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UL 507 & CSA C22.2 No. 113

Testing Seminar风扇测试研讨会

January 20, 2010

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王立勇工程师

UL 美华认证有限公司

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No smokingMute Cell Phone

Close laptop, and the like.

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After learning this course…学习此课程后…

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You will您将

Be in awareness of general knowledge of integral safety regulation system in US知晓美国安规体系的基本概念

Obtain a broader picture of testing rationale, philosophy, principle, method, practice… than ever before更加了解测试原因、理念、原理、方法及经验做法…

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And…还有…

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All control in your hand！一切尽在掌握！

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Know the whyControl the howExpediate completing project

知其然知其所以然加快贵司出货速度

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Agenda研讨会日程概览

2010-01-27， AMSafety regulation in US

美国安规

2010-01-27, PM & 2010-01-28 whole dayTesting theory & practice测试理论与实践

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p/12─ 数据源自 Opinion Research Corporation 2004 的調查

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It is…

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RR

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Safety Regulation

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美国国家劳工部授权其下属职能部门职业安全与卫生管理局依OSHAct法令出台29CFR去实施和监管.

29 CFR (Code of Federal Regulations)

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U.S. Consumer Product Safety Commission(CPSC)-market surveillance

(美国)消费品安全委员会 对市场进行监督

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End-product

终端成品标准

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标准存在的价值取决于其为人所接受与使用的程度！

任何成品标准技术委员会在开发与出版标准时，都会从环境、健康和安全的角度充分考虑器具在其整个生命周期内从设计、制造、包装、运输、安装、使用、维护、存储、维修到报废处理每个环节, 相关工业体系现实以及人类行为习惯在所有涉及层面中的

因素。

所有测试都是对现实中各方面可能发生情形之合情合理模仿！

The worth of any standard is measured by the degree of its acceptance and use.

After careful consideration, and in view of the state of the art and the generally better understanding of the all involved factors ranging from Design, Manufacture, Packing, Transport, Installation, Operation, Maintenance, Storage, Service,Waste Disposal…relevant industry reality, to Human Behavior in terms of Environment, Health & Safety during the whole lifespan of the appliance in question, the end-product standard Committee develop and publish the final approved version of Standards.

All Testing are simulation to foreseeable & reasonable conditions, situations etc likely occurred during each aspects in Reality.

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站在标准制定者的角度去理解和应用标准！All the factors must be considered from systematic standpoint because standard for safety is an organic, integral whole of all the factors involved.

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Lay ground for the meat …基础知识介绍…

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in North AmericaElectrical System

北美电力系统

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美国国家标准学会(American National Standard Institute,ANSI)是美国非营利性民间标准化团体.

The American National Standards Institute or ANSI is a privatenon-profit organization that oversees the development of voluntary consensus standards for products, services, processes, systems, and personnel in the United States.

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LOWVOLTAGE

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IEC 60364 LOW-VOLTAGE ELECTRICAL INSTALLATIONS

TN-C

TN

IEC classifications of Power Distribution network Systems

TN-ST

TN-C-S

Based on the Earthing of transformer secondaries

I

TT

IT

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nomenclature

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Typical U.S. Power Distribution network

Three-phase transformer secondary(U.S. commercial 120/240 V)

Single phasetransformer secondary(U.S. residential 240/120 V)

Three-phase transformer secondary(U.S. commercial 208/120 Vand 480/277 V)(Europe et al 230/400 V)

Three-phase transformer secondary(U.S. commercial 120/240 V)

Single phasetransformer secondary(U.S. residential 240/120 V)

Three-phase transformer secondary(U.S. commercial 208/120 Vand 480/277 V)(Europe et al 230/400 V)

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US RESIDENTIAL ELECTRICAL BRANCH CIRCUITS

TN System

PEN (protective earthing neutral)

TN System

PEN (protective earthing neutral)

p/36Copyright © 2007 Underwriters Laboratories Inc. ® All rights reserved

Service equipment(distribution panel)

