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Principle/Testing of IEC
60598-1/IEC 60598-2-1
Vicky Zhang IECEE Workshop IEC SYSTEM OF CONFORMITY ASSESSMENT
Product Expert August 26 & 27 SCHEMES FOR ELECTROTECHNICAL
DEKRA Nairobi - Kenya EQUIPMENT AND COMPONENTS
Shanghai
Content
• Why?
• What?
• How?
2 IECEE Workshop August 26 & 27, Nairobi - Kenya

• Why to use IEC standards?

Recalls by product categories
- 2012, EU
Recalls by type of risk
- 2012, EU

Product Risks

What is product safety?
No hazards
to environment
No hazards Product
to People Safety
No hazards to
other equipments

Provisions against Hazards
Electrical
Hazards
B
Mechanical Heat related

hazards A C
hazards
Provisions
Radiation E D Fire
hazards hazards
Advantage of IEC standards
Representing market needs
Transparent process
C Wide adoption
dards
Bases of national standard or regulations
Reducing risk, increasing quality, confidence

Technical committees
TC 34
SC 34D
SC 34A Lamps and
Luminaires
Lamps related
equipments
SC 34B
SC 34C
Lampcaps/
Auxiliaries
holders
for lamps

• What criterias are required in
IEC 60598-1/60598-2-1?

Standards
• IEC 60598-1
Luminaires –
Part 1: General requirements and tests

Standards
• IEC 60598-2-1
Luminaires –
Part 2- Particular requirements for Fixed
general purpose luminaires

Scope
• Fixed general purpose luminaire
• Working voltage <= 1000 V
• Tungsten filament, tubular fluorescent and
other discharge lamps

Definition – Fixed luminaire
• Not easily be moved from one place to
another
• A: only be removed with the aid of a tool
or
• B: for use out of arms reach

Classification
• Protection against electrical shock
• Class I luminaire:
basic insulation + protective earthing
• Class II luminaire:
basic + supplementary insulation or
reinforced insulation
• Class III luminaire:

SELV (safety extra-low voltage)
Conformity Assessment
Carried out by laboratory

Type To use standardized test method
Test To check compliance of the design of a product
Carried out by manufacturers after production

Routine To ensure every luminaire conforms with the
sample approved under type test
Test


Type To use standardized test method

Test

Component
• Suitable for use in the Luminaire
• Correct Classification and Ratings

• In compliance with relevant IEC
requirements
To ensure
safety of usage

Provision of Marking
• Marking on products
• Mounting Instructions
The height of letters and numerals ≥ 2 mm .
The height of symbol ≥ 5 mm

• Durability and legiability

Construction - Lampholder
• Positioning test

• Bending test

• Torque test

Construction – Terminal block
• Space
- Luminaire with connecting
leads requires a terminal
block to connect to fixed
wiring
- Adequate space for
terminal block

Construction – Reliable terminals
• 8 mm conductor
• live conductor
• earth conductor

• External cable & Internal wiring
• Retained by cord anchorage
• Clamped by spring terminal

• Internal wiring
- Anchored to a tag
before soldering
- Twisted in a reliable
manner
- Fasten by sleeve,
tape
- Inserted into a hole of
PCB, bend and
soldered
• Internal wiring
- Securely crimped
- Securely wrapped

Construction – Double/Reinforced
Insulation
• Metal encased class II luminaire
- No contact between mounting surface
and part with basic insulation only
Double
insulated wire
Terminal block
with a cover

Construction – Double/Reinforced
Insulation
• Metal encased class II luminaire
- No contact between accessible part and
basic insulation
→ Double insulated wire
→ Insulating lining, sleeve
Mechanical Electrical Thermal
strength strength strength
1.Retained by positive 1. Humidity 48 hrs 1. Thermal test
means
2. Insulation 2. T(wire)+20°C
2.Not be removed
resistance &
without being seriously 3. Aging T(wire)+20°C, 240
electric strength
damaged hrs, checked by electrical
31 IECEE Workshop August 26 & 27, Nairobi - Kenya strength
Construction – Screws
• Torque test
No damage
No creep

Construction – Screws
• Torque test
• 0,5 Nm for screws on cord anchorage
bearing directly on cable or cord

Construction – Glands
• Torque test

Construction – Mechanical Strength
• Impact test

• Impact test
- Live part shall not be accessible
- Insulation shall not be impaired
- No reduction on IP protection and
classification
- Removable/replaceable part can be
removed/replaced without breakage

• Metal part enclosing live part
- Pressure test by test finger
- 30 N
- Metal part shall not touch live part
- No reduction on creepage distance and
clearance

