrometers, Verniers, Height Gauges

 Scales/Balances

 Torque Wrenches & Screwdrivers

 Weight & Mass Sets

1.3.3 Process

The exact process of equipment calibration shall vary according to the type of
instrument, how critical its role is in the operation and standards that are followed
for the calibration purpose. Mentioned below is a typical process that needs to be
followed for equipment calibration.

 Attention given to the instrument design: When carrying out calibration,

special attention should be given to the design of the instrument which is
to be calibrated.

 Follow instructions: Instructions specified for carrying out equipment

calibration should be followed closely. Deviation from instruction or use
of wrong calibrator value may result in accuracy.

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  Check tolerance value: Tolerance value of the instrument should be taken
in regard. It may be noted that every calibrator has a particular tolerance
level this is due to the normal variations in the instrumentation and quality
control process. The tolerance level will vary according to several factors
including the industry sector and even the country in which the calibration
process is to be carried out.

 Accuracy ratio: Maintaining accuracy ratio is also critical in a calibration

process. This describes the accuracy of the test standard in comparison to
the accuracy of the instrument which is to be calibrated. Ensuring at least
4:1 accuracy ratio is essential. This suggests that the accuracy of the
standard should be at least four times greater that the instrument which is
to be calculated.

 Adhering to standards: Adhering to internationally recognized standards

is vital. Hence when calibrating equipment, all standard procedures
established under nationally or internationally recognized standards need
to be followed.

 Make uncertainty analysis: Uncertainty analysis is to be taken at the end

of the calibration process. This helps to evaluate any factor that may have
affected the results of calibration.

1.3.4 Need of Equipment Calibration

Calibration of equipment is not just desirable, it is rather a necessity. All

measuring instruments, whether they are used in factories, laboratories or at home,
need to be calibrated on a periodic basis to ensure they are offering accurate
results. However, in factories and laboratories, measurement results are usually of
a critical value. Deviation from accuracy can not only affect productivity but also
cause threat to the life of workers. Hence, it is imperative that instrument
calibration be carried out carefully and at regular intervals.

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1.4 DURABILITY AND ENVIRONMENTAL TESTING

Durability testing (also known as reliability testing and environmental testing)

allows the assessment of a product's response to the physical and climatic hazards
that may occur throughout the operational life of the product. This testing
provides recognition of compliance, analysis and resolution of damage issues, and
assurance of reliability and durability.Durability / Environmental Testing
Capabilities:

 Vibration Testing:vibration test conditions allows to reproduce damage

where it is likely to occur in real life, but without introducing unrealistic
damage mechanisms. laboratories have servo-hydraulic and
electromagnetic shaker systems spanning 0.5 to 2000 Hz. 10G sine and up
to 5 Grms random depending on test item mass

 Shock Testing : laboratories are equipped with shock machines that enable
product damage boundary analysis, and vibration testing equipment to
determine product resonant frequency analysis and response. equipment is
specified to deliver synthesized shock up to 20G. Free fall shock machine
up to 500G (depending on pulse energy) .

 Climatic Testing:Certainclimatic conditions affect varying packaging

formats.laboratories are equipped with numerous floor standing, bench-top
and walk-in chambers, with thermal range -50°C to 150 °C; selected
chambers have controlled elevated humidity.

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Chapter 2: Hazards

2.1. Introduction
Application of a safety standard is intended to reduce the risk of injury or damage
due to the following:
 electric shock;
 energy related hazards;
 fire;
 heat related hazards;
 mechanical hazards;
 radiation;
 chemical hazards

Electric shock
Electric shock is due to current passing through the human body. The resulting
physiological effects depend on the value and duration of the current andhazards
the path it takes through the body. The value of the current depends on the applied
voltage, the impedance of the source and the impedance of the body. The body
impedance depends in turn on the area of contact, moisture in the area of contact
and the applied voltage and frequency. Currents of approximately half a
milliampere can cause a reaction in persons in good health and may cause injury
indirectly due to involuntary reaction. Higher currents can have more direct
effects, such as burn or muscle tetanization leading to inability to let go or to
ventricular fibrillation.

Steady state voltages up to 42,4 V peak, or 60 V d.c., are not generally regarded as
hazardous under dry conditions for an area of contact equivalent to a human hand.
Bare parts that have to be touched or handled should be at earth potential or
properly insulated.

It is normal to provide two levels of protection for USERS to prevent electric

shock. Therefore, the operation of equipment under normal conditions and after a

19
single fault, including any consequential faults, should not create a shock hazard.
However, provision of additinal protective measures, such as protective earthing
or supplementary insulation, is not considered a substitute for, or a relief from,
properly designed BASIC INSULATION. Harm may result from:

(Table 2.1.)
Harm may result from Examples of measures to reduce
risks
Contact with bare parts normally at Prevent user access to parts at
hazardous voltages hazardous voltages by fixed or locked
covers, safety interlocks, etc. discharge
accessible capacitors that are at
hazardous voltages.

. Breakdown of insulation between Provide basic insulation and connect

parts normally at hazardous voltages the accessible conductive parts and
and accessible conductive parts circuits to earth so that exposure to the
voltage which can develop is limited
because overcurrent protection will
disconnect the parts having low
impedance faults within a specified
time; or provide a metal screen
connected to protective earth between
the parts, or provide double insulation
or reinforced insulation between the
parts, so that breakdown to the
accessible part is not likely to occur.

Contact with circuits connected to Limit the accessibility and area of

telecommunication networks that contact of such circuits, and separate
exceed 42,4 v peak or 60 v d.c. them from unearthed parts to which
access is not limited
Breakdown of USER-accessible

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insulation Insulation that is accessible to the user
should have adequate mechanical and
electrical strength to reduce the
likelihood of contact with hazardous
voltages
Touch current (leakage current) Limit touch current to a specified
flowing from parts at hazardous value, or provide a high integrity
voltages to accessible parts, or failure protective earthing connection.
of a protective earthing connection.
touch current may include current
due to emc filter components
connected between primary circuits
and accessible parts

Energy related hazards Injury or fire may result from a short-circuit between
adjacent poles of high current supplies or high capacitance circuits, causing:
 Burns;
 Arcing;
 Ejection of molten metal.

Even circuits whose voltages are safe to touch may be hazardous in this respect.
Examples of measures to reduce risks include:
 Separation;
 Shielding;
 Provision of safety interlocks.

Fire Risk of fire may result from excessive temperatures either under normal
operating conditions or due to overload, component failure, insulation breakdown
or loose connections. Fires originating within the equipment should not spread
beyond the immediate vicinity of the source of the fire, nor cause damage to the
surroundings of the equipment. Examples of measures to reduce risks include:
 providing overcurrent protection;
 using constructional materials having appropriate flammability properties
for their purpose;

21
  selection of parts, components and consumable materials to avoid high
temperature which might cause ignition;
 limiting the quantity of combustible materials used;
 shielding or separating combustible materials from likely ignition
sources;
 using enclosures or barriers to limit the spread of fire within the
equipment;
 using suitable materials for enclosures so as to reduce the likelihood of
fire spreading from the equipment.

Heat related hazards Injury may result from high temperatures under normal
operating conditions, causing:
 burns due to contact with hot accessible parts
 degradation of insulation and of safety-critical components;
 ignition of flammable liquids. Examples of measures to reduce risks
include:
 taking steps to avoid high temperature of accessible parts;
 avoiding temperatures above the ignition point of liquids;
 provision of markings to warn USERS where access to hot parts is
unavoidable.

Mechanical hazards Injury may result from:

 sharp edges and corners;
 moving parts that have the potential to cause injury;
 equipment instability;
 flying particles from imploding cathode ray tubes and exploding high
pressure lamps. Examples of measures to reduce risks include:
 rounding of sharp edges and corners;
 guarding;
 provision of safety interlocks;
 providing sufficient stability to free-standing equipment;
 selecting cathode ray tubes and high pressure lamps that are resistant to
implosion and explosion respectively;
 provision of markings to warn USERS where access is unavoidable

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Radiation Injury to users and to service persons may result from some forms of
radiation emitted by equipment. examples are sonic (acoustic), radio frequency,
infra-red, ultraviolet and ionizing radiation, and high intensity visible and
coherent light (lasers). Examples of measures to reduce risks include:
 limiting the energy level of potential radiation sources; − screening
radiation sources;
 provision of safety interlocks;
 provision of markings to warn users where exposure to the radiation
hazard is unavoidable.

Chemical hazards Injury may result from contact with some chemicals or from
inhalation of their vapours and fumes. Examples of measures to reduce risks
include:
 avoiding the use of constructional and consumable materials likely to
cause injury by contact or inhalation during intended and normal
conditions of use;
 avoiding conditions likely to cause leakage or vaporization;
 provision of markings to warn users about the hazards

2.2. Hazardous voltage

Voltage exceeding 42,4 V peak, or 60 V d.c., existing in a circuit that does not
meet the requirements for either a LIMITED CURRENT CIRCUIT or a TNV
CIRCUIT.

2.3. Hazardous energy level

Available power level of 240 VA or more, having a duration of 60 s or more, or a

stored energy level of 20 J or more (for example, from one or more capacitors), at
a potential of 2 V or more.

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Chapter 3: Important Features During Testing

3.1. GENERAL INSTRUCTIONS

1. Equipment under test shall be handled with care.
2. Before conducting the test the relevant specification , circuit, operating
manuals, safety relevant marking and environmental conditions should be
studied carefully.
3. Unless otherwise specified in this standard the test shall be made on a
single sample of equipments or parts which complied with all the relevant
tests.
4. Except where specific test conditions are stated elsewhere in this standard
and where it is cleared that there is a significant impact on the results of
the test, the test shall be carried out under the least favorable combination
within the manufacturers operating specification/reference test condition
like supply voltage, supply frequency, physical location of the equipments
and position of movable parts, operating mode adjustment of thermostats
and regulating device and polarity of dc operated equipment.
5. For the electrical requirements of this standard conducting liquids shall be
treated as conductive parts.
6. Before using all the equipments for testing, it shall be checked for their
validity for the calibration .

(Table3.1) MARKING SYMBOLS

Mark Description
VDE
The VDE Mark indicates conformity with the VDE standards or
European or internationally harmonized standards resp. and
confirms compliance with protective requirements of the
applicable EC Directive(s). The VDE Mark is a symbol for
electrical, mechanical, thermal, toxic, radiological and other
hazards.
For appliances in compliance with standards for
electromagnetic compatibilityThe VDE EMC Mark expresses

24
the conformity of a product with applicable standards for
electromagnetic compatibility. The reliable function of the
product in its electromagnetic environment is also included.
For cables, insulated cords, installation conduits and ducts,
the VDE Cable Mark is applicable.

For cables and cords, the VDE Identification Thread may be used.
Underwriters Laboratories Inc.
UL Listing Mark
This is one of the most common UL Marks. If a product carries
this Mark, it means UL found that samples of this product met
UL's safety requirements.. This type of Mark is seen commonly
on appliances and computer equipment, furnaces and heaters,
fuses, electrical panelboards, smoke and carbon monoxide
detectors, fire extinguishers and sprinkler systems, personal
flotation devices like life jackets and life preservers, bullet
resistant glass, and thousands of other products.
C-UL Listing Mark
This mark is applied to products for the Canadian market. The
products with this type of mark have been evaluated to Canadian
safety requirements, which may be somewhat different from U.S.
safety requirements. This type of Mark on appliances and
computer equipment, vending machines, household burglar
alarm systems, lighting fixtures, and many other types of
products.
Classification Mark
This mark appears on products which UL has also evaluated.
Products carrying this mark have been evaluated for specific
properties, a limited range of hazards, or suitability for use under
limited or special conditions.. Examples of types of equipment
Classified by UL include immersion suits, fire doors, protective
gear for fire fighters and industrial trucks.

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Recognized Component Mark and Canadian Recognized
Component Mark
These are marks consumers rarely see because they are
specifically used on component parts that are part of a larger
product or system. These components may have restrictions on
their performance or may be incomplete in construction. The
Component Recognition marking is found on a wide range of
products, including some switches, power supplies, printed
wiring boards, some kinds of industrial control equipment and
thousands of other products. Products intended for Canada carry
the Recognized Component mark "C."
International "emc-Mark"
The International "emc-Mark" appears on products meeting the
electromagnetic compatibility requirements of Europe, the
United States, Japan, Australia, or any combination of the four.
In the United States, some types of products can't be sold without
proof of compliance to U.S. electromagnetic compatibility
requirements. The types of products that are subject to EMC
testing include medical and dental equipment, computers,
microwave ovens, televisions, radios, transmitters, and radio-
controlled equipment.

