AALTO UNIVERSITY

SCHOOL OF SCIENCE AND TECHNOLOGY

Faculty of Electronics, Telecommunications and Automation

Department of Electronics
Lighting Unit

Matti Sinisalo

Standardisation of LED luminaires and controlgear for safety and performance

S-118.4250 Postgraduate seminar on illuminating engineering 2010

Seminar work

Espoo 2010-12-01

Supervisor Professor Liisa Halonen

AALTO-UNIVERSITY

SCHOOL OF SCIENCE AND TECHNOLOGY Abstract of Seminar Work

Author: Matti Sinisalo

Name of the work: Standardisation of Number of pages: 24 pages

LED luminaires and controlgear for
safety and performance

Date: 2010-12-01

Faculty: Faculty of electronics, communication and automation, Department of

electronics

Professorship: S-118

Supervisor: Liisa Halonen

Abstract text:

Light emitting diodes (LEDs) are seen an important technology to improve energy
efficiency in lighting. The efficacy and quality of LEDs are developing fast. While there
are thousands of products available on markets, their quality and performance are not
presented in clearly comparable manner.

The lack of standardisation has been commonly mentioned as a disadvantage of using

LEDs. To allow greater acceptance to LEDs, it is clear that in near future appropriate
standards are necessary to be developed. In this seminar paper, the current status of
international standardisation of LED luminaires and controlgear is reviewed. Both safety
and performance standardisation is taken into consideration.

Keywords: LED, controlgear, luminaire, standard

Preface
The Lighting Unit of Aalto University’s School of science and technology organised the
seminar on energy efficient LED lighting on 9–10 September 2010. Lecturers were
from Finland, the USA and Germany representing universities and the lighting industry.
Lecture topics covered LED lighting solutions for outdoor lighting, LED testing and
standardisation, optical, thermal and colour issues of LEDs and current technological
status and future development in LED lighting. By writing this seminar work, my goal
is to share information to my fellow students about current status of standardisation of
LED luminaires and controlgear. I would especially like to thank Mr. Markku Norhio
representing Helvar from all valuable information he gave to me. I would also like to
thank all lecturers, organisers and participants of this informative and succeeded
seminar.

Espoo 2010-12-01
Matti Sinisalo
Table of Contents
 

Preface ...............................................................................................................................3  

List of symbols and abbreviations.....................................................................................5  

1.   Introduction ...............................................................................................................6  

2.   LED product standardisation.....................................................................................7  

3.   Safety requirements and tests for controlgear for LED modules ..............................9  

4.   Performance requirements and tests for controlgear for LED modules ..................19  

Conclusions .....................................................................................................................23  

References .......................................................................................................................24  
List of symbols and abbreviations
LED light emitting diode
IEC International Electrotechnical Commission
PAS publicly available specification
SELV safety extra low voltage
IEV International Electrotechnical Vocabulary
tc rated maximum operating temperature of the case
of a controlgear
r.m.s. root-mean-square
t temperature
d.c. direct current
a.c. alternating current
λ power factor
tl maximum surface temperature (t-lifetime) of the
controlgear that allows a life of 50 000 h to
achieved
1. Introduction
Light emitting diodes (LEDs) are seen an important technology to improve energy
efficiency in lighting. The efficacy and quality of LED are developing fast. With LEDs
it is possible to realise many different kind of lighting needs; LEDs are highly effective
illuminants for work and reading luminaires, orientation aids, pathway lighting,
emergency lighting, decorative and architectural purposes and accent applications
(Pfanner, 2004). Nowadays, also for general lighting purposes in commercial, industrial
and residential facilities and outdoors, LEDs provide competitive solutions. While there
are thousands of products available on markets, their quality and performance are not
presented in clearly comparable manner. This deviation in quality and performance is
even greater in LED luminaires, since, for example, installation method, ambient
temperature and voltage variations affect the output of LEDs.

The lack of standardisation has been commonly mentioned as a disadvantage of using

LEDs (Halonen et al. 2010). To allow greater acceptance to LEDs, it is clear that in near
future appropriate standards are necessary to be developed (Ludwig 2010). In this
seminar paper, the current status of international standardisation of LED luminaires and
controlgear published by IEC is reviewed. Both safety and performance standardisation
is taken into consideration. The electromagnetic compatibility of LED luminaires and
controlgear is not discussed in this paper. Mainly this paper deals with the
standardisation of LED controlgear, since especially for LED luminaires there are only
a few safety requirements and performance requirements are not published.

