Checking electrical equipment conformity with standards. M. Mostafa
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2 Checking electrical equipment conformity with standards M. Mostafa 2
3 KTL Certification Eng. Ahmed Abo Elkhair 3
4 Outline 1. Introduction KTL 4. Factory Inspection 2. Certification Process Flow Chart 3. Documents Accompanied with Product 5. Safety Marking 6. Conclusion Eng. Ahmed Abo Elkhair 4
5 Preface 1) On July 1, 2000, Korea Testing Laboratory (KTL) is officially becoming as a National Certification Support the safety of electrical appliances to be compatible with IEC Standards In turn: So it become so easy to make deal with mutual recognition agreements on conformity assessment Eng. Ahmed Abo Elkhair 5
6 Certification Process Flow Chart Eng. Ahmed Abo Elkhair 6
7 Electrical appliances subject to the certification appliances with supplied input power between 50 volts and 1000 volts Eng. Ahmed Abo Elkhair 7
8 The application shall be accompanied by the following documents 1) Product manual (including user instructions) 2) Statement of major components, which have direct effects to electrical safety (include manufacturer of the component, model, input rating and electrical characteristics, etc.) 3) insulating materials for the power transformer (temperature characteristics, flammability class, etc.) 4) Circuit diagram 5) Letter of authorization (option for foreign manufacturers) Eng. Ahmed Abo Elkhair 8
9 Initial Factory Inspection Factory Inspection The Certification Committee shall visit the applicants factories to verify their manufacturing and facilities and systems in accordance with CENELEC (European Committee for Electro-technical Standardization) Note: If an earlier factory inspection for a model of the same type of product manufactured in the same factory was conducted, the certification body may accept results from the earlier factory inspection. Eng. Ahmed Abo Elkhair 9
10 Factory Inspection Follow-up Factory Inspection the certification body shall conduct regular factory inspections more than once a year. Technical Requirements (Electrical safety requirements) Product shall comply with Korean Safety requirement to enter the Korean Market and the Safety requirement is based on IEC standards Eng. Ahmed Abo Elkhair 10
11 Safety Marking for Electrical Equipment in Korea Safety certification mark Certification number Product Name Model name Input electrical rating Name of Manufacturer 回 mark for double insulation appliances Production date Phone number or address of service provider. Eng. Ahmed Abo Elkhair 11
12 Placement and methods to indicate the safety certification mark 1) The size of the mark should be symmetric with the size of the product. 2) be easily recognized. 3) The certification body name KTL and the safety certification number shall be indicated under the safety certification mark, remarked in Korean or English language. 4) The color of the mark is normally Black. Eng. Ahmed Abo Elkhair 12
13 Conclusion Korea becomes one of the greatest countries and credibility in Product Certification. Its necessary to ensure the certification label aren t Fake Eng. Ahmed Abo Elkhair 13
14 JQA Certification Eng. Ahmed Abo Elkhair 14
15 Outlines 1. About JQA 4. Application + Example of Testing 2. How does JQA Work 5. Design Of Logo 3. Procedures 6. Conclusion Eng. Ahmed Abo Elkhair 15
16 About JQA? Eng. Ahmed Abo Elkhair 16
17 How does it work? Eng. Ahmed Abo Elkhair 17
18 Procedures Eng. Ahmed Abo Elkhair 18
19 JQA may reject the acceptance of the application 1) When JQA cannot technically support the application, 2) When the application involves illegal acts 3) When the applicant has failed to submit testing samples 4) When JQA considered an application to be inappropriate for another reason. Eng. Ahmed Abo Elkhair 19
20 Application Eng. Ahmed Abo Elkhair 20
21 Example of testing Electrical Appliances Eng. Ahmed Abo Elkhair 21
22 Design of S-JQA Mark 1) The S-mark and JQA logo part 2) S-JQA mark shall be blue process color C90%+M60% 3) The height of S-mark shall be 2mm or more Eng. Ahmed Abo Elkhair 22
23 Conclusion Eng. Ahmed Abo Elkhair 23
24 CCC Certification M. Mostafa 24
25 Agenda 1. Introduction 7. CCC Testing 2. CCC Compulsory Catalogue 8. CCC Initial Factory Inspection 3. Exemptions 9. CCC Follow Up Inspection 4. CCC Certification Procedure 10. CCC Mark 5. CCC Required Documents 11. Conclusion 6. CCC Flow chart M. Mostafa 25
26 Abbreviations CCC AQSIQ CNCA CQC SAI EMC China Compulsory Product Certification State General Administration for Quality Supervision and Inspection and Quarantine of the People s Republic of China Certification and Accreditation Administration of the People s Republic of China China Quality Certification Centre The State Administration for Entry-exit Inspection Electromagnetic Compatibility M. Mostafa 26