26
CSA International
The CSA mark may appear alone or with indicators. If it appears
alone, it means that the product is certified for the Canadian
market, to the applicable Canadian standards.
CGA"Script"
The Canadian Gas Association (CGA) "Script" for components
of gas appliances and other liquid petroleum products indicates
certification to applicable Canadian standards.
A.G.A. Blue Star
The American Gas Association (A.G.A.) "Blue Star" mark for
gas appliances and other liquid petroleum products indicates
certification to applicable U.S. standards.
CSA Blue Star
The CSA Blue Star Mark for gas appliances and other liquid
petroleum products indicates certification to applicable U.S.
standards.
CSA Blue Flame
The CSA Blue Flame Mark for gas appliances and other liquid
petroleum products indicates certification to applicable Canadian
standards.

NEMKO
Shows that the product is Safety Certified and when relevant, that
the product is also compliant with the EMC Directive.The well-
known N-mark is a certification mark based on Nemko's own
testing or results from testing performed by often labratory
according to multi-national or bi-lateral agreement or by otherwise
Nemko accepted labratories including all authorized
manufacturers. The mark itself signifies that Nemko has tested or
certified the product according to national standards official safety
regulations in Norway. (which in principle are aquivalent to those
of the other European EU/EEA states)
DEMKO

27
DEMKO's D-Mark represents electrical product safety for a great
majority of consumers.
The D-Mark demonstrates that, from a safety point of view, the
tested product complies with:

 Harmonised standards, e.g. EN/HD

 International standards, e.g. IEC
 National standards, e.g. DS
 Other national standards e.g. American National or UL
Standards
 Other relevant parts of the above-mentioned standards
which form part of the basis for certification e.g. National
Deviations.

FIMKO
The SGS Fimko FI mark is a well-known and respected impartial
certification mark indicating the safety and quality of a product..
The FI mark can appear on the certified product, in the User’s
Manual and Installation Guide, in product catalogues and, for
example in newspaper, TV and radio advertisements.) More
information about the use of the FI mark can be found in
FIMKO’s FI handbook and on a diskette which can be obtained
free of charge.
SGS Fimko’s EMC mark can be granted to all products which are
in accordance with European standards, for example household
appliances, switches for household appliances, lighting fittings,
measurement instruments, electromedical equipment, IT
equipment, office machines, hand-held tools and consumer
electronics.
SEMKO
The S marking, which is volontary today, means that SEMKO as
an impartial testing laboratory certifies that the product fulfils
valid safety requirements.
The safety requirements include checking of e.g.

 electrical safety
 fire protection
 mechanical hazards
 radiation risks, e.g. of CD players and solaria

28
VARIOUS

The CE-marking is the manufacturer's statement to the EU

authorities that his product complies with all relevant CE-marking
Directives. It is important to emphasise that the CE-marking is not
a quality mark or a guarantee to consumers in EU.
The manufacturer is always responsible - within or outside EU -
for CE-marking. If the manufacturer is not located in EU, he can
authorise a representative located in EU who thus becomes
responsible for CE-marking
ENEC is an abbreviation for "European Norms Electrical
Certification". These four letters are part of the registered trade
mark that demonstrates that a product has been certified by one of
the national certification institutes in Europe. Today, there are 18
certification institutes who are signatories to the agreement. Apart
from the ENEC Mark itself, there is also a two digit number that
indicates which certification body has issued the ENEC
Certificate.
The ENEC Agreement was originally (in 1991 under the name,
the LUM Agreement) started with a view to providing
manufacturers of luminaires with a joint European certification
mark to replace all the different national marks. In 1999, the
agreement was expanded to include:

 Lighting
 Components for lampholders
 IT
 Electric office equipment
 Safety isolating transformers
 Isolating transformers and separating transformers
 Power supply units
 Switches

29
The GS-Mark is the German national mark that demonstrates that
a product has been tested and found to comply with the standards
for the product. The GS-Mark is very well recognised by German
consumers; so well recognised that certain products are nearly
impossible to sell without the GS-Mark.
For manufacturers and importers wishing to sell their electrical
products in Germany, it is a good idea to have a GS-Mark. There
are three particular areas where a GS-Mark is nearly a necessity:
tools, IT equipment and electromedical equipment.
Manufacturers of tools often have a hard, if not impossible, time
selling their products in Germany without a GS-Mark because
such marking is supported by consumers and the trade unions. IT
equipment is also effected by the requirement for GS-Marking;
the mark is a requirement if you wish to sell major companies or
institutions.
The third area where the GS-Mark is particularly important is
electromedicine because a GS-Mark is a prerequisite for a grant to
the institution in question from the German authorities.
ETL Listed Mark
ETL Listed Mark represents compliance to United States and/or
Canadian product safety standards. You will find the ETL Listed
Mark on electrical-gas-, or oil- fired products.

ENERGY STAR is the symbol for energy efficiency. It's a label --

created by the U.S. Environmental Protection Agency and the
U.S. Department of Energy -- to help consumers save money and
prevent air pollution. An appliance or product with the ENERGY
STAR label means that it's in the top of its class for energy
efficiency.

30
3.2. Marking
1. Maker's or responsible vendor's name, trade mark or identification mark;
2. Model number or type reference;
3. The symbol for class ii for apparatus without functional earth
for class ii apparatus with functional earth
4. Nature of supply:
– a.c. Only with the symbol:
– d.c. Only with the symbol:
– a.c. Or d.c. With the symbol:
– for three-phase systems;
5. Rated supply voltage or range of the rated supply voltages which can be
applied without operating a voltage setting device. Apparatus which can be set
to different rated supply voltages or ranges of rated
supply voltages shall be so constructed that the indication of the voltage or
range of voltages to which the apparatus is set, is discernible on the apparatus
when ready for use. A solidus shall be used for user selectable ratings, for
example “110/230 v” and a hyphen shall be used for a rating range, for
example “110-230 v”;
6. Rated current consumption or rated power consumption of apparatus which
can be supplied by supply apparatus for general use. As an alternative the
information may be given in the instruction manual. The measured
consumption at rated supply voltage shall not exceed the marked value by
more than 10 %;
7. Rated current consumption or rated power consumption for apparatus intended
for connection to an a.c. Mains supply. The measured consumption at rated
supply voltage shall not exceed the marked value by more than 10 %.

3.3.Selection of Electrical Test Instruments

Electrical standards specify protection from currents at levels well above a

system's rated capacity. Without this additional protection, transient overvoltages,
which are becoming increasingly common, can lead to equipment failure and
serious injury or death.

31
 Minimizing such risks requires that everyone working in electrical environments
has safety equipment as required. They need correctly rated gloves, eye
protection, and electrical test instruments that provide appropriate protection.
Having the correct electrical test and measurement instruments and using the
correct procedures can improve job safety.

In connection with this, a quick review of the four category (CAT) ratings is in
order:

Category I — typically covers electronic equipment. Signal level for

telecommunications, electronic equipment, and low-energy equipment with
transient-limiting protection. The peak impulse transient range is from 600 to
4,000 volts with a 30-ohm source.

 Protected electronic equipment

 Equipment connected to (source) circuits in which measures are taken to limit
transient overvoltages to an appropriately low level
 Any high-voltage-low-energy source derived from a high-winding resistance
transformer, such as the high-voltage section of a copier.

Category II — single-phase receptacle connected loads. Local level for fixed or

non-fixed powered devices – everything from lighting to appliances to office
equipment. Also, all outlets at more than 10 m (30 feet) from Category III sources
and all outlets at more than 20 m (60 feet) from Category IV sources. The peak
impulse transient range is from 600 to 6,000 volts with a 12-ohm source.

 Appliance, portable tools and other household and similar loads

 Outlet and long branch circuits
 Outlets at more than 10 metres from CAT III source
 Outlets at more than 20 metres from CAT IV source

Category III — three-phase distribution, including single-phase commercial

lighting; distribution level-fixed primary feeders or branch circuits. These circuits
are usually separated from Category IV (whether utility service or other high-
voltage source) by a minimum of one level of transformer isolation; for example,
feeders and short branch circuits, distribution branch panels and heavy appliance

32
 outlets with "short" connections to service entrance. The peak impulse transient
range is from 600 to 8,000 volts with a 2-ohm source.

 Equipment in fixed installations, such as switchgear and polyphase motors

 Bus and feeders in industrial plants
 Feeders and short branch circuits, distribution panel devices
 Lighting systems in larger buildings
 Appliance outlets with short connections to service entrance

Category IV — three-phase at utility connection, any outdoor conductors or

primary supply level. It will cover the highest and most dangerous level of
transient overvoltage you are likely to encounter-in utility service to a facility both
outside and at the service entrance, as well as the service drop from the pole to the
building, the overhead line to a detached building, and the underground line to a
well pump. The peak impulse transient range is from 600 to 12,000 volts with a
less than 1-ohm source.

 “Origin of installations,” such as where low-voltage connection is made to

utility power
 Electricity meters, primary overcurrent protection equipment
 Outside and service entrance, service drop from pole to building, run between
meter and panel
 Overhead line to detached building, underground line to well pump

3.3.1.Overvoltage categories

 overvoltage category IV : use at the origin of the installation. for equipment

installed at or near the origin of the electrical supply to a building,
between the building entrance and the main distribution board.
Example: Electricity meters and primary overcurrent protection equipment.

 overvoltage category III : is for equipment intended to form part of a building

wiring installation. Such equipment includes socket outlets, fuse panels, and
some MAINS installation control equipment.
1. in fixed installations

33
 2. cases where the reliability and the availability of the equipment is subject
to requirement.

Example: industrial use with permanent connection to the fixed installation.

 overvoltage category II : energy-consuming equipment to be supplied from

the fixed installation. Both to plug-connected equipment and to
PERMANENTLY CONNECTED EQUIPMENT. Examples: appliances,
portable tools and other household and similar loads

[If such equipment is subjected to special requirements with regard to reliability

and availability, overvoltage category III applies.]

 overvoltage category I: equipment for connection to circuits in which

measures are taken to limit transient overvoltages to an appropriately low
level.

3.3.2.Pulltion degrees

Numeral indicating the level of POLLUTION that may be present in the

environment

 POLLUTION DEGREE 1: no POLLUTION or only dry, non-conductive

POLLUTION occurs, which has no influence.

 POLLUTION DEGREE 2: only non-conductive POLLUTION occurs except

that occasionally a temporary conductivity caused by condensation is
expected.

 POLLUTION DEGREE 3 : conductive POLLUTION occurs, or dry, non-

conductive POLLUTION occurs which becomes conductive due to
condensation which is expected
NOTE: In such conditions, equipment is normally protected against exposure
to direct sunlight, precipitation, and full wind pressure, but neither
temperature nor humidity is controlled.

34
 POLLUTION DEGREE 4: continuous conductivity occurs due to conductive
dust, rain or other wet conditions.

3.3.3.Classes of insulation

 Class I :Equipment where protection against electric shock is achieved by:

a) using basic insulation, and also
b) providing a means of connecting to the protective earthing conductor in the
building wiring those conductive parts that are otherwise capable of assuming
hazardous voltages if the Basic Insulation fails.

 Class II: Equipment in which protection against electric shock does not rely
on basic insulation only, but in which additional safety precautions, such as
double insulation or reinforced insulation, are provided, there being no
reliance on either protective earthing or installation conditions

 Functional isolation : isolation on appliance inlet and switch .

When isolation is used to enable the system to function properly, but not
necessarily to serve as a barrier against shock, it is called functional
isolation.

35
Chapter 4: Terminologies Used

4.1.D.C. mains supply

D.C. power distribution system, with or without batteries, external to the
equipment, for
supplying power to D.C. powered equipment, excluding the following:
 a D.C. supply providing power over telecommunication network wiring to
remote
equipment;
 a limited power source whose open circuit voltage is less than or equal to
42,4V D.C.;
 D.C. supply whose open circuit voltage is greater than 42,4 V D.C. and less
than or equal to 60 V D.C., and whose available power output is less than
240 VA

Circuitry connected to a DC MAINS SUPPLY is considered to be a

SECONDARY CIRCUIT.

4.2.A.C. mains supply

A.C. power distribution system external to the equipment for supplying power to
a.c.powered
equipment These power sources include public or private utilities and, unless
otherwise specified in the standard, equivalent sources such as motor-driven
generators and uninterruptible power supplies.

