First, the status of LED North American standards
LED energy-saving lamps as a new type of products, the current North American product safety standards do not specifically address the technical requirements of such products, LED product testing has become a topic in the industry. For the current industry situation, UL Labs of the United States is organizing the preparation of LED energy-saving lamp safety certification standard UL8750, which is still drafted and has not been officially adopted as the certification standard. Therefore, the certification test problem of LED energy-saving lamps has not been completely solved.
The basic principle of the LED energy-saving lamp is to convert the AC power to DC power through the switch-type power module to supply power to the LED. According to the basic principle and structural characteristics of LED energy-saving lamps, MET Labs of the United States proposes a transitional detection scheme at the present stage: the US certification standard UL1993 (corresponding to the Canadian standard CAN/CSA-C22.2No.0, CAN/ CSA-C22.2No.74), and power module standard UL1310 or UL1012 (corresponding to Canadian standard CAN/CSA-C22.2No.107) test and certification of LED energy-saving lamps.
Second, the technical points in the test
The following is a description of the key issues in the LED energy-saving lamp certification test based on the UL1993, UL1310 and UL1012 standards.
1. material
The LED energy-saving lamp can be made into various shapes. For example, the fluorescent tube type LED energy-saving lamp has the same shape as the ordinary fluorescent tube, and the power module and the light-emitting diode are enclosed by the tubular transparent polymer casing of the fluorescent lamp. The transparent polymer housing provides fire and shock protection in the product. According to the standard requirements, the energy-saving lamp housing material must reach the V-1 level or above, so the transparent polymer housing must be made of V-1 or higher. It should be noted that the product casing must meet the required V-1 rating, and its thickness must be greater than or equal to the thickness required for the V-1 grade of the raw material. The fire rating and thickness requirements can be found on the UL yellow card of the raw material. . In actual testing, it was found that in order to ensure the brightness of the LED lamp, the manufacturer often made the transparent polymer casing thin, which required the inspection engineer to ensure that the material meets the required thickness of the fire rating. Since different raw materials have different thickness requirements for the same fire rating, some raw materials can meet higher fire rating requirements at a lower thickness. It is recommended that the manufacturer can select the appropriate raw material for the product casing.
2. Drop test
According to the requirements of the product standard, the product should simulate the drop test that may occur during the actual use, and the product should fall from the height of 0.91 m to the hard board. The outer casing of the product should not be broken to expose the dangerous parts inside. This strength requirement must be considered when the manufacturer selects the material for the product's outer casing.
3. Dielectric strength
The transparent casing encloses the power module inside, and the transparent casing material must meet the electrical strength requirements. According to the standard requirements, based on the condition of 120 volts in North America, the internal high-voltage live parts and the outer casing (tested with metal foil) should be able to withstand the 1240 volt AC resistance test. Under normal circumstances, the thickness of the product shell reaches about 0.8 mm, which can meet the requirements of this electric strength test.
4. Power module
The power module is an important part of the LED energy-saving lamp. The power module mainly uses switching power supply technology. Different types of power modules can be considered for testing and certification. If the power module is a class II power supply, this can be tested with UL1310. The class II power supply is a power supply that uses an isolated transformer with an output voltage lower than 60 VDC and a current less than 150/Vmax amps. For non-class II power supplies, UL1012 is used to test the certification. The technical requirements of these two standards are very similar and can be referred to each other. Most of the internal power modules of LEDs use a non-isolated power supply. The DC output voltage of the power supply is also greater than 60 volts. Therefore, the UL1310 standard is not applicable, and UL1012 is applicable.
5. Insulation requirements
Due to the limited internal space of LED energy-saving lamps, in the structural design, attention should be paid to the insulation requirements between dangerous live parts and accessible metal parts. The insulation can be a space distance and a creepage distance, or it can be an insulating sheet. According to the standard requirements, the distance between the hazardous live parts and the accessible metal parts should be 3.2 mm, and the creepage distance should be 6.4 mm. If the distance is not enough, you can add insulation sheet as additional insulation. The thickness of the insulation sheet is greater than 0.71 mm. If the thickness is less than 0.71 mm, the product should be able to withstand a high voltage test of 5000V.
6. Temperature rise test
The temperature rise test is a mandatory item for product safety testing. The standard has certain temperature rise limits for different components. In the product design phase, manufacturers should pay great attention to the heat dissipation of the product, especially for certain components (such as insulation sheets).
Parts that work under high temperature conditions for a long period of time are prone to damage, posing a fire or electric shock hazard. The power module inside the luminaire is in a tight space and the heat dissipation is limited. Therefore, when making a component selection, the manufacturer should pay attention to selecting the specifications of the appropriate components to ensure that the components work under a certain margin, so as to avoid the components working under conditions of near full load for a long time.
7. structure
The power module of the LED energy-saving lamp is installed inside the casing, and the space is limited. Some manufacturers can solder the surface of the pin-type component to the PCB in order to save space. This is unacceptable. These surface-welded pin-type components are likely to fall off due to soldering or the like, posing a hazard. Therefore, it is necessary to adopt a jack welding method for these components. If the surface welding method has to be used, it is necessary to provide additional protection for the component by means of glue fixing.
8. Fault test
Product failure testing is a critical test item in product certification testing. This test item is to short-circuit or open some components on the line to simulate the failures that may occur during actual use to evaluate the safety of the product under a single fault condition. In order to meet this safety requirement, it is necessary to consider adding a suitable fuse at the input end of the product to prevent an overcurrent in the output short circuit or internal component failure, resulting in a fire hazard.
Third, factory inspection
North American product certifications are subject to factory inspections, and factory inspections include first factory inspections and follow-up inspections. If the factory is applying for North American product certification for the first time, the first factory inspection is required. The first factory inspection is mainly for the quality assurance system of the factory. The factory is required to have a complete quality assurance system to ensure that the quality of the products is effectively regulated and guaranteed. If the factory has established a quality management system in accordance with ISO9000 standards and passed ISO9000 certification, it can basically meet the requirements of the first factory inspection management system. If the factory does not pass the ISO9000 certification, it must have clear program files in the procurement of raw materials, incoming inspection, inventory management, product design, engineering changes, production line testing, instrument calibration and complaint follow-up, and effectively implement. The follow-up inspection is mainly for the structural inspection of the product and the testing of the production line products to ensure that the product structure and the certified samples produced by the production line are consistent and passed the relevant production line test. After the product has passed the test and certification, the manufacturer must strictly follow the structure and component list of the certified samples for production. Any changes that may involve product safety must be notified to the certification body for evaluation. If necessary, retesting and reporting modifications may be required. The test report of the product has clear requirements for the production line test of the product. The manufacturer must carry out relevant tests according to the requirements, such as high voltage test and grounding continuity test.
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