6
2. LED product standardisation
LED product standards can be divided into safety and performance requirements. In
general, the standardisation is further in safety than in performance requirements. The
safety and performance requirements for LED luminaires and controlgear are listed in
Table 1. For luminaires, IEC 60598-1 is the most important standard, since it gives all
the general requirements for safety. Particular requirements, for example for recessed
luminaires (IEC 60598-2-2), luminaires for emergency lighting (IEC 60598-2-22) or
floodlights (IEC 60598-2-5), are expressed in IEC 60598-2 series. There is not
performance standard for luminaires but for LED luminaires the standardisation is in
progress by IEC (Norhio, 2010). For controlgear both safety and performance standards
are already published. LED controlgear must meet the general requirements given in
IEC 61347-1 and, in addition, particular requirements given IEC 61347-2-13. The
performance requirements for controlgear for LED modules are given in IEC 62384 and
its amendment 1.

Table 1. The overview of IEC standards for LED luminaires and controlgear (CELMA 2010).

Product type Safety standard Performance standard

LED luminaires 60598-1 PAS XXXXX
60598-2 series
LED controlgear 61347-1 62384
61347-2-13

As shown in Figure 1, LED products are divided into three groups: Self-ballasted LED
lamps, electronic controlgear for LED modules and self-ballasted LED modules.
Controlgear can, with suitable connection system, form an illuminant system with LED
modules.

Figure 1. Overview of systems composed of LED modules and controlgear (IEC 62031, 2008).

7
Self-ballasted LED modules are designed to for connection to the supply voltage.
However, if the self-ballasted LED module is equipped with a lamp cap, it is regarded
to be a self-ballasted LED lamp (IEC 62031). The unit that is inserted between the
supply and LED modules, which serves to supply the LED modules with their rated
voltage or rated current, is defined as the electronic controlgear for LED modules (IEC
61347-2-13). The controlgear may include means for dimming, correcting the power
factor and suppressing radio interference.

LED modules are classified, according to the method of installation, as built-in, integral
and independent modules. If a self-ballasted LED module, an electronic controlgear for
LED module or their combination are regarded as a built-in component, it means that it
is designed to form a replaceable part built into a luminaire and it is not intended to be
mounted outside a luminaire. If they are regarded as an integral component, it means
that they are generally designed to form a non-replaceable part of a luminaire.
Independent components are designed so that they can be mounted or placed separately
from a luminaire and they provide all the necessary protection with regard to safety
(IEC 62031).

Controlgear are classified, according to the method of installation, as built-in,

independent or integral. An example of each controlgear class is presented in Figure 2.
Built-in controlgear are generally designed to be built into a luminaire, a box, an
enclosure or the like and not intended to be mounted outside a luminaire. Independent
controlgear consists of one or more separate elements so designed that it can be
mounted separately outside a luminaire, with protection according to the marking of the
controlgear and without any additional enclosure. Integral controlgear forms a non-
replaceable part of a luminaire and it cannot be tested separately from the luminaire
(IEC 61347-1). Sometimes term ballast is used as byword for controlgear but according
to IEC 61347-1 it means unit that is inserted between the supply and one or more
discharge lamps which by means of inductance, capacitance, or a combination of both,
serves mainly to limit the current of the lamp to the required value. That is why ballast
should not be used in place for controlgear for LED modules. Controlgear are also
classified according to protection against electric shock, as SELV-equivalent or
isolating controlgear, auto-wound controlgear and independent SELV controlgear (IEC
61347-2-13).

Figure 2. A built-in (a), an independent (b) and an integral (c) controlgear (Tridonic, 2010; 2009;
2008a).

8
3. Safety requirements and tests for controlgear for
LED modules
An overview of safety requirements and tests are presented in Figure 3. Controlgear
shall be so designed and constructed that in normal use it operates without danger to the
user or surroundings. Compliance is checked by carrying all the tests specified in IEC
61347-1, IEC 61347-2-13 and, if applicable, in IEC 60598-1 and IEC 60065.

Figure 3. The overview of safety requirements of and tests for controlgear for LEDs.