4.3. Mains supply

power distribution system that is either an AC or a DC mains supply

4.4. Rated voltage

supply voltage (for a three-phase AC mains supply, the line-to-line voltage) from
which the equipment is to be operated as declared by the manufacturer rated
voltage range supply voltage range as declared by the manufacturer, expressed by

36
its lower and upper rated voltages .This means that the equipment is designed to
be connected to anAC mains supply having any voltage between 220 V and 240
V.

4.5 Rated current

input current of the equipment as declared by the manufacturer rated frequency
supply frequency as declared by the manufacturer

4.6. Rated frequency

Range supply frequency range as declared by the manufacturer, expressed by its
lower and upper rated frequencies operating conditions.

4.7.Normal load
Mode of operation, used for testing purposes, which represents as closely as
possible the most severe conditions of normal use which can reasonably be
expected If the conditions of actual use can reasonably be expected to be more
severe than the maximum load conditions recommended by the manufacturer,
including rated operating time and rated resting time, a mode of operation is used
that represents these more severe conditions.

4.8.Rated operating time

maximum operating time assigned to the equipment by the manufacturer

4.9.Rated resting time

Minimum time, assigned by the manufacturer, during which the equipment is
switched off or running idle between periods of rated operating time

4.10.Classes of equipment

 Class I equipment equipment where protection against electric shock is

achieved by
 using basic insulation

37
  providing a means of connection to the protective earthing
conductor in the building wiring those conductive parts that are
otherwise capable of assuming hazardous voltages if the basic
insulation fails note class I equipment may have parts with double
insulation or reinforced insulation.

 Class II equipment equipment in which protection against electric shock
does not rely on basic insulation only, but in which additional safety
precautions, such as double insulation or reinforced insulation are provided,
there being no reliance on protective earthing

 Class III equipment equipment in which protection against electric shock

relies upon supply from selv circuits and in which hazardous voltages are not
generated .

4.11.Primary circuit
circuit that is directly connected to the AC mains supply It includes, for example,
the means for connection to the AC mains supply, the primary windings of
transformers, motors and other loading devices.

4.12.Secondary circuit
circuit that has no direct connection to a primary circuit and derives its power
from a
transformer, converter or equivalent isolation device, or from a battery.

4.13.ELV circuit
Secondary circuit with voltages between any two conductors of the circuit, and
between any
one such conductor and earth , not exceeding 42,4 v peak, or 60 v d.c.,
undernormal operating conditions, which is separated from hazardous voltage by
basicinsulation, and which neither meets all of the requirements for an selv circuit
nor meets allof the requirements for a limited current circuit

38
4.14.SELV circuit
Secondary circuit that is so designed and protected that under normal operating
conditions
and single fault conditions, its voltages do not exceed a safe value.The limit
values of voltages under normal operating conditions and single fault conditions
are :

General requirements
SELV circuits shall exhibit voltages that are safe to touch both under normal
operating conditions and after a single fault. If no external load is applied to the
SELV circuit (open circuit), the voltage limits shall not be exceeded.

Voltages under normal conditions

In a single SELV circuit or in interconnected SELV circuits, the voltage between
any twoconductors of the SELV circuit , and between any one such conductor and
earth, shall not exceed 42,4 V peak, or 60 V d.c., under normal operating
conditions.

NOTE 1a circuit that meets the above requirements, but that is subject to
overvoltages from a
telecommunication network or a cable distribution system, is a TNV-1 circuit.

NOTE 2 For normal conditions, the SELV circuit voltage limit is the same for an
ELV circuit; an SELV circuitmay be regarded as an ELV circuit with additional
protection under fault conditions.

Voltages under fault conditions

the voltagesbetween any two conductors of the SELV CIRCUIT or CIRCUITS
and between any one suchconductor and earth shall not exceed 42,4 V peak, or 60
V d.c for longer than 200 ms. Moreover, the voltage shall not exceed 71 V peak
or120 V d.c peak.
For voltages having a repetitive nature after a fault (for example, from power
supplies in

39
"hiccup" mode), additional pulses exceeding V1 (but not exceeding V2) are
permitted under
the following conditions:
− ift1 ≤ 20 ms, t2 shall be greater than 1 s;
− ift1 >20 ms, t2 shall be greater than 3 s;
− t1 shall not exceed 200 ms
SELV circuit obtains its supply conductively from a secondary circuit that is
separated
from a hazardous voltage circuit by either:
 double insulation or reinforced insulation;
 an earthed conductive screen that is separated from the hazardous voltage
circuit by
basicinsulation,theselv circuit shall be considered as being separated from the
hazardous voltage circuitby the same method.

(Figure 4.1)

4.15.Limited current circuit

40
circuit that is so designed and protected that, under both normal operating
conditions and
single fault conditions, the current that can be drawn is not hazardous.

4.16.TNV circuits
TNV circuit that is in the equipment and to which the accessible area of contact is
limited and that is so designed and protected that, under normal operating
conditions and single fault conditions , the voltages do not exceed specified limit
values. A TNV circuit is considered to be a secondary circuit in the meaning of
this standard.

TNV-1 CIRCUIT TNV CIRCUIT

 whose normal operating voltages do not exceed the limits for an SELV
circuit under normal operating conditions and
 on which overvoltages from telecommunication networks and cable
distribution systems are possible.

TNV-2 CIRCUIT TNV CIRCUIT

 whose normal operating voltages exceed the limits for an SELV circuit
under normal operating conditions and
 which is not subject to overvoltages from telecommunication networks

TNV-3 CIRCUIT TNV CIRCUIT

 whose normal operating voltages exceed the limits for an SELV circuit
under normal operating conditions and
 on which overvoltages from telecommunication networks and cable
distribution systems are possible
NOTE: Limits of TNV-2 or TNV-3: Continuous voltages, combination
of AC and DC values, are such that :

41
4.17.Working voltage highest voltage to which the insulation or the component
under consideration is, or can be, subjected when the equipment is operating
under conditions of normal use.

4.18.Functionalearthingearthing of a point in equipment or in a system, which is

necessary for a purpose other than safety.
where terminals for the connection of a supply are provided on a component (for
example,
a terminal block) or subassembly (for example, a power supply unit), the symbol

is permitted for the protective earthing terminal instead of ;

− on subassemblies or components, the symbol is permitted in place of the
symbo l
provided that it does not give rise to confusion.
4.19.Touch current electric current through a human body when it touches one or
more accessible parts.
4.20.Power interface AC power distribution systems AC power distribution
systems are classified as TN-C, TN-C-S, TN-S, TT or IT.
The system codes used have the following meaning:
 First letter: relationship of the power distribution system to earth;
 T means direct connection of one pole to earth,
 I means system isolated from earth, or one point connected to earth
through an impedance.
 Second letter: earthing of the equipment;
 T means direct electrical connection
 N means direct electrical connection of the equipment to the
earthed point of the power distribution system (in a.c. systems, the
earthed point of the power distribution system is normally the
neutral point or, if a neutral point is not available, a phase
conductor).
 Subsequent letters if any: arrangement of neutral and protective
conductors;

42
  S means the protective function is provided by a conductor
separate from the neutral or from the earthed line (or in a.c.
systems, earthed phase) conductor,
 C means the neutral and protective functions are combined in a
single conductor

4.21.Input current The steady state input current of the equipment shall not
exceed the rated current by more than 10 % under normal load.
4.22.Neutral conductor The neutral conductor, if any, shall be insulated from
earth and from the BODY throughout the equipment as if it were a line conductor.
Components connected between neutral and earth shall be rated for the line-to-
neutral voltage.

43
Chapter 5: Testing Instrument Review

5.1.High Voltage Test (Dielectric Voltage-withstand Test)

This test is carried out by applying a significantly higher than operating voltage to
the device under test. In this test, the insulation of a product, stressed to a greater
extent than under normal operating conditions, should not be breached for the
product to pass. In most cases, the device is stressed to twice its normal operating
voltage. During type testing, i.e. testing during designing a product or for a double
insulated product, however, much larger voltage may be applied. For all electrical
products, the high voltage test is a universal test, meaning that every unit should
pass before it can be used.

(figure 5.1)

5.2.Insulation Resistance Test

This test is to measure the total resistance of a product’s insulation by applying a

voltage of 500 V – 1000 V for low voltage systems. The minimum acceptable
value of resistance for a product to pass an insulation resistance test is 1 megohm
(1000 kΩ). The insulation resistance test is not a substitute for the high voltage
test. Many standards and safety agencies have specified this is a universal test for
all products. This test may also be carried out after every maintenance procedure
or repair.

44
 (figure5.2)

5.3.Earth Continuity Test

This test is performed by measuring the resistance between the third pin (ground)
and outside metal body of the product under test. The maximum acceptable value
is generally 0.5 ohms although certain standards may specify 0.1 ohms. This test
is generally carried out at a slightly higher current

(e.g. 25–60 A) so that the ground bond circuit maintains safe voltages on the
chassis of the product, even at a high current, before the circuit breaker trips. This
test is essential so that the product does not cause an electric shock resulting from
insulation failure. In India current specified is 16 A so the test is done at double of
the current i.e. 32 A.

Figure(5.3)

5.4.Leakage Current Test (Line Leakage Test)

This test is to measure the undesirable leakage current that flows through or across
the surface of the insulation or the dielectric of a capacitor. This test is generally
carried out at 100%-110% of the rated input voltage of the product under test. The

45
maximum acceptable limit of a leakage current is generally 210 micro amperes.
At first, this test was mandatory for medical devices only.

(table 5.1)Values for Leakage Current Limits

Class Equipment Type Maximum Leakage
Current

II Ungrounded All 0.25mA

0.75mA
I Grounded Hand-held
Movable 3.5mA
I Grounded
(Not hand-held)

Fig.3.4 earth leakage current tester

3.5.Ball pressure test

 Prepare a test specimen having thickness of at least 2.5 mm.Set the

temperature of oven to as specified in the specification, within tolerance
.Now place the test specimen support and loading device inside the
chamber and maintain it until thermal equilibrium is reached.Place the test
specimen on the approximate centre of the test specimen support so that its
upper surface is horizontal and the spherical part of apparatus is pressed
against this surface with a force of 20N.
 Gently lower the pressure ball on to the approximate centre of the test
specimen. Ensure that no conditions exist that will cause the pressure ball
to move other than in a downward direction during the test.After 1 hour,

46
 remove the pressure ball from the test specimen and within 10 s immerse
the test specimen in cold water.
 Immediately thereafter keep immersion for 6 min-2 min.Now remove the
test specimen from the water and eliminate all traces of water.Within 3
min of removal from the water measure dimension d, toone decimal place
using the profile projector or optical measuring instrumentDimensiondis
the greatest dimension across the indentation caused by the pressure ball.
 The diameter of the impression caused by the ball shall not exceed 2mm

(figure 5.4)

5.6.Determine the Temperature of Winding under Short Circuit

1. Power ‘ON’ the Micro-Ohm Meter for warm-up for some time.

2. And also power ‘ON’ the Mobile Corder .

3. Measure the room Temp. at the start of short circuiting..

4. Now select appropriate range of measurement and connect the Current

Source leads (I+ & I-) on both the Ends of naked conductor fixed on the
bench.

5. Then connect Voltage leads (U+ & U-) on both the Ends of naked conductor
fixed on the bench exact at 1 meter.

6. Press the measure button on the Micro-Ohm Meter and Record the observed
resistance in or m.

47
7. Measure the cold resistance or initial resistance of primary &Secondary
windings in turns and record their values Pri, Sec.1, Sec.2 etc.

8. Also record the Temp. T1 at the time of measrement

9. Now connect the power to the primary winding of transformer by keeping

one of the secondary winding shorted and other winding in normal load.

10. Immediately after completion of test, power off the DUT , and again measure
the resistance or Final resistance of primary & Secondary windings in turns
and record their values Pri, Sec.1, Sec.2 etc& also record the Temp. T2 at the
time of measrement.

11. Now scratch sligthly the winding wire to ensure the type of winding wire or
from available data whether winding wire used is Aluminium or Copper

12. Now calculate the temperature rise by following formulae

(equation 5.1)
where
Δt is the temperature rise of the winding;
R1 is the resistance at the beginning of the test;
R2 is the resistance at the end of the test;
k is equal to 234,5 for copper windings and 225 for aluminium windings;
t1 is the room temperature at the beginning of the test;
t2 is the room temperature at the end of the test.