• All Suspended luminaires
- Loading test
- 4 x weight of luminaire
- 1 hrs
- No deformation on suspension system

• Rigid Suspended luminaires
- Torque test
- 2,5 Nm, 1 min
- Clockwise and anti-clockwise
- No rotation more than one revolution in both
directions

• Rigid Suspension bracket (heavy duty)
- Loading 40 N, >=2,5 Nm, at free end
- 1 min
- No permanent displacement, deformation

• Rigid Suspension bracket (light duty)
- Loading 10 N, >=1,0 Nm, at free end
- 1 min
- No permanent displacement, deformation

• Track mounted luminaire
- Luminaire mass < max. load for track

• Adjusting device
- No twisting over 360

• Flexing test
- Strands broken < 50%
- Insulation resistance & electric strength

Construction – Flammable Material
• Glow‑wire test 650 C
• Spacing  30 mm
• No fiercely burning material

External Wiring
• Supply connection
Supply cable & Plug
Adaptor for track
Terminals
External Wiring
• Supply connection
Connecting leads
Appliance inlet
External Wiring
• Type of cable
• 0,75 mm2 for ordinary luminaires;

• 1,0 mm2 for other luminaires
External Wiring
• Type of connection
- Type X attachment
- Type Y attachment
- Type Z attachment

External Wiring
• Cord anchorage

External Wiring
• Cord anchorage
- Pull test (25 time, displacement <= 2mm)
- Torque test

Internal Wiring
• Internal wiring directly connected to
fixed wiring
Operating current >= 2 A Operating current < 2 A
min. 0,5 mm2 min. 0,4 mm2
Insulation thickness: min. Insulation thickness:

0,6 mm min. 0,5 mm
(PVC or Rubber) (PVC or Rubber)
1,5 mm2 for through --
wiring
Internal Wiring
• Internal wiring connected to fixed wiring
via current limiting device <= 2 A
If current-carrying capacity and the mechanical

properties are adequate
- Cross-sectional area min. may be less than 0,4 mm2
- Insulation thickness may be less than 0,5 mm

External & Internal Wiring
• Soldering
Clamping terminal
Spring terminal

External & Internal Wiring
• Soldering
Spring terminal
Cold flow
Bad electrical
connection
Clamping terminal

Earthing
• Accessible metal part, basic insulated
• Non-accessible metal part, basic
insulated, but in contact with
supporting surface
- Reliably connected to earthing
terminal or earthing contact

Earthing

Earthing
• Location of earthing terminal
• Adjacent to mains terminal (type X, Y)
• Material of earthing terminal

• Brass or non-rusting material
• Bare contact surface

Earthing
• Cord for earthing
• Green-yellow cord shall only be used
for earthing connection
• Earthing make contact first
• Earthing detached later

Earthing
• Terminal blocks with integrated
screwless earthing contacts

Earthing
• Pull test 20 N – terminal block shall be in
place
• Pull test 50 N – applies only to earthing
contact – no damage, no loosen on
earthing contact
• Earthing contact – supporting plate
< 0,05 ohm

Earthing
• Voltage drop test
• Resistance < 0,05 ohm

Protection against electrical shock
• Live parts not accessible when

luminaire installed and wired as in
normal use or during lamp/starter
replacement
- Wall-mounted luminaires: within arm reach,

no access to basic insulated parts by means of
a Ø 50 mm probe

• Basis insulated parts of Class II

luminaires to be regarded as live parts

• No basic insulated components on

outside of luminaire
• Luminaires incorporating a capacitor
>0,5μF must be provided with a
discharge device

Resistance to dust and moisture
• Dust Test (IP#X)

• Dust Test (IP#X)
• Solid-object-
proof (IP2X)
• Solid-object-
proof (IP3X or
IP4X)
• Dust-proof
(IP5X)
• Dust-tight proof
(IP6X)
• IP Test (IPX#)
• Drip-proof (IPX1) • Drip-proof (IPX2)

• IP Test (IPX#)
• Rain-proof (IPX3) and splash-proof (IPX4)

• IP Test (IPX#)
• Jet-proof (IPX5) and powerful water jet-proof
(IPX6)
IP X5
15 min / distance = 3 m / 12,5 l/min ± 5 % (30 kN/m2)
IP X6
3 min / distance = 3 m / 100 l/min ± 5 % (100 kN/m2)

• IP Test (IPX#)
• Watertight (IPX7)
• 30 min in water / 150 mm of water above the top of
the speciment and the lowest portion is subjected
to at least 1 m head of water
• Pressure watertight (IPX8)
• 30 min in water / water pressure 1,3 x pressure
which corresponds to the rated maximum
immersion depth