Particular safety requirements for controlgear for LED modules state that following
items must be marked either on the controlgear or made available in the manufacturer’s
catalogue. The mark of origin of product (trade mark, manufacturer’s name or name of
the responsible vendor/supplier) and model number must be presented. If controlgear is
classified as independent, it must be presented with an appropriate symbol (Figure 4f).

Figure 4. Marking symbols for controlgear (IEC 61347-1).

9
The correlation between replaceable and interchangeable parts, including fuses, of
controlgear shall be marked unambiguously by legends on the controlgear or be
specified in manufacturer’s catalogue.

If the controlgear has earthing terminals, they shall be identified by the appropriate
symbol. Symbol presented in Figure 4a describes a terminal to which are connected
parts connected to earth for safety reasons. Symbol presented in Figure 4b describes a
terminal to which are connected parts which may be necessary to connect to earth for
reasons other than safety. A terminal whose potential is taken as reference is presented
in Figure 4c. The earthing terminal marking symbols shall not be placed on screws or
other easily removable parts. The earthing symbols presented in IEC 61347-1 may be,
however, slightly misleading since International Electrotechnical Vocabulary (IEV)
chapter 195 (Earthing and protection against electric shock) recognises only two kinds
of earthing: protective earthing (195-01-11) and functional earthing (195-01-13) (IEV,
2010). That is why it is not clear why there should be needs for any other symbols for
marking earthing terminals.

Symbol presented in Figure 4e is for temperature declared, thermally protected

controlgear. The dots in the triangle shall be replaced by the value of the rated
maximum case temperature in degrees Celsius assigned by the manufacturer. The
controlgear case temperature at any place shall not exceed the marked value (IEC
61347-1). The F mark (Figure 4d) requirement has been removed from the latest edition
of IEC 60598-1. It assumed that all products have to comply with mounting on normally
flammable surfaces. If a product cannot meet this requirement, then it shall be marked
accordingly.

Wiring diagram must indicate the position and purpose of terminals. In the case of lamp
controlgear having no terminals, a clear indication shall be given on the wiring diagram
of the significance of the code used for connecting wires (for example colours).
Controlgear that operates in specific circuits only shall be identified accordingly, for
example by marking or wiring diagram. The value of tc (rated maximum temperature on
the outer surface) must be indicated and if it relates to a certain place on the controlgear,
this place shall be indicated or shall be specified in the manufacturer’s catalogue (Figure
5). Rated supply voltage (or voltages, if there are several), voltage range and supply
frequency must be marked on controlgear. Supply current, however, may be given in the
manufacturer’s literature. For constant voltage types the rated output voltage and for
constant current types the output current together with maximum output voltage must be
presented. If the controlgear is suitable for operation with LED modules only, it must be
indicated (IEC 61347-1; IEC 61347-2-13).

10
Figure 5. Tc point indication on controlgear (Tridonic, 2008b).

In addition to above mandatory markings, if applicable, a mention whether the

controlgear has mains-connected windings or whether controlgear is SELV-equivalent
must be presented. An indication that the controlgear does not rely on the luminaire
enclosure for protection against accidental contact with live parts shall be made.
Suitable conductor cross-sections for terminals, if any, shall be given. Also, if
applicable, LED module type and rated wattage or wattage range for which the
controlgear is suitable shall be made available (IEC 61347-1; IEC 61347-2-13).

Durability and legibility of marking

The durability and legibility of markings must be checked by inspection and by trying to
remove the marking by rubbing lightly, for 15 s each time, with two pieces of cloth, one
soaked with water and the other with petroleum spirit. Markings shall be durable after
the test. (IEC 61347-1)

Protection against accidental contact with live parts

Controlgear, which do not rely upon the luminaire enclosure for protection against
electric shock, must be sufficiently protected against accidental contact with live parts
when installed in normal use. Integral lamp controlgear, which relies upon the luminaire
enclosure for protection, shall be tested according to its intended use. Parts providing
protection against accidental contact shall have adequate mechanical strength and shall
not work loose in normal use. It shall not be possible to remove them without the use of
a tool. Lamp controlgear incorporating capacitors of total capacitance exceeding 0,5 µF
shall be constructed so that the voltage at the lamp controlgear terminations does not
exceed 50 V, 1 min after disconnection of the lamp controlgear from a source of supply
at rated voltage. Compliance is checked by inspection and by a manual test, and with
regard to protection against accidental contact, by means of the test finger using an
electrical indicator to show contact. (IEC 61347-1)