5.7.Heat Deflection Test

1. Prepare a test specimen having thickness of at least 4 mm x 10mm x 80 mm.
2. Measure dimensions b and h to the nearest 0,1 mm and dimension L to the
nearest 0,5 mm.
3. Now calculate the applied force by one of the following formulae

48
 (equation 5.2)
where
F is the load, in newtons;
 is the flexural stress, in megapascals, at the test-specimen surface;
B is the width, in millimetres, of the test specimen;
H is the thickness, in millimetres, of the test specimen;
L is the span, in millimetres, between the supports.
1. Set the temperature of Vicat Tester to 130 2 C’.
2. If specimen flat wise, set the span between support 64 mm and centrally
place one specimen each one of the plateform.
3. Now apply the load on each specimen by calculated load.
4. Immerse the platefom side the oil bath and slowly align the dial gauge
micrometer to zero..
5. As the temperature start increasing towards set temp. , needle of dial gauge
unit keep on moving.

Keep oneye on the dial gauge & as well as changing temp

Record the reading of both which come first whether the standard deflection or
standard temp.

(figure5.5)

49
5.8.Clearances, Creepage distance and Solid insulation
In allocation of the equipment to an installation category, the following factors
shall be taken into account
● Overvoltages which can enter the equipment from outside across the terminals.
● Overvoltages generated in the equipment itself and occurring at the terminals.
5.8.1.Insulation parameters
The following insulation parameters apply to:
 Installation category I : Equipment is intended for use only in appliances
or installation parts, in which no overvoltages can occur. Equipment in
this installation category in normally operated at extra low voltage.
 Installation category II : Equipment is intended for use in installations or
parts of installations, in which lightning overvoltages need not be
considered. Overvoltages caused by switching must be taken into account.
This includes for example domestic appliances.
 Installation category III: Equipment is intended for use in installations or
parts of installations, in which lightning overvoltages need not be
considered, but which are subject to particular requirements with regard to
the safety and availability of the equipment and its supply systems. This
includes equipment for fixed installation such as protective devices,
relays, switches and sockets.
 Installation category IV: Equipment is intended for use in installations or
parts of installations, in which lightning overvoltages must be taken into
account. This includes equipment for connection to overhead lines such as
omnidirectional control receivers and meters.

For circuits or parts of circuits inside the equipment, clearances may be

dimensioned directly for the expected overvoltages. If the expected overvoltages
are not impulse voltages but DC or AC voltages, the maximum value of these
voltages shall be determined as the rated impulse withstand voltage for clearances
both for homogeneous and inhomogeneous field. Degree of pollution:
 Pollution degree 1: No pollution or only dry, non-conductive pollution
occurs. The pollution has no influence.
 Pollution degree 2: Only non-conductive pollution occurs. A temporary
conductive caused by condensation must be expected occasionally.

50
[The degrees of pollution 3 and 4 are in this case not considered, as they are not
relevant for the connectors shown in this catalogue].
5.8.2.Clearance: The clearance is defined as shortest distance through the air
between two conductive elements. Clearance.

(figure5.6)

To identify the clearance distance

● Define the installation category
● Define the degree of pollution expected
● Select the rated impulse withstand voltage from table 00.01
● Select the minimum required clearance from table
Voltage can be used, if the clearance, the installation category and the degree of
pollution are known:

(table 5.2)

Clearance Installation Degree of Voltage

Category category pollution
phase-to-earth
1.2 mm II 2 150 V
3.0 mm II 2 600 V
4.5 mm II 2 600 V

5.8.3.Creepage: The creepage is defined as shortest distance on the surface of an

insulating material between two conductive elements.

(figure5.7)

51
To identify the creepage distance
● Define the installation category
● Define the degree of pollution expected
● From the nominal voltage and the type of supply system select the rated voltage
from table 00.03 a/b
● From the rated voltage and degree of pollution select the minimum creepage
required in table 00.04 [For the dimensioning of the creepage distance the tracking
formation of the insulating material has to be considered. If not indicated contrary,
the CTI value of the insulating material is III a/b].
voltage can be used, if the creepage, the installation category and the degree of
pollution are known:

(table5.3)

Creepage Installation Degree of Nominal

Category category Voltage of
supply system
1.2 mm II 2 50 V
3.0 mm II 2 220V
8.0 mm II 2 600 V

5.9.Dielectric Strength Tests

A dielectric strength test, commonly called a"dielectric withstand", "high

potential", or "hipot"test, is a stress test of the insulation of a device under test
(DUT). Such a test applies a voltageto the DUT that is much higher than normal
operating voltage, typically 1000V AC plus twice the normal operating voltage.
For a household appliance designed to operate at120 or 240V AC, the test voltage
is therefore usually about 1250 to 1500V AC. A DC hipot test can usually be
substituted for an AC hipottest.

The best voltage for a DC hipot is normally higher than the AC test voltage by a
factor of 1.414. A product that would be tested at 1500V AC would be tested at
2121V DC. For double-insulated products, the required test voltages may be much

52
higher, such as 2500 VAC or even 4000 VAC for a 120 VAC power tool. The
voltage is applied between the operating circuits and the chassis or ground (the
parts of a product that a consumer might touch or otherwise come in contact
with).The purpose of the test is to make sure that consumers do not receive an
electrical shock when they use the product, which might be caused by a
breakdown of the electrical insulation.

diaelectric strength test procedure (figure5.8)

5.9.1.Arcing

No arcing or "sparking" should occur in an insulation stress test. If it does start to

occur, the insulation is about to fail. A good tester, therefore, should detect
presence of any arcing before real damage occurs. An electrical arc is
characterized by very rapid variations in voltage and current. It also produces an
audible crackling or "zapping" sound. Because of these rapid changes, arcingcan
be detected - as soon as it starts to occur -by sensing for the presence of high
frequencyenergy. This can be accomplished through the use of an electrical filter
circuit in the tester

53
 arcing graph(figure 5.9)

5.9.2.Min/Max Current Detection or Setting Low/High Current Limits

Agency requirements specify a maximum current limit for a successful hipot test,
but they do not specify any minimum level. Omission of such a requirement,
however, means that under some conditions it is possible for a tester to pass
defective DUTs. Setting a maximum (high) current limit tells the hipot tester to
shut down when that current level is reached. Any value above the high current
limit is considered a Fail and any value below the set high limit is considered a
Pass. Setting
a minimum (low) current limit tells the hipottester to shut down if there is not the
specified minimum amount of current after the test is initiated Any value above
the low current limit is considered a Pass and any value below the set low limit is
considered a Fail.

54
 Current v/s time for minimum current test pass and fail (figure 5.10)

5.10.Leakage Current Tests

All products that use an AC line source aspower have some associated leakage
current when the device is turned on and operating. This leakage current normally
flows from the AC line source through the ground path in theproduct and back to
earth ground through theground blade on the power cord. On products without a
ground blade or those in which the ground is malfunctioning, a potential can
develop on metal surfaces of the product.

If an individual then comes in contact with the exposed metal surface, this
individual then becomes the ground path for the product.Under this condition, a
certain amount of leakage current flows through the person exposed to the metal
surface. If the leakage current is extremely low, typically less than 0.5mA, the
person should not notice he/she is in the path of the current flow. At levels higher
than this, the person can experience a startle reaction or worse. For this reason,
products that do not use a ground on the power cord generally are limited to a
maximum leakage current of 0.5mA or less. Products that exceed this level
normally have a ground on the power cord to conduct the leakage current back to
ground, thereby protecting a person who comes in contact with any exposed metal
on the product. Limits on leakage current are significantly less on medical
products.

The leakage current discussed here is different from the measurement of leakage
current during a dielectric withstand or hipot test. During a dielectric withstand
test, a high voltage generally greater than 1000V is applied between the hot and
neutral lines and the ground of the DUT. The leakage current is then measured. In
a leakage current test, the product is on and operating via standard line voltage,
such as 120VAC. The leakage current is then measured using a special circuit that
simulates the impedance of the human body.

5.11.Glow Wire Test

55
Test procedure to simulate the effect of thermal stresses which may be produced
by heat sources such as glowing elements or overloaded resistors, for short
periods, in order to assess the fire hazard by simulation technique.
The test specimen is considered to have satisfactorily withstood the test if there is
no ignition of the test specimen, or
a) if flames or glowing of the test specimen extinguish within 30 s after removal
of the glow wire and
b) there is no ignition of the wrapping tissue.

(figure5.11)Glow wire test

5.12.Cables Testing
5.12.1.Polyvinyl chloride compound (PVC)[ insulating and sheathing
materials]
Combination of materials suitably selected, proportioned and treated, of which the
characteristic constituent is the plastomer polyvinyl chloride or one of its
copolymers. The same term also designates compounds containing both polyvinyl
chloride and certain of its polymers.
5.12.2.Definitions relating to the tests
 Type tests (symbol T)

Tests required to be made before supplying a type of cable covered by this

standard on a general commercial basis in order to demonstrate satisfactory
performance characteristics to meet the intended application. These tests are of
such a nature that, after they have been made, they need not be repeated unless
changes are made in the cable materials or design which might change the
performance characteristics.
 Sample tests (symbol S)

56
Tests made on samples of completed cable or components taken from a completed
cable, adequate to verify that the finished product meets the design specifications.
Rated voltage
U○ being the r.m.s value between any insulated conductor and "earth" (metal
covering of the cable or the surrounding medium);
U being the r.m.s value between any two-phase conductors of multicore cable or
of a systemof single-core cables.
5.12.3 Marking
Cables shall be provided with an indication of the manufacturer, which shall be
either an identification thread or a repetitive marking of the manufacturer's name
or trade-mark.
Cables for use at a conductor temperature exceeding 70°C shall also be marked
either with the code designation or with the maximum conductor temperature.
Marking may be printed or by reproduction in relief on or in the insulation or
sheath. Each specified mark shall be regarded as continuous if the distance
between the end of the mark and beginning of the next identical mark does not
exceed
-550mm if the marking is on the outer sheath of the cable;
-275mm if the marking is
a) on the insulation of an unsheathed cable;
b) on the insulation of sheathed cable;
c) on a tape within a sheathed cable.
5.12.4.Legibility
All marking shall be legible .The colours of the identification threads shall be easy
to recognize or safety made recognizable, if necessary, by cleaning with petrol or
other suitable solvent.
5.12.5.Core identification
Ientification of the cores of a cable shall be achieved by the use of coloured
insulation or other suitable method. Each core of a cable shall have only one
colour, except the core identification by combinations of the colours green-and-
yellow.The colours red, grey, white and when not in combination, green and
yellow, shall not be used for any multicore cable.Colours scheme
The preferred colour scheme for flexible cables and single-core cables is :
(table 5.4)

57
Cable type Color
single-core cable no preferred cable colour scheme
two-core cable no preferred colour scheme
three-core cable either green-and-yellow, light blue,
brown, or light blue, black brown;

four-core cable either green-and-yellow, light blue,

black, brown, or light , blue, black,
brown, black or brown

five-core cable either green-and-yellow, light blue,

black, brown, black or brown, or light
blue, black, brown, black or brown

5.12.6. Filter
For each type of cable, the particular specificationspecify whether that cable
includes filters or whether the sheath or inner covering may penetrate between the
cores, thus forming a filling.
The filters shall fill the spaces between the cores giving the assembly a practically
circular shape. The filters shall not adhere to the cores. The assembly of cores and
filters may be held together by a film or a tape.
5.12.7 Thickness
The mean value of the thickness shall not be less than the specified value for each
type and size of cable shown in the tables of particular specifications However,
the thickness at any place may be less than the specified value provided that the
difference does not exceed 0.1mm+ 15% of the specified value, unless otherwise
specified

Cable tests
(table 5.5)

Sl. Test Discription

No.
1 Electric test
1.1 Resistance of
conductor
1.2 Voltage test at 2500v
1.3 Insulation resistance  Immerse specimen in water at 70◦C
at 70◦C for 1 hour.
 Set the IR voltage between 80V to
1000V.

58
  Set Min. IR value 2MΩ.
 Value of insulation is calculated by
R= 0.0367*log10(D/d)
2 Provision covering constructional and dimensional characteristics

2.1 Checking the  Assembly of core(circular cord: core

compliance with shall be twisted or flat chord: shall be
constructional laid parallel),color of insulation ,filer
provision  Calculate cross section area of
conductor A= 𝜋𝑟 2 ∗
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟𝑠.
3.1 Tensile Test before Accelerated ageing takes place in ovens using
and after ageing prescribed temperature, air flow and air
disturbance. The temperature and duration of
ageing is dependent on the type of compound
and its temperature rating, for example, a V-
90 compound will be aged at 115 ± 2°C for
504 hours.
The test consists of a comparison of the
physical characteristics (tensile and
elongation) of the compound based on before-
and after-ageing values, effectively reporting
loss in mechanical properties.