27 Introduction M. Mostafa 27
28 CCC Compulsory Catalogue In 2002, AQSIQ and CNCA were authorized to publish the First Catalogue of Products Subject to CCC. The first catalogue covers 135 products divided into 19 categories. The current CCC catalogue contains about 150 products divided into 21 categories. M. Mostafa 28
29 CCC Compulsory Catalogue M. Mostafa 29
30 Exemptions M. Mostafa 30
31 Exemptions M. Mostafa 31
32 Exemptions M. Mostafa 32
33 Exemptions M. Mostafa 33
34 Exemptions M. Mostafa 34
35 Exemptions Products and parts eligible for exemption need Special Exempt Approval. The application should be submitted to the CNCA with supporting documentation proving above conditions are met. Exemptions should be applied for at least 1 month in advance and validity of the exemption certificate depends on the conditions of use. M. Mostafa 35
36 CCC Certification Procedure During the whole procedure, CQC will act as a certification body to review and approve the CCC certification. When the products meet all of the requirements, then CQC will issue the CCC certificate. Usually, a CCC certificate is valid for 5 years. M. Mostafa 36
37 1. Application form 2. Business licenses of applicant, manufacturer and factory separately 3. ODM or OEM declaration, ((Original Device Manufactures),(Original Equipment Manufactures)) 4. Declaration of Conformity 5. Product assembly chart, circuit diagram for product and power supply 6. List of critical components and materials 7. Description of the difference between the different model of products in the same application unit 8. Label and Label location 9. User s Manual in Chinese 10. CB report if applicable 11. The Questionnaire for Factory Inspection if applicable 12. Other necessary documents CCC Required Documents M. Mostafa 37
38 CCC Flow chart M. Mostafa 38
39 CCC Flow chart M. Mostafa 39
40 CCC Flow chart M. Mostafa 40
41 CCC Testing CCC requires in-country testing by one of the accredited labs. That means the test labs must be authorized by CNCA and have designated product testing scope. CCC focuses on Safety and EMC testing Test standards are China GB Guobiao standards. When the testing standards updated, then the products need to apply for updating application to update the standards on the certificate and test report. If the applicant doesn t do this, then the certificate will be superseded or canceled. M. Mostafa 41
42 CCC Initial Factory Inspection M. Mostafa 42
43 Inspection items: CCC Initial Factory Inspection 1. interview the responsible engineers in the factory 2. review the product quality system 3. witness the Dielectric Strength and Ground Resistance tests on the product M. Mostafa 43
44 CCC Follow Up Inspection Follow up inspection (Annual Factory Audit ) is for an approved product to maintain the CCC certificate. This factory audits focus on the manufacturing process of a specific product on the CCC certificate. It will be performed once or twice every year from the following year after granted. If the follow up inspection fails, then the CCC certificate will be suspended or cancelled. M. Mostafa 44
45 CCC Mark M. Mostafa 45
46 CCC Mark These are a few different types of CCC mark: The letter on the mark reflects the type of certification. S represents Safety ; S & E represents Safety and EMC EMC represents EMC ; F represents Fire Fighting M. Mostafa 46
47 Conclusion M. Mostafa 47
48 Hazard Management Program South Australia University M. Mostafa 48
49 Agenda 1. Introduction 2. Basic Electrical Safety Principles 3. Training Requirements 4. Initial Training 5. Retraining 6. Documenting Training and Experience 7. Reference M. Mostafa 49
50 Introduction M. Mostafa 50
51 Introduction M. Mostafa 51
52 Procedure Regulatory responsibility for inspection and testing The university must ensure that electrical equipment is regularly inspected and tested by a competent person if the electrical equipment is: M. Mostafa 52
53 Procedure Regulatory responsibility for inspection and testing The university must ensure that electrical equipment is regularly inspected and tested by a competent person if the electrical equipment is: M. Mostafa 53
54 Procedure Principal workplace safety controls Instigate a program of regular inspection and testing M. Mostafa 54
55 Principal workplace safety controls Engage a competent Procedure M. Mostafa 55
56 Procedure Principal workplace safety controls M. Mostafa 56
57 Procedure Principal workplace safety controls Check through visual inspection that new equipment is not showing signs of damage or wear M. Mostafa 57
58 Procedure Principal workplace safety controls Check during regular workplace inspections that there are no visual signs of damage or wear to electrical equipment, that any applicable electrical equipment has been properly tested and tagged and that testing is up-to-date M. Mostafa 58