For SELV-equivalent controlgear, the accessible parts shall be insulated from live parts
by double or reinforced insulation. Output circuits of SELV- or SELV-equivalent
controlgear may have exposed terminals, if the rated output voltage for constant voltage

11
controlgear or maximum output voltage for constant current controlgear under no load
does not exceed 25 V r.m.s. and if the no-load output voltage does not exceed 33 V
r.m.s. and the peak does not exceed 33√2 V. Compliance is checked by measuring the
output voltage when steady conditions are established, the controlgear being connected
to rated supply voltage and rated frequency. For the test under load, the controlgear is
loaded with a resistance, which would give rated output at rated output voltage. For
controlgear with more than one rated supply voltage, the requirement is applicable for
each of the rated supply voltages. Controlgear with a rated output voltage above 25 V
shall have insulated terminals. (IEC 61347-2-13)

Terminals

Altogether, seven types of terminals are defined in IEC 60598-1: pillar, screw, stud,
saddle, lug, mantle and screwless terminals. Requirements presented in this standard,
however, do not exclude terminals of types other than defined. Terminals shall provide
adequate connection of the conductors and shall withstand the mechanical, electrical
and thermal stresses occurring in normal use. Compliance is checked by mechanical,
and electrical tests.

Resistance to corrosion is checked by the corrosion test. Terminals shall be fixed. When
tightened or loosened, or when conductors are inserted or withdrawn, the terminals shall
not work loose, internal wiring shall not be subjected to stress, and creepage distances
and clearances shall not be reduced. Compliance is checked by inspection, by
measurement and by testing. Terminals shall clamp the conductor reliably between
metal surfaces. Compliance is checked by inspection and by pulling test. During the
test, the conductor shall not move noticeably in the terminal. Terminals shall clamp the
conductor without undue damage to the conductor. Conductor are unduly damaged if
the show deep or sharp indentations. (IEC 60598-1)

Provision for protective earthing

Earthing terminals have the same requirements that all the terminals have. The electrical
connection shall be adequately locked against loosening, and shall not be possible to
loosen the electrical connection by hand without the use of a tool. For screwless
terminals, it shall not be possible to loosen the electrical connection unintentionally.
Earthing of lamp controlgear (other than independent lamp controlgear) via means of
fixing the lamp controlgear to the earthed metal is permitted. However, if a lamp
controlgear has an earthing terminal, this terminal shall only be used for earthing the
lamp controlgear. All parts of an earthing terminal shall be such as to minimize the
danger of electrolytic corrosion resulting from contact with the earth conductor or any
other metal in contact with them. The screw and the other parts of the earthing terminal
shall be made of brass or other metal no less resistant to corrosion, or material with a
non-rusting or any other metal in contact with them. Compliance is checked by
inspection, by manual test and by mechanical and electrical test that are required for
terminals. (IEC 61347-1)

12
Moisture resistance and insulation

Lamp controlgear shall be moisture-resistant. They shall not show any appreciable
damage after being subjected to the following test. The lamp controlgear is placed in the
most unfavourable position of normal use, in a humidity cabinet containing air with a
relative humidity maintained between 91% and 95%. The temperature of the air at all
places where samples can be located shall be maintained within 1 ºC of any convenient
value t between 20 ºC and 30 ºC. Before being placed in the humidity cabinet, the
sample is brought to a temperature between t and (t+4) ºC. The sample shall be kept in
the cabinet for 48 h. Before the insulation test, visible drops of water, if any, are
removed by means of blotting paper. Immediately after the moisture treatment, the
insulation resistance shall be measured with a d.c. voltage of approximately 500 V,
1 min after application of the voltage. Lamp controlgear having an insulating cover or
envelope shall be wrapped with metal foil. Insulation resistance shall be not less than
2 MΩ for basic insulation. Insulation shall be adequate

- between live parts of different polarity which are or can be separated;

- between live parts and external parts, including fixing screws;
- between live parts and control terminals, where relevant.