3.2 Loss of mass test  Prepare sample in dumble shape and

calculate surface area
 Place test piece for 20h at ambient
temperature and weigh (W1) after it.
 Place vertically test piece for 168h in
oven at PVC type compound
 After conditioning place test piece in
dessicator to come back in normal
condition.
 Check sample if cracked sample is
failed if not then place it in heat for
20h and weight(w2)
 Loss of mass=(w1-W2)/A mg/cm2
 Loss of mass is within 2.0mg/cm2
4 Pressure test at high
Temperature
6 Heat Shock Test Heat-shock testing is a measure of a
compound’s ability to withstand heating
under stress without cracking. In this test,
specimens are wound onto a mandrel and
heated at 150 ± 3°C for one hour. After
cooling the specimens are examined for any
cracking.

59
Chapter 6: Major Work

6.1.Switching adapter
Switching adapter is tested under IEC 60950-1 at different clauses according to
adapter manufacturing.
1. (Cl. No.1.5).Components

Components shall be complying with IEC 60950-1 or relevant component

standard. Subassemblies approved for IEC 62368-1 can be considered as
complying with this standard. Evaluation and testing of components Verified
by relevant data & tests . Interconnecting cable used which operate on SELV.
Interconnection circuit is working on SELV

Secondary circuit that is so designed and protected that under normal

operating conditions and single fault conditions, its voltages do not exceed a
safe value.The limit values of voltages under normal operating conditions and
single fault conditions.

C1, Capacitor bridging primary & secondary insulation is used which is safety
certified. Discharge of capacitors in equipment is not in primary since no
capacitor in d.c mains supply.Resistors bridging double insulation or
reinforced insulations s used between the a.c. mains supply and circuits
connected to an antenna or coaxial cable.Components used in equipment for
IT power distribution systems.

60
 Figure 6.1.1.1 internal view of adapter

2. (Cl. No.1.6).Power Interface

Considered for TN-S power distribution system. Bridging of supplementary,

double or reinforced insulation by a VDR is not used.

AC power distribution systems is Considered for TN-S power distribution

system. the protective function is provided by a conductor separate from the
neutral or from the earthed line (or in a.c. systems, earthed phase) conductor.
Neutral conductor is not given.

3. (Cl. No.1.7).Markings and Instructions

Power rating and identification markings are shown Input 130-270V, 50Hz,
50Hz, 0.3A. Power outlets on the equipment is not used. Rated voltage(s) or
voltage ranges(s) (V) are 130-270Vac. Rated current (mA or A) is 1000mA.

Figure 6.1.3.1 marking on adapter

Manufacturer’s name or trade-mark or identification mark (raion).

4. (Cl. No.2.1).Protection from electric shock and energy hazards

Overcurrent protective devices pluggable equipment type a. No tool required

to access operator access area. ozone is not produced in adapter. Isolation of

61
 multiple power sources is not needed due to single supply. Marking is durable
and legible on adapter.

5. (Cl. No.2.3).TNV circuits

TNV circuit that is in the equipment and to which the accessible area of
contact is limited and that is so designed and protected that, under normal
operating conditions and single fault conditions , the voltages do not exceed
specified limit values i.e. no TNV circuit is required.
6. (Cl. No.2.5).Limited power sources

Limited current 0.7mA peak, Peak working voltage 381V peak, RMS working
voltage 270V~ max. observed by supplying rated voltage at raped frequency.
Different current ,voltage and power ratings are are noted at by varrying
parameters to get Maximum and Minimum output voltage (V), Maximum and
Minimum output current (A) and Maximum and Minimum apparent power (VA)
values as well as r.m.s and peak values of current and voltage.

7. (Cl. No.2.6).Provisions for earthing and bonding

Functional earthing is not available due tothe Functional earthing either separated
from hazardous voltages by double or reinforced insulation or by protectively
earthed screen or conductive part separated by at least basic insulation, or safely
connected to Protective Bonding Conductorr. In adapt no such insulation is present.

8. (Cl. No.2.7).Overcurrent and earth fault protection in primary circuits

Under this clause basic requirements: The built-in device fuse provides over
current protection. OR The equipment is protected by the built-in circuit
breaker.
Short-circuit backup protection is measured from multimeter in case fault
simulated.

62
 Multimeter

9. (Cl. no. 2.8).Safety Interlocks

No safety interlock provided for moving parts, switches and relays and their related
circuits, separation distances for contact gaps and their related circuits,
electric strength test, mechanical actuators.

10. (Cl. no. 2.9). Electrical insulation

Natural rubber, materials containing asbestos and hygroscopic materials are

not used as insulation.

Humidity conditioning is tested under environmental test. This test is carried in

a chamber with Relative Humidity : (93±3)%, Temperature: 40±2ºC and
Duration : 120 Hours. This test is essential to test specimen under every climatic
conditions. This shows weather specimen will work or not in such conditions.
This requirement is important for specimen in coastal areas. For adapter RH
95%, T=40 ºC is taken.

Grade of insulation: Functional insulation(Reinforced /double insulation).

Double or reinforced insulation between the parts to be separated
11. (Cl. no. 2.10). Clearances, creepage distances and distances through
Insulation

CREEPAGE: The shortest path between two conductive parts, or between a

conductive part and the bounding surface of the equipment, measured along

63
 the surface of the insulation . One additional term that is related to these
definitions in a high voltage design is “bounding surface.”

CLEARANCE is the electrical isolation between two conductive

components, whereas the creepage indicates the conduction
of electricity across the surface of a nonconductive component.

Creepage and clearance are measured by digital vernier caliper which gives
accurate measure of distance.

Digital vernier calliper

At frequency 50 Hz Pollution degrees is measured Considered Pollution degree

I(No pollution or only dry, nonconductive pollution occurs. The pollution has
no effect.). Normal transient voltage considerd 2.5KV which will decide the
distance and degree of specimen for both creepage and clearance.

Solid insulation consider for PCB & Enclosure is Thin sheet material Used in
sealed type transformer. Uncoated printed boards are used.

12. (Cl.no. 3.1). Wiring, connections and supply

Current rating and overcurrent protection have Adequate cross sectional area of
wire used interconnecting cable (SELV Connection). Means of connection to
an a.c. mains supply is direct plug in Switching Adapter and no d.c. mains

64
 supply. Wiring terminals for connection of external conductors of switching
Adaptor is direct plug in equipment.

Appliance inlets: Are so Located that parts at hazardous voltage are not
accessible during insertion or removal of the connector, connector can be
inserted without difficulty and after insertion of the connector, the equipment is
not supported by the connector for any position of normal use on a flat surface
( appliance inlets complying with IEC 60309 or IEC 60320 considered to
comply with this requirement.

Cord anchorages and strain relief is not applicable

13. (Cl.no. 3.4). Disconnection from the mains supply

To disconnect device or a device shall be provided to disconnect the equipment

from the mains supply for servicing is direct plug in Switching Adaptor. It is not
a three phase equipment so No parts remains energized when the disconnect
devices is removed.

14. (Cl.no. 4.1). Physical Requirements

 A unit having a mass of 7 kg or more shall not fall over when tilted to an
angle of 10° from its normal upright position. Alternatively, the unit is
placed in its intended position of use on a plane, inclined at an angle of
10° to the horizontal, and then rotated slowly through an angle of 360°
about its normal vertical axis.

 A floor-standing unit having a mass of 25 kg or more shall not fall over

when a force equal to 20 % of the weight of the unit, but not more than
250 N, is applied in any direction except upwards, at a height not
exceeding 2 m from the floor.

65
  A floor-standing unit shall not fall over when a constant downward force
of 800 N is applied at the point of maximum moment to any horizontal
surface of at least 125 mm by at least 200 mm, at a height up to 1 m
from the floor.

15. (Cl.no. 4.2). Mechanical Strength

 Adequate mechanical strength with no hazards when subjected to

unexpected handling.
 Steady force test, 10 N
 Steady force test, 30 N

Above forces are applied to test specimen. Result is No damage and no

hazard.
This test is done due ed to check in any situation if specimen is pressed
under heavy weight so it will be crushed/ damaged or not.

 Fall test/ Drop test is very essential since many times movable/portable
specimens fall so it is tested weather specimen will break in short fall
or not. Hence at 4-5m of height specimen is droped.

 Stress relief test is carried out at 70 °c, for a period of 7 h. No

shrinkage or distortion occurred on switching adaptor.

16. (Cl.no. 4.3). Design and Construction

Under this clause observational study of specimen is required to check design

and construction because pointed edges or screws harm user and many other
constructions done by manufacturer to make it suitable for user.
 Edges and corners are smooth and rounded
 Direct plug-in equipment
 Torque: Maximum torque of 0.1N/m
 Flammable liquids not used

66
  No ionizing radiation generated
 Flammable liquids not used
 No Human exposure to ultraviolet radiation used
 No lasers or laser diodes used
 Low Power LED for indication

No hazardous moving part in operator access area.

17. (Cl.no. 4.5). Thermal Requirements

Yokagava temperature measurement device is used to test the temperature of

specimen. Yokagava is used for specimen which have many components to test
temperature. Specimen is given power supply . Electronic components od
specimen are attached to the wires from yokagava . These wires are made up of
copper who’s temperature will rise as per component’s and shown on screen
for different wire. This test is continued for 4 hours.

Yokagava temp. measurement devise

Adapter has limited components(battery ,resistors and plastic body) so it

measured by digital temperature meter. Components are power supplied for 1
hour. Temperature limits are noted which should be within standard limit of
every component.
Abnormal heat is given to resistance in case to check if resistance may
malfunction at high temperature or not.

18. (Cl.no. 4.7). Resistance to fire

 Reducing the risk of ignition and spread of flame

67
  Parts not requiring a fire enclosure for Motors, Transformer, PVC Cable
 Enclosure material passing the glow-wire test at 550 °C according to
IEC 60695-2-11 is acceptable as an alternative to check the cover
weather it will catch flame or not.
 Plastic materials of a FIRE ENCLOSURE located less than 13mm
through air from non-arcing parts which, under any condition of normal
or abnormal operation, could attain a temperature sufficient to ignite the
material, shall be capable of passing the test of IEC 60695-2-20.
 The average time to ignition of the samples shall be not less than 15sec.
If the sample melts through without igniting, the time at which this
occurs is not considered to be the time to ignition.

19. (Cl.no. 5.2). Electric strength

This test is carried under HVDC for dielectric test. For plastic body 1.5kv-3kv
and for metal body 1kv-2kv is supplied for 60seconds. This will show the
specimen will bear the high voltage.
During the tests no flame in the equipment, no molten metal emitted. After the
tests Meet the Electric strength test.

6.2.Test of cable

Cable test is performed under ICE 605227 for PVC unsheathed.

1. Provisional covering constructional and dimensional characteristic

This test id used for measure the Checking of the durability of colors and
markings by rubbing with wool cloth. Measurement of insulation thickness of
sheath is done by Profile projector or measuring microscope of at least 10 x
magnification.

68
 Profile Projector

A very small piece of wire is cut and put it under projector.

Small Piece Of Cable On Projector Lense

Piece is placed between the mid of the profile projector then dimensions are
taken.
Inside the piece surface is not smooth so dimensions are measured from
broad and narrow sides. Different readings are taken by rotating at 60°. 5-6
measurements are noted .Average of measured dimension should be in range
of 0.642 to 0.455mm.through this test radius is calculated which give area of
conductor(A).
𝐴 = 𝑁𝜋𝑟 2
Where N= no. of conduction wires

69
 Now wire resistance is measured
R20= Rt*Kt*1000/L

Where,
K=0.984(constant)
R20 = Resistance at 20C
Rt = Resistance at room temperaturC
Kt = Correction factor corresponding to room temperature C

Cable Resistance Measurement Device

2. Insulation resistance test

Electrical resistance of conductor is measured in Water bath. A Measuring

bridge or equivalent electronic equipment required with Thermometer or
temperature compensation to 20°C. Voltage test carried out on completed cables
at AC voltage source (AC 0...2500 V). Insulation resistance tester with DC source
between 80 V and 500 V in heatable water bath and thermometer.

As per sub clause2.4 of IEC 60227-2

IR = IR(M) x 5/1000 M .Km

Temp: 70 C for 2 hr (min. ) in water. At 500Vd.c. for five minutes between

conductor and water.

70
 Bath tub

3. Voltage test on Cores

As per sub clause2.3 of IEC 60227-2

Temp: 20C5 C for 1 hr (min. ) in water bathtub at 2000Va.c. between
conductor and to the water. Cable is attached to supply from one side and
other side is left to water for 1hr.