59 Procedure Principal workplace safety controls Report a hazard if in the course of work it is noticed that an item of electrical equipment is showing signs of damage or wear or might be unsafe M. Mostafa 59
60 Procedure Principal workplace safety controls Take appropriate action when equipment is identified as noncompliant or might be unsafe. M. Mostafa 60
61 Training and competence Procedure M. Mostafa 61
62 Procedure Workplace inspections and electrical safety M. Mostafa 62
63 Procedure Workplace inspections and electrical safety M. Mostafa 63
64 Procedure Deciding what needs to be tested M. Mostafa 64
65 Procedure Deciding what needs to be tested M. Mostafa 65
66 Procedure Deciding what needs to be tested M. Mostafa 66
67 Procedure Deciding what needs to be tested M. Mostafa 67
68 New equipment Procedure Equipment introduced into the university M. Mostafa 68
69 Procedure Equipment introduced into the university Second-hand or hired equipment M. Mostafa 69
70 Procedure Equipment introduced into the university Personal electrical items brought from home M. Mostafa 70
71 Procedure Equipment introduced into the university Untested electrical equipment M. Mostafa 71
72 Repaired equipment Procedure Equipment introduced into the university M. Mostafa 72
73 Equipment introduced into the university Equipment out of service Procedure M. Mostafa 73
74 Procedure Testing Frequency M. Mostafa 74
75 Procedure Actions resulting from inspection and testing M. Mostafa 75
76 Procedure Actions resulting from inspection and testing M. Mostafa 76
77 Conclusion M. Mostafa 77
78 Health and Safety Electrical Appliances Testing and Inspection in New Zealand M. Mostafa 78
79 Outline 1. Introduction 6. Non Compliant Appliances 2. Visual Checks 7. Imported Appliances 3. Competent person & Training 8. Testing And Inspection Intervals 4. Test Equipment (P.A.T) 9. Labeled After Testing, Documentation & Records 5. Inspection & Testing Process 10. Some Advises Eng. Ahmed Abo Elkhair 79
80 Introduction Eng. Ahmed Abo Elkhair 80
81 Who can contribute to recognize of Damage by Visual checks Students: Laboratories Staff: Eng. Ahmed Abo Elkhair 81
82 The Faults can be detected by Visual Inspection Such as Damage in conductor Degradation in Insulation Insecure plug or Bent electrodes Missing screws Eng. Ahmed Abo Elkhair 82
83 Competent (Qualification) person Approved Competent Persons include those with registration and current practicing licenses Eng. Ahmed Abo Elkhair 83
84 Training 1) Testing on various Electrical Appliances 2) Using Electrical Equipment Testers 3) Knowing AS/NZS 3760 Standards Eng. Ahmed Abo Elkhair 84
85 Test Equipment: Using P.A.T (Portable Appliance Tester) or any Tester compatible with AS/NZS 3760 P.A.T should be calibrate each 6 months to ensure from its safety and the Error not exceed 5% Using of P.A.T: 1) Earth Bonding Testing 2) Insulation Leakage Testing 3) Knowing Consumption Power Eng. Ahmed Abo Elkhair 85
86 Inspection process involve 1) check for obvious external damage 2) check for damage to outlet sockets, connectors or plugs 3) check that mechanical safety devices are in good working 4) special inspection for equipment greater than 10 years old Eng. Ahmed Abo Elkhair 86
87 1) Earth test to ensure that there is less than 1 Ω between exposed metal parts and earth Testing process involve 2) Insulation test to ensure that there is more than 1M Ω resistance between phase and neutral and earth Eng. Ahmed Abo Elkhair 87
88 Non compliant Appliances Electrical appliances which fails to comply with the standard when tested shall be : 1) withdrawn from service immediately, 2) labeled with a warning against further use and arrangements made 3) disposal or destruction Eng. Ahmed Abo Elkhair 88
89 Equipment made outside New Zealand may have different: 1) wire colors 2) voltage Settings 3) Plugs Imported Appliances So Imported Appliances should be checked by an electrically certified technician. Eng. Ahmed Abo Elkhair 89
90 Testing And Inspection Intervals Based on the frequency of use and level of risk, as follows: Firstly, electrical appliances, which are in regular use in workshops and laboratories on an annual basis. Secondly, electrical appliances, which are used occasionally and are low risk, may be prioritized to be tested in the next 1-2 years. For rarely used appliances in office environments, testing should be carried out at least 5 yearly. Eng. Ahmed Abo Elkhair 90
91 Testing And Inspection Intervals Based on the frequency of use and level of risk, as follows: Eng. Ahmed Abo Elkhair 91
92 Interval between Testing And Inspection Eng. Ahmed Abo Elkhair 92