In the case of lamp controlgear having an internal connection or component between

one or more output terminals and the earth terminal, such a connection shall be removed
during this test. (IEC 61347-1)

For SELV-equivalent controlgear, the insulation between input and output terminals not
bonded together shall be adequate. With double or reinforced insulation, the resistance
shall be not less than 4 MΩ. (IEC 61347-2-13)

Electric strength

Controlgear shall have adequate electric strength. Immediately after the measurement of
insulation resistance, the controlgear shall withstand an electric strength test for 1 min
applied between the parts specified. The test voltage of substantially sine-wave form,
having a frequency of 50 Hz or 60 Hz shall correspond to the values in Table 2.
Initially, not more than half the specified voltage shall be applied, the voltage then being
raised rapidly to the prescribed value. (IEC 61347-1)

Table 2. Electric strength test voltage (IEC 61347-1).

Working voltage U Test Voltage

V
Up to and including 42 V 500
Above 42 V up to and including 1 000 V Basic insulation 2U + 1000
Supplementary insulation 2U + 1750
Double or reinforced insulation 4U + 2750

13
Insulation conditions of windings of separating transformers in SELV-equivalent
controlgear shall apply according to 14.3.2 of IEC 60065. (IEC 61347-2-13)

Fault conditions

Controlgear shall be so designed that, when operated under fault conditions, there shall
be no emission of flames or molten material or production of flammable gases. The
protection against accidental contact shall not be impaired. For lamp controlgear marked
with symbol presented in Figure 4e, the case temperature at any place shall not exceed
the marked value.

Operation under fault conditions denotes that each of the following conditions is applied
in turn and, associated with it, those other fault conditions:

- Short circuit across creepage distances and clearances;

- short-circuit across or, if applicable, interruption of semi-conductor devices;
- short-circuit across insulation consisting of covering of lacquer, enamel or
textile;
- short circuit across electrolytic capacitors.

Compliance is checked by operating the controlgear at any voltage between 90% to

110% of the rated supply voltage with the lamp connected and with the lamp
controlgear case at tc; then, each of the fault conditions shall be applied in turn.
Components such as resistors, capacitors, semiconductors, fuses, etc. may fail during
fault conditions. It is permitted to replace such components so as to continue the test.

After the tests, when the lamp controlgear has returned to ambient temperature, the
insulation resistance measured at approximately 500 V d.c. shall be not less than 1 MΩ.

To check whether gases liberated from component parts are flammable or not, a test
with a high-frequency spark generator is made. Whether accessible parts have become
live has to be checked by testing. To check whether emission of flames or molten
material might present a safety hazard, the test specimen is wrapped with a tissue paper
and shall not ignite.

Transformer heating

In SELV-equivalent controlgear, the windings of separating transformers shall be tested.

During normal operation, no part of the apparatus shall attain an excessive temperature.
Compliance is checked by measuring the temperature rise under normal operating
conditions after 4 h of operation. When the apparatus is operated under fault conditions,
no part shall reach such a temperature that there is a danger of fire to the surroundings
of the apparatus and safety is impaired by abnormal heat developed in the apparatus.
Compliance is checked by the tests.

14
For normal operation, the values in the second column of Table 3 shall apply. For
operation under abnormal conditions and fault conditions, the values in the third column
of Table 3 shall apply.

Table 3. Permissible temperature rise of parts of the apparatus (IEC 60065).

Parts of the apparatus Normal Fault

operating conditions
conditions
K K
a) Accessible parts
Knobs, handles, etc. if
- metallic 30 65
- non-metallic 50 65
Enclosures if
- metallic 40 65
- non-metallic 60 65
b) Parts providing electrical insulation
Supply cords and wiring insulation with
- PVC or synthetic rubber
- not under mechanical stress 60 100
- under mechanical stress 45 100
- natural rubber 45 100
Other insulations of:
- thermoplastic materials varies varies
- non-impregnated paper 55 70
- non-impregnated cardboard 60 80
- impregnated cotton, silk, paper and textile 70 90
- laminates based on cellulose or textile, bonded with
- phenol-formaldehyde, melamine-formaldehyde, phenol-furfural or 85 110
polyester
- epoxy 120 150
- mouldings of
- phenol-formaldehyde or phenol-furfural, melamine and melamine
phenolic compounds with
- cellulose fillers 100 130
- mineral fillers 110 150
- thermosetting polyester with mineral fillers 95 150
- alkyd with mineral fillers 95 150
- composite materials of
- polyester with glass-fibre reinforcement 95 150
- epoxy with glass-fibre reinforcement 100 150
- silicone rubber 145 150
c) Parts acting as a support or a mechanical barrier including the inside of
enclosures
Wood and wood-based materials 60 90