4. Measurement of insulation Thickness and of overall dimensions

As per sub clause 1.1 and 1.11 of IEC 60227-2

Insulation Thickness Specified value 0.7 mm and Minimum value 0.53
mm.thickness is measured by profile projector which is correlated from standard
table if more than 0.7mm or less than 0.53 mm test is fail .This test is performed
at very first then further test is performed.
5. Loss of mass, Insulation

As per sub clause 8.1 of IEC 60811-3-2

Air oven with natural air flow, airflow rate: 8...20 complete air change per
hour. Analytical balance with a sensitivity of 0.1 mg.
 Prepare sample in dumble shape and calculate surface area
 Place test piece for 20h at ambient temperature and weigh (W1) after it.
 Place vertically test piece for 168h in oven at PVC type compound
 After conditioning place test piece in dessicator to come back in normal
condition.

71
  Check sample if cracked sample is failed if not then place it in heat for 20h
and weight(w2)

a) For tubular specimens

Surface A = outer surface + inner surface + cut surface
A = 2 (D – S) x (L + S) cm2
where:
S = average thickness of the test piece, in mm
D = mean outer diameter of the test piece, in mm
l = length of the test piece, in millimetres, to one decimal place
ACore 1 = cm2 ; ACore 2 = cm2 ; ACore 3 = cm2
Loss of mass=[W = W1 - W2 (mg)orA mg/cm2] (Loss of mass is within
2.0mg/cm2 )
6. Pressure test at high temperature core/sheath

As per sub clause 8.1 of IEC 60811-3-1

a) For tubular specimens

= ………..N
where:
k is a coefficient which shall be specified in the standard for the type of cable if a
value is given, or, if a value is not specified in the cable standard, shall be k = 0.6
for flexible cords and cores of flexible cables
 = average thickness of the test piece, in mm,
D = mean outer diameter of the test piece, in mm
Impression of blade shall not exceed 50%

7. Cold Bending test (Post Measurements)

Cold bend test apparatus consisting essentially of a revolving mandrel and

guiding devices for the test pieces. Refrigerator, mandrels with different diameters
are noted in Cold elongation test for insulation .Tensile machine with a cooling
device or elongation machine installed in a cooling chamber. Number of turns 4
over a steel mandrel of 21 mm after conditioning.

72
There shall not be any cracks over insulation after pre conditioning for16 hr at –
15 C. wire is rolled over mandrel tightly and then crack is checked on insulation.
if any crack occur then test is fail otherwise fail .These cracks are due to change in
temperature %age Elongation at break shall be 20%min.

Cable rolled on mandrel

8. Cold Impact test

In this test a hammer is placed on wire rolled on mandrl and again cracks are
measured since in cold area when air or other circumstances press the wire
with force/pressure then wire will resist that or not.
There shall not be any cracks over insulation.

9. Heat shock test

Heat-shock testing is a measure of a compound’s ability to withstand heating

under stress without cracking. Cable is hang on thread for hour at 150 ± 3°C
and placed in a heat chamber. After few minute specimen is wound onto a
mandrel . After cooling the specimens are examined for any cracking.

10. Test under fire conditions

Propane gas burner, 3-sided metallic screen 1200 mm high, 300 mm wide and
450 mm deep with open front and closed top and bottom. Time taken to
diffuse the flame is calculated that will be in seconds.
Flame applied for 60Sec. (60Sec + m/25)  Sec.
Where m is mass of sample having length 650mm
After burning has seased, no affection within 50 mm from lower part of upper
clamp.

73
11. Mechanical strength of completed cable (flexing test)

According to 3.1 of IEC 60227-2.No. of Flexing test 15 000 backward and

forward movements. The carrier makes cycles (forward and backward
movements) over a distance of 1 m at an approximately constant speed of 0,33
m/s between each reversal of the direction of movement.
Multi core cables: all cores to be loaded with 1 A/mm2 100 % and loaded
current is measured.
 During the test with 15 000 backward and forward movements, i.e. 30 000
single
strokes, neither interruption of the current nor short circuit between the
conductors shall occur.
 After the test, the sample shall withstand the voltage test carried out in
accordance with 2.2 of IEC 60227-2.

12. Tensile Strength & Elongation at Break (Before & after ageing) Insulation

Accelerated ageing takes place in ovens using prescribed temperature, air flow
and air disturbance. The temperature and duration of ageing is dependent on the
type of compound and its temperature rating, for example, a V-90 compound will
be aged at 115 ± 2°C for 504 hours.

Test is done with different samples of 10mm length. copper wire is removed
from inside. The test consists of a comparison of the physical characteristics of
tensile and elongation compound based on before- and after-ageing values,
effectively reporting loss in mechanical properties.

74
This test is done in sense of climatic conditions which a wire will bear when
used.

Cable of 10mm

6.3 Printer

The sample of thermal printer , model th200i is complying with all relevant
clauses of is IS 13252 (part 1) and IEC 60950.

1. (Cl. No.1.5).component

Components shall be complying with IEC 60950-1 or relevant component

standard. Resistors bridging double or reinforced insulation between a.c.
mains and other circuits and stepper motor

75
 Internal View Of Printer PCB With Component

Components shall be complying with IEC 60950-1 or relevant component

standard. Subassemblies approved for IEC 62368-1 can be considered as
complying with this standard. Evaluation and testing of components Verified
by relevant data & tests . Interconnecting cable used which operate on SELV.
Interconnection circuit is working on SELV

Secondary circuit that is so designed and protected that under normal

operating conditions and single fault conditions, its voltages do not exceed a
safe value.The limit values of voltages under normal operating conditions and
single fault conditions.

2. (Cl. No.1.6).Power Interface

TN-S power distribution system considered for AC-DC adapter. AC power

distribution systems is Considered for TN-S power distribution system. the
protective function is provided by a conductor separate from the neutral or
from the earthed line (or in a.c. systems, earthed phase) conductor. Neutral
conductor is not given.

3. (Cl. No.1.7). Marking and instruction

Power rating and identification markings Class III appliance. Equipment in

which protection against electric shock relies upon supply from selv circuits
and in which hazardous voltages are not generated. Function of controls and
indicators are clearly identified.

Rated voltage(s) or voltage ranges(s) (V) is 24V.

Rated current (mA or A) is 2.0A

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 Marking On Printer

4. (Cl. No.2.0). Protection from electric shock and energy hazards

No access with test finger to hazardous voltage circuit. Voltages under fault
conditions are in SELV limits not exceeded under normal condition

Safety Sign

5. (Cl. No.2.3). TNV circuits

TNV circuit that is in the equipment and to which the accessible area of
contact is limited and that is so designed and protected that, under normal
operating conditions and single fault conditions , the voltages do not exceed
specified limit values i.e. no TNV circuit is required.

6. (Cl. No.2.6). Provisions for earthing and bonding

Functional earthing is available due to the Functional earthing either separated

from hazardous voltages by double or reinforced insulation or by protectively
earthed screen or conductive part separated by at least basic insulation, or safely
connected to Protective Bonding Conductor.

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EUT is Class III appliance, working at SELV supply derived from Safety
certified AC-DC adapter. Secondary functional earthing is separated to primary
by reinforced or double insulation

PE connections make earlier and break later than the supply connections in
following:
 a plug on a power supply cord;
 an appliance coupler.

7. (Cl. No.2.9). Electrical insulation

Class III appliance with safety certified AC DC Adapter, hence conditioning

carry out while EUT connected with adapter. separated from hazardous
voltages Double Insulation.

Humidity conditioning is tested under environmental test. This test is carried in

a chamber with Relative Humidity : (93±3)%, Temperature: 40±2ºC and
Duration : 120 Hours. This test is essential to test specimen under every climatic
conditions. This shows weather specimen will work or not in such conditions.
This requirement is important for specimen in coastal areas. For adapter RH
95%, T=40 ºC is taken.

8. (Cl. No.2.10). Clearances, Creepage Dstances And Distances Through

Insulation

Clearance is the shortest distance in air between two conductive parts.

Creepage distance means the shortest distance along the surface of a solid
insulating material between two conductive parts.

Safety certified AC/DC adapter used in printer all other parts are working at
SELV supply. Considered Pollution degree II
Creepage distances and Clearances Safety certified AC/DC adapter used.

78
 Insulation part of safety certified AC/DC adapter used. Minimum Thickness
of insulation 0.4mm in wound components. Uncoated printed boards of PCB.

9. (Cl. No.3.0). Wiring, Connections And Supply

Appliance inlets: Are so Located that parts at hazardous voltage are not
accessible during insertion or removal of the connector, connector can be
inserted without difficulty and after insertion of the connector, the equipment is
not supported by the connector for any position of normal use on a flat surface
( appliance inlets complying with IEC 60309 or IEC 60320 considered to
comply with this requirement.

 Current rating and overcurrent protection has adequate cross sectional

areas on internal wires and interconnecting cables used.
 Wire ways are smooth and free from sharp edges i.e. no mechanical
damage
 Internal wirings are well secured
 Termination of conductors : 10 N pull test
 Sleeving on wire can only be removed by breaking or cutting

10. (Cl. No.3.0). Connection Of Mains Supply

Rated current (A), cross-sectional area (mm²) is 6A, 0.75 mm2 respectively.
Current rating and overcurrent protection have Adequate cross sectional area of
wire used interconnecting cable (SELV Connection). Means of connection to
an a.c. mains supply is direct plug in Switching Adapter and no d.c. mains
supply. Wiring terminals for connection of external conductors of switching
Adaptor is direct plug in equipment.

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 11. (Cl. No.3.4). Disconnection From The Mains Supply
 To disconnect device or a device shall be provided to disconnect the
equipment from the mains supply for servicing is direct plug in Switching
Adaptor. It is not a three phase equipment so No parts remains energized
when the disconnect devices is removed,

 Number of poles - single-phase and d.c. equipment are disconnected

both the poles simultaneously.
 Safety certified plug with the power cord is considered as disconnect
device.

13. (Cl. No.4.0). Physical Requirements

 A unit having a mass of 7 kg or more shall not fall over when tilted to an
angle of 10° from its normal upright position. Alternatively, the unit is
placed in its intended position of use on a plane, inclined at an angle of 10°
to the horizontal, and then rotated slowly through an angle of 360° about its
normal vertical axis.

 A floor-standing unit having a mass of 25 kg or more shall not fall over

when a force equal to 20 % of the weight of the unit, but not more than 250
N, is applied in any direction except upwards, at a height not exceeding 2 m
from the floor.

 A floor-standing unit shall not fall over when a constant downward force of
800 N is applied at the point of maximum moment to any horizontal surface
of at least 125 mm by at least 200 mm, at a height up to 1 m from the floor.

14. (Cl. No.4.2). Mechanical Strength

Mass of the printer is 2.1Kg.

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  Adequate mechanical strength with no hazards when subjected to
unexpected handling.
 Steady force test, 10 N
 Steady force test, 30 N
 Steady force test, 250 N

Above forces are applied to test specimen. Result is No damage and no

hazard.
This test is done due ed to check in any situation if specimen is pressed
under heavy weight so it will be crushed/ damaged or not.

 Fall test/ Drop test is very essential since many times movable/portable
specimens fall so it is tested weather specimen will break in short fall
or not. Hence at 4-5m of height specimen is droped.

 Stress relief test is carried out at 70 °c, for a period of 7 h. No

shrinkage or distortion occurred on switching adaptor.

15. (Cl. No.4.3). Design and Construction

Under this clause observational study of specimen is required to check design

and construction because pointed edges or screws harm user and many other
constructions done by manufacturer to make it suitable for user.
 Edges and corners are smooth and rounded
 Direct plug-in equipment
 Torque: Maximum torque of 0.1N/m
 Flammable liquids not used
 No ionizing radiation generated
 Flammable liquids not used
 No Human exposure to ultraviolet radiation used
 No lasers or laser diodes used
 Low Power LED for indication

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 No hazardous moving part in operator access area.
No misconnection likely to create hazard all are tightly attached and stick
with glue with full insulation.
Low power LEDs are used for indication purpose

16. (Cl. No.4.4). Protection against hazardous moving parts

Unintentional contact with moving parts is not feasible during servicing

operation

17. (Cl. No.4.4). Thermal Requirements

Yokagava temperature measurement device is used to test the temperature of

specimen. Yokagava is used for specimen which have many components to test
temperature. Specimen is given power supply . Electronic components od
specimen are attached to the wires from yokagava . These wires are made up of
copper who’s temperature will rise as per component’s and shown on screen
for different wire. This test is continued for 4 hours.