Maincircuitbreakeror fuses

Branch circuit breakers or fuses

Generalusereceptacle

NeutralBus

Equipment grounding(earthing) bus

Utility transformer

Utilitypole

EARTH

Typical Residential Electrical Service Typical Residential Electrical Service ((TNTN--CC--SS system) Used in USAsystem) Used in USA-- 120/240 120/240 vacvac, 60 Hz, 60 Hz

Copyright © 2001, Underwriters Laboratories Inc. All rights reserved

7-14 kV

240 v120v

120v

Main bondingjumper

Utilityearthingelectrode

240 v120 v

Buildinggrounding (earthing)system (TN System)

Typical ConnectionsTypical Connections

Branch circuit conductors

Ungrounded (hot) conductor

PEN Conductor(combinationneutral andgroundingconductor)

(Separate from Neutral (N) conductor)

Neutral (N) conductor

Protective earthing (PE) conductor

Watt-hourmeter

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NECNEC

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(eg. NM-B per NEC 334.80)

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The Branch Circuits

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Circuit Breakers & Fuses

IEC 60269

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5-15P5-20R

5-15R

ANSI/NEMA WD 6 _straight blade

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Article 314 • NEC

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Harmonization Distortion

IEEE Std 519-1992IEEE Recommended Practices andRequirements for Harmonic Control inElectrical Power Systems

POWER QUALITY

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美国的住宅

　　在美国，木材是首选的住宅建造材料。 近每年都有150万的新住宅建成，

其中约75%为单户住宅而25%为多户。而前者中有近90%是采用木框架结构。

摘自2007《世界建筑》

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Plasterboard

(dry wall)Gypsum wall

石膏墙

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Stud

Joist

立

柱

托梁

NECIRC

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Ceiling （before finishing）

天花板（未完工）

Wall 墙

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THERMAL INSULATION隔 热 棉

cellulosic insulation for house

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Fiberglass thermal insulation for用于休闲车的玻纤隔热棉

RECREATIONAL VEHICLE

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You should test it before concluding

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For your product, so does it.

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…

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General Knowledge in Engineering

Factor of safety (FoS) can mean either the ratio of a product performance capability over that actually required, or amultiplier applied to the maximum expected load to which a product will be subjected, or to the basic theoretical empirical parameters required in standards for design and engineering.

FoS is required to accommodate, allow and compensate for the uncertainties & variations in terms of design, material, manufacture, usage…

Margin of Safety (M.S.) — if the product is loaded to the maximum load it should ever see in service, how many more loads of the same force can it withstand before failing. In effect, margin of safety is a measure of excess capacity.

The relationship between M.S. and FoS is M.S. = FoS − 1.

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Testing Philosophy

The theory behind many testing is that if a deliberate over loaded M.S. 1, 2, 3, 4, 5, 10… …times normal values to which it will be subject in service does not cause the product in question to break down (fail), the product will be safe to use under normal operating during its whole lifespan.

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Testing Philosophy

When various different conditions/situations/criteria are applicable

for optional with respect to testing,

you can, beyond doubt, conclude that the more severe for the product in question

prevail.

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Hazards ∆危险三角

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Hazards ∆

Electric Shock电击

Injury to Person人身伤害

Risk of Fire火灾

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Dangerous…

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Oh, my God.

p/71The three are of organic integration.

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NSULATION

p/73Avantar [Na`vi]Human

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Human AvantarVs.

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p/76Structure determines property.

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Whether it is one homogeneous piece, or comprises several layers [any combination arrangement of solid, liquid and gas material ], theinsulation will be equivalent circuit as follows for analyze purpose,

Theoretical Background:

IL-Over Insulation IL-Through Insulation ICCapacitanceLeakage Leakage

AC(Alternating current)

IAAbsorption

ITotal

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0 180 360 540 720 900

0 180 360 540 720 900

0 180 360 540 720 900

Voltage

IL

IC

Insulation Resistance

Capacitance

Current in phase with Voltage

Current leading by 90°out of phase with

Voltage

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Physics Common Sense recap,

Resistance (R) is essentially friction against the motion of electrons.

Reactance (X) is essentially inertia against the motion of electrons.

It is measured in ohms just like resistance (R).