15
 Thermoplastic materials varies varies
Other materials varies varies
d) Winding wires
- insulated with
- non-impregnated silk, cotton, etc. 55 75
- impregnated silk, cotton, etc. 70 100
- oleoresinous materials 70 135
- polyvinyl-formaldehyde or polyurethane resins 85 150
- polyester resins 120 155
- polyesterimide resins 145 180
e) Other parts
These temperature rises apply to parts not covered by items a), b) c) and d):
Parts of wood and wood-based material 60 140
Lithium batteries 40 50
Resistors and parts of metal, glass, ceramic, etc. no limit no limit
All other parts 200 300

Abnormal conditions

The controlgear shall not impair safety when operated under abnormal conditions. For
controlgear, which are of the constant voltage or constant current output type, the
following conditions shall be applied for 1 h:

a) No LED module is inserted

b) Double the LED modules or equivalent load for which controlgear is
designed.
c) The output terminals of the controlgear shall be short-circuited.
During and at the end of the tests specified, the controlgear shall show no defect
impairing safety, nor shall any smoke or flammable gases be produced. In addition, for
controlgear of constant current output type the maximum output voltage shall not be
exceeded. Compliance shall be tested at any voltage between 90% and 110% of the
rated supply voltage.

Construction

Wood, cotton, silk, paper and similar fibrous material shall not be used as insulation,
unless impregnated. Compliance is checked by inspection. (IEC 61347-1)

Socket-outlets in the output circuit shall not accept plugs complying with IEC 60083
(plugs and socket-outlets for domestic and similar general use standardized in member
countries of IEC) and IEC 60906 (IEC System of plugs and socket-outlets for household
and similar purposes); neither shall it be possible to engage plugs accepted by socket-
outlets in the output circuit with socket-outlets complying with IEC 60083 and IEC
60906. Compliance is checked by inspection and by manual test. (IEC 61347-2-13)

16
 Creepage distances and clearances

Creepage distances and clearances shall be not less than the values given in Table 4 and
Table 5, as appropriate. The contribution to the creepage distance of any groove less
than 1 mm wide shall be limited to its width.

Table 4. Minimum distances for a.c. (50/60 Hz) sinusoidal voltages (IEC 61347-1).

Working voltage not exceeding

V (r.m.s.)
Minimum clearance mm 50 150 250 500 750 1 000
a) Between live parts of different polarity, and
b) Between live parts and accessible metal parts
which are permanently fixed to the lamp
controlgear, including screws or devices for
fixing covers or fixing the lamp controlgear to
its support
c) For ballasts declared not to rely on the luminaire
enclosure for protection against electric shock –
between live parts and the outer accessible
surface of insulating parts
- Creepage distances
Insulation PTI ≥ 600 0,6 1,4 1,7 3 4 5,5
< 600 1,2 1,6 2,5 5 8 10
- Clearances 0,2 1,4 1,7 3 4 5,5
c) Between live parts and a flat supporting surface
or a loose metal cover, if any, if the construction
does not ensure that the values under b) above
are maintained under the most unfavourable
circumstances
- Clearances 2 3,2 3,6 4,8 6 8

Table 5. Minimum distances for non-sinusoidal pulse voltages (IEC 61347-1).