Temperatures are calculated according to IEC clause with regard to the

maximum ambient operation temperature of 45°C (Tma), as specified by
manufacturer. Temperature is measured of Stepper Motor , Internal Wire,
Printing Head, Bottom enclosure , AC adapter Enclosure, Mains Cord
(Coupler);[test pass all measured temperature are below allowed temperature]

18. (Cl. No.4.6). Openings in enclosures

Top and side openings

19. (Cl. No.5.1). ). Resistance to fire

 Reducing the risk of ignition and spread of flame
 Parts not requiring a fire enclosure for Motors, Transformer, PVC Cable

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  Enclosure material passing the glow-wire test at 550 °C according to
IEC 60695-2-11 is acceptable as an alternative to check the cover
weather it will catch flame or not.
 Plastic materials of a FIRE ENCLOSURE located less than 13mm
through air from non-arcing parts which, under any condition of normal
or abnormal operation, could attain a temperature sufficient to ignite the
material, shall be capable of passing the test of IEC 60695-2-20.
 The average time to ignition of the samples shall be not less than 15sec.
If the sample melts through without igniting, the time at which this
occurs is not considered to be the time to ignition.

20. (Cl.no. 5.2). Electric strength

This test is carried under HVDC for dielectric test. For plastic body 1.5kv-3kv
and for metal body 1kv-2kv is supplied for 60seconds. This will show the
specimen will bear the high voltage.
During the tests no flame in the equipment, no molten metal emitted. After the
tests Meet the Electric strength test.

Basic insulation, supplementary or reinforced insulation are required for peak

working voltage and required withstand voltage.

6.4.Electric Fence

Electric fence takes electric energy from fence energiser and delivers to fence as
pulses under IEC 60335-1:2010 (Fifth Edition).

1. (Cl. No.5).General Conditions For The Tests

Tests performed according to clause 5, e.g. nature of supply, sequence of

testing, etc. One sample is being subjected to all tests.The energiser uses
capacitors to store the charge and releases it down the fence line or live wire
and when a grounded object like an animal is touching the fence an electrical

83
 stream flows through the body of the animal and back through the ground to
the earth return terminal of the energiser.

The energizer is mounted in a normal position. For energizers where the

supply terminals for connection of a battery have no indication of polarity, the
more unfavorable polarity shall be applied. Energizer works at 12V DC supply
and Supply terminal’s polarities are marked. The reference source impedance
of the mains supply is 0.4 Ω ± 0.25 Ω

2. (Cl. No.6). Classification

 Energiser is Metal Encased class II equipment. Equipment in which

protection against electric shock does not rely on basic insulation
only, but in which additional safety precautions, such as double
insulation or reinforced insulation, are provided, there being no
reliance on either protective earthing or installation conditions
 Protection against electric shock and moisture.

3. (Cl. No.7.0). Marking And Instructions

Marking clearly legible and durable, rubbing test as specified

 Rated voltage or voltage range (V) is 12V
 Symbol for nature of supply
 Rated power input (W), or Joule(J)=2-5J
 Rated current (A)=0.5
 Manufacturer's or responsible vendor's name, trademark or
identification mark
 Symbol for class II appliances is on marking plate

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 Marking On Fence Enerzisser

For fixed appliances, name, trademark or identification mark and model or type
reference visible after installation according to the instructions. No earthing
symbol present show below:

Supply terminals for connection of the battery clearly indicated by symbols IEC
60417-5005 are + & - symbols are present for connection to battery

Image: Rear view of Fence Energizer

Appliance is operated by batteries as well as using solar power. For battery-
operated energizers: marked with symbol "connection to mains-operated equipment
prohibited" or ” WARNING: Do not connect to mains-operated equipment
including battery chargers”. Proper marking or placing of switches which may not
cause a hazard. Indications of switches on stationary appliances and controls on
all appliances by use of figures, letters or other visual means.
Requirement met if frequent changes are not required and the rated voltage or
rated frequency to which the appliance is to be adjusted is determined from a
wiring diagram.

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4. (Cl. No.7.12). Instructions for safe use provided

the appliance is not to be used by persons (including children) with reduced

physical, sensory or mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction.

Instructions for class III appliances state that it must only be supplied at
SELV, unless it is a battery-operated appliance, the battery being charged
outside the appliance.Suitable for connection to the mains consisting of an
impulse generating circuit (battery).It is stated that during charging, batteries
must be placed in a well-ventilated area.

Stationary appliances not fitted with means for disconnection from the supply
mains having a contact separation in all poles that provide full disconnection
under overvoltage category III, the instructions state that means for
disconnection must be incorporated in the fixed wiring in accordance with the
wiring rules. Operated by battery or solar energy/Not to be connected to
mains.

Banana terminals & provision for detachable wires are provided

5. (Cl. No.8.0). Protection Against Access To Live Parts

 Insertion or removal of lamps, protection against contact with live

parts of the lamp cap
 Use of test probe B of IEC 61032, with a force not exceeding 1 N: no
contact with live parts
 Use of test probe B of IEC 61032 through openings, with a force of
20 N: no contact with live parts
 Use of test probe 13 of IEC 61032, with a force not exceeding 1 N,
through openings in class 0 appliances and class II appliances/
constructions: no contact with live parts. Test probe 13 also applied

86
 through openings in earthed metal enclosures having a non-conductive
coating: no contact with live parts
 Accessible part not considered live if safety extra-low a.c. voltage:
peak value not exceeding 42.4 V or safety extra-low d.c. voltage: not
exceeding 42.4 V.
 Live parts protected at least by basic insulation before installation or
assembly.
 Class II appliances and constructions constructed so that there is
adequate protection against accidental contact with basic insulation
and metal parts separated from live parts by basic insulation only

6. (Cl. No.8.0). Protection Against Access To Live Parts

Power input at normal operating temperature, rated voltage and normal

operation not deviating from rated power input by more than specified. If the
power input varies throughout the operating cycle and the maximum value of
the power, current and voltage input exceeds, by a factor greater than two,
the arithmetic mean value of the power, current and voltage input occurring
during a representative period, the power input is the maximum value that is
exceeded for more than 10 % of the representative period.

Current at normal operating temperature, rated voltage and normal operation

not deviating from rated current by more than 0.7A.

7. (Cl. No.11). Heating

Largest type of battery is used and discharged at 0.75 times nominal value.
Temperature rises, other than of windings, determined by thermocouples.
During this temperature rise atleast 2 temperature rise are noted by giving
load through applying 2 different high resistances.

87
 Motor-operated appliances operated under normal operation at most
unfavourable voltage between 0.94 and 1.06 times rated voltage (V) operated
at 12.72V DC.

8. (Cl. No.13). Leakage Current And Electric Strength At Operating

Temperature

Leakage current not excessive and electric strength adequate due to Not a
mains operated appliance. Hence Heating appliances operated at 1.15 times
the rated power input (W) and Protective impedance and radio interference
filters disconnected before carrying out the tests.

For class 0, class II and class III appliances, and class II constructions,
leakage current measured by means of the circuit described in figure 4 of
IEC 60990.[ Metal Encase Class II Appliance].

Result is no breakdown during the tests.

9. (Cl. No.14.0). Transient Overvoltages

Clearances having a value less than specified in clause subjected to an

impulse voltage test, the test voltage specified . No flashover during the test,
unless of functional insulation if the appliance complies with clause 19 with
the clearance short-circuited.

10. (Cl. No.15.0). Moisture Resistance

Enclosure provides the degree of moisture protection according to

classification of the appliance. The specimen is placed in water tank for
24hours to test that water will enter in enerziser or not .The purpose of testing
is that fence has to work in open places so rain humidity can moisturized
inside it

88
 No trace of water on insulation which can result in a reduction of clearances
or creepage distances below values specified in clause 29. Water valves
containing live parts in external hoses for connection of an appliance to the
water mains tested as specified for IPX7 appliances.

Appliances placed or used on the floor or table placed on a horizontal

unperforated support, , the movement is limited to two times 90 for a period
of 5 min, the support being placed at the level of the pivot axis of the
oscillating tube Appliances normally fixed to a wall and appliances with pins
for insertion into socket-outlets are mounted on a wooden board.

11. (Cl. No.15.2). Spillage Of Liquid

Spillage of liquid does not affect the electrical insulation. Spillage solution
comprising water containing approximately 1% NaCl and 0.6 % rinsing
agent.

12. (Cl. No.16.0). Humid Conditions

Detachable parts removed and subjected, if necessary, to the humidity test

with the main part .Humidity test for 48 h in a humidity cabinet Conditioned
at 95% RH, 30°C. The appliance withstands the tests.

13. (Cl. No.15.3). Leakage Current And Electric Strength

Leakage current not excessive and electric strength adequate at 0.07A and
1kV. This test is carried by HVDC instrument. Tests carried out at room
temperature and not connected to the supply. Single-phase appliances: test
voltage 1.06 times rated voltage (V): Class II appliance is working at 12V DC
Supply. Test voltage applied between the supply cord and inlet bushing and
cord guard and cord anchorage as specified.

14. (Cl. No.18.0). Endurance

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 Operating 168 h at – 15 °C (500 Ω load for 84 h) and + 50 °C (500 Ω load for
84 h) with O/P terminals are loaded with a non inductive resistor of 500 Ω.
Measured characteristics as specified in 22.108 are within ± 10 %.

15. (Cl. No.19.11).Fault Condition

Electronic circuits, compliance checked by evaluation of the fault conditions

specified in 19.11.2 for all circuits or parts of circuits, unless they comply
with the conditions specified in 19.11.1.
restarting does not result in a hazard.

If a conductor of a printed board becomes open-circuited, the appliance is

considered to have withstood the particular test, provided both of the
following conditions are met:
 base material of the printed circuit board withstands the test.
 any loosened conductor does not reduce clearance or creepage
distances between live parts and accessible metal parts below the
values specified in clause 29.
During and after each test the following is checked temperature of the
windings do not exceed the values specified.

16. (Cl. No.19.11.1).Fault Condition

 the electronic circuit is a low-power circuit, that is, the maximum

power at low-power points does not exceed 15 W according to the
tests specified.
 the protection against electric shock, fire hazard, mechanical hazard
or dangerous malfunction of other parts of the appliance does not rely
on the correct functioning of the electronic circuit.

17. (Cl. No.19.11.2).Fault Condition

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This fault condition is not applied between the two circuits of an optocoupler.
Each low power circuit is short-circuited by connecting the low-power point to the
pole of the supply source from which the measurements were made.

18. (Cl. No.21.0). Mechanical Strength

Appliance has adequate mechanical strength and is constructed as to

withstand rough handling. The appliance shows no damage impairing
compliance with this standard, and compliance with 8.1, 15.1 and clause 29
not impaired.

Accessible parts of solid insulation having strength to prevent penetration by

sharp implements. Test not applicable if the thickness of supplementary
insulation is at least 1 mm and reinforced insulation at least 2 mm.

19. (Cl. No.22.0). Construction

Appliance marked with the first numeral of the IP system, relevant

requirements of IEC 60529 are fulfilled. Fence energiser is a rectangular box.
Stationary appliance: means to ensure all-pole disconnection from the supply
being provided. Battery Operated Appliance having provision for solar
power.

 Singe-pole switches and single-pole protective devices for the

disconnection of heating elements in single-phase, permanently
connected class 01 and class I appliances, connected to the phase
conductor.

 Energiser not containing liquid, gases or steam producing devices. No

containers,hoses, couplings that can affect Electrical Insulation are
parts of the appliance.

91
  All edges or corners are rounded and smoothed. No exposed pointed
ends of self-tapping screws or other fasteners, likely to be touched by
the user in normal use or during user maintenance.

 No other components or lamps, containing mercury.

 Clearance between parts of opposite polarity for connection the battery

≥ 2 mm.

20. (Cl. No.22.2). Appliance provided with pins: no undue strain on socket-
outlets

Applied torque not exceeding 0.25 Nm i.e. no pins in appliance. Pull force of
50 N to each pin after the appliance has being placed in the heating cabinet;
when cooled to room temperature the pins are not displaced by more than 1
mm.

No risk of electric shock when touching the pins of the plug, for appliances
having a capacitor with rated capacitance equal to or greater than 0.1 F,
appliance being disconnected from the supply at the instant of peak voltage
34V.

21. (Cl. No.22.12). Handles, knobs etc. fixed in a reliable manner

No hazardous knobs, handles or levers exists on this unit. Fixing in wrong

position of handles, knobs etc. indicating position of switches or similar
components not possible.

Axial force 15 N applied for 1minute to parts, the shape being so that an axial
pull is unlikely to be applied.