Inductive reactance formula:

Capacitive reactance :

Impedance (Z) is a comprehensive expression of any and all forms of oppositionto electron flow, including both resistance (R) and reactance (X).

fLX L π2=

fcX C π2

1=

Source: Lessons In Electric Circuits, VolumeⅡ-AC by Tony R. Kuphaldt

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COMPLEX Vector,

iXXRZ LC )( ++=

imaginary

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X CX C

Rimaginary

Z (Vector sum)

IL

IC ITotal

Cap

aciti

vely

coup

led

curre

nts

DO

MIN

ATE

NOTE:Relative Value

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Theoretical Background:

IC IALeakage Capacitance AbsorptionIL-Over Insulation IL-Through Insulation

Leakage

+ −+ −DC

(Direct current)

+

-

ITotal

Source: IEEE Std 43-2000(R2006)

IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery

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several order of magnitude

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Factors to affect Insulation Property

MaterialThickness, Shape, Contour…Manufacture processTemperature, HeatHumidity, Moisture …Vibration, Abrasion, Mechanical abuse…Pollution degree, Contamination, environmental…Working Voltage, voltage surges and transients …Aging…

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Spacing

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The difference betweenClearance and Creepage distances

(UL 840 & IEC 60664)

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Test Starting…

…

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Power Quality Assessment

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31 Test Voltages

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32 Leakage Current Test

Metal foil area: 10 X 20 cm

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32 Leakage Current Test

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33 Continuity of Grounding Circuit Test

FAIL?

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33 Continuity of Grounding Circuit Test

可替换的重测方法：

模拟实际电流出错情况下，来检测接地连续性电路的阻值

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33 Continuity of Grounding Circuit Test

与UL 507 Cl. 33可替换的重测方法 对应的： CSA C22.2 No.0.4Impedance Test

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34 Starting Current Test

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34 Starting Current Test

又叫启动电流

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35 Input Test检测所有可能负载模式，找出 大值

1) 使用标称电压

2) 运行至热稳定

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36 Temperature Test

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典型测试设备-数据记录仪

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1、校验证书 + 出厂COC

2、常用J型和K型， 温升数据记录仪校验需与之配合热电偶Thermocouple 3、热电偶接点建议规格见下图

4、热电偶线径规格： 不小于30 AWG，不大于24 AWG

5、选择合适接点设备，胶水与催化剂

Outer insulation

Thermocouple wire insulation

Junction

Approximately 1.5mm

Approximately 15mm

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热电偶选点原则

TC locations

以UL 507 表36.1为导向

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热电偶点温度热稳定判定

Thermal equilibrium

T温度℃

0时间：mint

已测试时间：te min

两次间隔三次读数

间隔为初次读数时已测试时间的百分之十，如少于5 min以5 min 为准

COMMON PRACTICE：趋势平稳或下滑， 各温度点三次读数相差1℃以内

读数间隔时间：te x 10% min

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电阻法 测温升Change of Resistance

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p/109Rule 1 Least squares (R-squared value, R2 ≥0.90 is acceptable)

Recommended Practice

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温升测试状态Each Condition

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37 Dielectric Voltage Withstand TestThe primary purpose of dielectric strength (alternating

current or direct current) testing is to determine,

1) if the dielectric can operate safely and reliably at its rated voltage and

2) if it can withstand high voltage surges and transients during its whole expected lifespan.

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37 Dielectric Voltage Withstand Test

A. 塑胶壳表面需要贴导电薄纸

B. 以马达输标称出和电压为选取测试电压依据

C. 如有across-the-line 或 line-to-ground电容，需要用DC 电压进行测试，在AC值上乘于1.414倍

D. 如有可换向罩极马达，在罩极环与定子与硅钢片或者定子绕组之间打耐压

E. 跳断电流设置： 遵循120 k ohm 原则

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41 Humidity Conditioning Test

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Ball Impact Test

球冲击测试

Free drop

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Ball Impact Test

球冲击测试

Free drop

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Mold Stress Relief Test

模压应力测试

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CSA C22.2 No. 113-08

Extreme Voltage Test

Under/Over Voltage Test

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“The formulation of a problem is often more essential than its solution”

—Albert Einstein

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