Rated pulse voltage

peak kV
2,0 2,5 3,0 4,0 5,0 6,0 8,0 10 12 15 20 25 30 40 50 60 80 100
Minimum clearance
1,0 1,5 2 3 4 5,5 8 11 14 18 25 33 40 60 75 90 130 170
mm

Screws, current-carrying parts and connections

Screw, current-carrying parts and mechanical connections, the failure of which might
cause the controlgear to become unsafe, shall withstand the mechanical stresses
occurring in normal use. Requirements are the same as are required for luminaires.
Compliance is checked by inspection and the tests of 4.11 and 4.12 of Clause 4 of IEC
60598-1. (IEC 61347-1)

17
Resistance to heat, fire and tracking

Parts of insulating material either retaining live parts in position or providing protection
against electric shock shall be sufficiently resistant to heat. Compliance is checked by
the certain resistance-to-heat test in accordance with IEC 60598-1. External parts of
insulating material providing protection against electric shock and parts of insulating
material retaining live parts in position shall be sufficiently resistant to flame and
ignition or fire. (IEC 61347-1)

For materials other than ceramic, compliance is checked by the test in which external
parts of insulating material providing protection against electric shock shall be subjected
for 30 s to the glow-wire test in accordance with IEC 60695-2-10 or by the in which
parts of insulating material retaining live parts in position shall be subjected to the
needle-flame test in accordance with IEC 60695-11-5, as appropriate. Controlgear
intended for building into luminaires other than ordinary, independent controlgear, and
controlgear having insulation subject to starting voltages with a peak value higher than
1500V shall be resistant to tracking. (IEC 61347-1)

Resistance to corrosion

Ferrous parts, the rusting of which might cause the lamp controlgear to become unsafe,
shall be adequately protected against rusting. Compliance is checked by the following
test:

All grease is removed from the parts to be tested. The parts are then immersed for
10 min in a 10% solution of ammonium chloride in water at a temperature of 20 °C ±
5 °C. Without drying, but after shaking off any drops, the parts are placed for 10 min in
a box containing air saturated with moisture at a temperature of 20 °C ± 5 °C. After the
parts have been dried for 10 min in a heating cabinet at a temperature of 100 °C ± 5 °C,
their surfaces shall show no signs of rust. (IEC 60598-1)

18
4. Performance requirements and tests for controlgear
for LED modules
Performance requirements for d.c. (<250 V) or a.c. (<1000 V at 50/60 Hz) supplied
electronic gear for LED modules (according to IEC 62031) are presented in IEC 62384
(2006) and its amendment 1 (2009). An overview of performance requirements and tests
are presented in Figure 6. In performance criteria, there are presented controlgear
classifications (Figure 7), product markings, the properties of output voltage and
current, total circuit power, power factor, supply current, impedance at audio-
frequencies, operational test and endurance.

Figure 6. The overview of performance requirements and tests of controlgear for LED modules.

Electronic controlgear for LED modules can be classified according to the load, the
output voltage or the output current. If a controlgear is classified according to the load,
this type of controlgear is designed either for use with one specific output wattage only
(one or more LED modules) or for use with one or more LED modules with a total load
within the declared wattage range. Furthermore, both voltage and current classified
controlgear are divided into two subclasses depending whether their output voltage or
current is stabilised or not.

19
Figure 7. The classification of electronic controlgear for LED modules.

Marking

The circuit power factor has to given as, for example λ = 0.9 C. Letter C after power
factor value must be marked if the power factor is less than 0.95 leading. In addition to
this mandatory marking, if applicable, limits of permissible temperature range, an
indication that the controlgear has a stabilised output voltage (or current), an indication
that the controlgear is suitable for operation with a mains supply dimmer and an
indication of the operation mode (e.g. phase control) must be given. These information
must be given on the controlgear or made available in manufacturer’s catalogue,
excluding power factor, which must be clearly be marked on controlgear. (IEC 62384)

Controlgear manufacturer can, naturally, present additional information on product. IEC

62384 recognises as optional markings total circuit power and, if applicable, the symbol
(indicating compliance with conditions for audio-frequency impedance) and the
symbol indicating that the controlgear is a short circuit proof type.

Output voltage and current

For output voltage and current there are requirements for starting and connecting,
normal operation, capacitive load and voltage surges during switching and operation.
The output of controlgear, after starting or connecting, should be within 110% (if output
voltage is a.c., the 110% is the percentage of the r.m.s. value) of its rated value within 2
s. Maximum current or maximum voltage shall not exceed the values given by the
manufacture. When operating at rated supply voltage, the output must not differ by
more than ±10% from the rated voltage of the LED modules, if a controlgear is
classified according to non-stabilised output voltage. For a controlgear having stabilised
output voltage, the output voltage must not differ more than ±10% from the rated
voltage of the LED modules, when supplied at within the range of 92…106% of the
rated supply voltage. Same criteria are presented for current during operation. If a
controlgear is classified as multiple load controlgear, it shall be tested with both

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minimum and maximum load. Values for permissible voltage surges during switching
and operation are under consideration. If the LED module contains capacitors, current
pulses may be generated when connecting the LED module to the controlgear. This
must neither disturb the proper functioning of overcurrent detection nor the starting
process of the controlgear. (IEC 62384)

Total circuit power

At rated voltage, the total circuit power shall not be more than 110% of the value
declared by the manufacturer, when the controlgear is operated with LED modules (IEC
62384).