93 The minimum requirement is for the following information to be recorded on the label attached to the appliance: The date of testing The date of next testing Person performing the test Labeled After Testing Eng. Ahmed Abo Elkhair 93
94 Test 6 monthly red Test annually green Test biannually blue Test 5 yearly yellow Documentation/Records Eng. Ahmed Abo Elkhair 94
95 Some Advises (Safe working practices) Eng. Ahmed Abo Elkhair 95
96 Managing Safety in Using Portable Electrical Equipment Reda El-Khadrawy 96
97 Content Introduction Authority Inspection Procedure Conclusion Reda El-Khadrawy 97
98 Introduction We are going to provides practical advice on managing inspection, testing, and maintenance of portable electrical equipment in the workplace. Reda El-Khadrawy 98
99 Definitions Portable Electrical Equipment (PEE). Competent person. Hostile operating environment. Inspection. Testing. Reda El-Khadrawy 99
100 Portable Electrical Equipment (PEE) Reda El-Khadrawy 100
101 How to select PEE? Complies with national legislation and relevant Directives. Technical support and training. Level of Maintenance / Reliability. Warranty period. Quality management system. Reda El-Khadrawy 101
102 Manner of using. Service. Transport. Appropriate installation. Storing. Safe use and Care of PEE Reda El-Khadrawy 102
103 Authority The International Social Security Association (ISSA) Reda El-Khadrawy 103
104 Inspection Procedure PEE Inspection & Tests Safe Unsafe Reda El-Khadrawy 104
105 Inspection & Testing Inspection by user. Inspection by competent person. Testing by competent person. Reda El-Khadrawy 105
106 Inspection by User Reda El-Khadrawy 106
107 These checks could be Appliance Inspection by User Is the on/off switch working correctly? Is there any sign of damage to casing? Are there any loose parts or missing screws? Is there evidence of overheating or moisture? Reda El-Khadrawy 107
108 Inspection by User Cable/mains lead It should be securely anchored to the plug and to the appliance/tool, with no: Signs of cuts. Fraying. Brittle cable. leads kinked or coiled. Taped joints or overloading. Cable cores should not be externally visible. Reda El-Khadrawy 108
109 Inspection by Competent Person Plug The cable should be securely anchored, with no signs of cracked casing, overheating, loose or bent pins. Socket-outlet Is it free from cracks or other damage? Are there any signs of overheating? Reda El-Khadrawy 109
110 Tool/Appliance Class of equipment. Inspection by Competent Person Environment, has it an appropriate (IP) rating &"Ex Rating. Rating plate. Reda El-Khadrawy 110
111 Cable/mains lead is secure at both the tool/appliance and plug. Plug Inspection by Competent Person cores are secure and correctly connected. no excess insulation removed and with no bare loose strands. fusing is correct. Reda El-Khadrawy 111
112 Why?!!! Testing Second-hand and previous history is unknown. As a result of inspections carried out. Manufacturer's instructions. After repairs or a prolonged period of non-use. Where previous history involves accidents or near misses. Use of equipment in a hazardous environment. Reda El-Khadrawy 112
113 Testing Types of Tests Polarity. Earth continuity. Insulation resistance. Functional Check. Any necessary other tests. Reda El-Khadrawy 113
114 Voltage supply Electrical Installation Safety Features Reda El-Khadrawy 114
115 Electrical Installation Safety Features Residual Current Devices (RCDs) Reda El-Khadrawy 115
116 Testing of RCD Electrical Test. Mechanical test. Reda El-Khadrawy 116
117 Frequency? Reda El-Khadrawy 117
118 Conclusion For safe operation, all electrical equipment must be certified by competent person. Reda El-Khadrawy 118
119 Portable Electrical Appliance Inspection and Testing Reda El-Khadrawy 119
120 Introduction. Work Duties. Definitions. Types of Equipment. Schedule of Inspection and Testing. Appliances Classes. Electrical Tests For Appliances of Class I&II. Content Frequency of Inspection and Testing. Recording of Inspection and Testing Results. Remedial Action. Who does the Inspection and Testing? Conclusion(Frequently Asked Questions). Reda El-Khadrawy 120
121 Introduction This document is published for the Staffordshire University s in The United kingdom. The university objective is to eliminate hazards and reduce the risk of injury to employees caused by electrical incidents. Reda El-Khadrawy 121
122 Work Duties The following duties apply to all work activities Manufacturers and suppliers covering the initial integrity (safety) of new electrical appliances. Covering the use and maintenance of appliances, designed to ensure that they remain in a safe condition. Relating to the use and maintenance of electrical appliances. Reda El-Khadrawy 122
123 Electrical Appliance : (H) Hand held (P) Portable (M) Movable (S) Stationary Definitions Competent Person. Portable Appliance Tester. Reda El-Khadrawy 123