22. (Cl. No.23.3). Electrical connections and internal conductors movable

relatively to each other not exposed to undue stress

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  No damage after 10 000 flexings for conductors flexed during normal
use
 Adequate insulating lining provided inside a coiled spring, the turns
of which touch one another.
 Not more than 10 % of the strands of any conductor broken .
 no breakdown when a voltage of 2000 V is applied for 15 min
between the conductor and metal foil wrapped around the insulation .

23. (Cl. No.24.1).Components

Components comply with safety requirements in relevant IEC standard.

Motors and relays not required to comply with IEC 60034-1, they are tested
as part of the appliance. Power electronic converter circuits not required to
comply with IEC 62477-1, they are tested as part of the appliance.

Components not tested and found to comply with relevant IEC standard and
components not marked or not used in accordance with its marking, tested
under the conditions occurring in the appliance.Components can comply with
the requirements for clearances and creepage distances for functional
insulation in the relevant component standard. Capacitors likely to be
permanently subjected to the supply voltage and used for radio interference
suppression or for voltage dividing, comply with IEC 60384-14

Switches intended for all-pole disconnection of stationary appliances are

directly connected to the supply terminals and have a contact separation in all
poles, providing full disconnection under overvoltage category II conditions.

93
 Internal view of Fence Energizer

24. (Cl. No.27.1). Provision For Earthing

Accessible metal parts of Class II appliances permanently and reliably

connected to an earthing terminal or earthing contact of the appliance inlet.
Clamping means of earthing terminals adequately secured against accidental
loosening.

25. (Cl. No.29.1). Clearances, Creepage Distances And Solid Insulation

For coatings used on printed circuits boards to protect the microenvironment

(Type 1) or to provide basic insulation (Type 2). The microenvironment is
pollution degree 2 under type 1 protection. only non-conductive pollution
occurs, except that occasionally a temporary conductivity caused by
condensation is to be expected

Clearances not less than the values specified in table 16, taking into account
the rated impulse voltage for the overvoltage categories for basic insulation
and functional insulation they comply with the impulse voltage test of clause
14. However, if the distances are affected by wear, distortion, movement of
the parts or during assembly, the clearances for rated impulse voltages of
1500V and above are increased by 0.5 mm and the impulse voltage test is not
applicable.

94
 Clearances of reinforced insulation not less than those specified for basic
insulation , using the next higher step for rated impulse voltage. Clearances for
functional insulation are the largest values determined from rated impulse
voltage 500V.

26. (Cl. No.20.1). Resistance To Heat And Fire

External parts of non-metallic material , parts of thermoplastic material

providing supplementary or reinforced insulation sufficiently resistant to heat.
Parts of non-metallic material resistant to ignition and spread of fire. parts
having a mass not exceeding 0.5 g, provided the cumulative effect is unlikely
to propagate flames that originate inside the appliance by propagating flames
from one part to another, or decorative trims, knobs and other parts unlikely to
be ignited or to propagate flames that originate inside the appliance.

Parts of non-metallic material supporting connections carrying a current

exceeding 0.2 A during normal operation, and parts of non-metallic material,
other than small parts, within a distance of 3 mm, subjected to the glow-wire
test of IEC 60695-2-11 with a test severity of 850 °C.

Ball-pressure test according to IEC 60695-10-2 Class II metal Encased

Energiser.

27. (Cl. No.31). Resistance To Rusting

Relevant ferrous parts adequately protected against rusting. Metal-encased

class II energizers protected against corrosion (IEC 60335-2-76).

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 Siren for Fence Energizer

6.5.Control Gear

This standard specifies performance requirements for electronic control gear for
use on d.c. supplies up to 1 000 V and a.c. supplies up to 1 000 V at 50 Hz with an
output frequency which can deviate from the supply frequency, associated with
LED modules according to IS 16103 (Part 1) : 2012 ‘LED modules for general
lighting: Part 1 Safety requirements’. Control gear for LED modules specified in
this standard are designed to provide constant voltage or current. Deviations from
the pure voltage and current types do not exclude the gear from this standard.

1. (Cl.No.2.1).Construction

Components shall be complying with IEC 60950-1 or relevant component

standard. Subassemblies approved for IEC 62368-1 can be considered as
complying with this standard. Evaluation and testing of components Verified
by relevant data & tests . Interconnecting cable used which operate on SELV.
Interconnection circuit is working on SELV

Secondary circuit that is so designed and protected that under normal

operating conditions and single fault conditions, its voltages do not exceed a
safe value.The limit values of voltages under normal operating conditions and
single fault conditions.

2. (Cl.No.2.1). Ball Pressure Test

96
  Prepare a test specimen having thickness of at least 2.5 mm.Set the
temperature of oven to as specified in the specification, within tolerance ..
Place the test specimen on the approximate centre of the test specimen
support so that its upper surface is horizontal and the spherical part of
apparatus is pressed against this surface with a force of 20N.
 Gently lower the pressure ball on to the approximate centre of the test
specimen. After 1 hour, remove the pressure ball from the test specimen
and within 10 s immerse the test specimen in cold water.
 Immediately thereafter keep immersion for 6 min-2 min.Now remove the
test specimen from the water and eliminate all traces of water.Within 3
min of removal from the water measure dimension d, toone decimal place
using the profile projector or optical measuring instrument dimensiondis
the greatest dimension across the indentation caused by the pressure ball.

Control gear body ia tested at temperature = 70±2°C, 1hour.

3. (Cl.No.5.1). Classification

Classification According to the Load

a) Single Value Load Control Gear : This type of control gear is designed for use
with one specific output wattage only, which may be dissipated by one or
more LED modules.
b) Multiple Value Load Control Gear : This type of control gear is designed for
use with one or more LED modules with a total load within the declared
wattage range.
Classification According to the Output Voltage
a) Control gear having a stabilized output voltage;
b) Control gear without a stabilized output voltage.
Classification According to the Output Current
a) Control gear having a stabilized output current;
b) Control gear without a stabilized output current.

4. (Cl.No.6.0). Marking

97
 Mandatory Marking on Control gear shall be clearly marked as follows:
Circuit power factor, for example λ = 0.9 If the power factor is less than 0.95
leading, it shall be followed by the letter ‘C’, for example λ = 0.9 C.

A symbol which indicates that the control gear is a short-circuit proof type
(the symbol is underconsideration).

Marking Plate

5. (Cl. No. 7.0). Output Voltage And Current

Starting and Connecting Requirements After starting or connecting a LED

module, the output should be within 110 percent of its rated value within 2 s.
Maximum current or maximum voltage shall not exceed the values given by
the manufacturer. This performance is tested with the minimum rated power.

6. (cl.no.7.2). Voltage and Current During Operation

For control gear having a non-stabilised output voltage, when supplied with
the rated supply voltage, the output voltage shall not differ by more than ±10
percent from the rated voltage of the LED modules; for control gear having a
stabilised output voltage when supplied at any supply voltage between 92
percent and 106 percent of the rated supply voltage ,t he output voltage shall
not differ by more than ±10 percent from the rated voltage of the LED

98
 modules. Multiple load control gear shall be tested with both the minimum
and maximum load.

7. (Cl. No.7.3). Capacitive Load Requirement

If the LED module or any additional control unit connected to the convertor
contain capacitors for control and/or driving circuitry on the modules, current
pulses may be generated when connecting the LED module to the control gear.
This shall not disturb the control gear overcurrent detection nor the starting
process of the control gear. Compliance requirement when connecting the
measurement circuit to the control gear, the detection device shall not trip.

8. (Cl. No.7.4). Voltage Surges During Switching and Operation

Voltage surges superimposed on the output voltage shall not exceed the
values specified (values under consideration).

9. (Cl. No.8.1). Total Circuit Power

At rated voltage, the total circuit power shall not be more than 110 percent of
the value declared by the manufacturer, when the control gear is operated with
LED module(s).

10. (Cl. No.8.2). Circuit Power Factor

The measured circuit power factor shall not be less than the marked value by
more than 0.05 when the control gear is operated on its rated wattage with
LED module(s) and the whole combination is supplied with rated voltage and
frequency.

Power factor of gear is 0.87.

11. (Cl. No.9.0).Supply Current

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 At rated voltage, the supply current shall not differ by more than +10 percent
from the value marked on the control gear or declared in the manufacturer’s
literature, when that control gear is operated on its rated wattage with LED
module(s).

12. (Cl. No.10.2). Impedance At Audio Frequencies

Control gear marked with the audio frequency symbol shall be tested in
accordance with A-3 using the circuit For every signal frequency between
400 Hz and 2 000 Hz, the impedance of the control gear when operated with
the rated LED module load at rated voltage and frequency shall be inductive in
characteristic. Its impedance in ohms shall be at least equal to the resistance of
the resistor which would dissipate the same power as the LED module control
gear combination when operating at its rated voltage and frequency.

The control gear impedance is measured with a signal voltage equal to 3.5
percent of the rated supply voltage(220-240 V) of the control gear. Between
250 Hz and 400 Hz, the impedance shall be at least equal to half the minimum
value required for frequencies between 400 Hz and 2 000 Hz.
13. (Cl. No.11.0). Operational Tests For Abnormal Conditions

The control gear shall not be damaged under following conditions :

a) Test without LED Module(s) Inserted : The control gear shall be supplied
with rated voltage for 1 h without LED module(s) inserted. At the end of this
test, the LED module(s) operate normally.

b)Tests for Short-Circuit Proof Control Gear : The control gear is short-
circuited for 1 h or until a protecting device opens the circuit. After these tests
and after restoration of a possible protecting device, the control gear function
normally.

14. (Cl. No.13.1). Endurance

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 The control gear shall be subjected to a temperature cycling shock test and a
supply voltage switching test as follows:

a) Temperature Cycling Shock Test : The nonenergised control gear shall be

stored firstly at –10°C for 1 h in a chamber. The control gear is then moved
into a cabinet having a temperature of tc. Five such temperature cycles shall be
carried out.

c) Supply Voltage Switching Test : At rated supply voltage the control gear shall
be switched on and off for 30 s. The cycling shall 4 IS 16104 : 2012 be
repeated 200 times with no load and 800 times with maximum load
conditions. LED modules failing during this test shall be replaced
immediately.

At the end of these tests the control gear shall operate an appropriate LED
module or LED modules correctly for 15 min.

d) Test Voltage and Frequency : Unless otherwise specified, the control gear to
be tested shall be operated at its rated supply voltage and frequency. When a
control gear is marked for use on a range of supply voltages, or has different
separate rated supply voltages, any voltage for which it is intended may be
chosen as the rated voltage.

e) Stability of Supply Voltage and Frequency : During the tests, the supply
voltage and the frequency shall be maintained constant within ±0.5 percent.
However, during the actual measurement, the voltage shall be adjusted to
within ±0.2 percent of the specified testing value.

Control gear pass all the test successfully. Only markimg plate has some
data and certified sign were missing that will be corrected by manufacturer.

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Chapter 7: Conclusion

Only qualified persons are permitted to perform tasks such as testing,

troubleshooting, and voltage measuring, due to the electrical hazards associated
with energized work. All associated hazards must be used when performing these
tasks. Test instruments must be rated for the conditions under which testing is to
be performed. Testing is performed under different specification according to
specimen. This testing purpose is to check the specimen hazards in very worst
situation so as to make safe for user. Certified Electrical and Electronic
devices/components from safety labs should be used. This reduces the risk for
user.

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Chapter 8: References

Online sources to study:

[1] file:///C:/Users/kk/Downloads/60227-2.pdf

[2]https://www.google.co.in/search?biw=1366&bih=613&ei=SeYXW5XZNseo9
QPqz5DwD
A&q=testing+of++pvc+cables+according+to+iec60227&oq=testing+of++pvc+ca
bles+according+to+iec60227&gs_l=psy-ab.3...194067.195983.0.196801.5

[3] http://www.intertek.com/blog/2011/07-04-iec-60601-1/

[4] http://www.bis.org.in/sf/etd/ETD_WC_06072017

[5] http://www.stqc.gov.in/content/electronics-and-electrical-testing

[6] https://en.wikipedia.org/wiki/Consumer_electronics

[7]http://10.newegg.com/UploadFilesForNewegg/itemintelligence/ClearPond/is.1
6104.20121401470272583.pdf

Standards studied:

1) IEC 60227-2 – For Cable Testing

2) IEC 15885-1 – For Control Gear Testing
3) IEC 60950-1 – For Switching Adapter Testing
4) IEC 60950-1 – For Printer Testing
5) IEC 60335-1 – Electric Fence Energizer Testing

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