Circuit power factor

The measured circuit power factor must not be less than marked by more than 0,05
when operating on rated wattage with LED module(s) and with rated supply voltage and
frequency (IEC 62384).

Supply current

At rated voltage, the supply current must not differ by more than +10% from the value
marked on the controlgear or declared in the manufacturer’s literature, when that
controlgear is operated on its rated wattage with LED modules (IEC 62384).

Impedance at audio-frequencies

For every signal frequency between 400 Hz and 2000 Hz, the impedance of the
controlgear 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 resistance of the resistor which would dissipate the same
power as the LED module-controlgear combination when operating at its rated voltage
and frequency. The controlgear impedance is measured with a signal voltage equal to
3,5% of the rated supply voltage of the controlgear. Between 250 Hz and 400 Hz, the
impedance shall be at least equal to half the minimum value required from frequencies
between 400 Hz to 2 000 Hz. (IEC 62384)

Operational tests for abnormal conditions

The controlgear shall not be damaged under operational test for abnormal conditions
such as no LED module(s) inserted, reduced LED module resistance and short-circuit (if
short-circuit proof type). After test simulating these conditions and after restoration of a
possible protecting device, the controlgear shall function normally. (IEC 62384)

Endurance

To proof its endurance a controlgear must be subjected to a temperature cycling shock

test and supply voltage switching test. At the end of these test the controlgear shall
operate an appropriate LED module or LED modules correctly for 15 min. Temperature
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cycling shock test is made up of five cycles, in which the non-energised controlgear is
stored firstly at -10C (or lower value, if marked) for 1 h and then the controlgear is
moved into a cabinet having a temperature of rated maximum operating temperature of
the case of a controlgear (tc) and stored for 1 h. Supply voltage switching test consists of
200 cycles with no load and 800 cycles with maximum load conditions of switching
controlgear on and off for 30 s. After these tests the controlgear shall then be operated
with appropriate LED modules at rated supply voltage and at the ambient temperature,
which produces tc, until a test period of 200 h has passed. At the end of this period, and
after cooling down to room temperature, the controlgear shall operate appropriate LED
modules correctly for 15 min. (IEC 62384)

Product life and failure rate

It is recommended in IEC 62384 that manufacturer would provide in a product

catalogue the maximum surface temperature (tl) that allows a life of 50 000 h to be
achieved and the failure rate at the maximum temperature (tl).

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Conclusions
Lighting solutions utilising LEDs are increasing with wide leaps. In the future, a major
part of light produced is most likely from them. LEDs certainly have features, such as
great potential to very good energy efficiency and colour mixing capabilities that are
seen very positive. Presently, however, the lack of standardisation and common criteria
to meaningfully compare different products are seen as one important disadvantage of
projecting with LEDs.

General safety requirements for luminaires have been available already for years and, of
course, also LED luminaires must meet those requirements. At the moment, there are no
performance requirements for luminaires but for LED luminaires the standardisation is
in progress. The performance requirements are really needed for luminaries, since
presently it is hard to meaningfully compare different LED luminaries based on
information presented by manufacturers in their catalogues. Also controlgear for LED
modules must meet the general and particular requirements for safety. For controlgear
there are already performance requirements standardised on international level. They
form a guideline to manufacturers in presenting necessary information on their products.
Despite there is international performance standard for controlgear, only few
controlgear manufacturers publish information about product life and failure rate. Since
users do not have long-term experience on using LED controlgear, it is natural that
users are cautious to invest in large-scale to LED lighting systems.

As further technological development continues and the efficiency, light output,

reliability of LED lighting solutions improve and costs are getting more competitive
against conventional solutions, the utilisation of LED luminaires would be possible in
large-scale installations in general lighting.

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