124 Personal Equipment. Repaired Equipment. Equipment of Residual Current Devices. Types of Equipment Suppression Capacitors and Neon Lamps. Extension Cables. Reda El-Khadrawy 124
125 User Check without any formal training. Formal Visual Inspection- suitably trained person. Electrical Tests- suitably trained person, with suitable equipment. Schedule of Inspection and Testing Reda El-Khadrawy 125
126 Mains Lead Cuts/Fraying Tool long/short Taped joints Plug flex secured in gripper? Shows signs of overheating Cracked casing Job Suitability for the work to be undertaken User check inspection Appliance Does it work? On/Off switch functioning Cracked casing Chemical or corrosion damage to casing Damage resulting in access to live parts Environment Suitability for the environment it will be used in. Socket outlet or Mains Lead outlet Shows signs of overheating Cracked casing Reda El-Khadrawy 126
127 Plug Cracked casing Bent pins Incorrectly rated fuse Incorrectly connected wires Loose connections Loose cable clamp Formal Visual Inspection Mains Lead Cuts, fraying, brittle Kinked, coiled Taped joints Overloaded (overheated) Male connector (if fitted) Non-standard (IEC 320, BS4491, CEE22) Not secured by grommet/clamp on appliance Reda El-Khadrawy 127
128 Formal Visual Inspection Appliance Suitability for the environment or work being undertaken Damage/faulty operation of off/on switch Damage to casing Loose parts Missing screws Evidence of overheating Evidence of moisture Missing double insulation mark () on insulating casing (where appropriate) Accessible fuse holders: damage or removal of carrier permits live part to be touched Exposed output connections have marked voltage rating >50V Reda El-Khadrawy 128
129 Class I Rely on one layer of insulation covering its live internal parts such as : toasters, kettles, washing machines, lathes and pillar drills. Appliances Classes Class II Rely on two layers of insulation between live internal parts such as : food mixers, Drills, table lamps. Reda El-Khadrawy 129
130 Earth Continuity / Bonding Test (Only for Class I) Insulation Test Test voltage Electrical Tests For Appliances of Class I&II Earth Leakage Test Flash Test (Dielectric strength test) Operation V/A Test (Optional) Reda El-Khadrawy 130
131 Very Sensitive Electronic Equipment Earth Continuity / Bonding Test only. Do not use a PAT device. Using a multi-meter able to read to 300 milliohms, the resistance between the earth pin and any exposed metal (not signal sockets) should be less than 300 milliohm. Tests for Special Appliances Three phase equipment Under service contract or, By Buildings and Estates Division, Electrical Section. Reda El-Khadrawy 131
132 Frequency of Inspection and Testing A matter of judgement, and should be based on an assessment of risk to choose the frequency of inspection and testing and some factors should be considered: Environment. Users. Equipment construction. Equipment type. Reda El-Khadrawy 132
133 Frequency of Inspection and Testing NOTES: (1) Equipment types S, IT, M, P, H. (2) User checks. (3) The formal visual inspection &the combined inspection. (4) Class undefined. (5) Recording results. (6) Daily check for some appliances. (+)User check performed by the supervisor/member of staff. (#) Equipment with RCD circuits. Reda El-Khadrawy 133
134 Frequency of Inspection and Testing Reda El-Khadrawy 134
135 Frequency of Inspection and Testing Reda El-Khadrawy 135
136 Recording Results A dated test label must be affixed to the appliance show the following: Pass or Fail. Test given. Unique identification for the equipment. The due date of the next test. Note: A record must be kept either as paper records or computer records. Reda El-Khadrawy 136
137 Remedial Action If appliance fails tests, it is unsafe and it must be taken out of service until remedial action is taken. Suspected equipment should be locked away. Can not be repaired, or is not required any more, it must be disposed. Reda El-Khadrawy 137
138 Who does the Inspection and Testing? Inspection and Testing must be carried out by Competent Persons or individuals, should have the required skills Electrical knowledge. Electrical experience. Understanding of the system/equipment to be worked on. Understanding of the hazards which could arise. The ability to recognize at any time whether it is safe to continue to work. Reda El-Khadrawy 138
139 Conclusion What should I do if the equipment is broken or not working? What if the equipment has no CE(Conformité Européene)mark? Do I fail the equipment if it only fails one or more of the tests? Should I do a flash test (dielectric strength test)? Do I need to test New Equipment? Reda El-Khadrawy 139
140 Checking electrical equipment conformity with standards 140
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