• Humidity test
• R.H. 91% to 95 %
• 10 ºC – 30 ºC
• 48 hrs

Insulation Resistance
• Class I luminaire: 2 Mohm
• Basic/Supplementary insulation: 2Mohm
• Double/Reinforced insulation: 4 Mohm
• Class III luminaire: 1 Mohm

Electric Strength
• Class I luminaire: 2U + 1000 V
• Basic/Supplementary insulation: 2U + 1000 V
• Double/Reinforced insulation: 4U + 2000 V
• Class III luminaire: 500 V

Creepage distance & Clearances
• Live Parts of different polarity
• Live Parts  Adjacent Metal Parts
• Live Parts  Body or Housing
• Live Parts  Mounting Surface

Creepage distance & Clearances

Endurance and Thermal test
• Endurance  7 or 10 Days
• Thermal Test  Normal operation
• Thermal Test  Abnormal operation
• Thermal Test on luminaires classified for
mounting on normally flammable
surfaces
• Thermal Test on thermalplastic
luminaires
Resistance to heat, fire and tracking
• Ball Pressure Test
• Needle Flame Test

Resistance to heat, fire and tracking
• Glow-wire Test 650 ºC
• Tracking Test on IP>20

Luminaire


Type Use standardized test method

Test

Routine test by Manufacturer
• Visual check
• Function test
• Earth continuity (earthing resistance:
0,05ohm)
• Electric strength or insulation
resistance (for metal encased)
• Polarity (for Class I luminaire)

• How to build up a laboratory
carrying out testing of IEC
60598-2-1?

What is a laboratory?
• Area where tests are conducted
(electrical, chemical, physical, mechanical etc.)
Why are tests conducted in a

laboratory?
• External influences on the test results are
ruled out!
• Conditions for testing are controlled!

Conditions which can influence
test results in your laboratory?
Manpower Human factors
Machines
Environmental conditions
Equipment
Test methods/validation
Measurement traceability
Methods
Sampling
Handling of test items
Means Consumable goods/ items

Process model
Manpower Machines
Input Process Output
Means Methods
Manpower Machines
Manpower Input Process Output
• Competent staff Means Methods
• Staff in training (adequate supervision needed)

• Personnel competent and qualified
• Goals and policy / procedures for training and
qualification requirements
• Job descriptions (management, technical and
supporting)
• Records of all personnel maintained, readily
available (authorizations, competences,
qualifications, training, skills, experience…)
Manpower Machines
Machines (1) Input Process Output
Means Methods
• Facilitate correct performance of tests

• Technical requirements that can effect the
results documented
• Monitor, control, record environmental
conditions and stop testing when
environmental conditions jeopardize results
• Effective separation of incompatible areas
• Access and use shall be defined and
controlled
Manpower Machines
Means Methods
• Lab with all equipments required for the correct

performance of tests
• Equipment capable of achieving accuracy
needed
• Authorized personnel; up to date instructions
• Unique identification
• List of records for each piece of equipment

Manpower Machines
Means Methods
• IECEE – CTL testing equipments under CB

scheme
http://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm
• IECEE-CTL Operational Procedures

CTL-OP 108 Use of thermocouples
CTL-OP 109 Acceptance of thermocouples
CTL-OP 110 Procedure for measuring power source characteristic
CTL-OP 111 Traceability of calibrations and calibration intervals
• http://www.iecee.org/ctl/operational/Operational_procedures.htm
Manpower Machines
Means Methods
• Refer to CTL-OP 110 “Procedure for

Measuring Laboratory Power Source
Characteristics”
8.1 When not otherwise specified in the testing standard, the

power source used for testing shall meet the following
requirements:
A. Voltage stability: ± 3 % maximum
B. Frequency stability: ± 2 % maximum
C. Total harmonic distortion (THD): maximum 5 %

Manpower Machines
Means Methods
• Note:
IEC 60598-1, cl. 12.4.1 e) ±1% (preferred ± 0.5%)

voltage stability instead of ± 3%!

Manpower Machines
Means Methods

Manpower Machines
Means Methods

Manpower Machines
Means Methods

Manpower Machines
Means Methods

Manpower Machines
Methods Input Process Output
Means Methods
• Appropriate methods for all tests within scope

• Instructions for all equipment
• Up to date and readily available to personnel
• Methods must meet the requirements of
standards
• Latest valid editions of standards to be used

Manpower Machines
Means Input Process Output
Means Methods
• Policy and procedures for selection & purchase

of services and supplies, when relevant for
tests
• Procedures for inspecting supplies prior to use
• Purchasing documents reviewed and approved
for technical content prior to release

Manpower Machines
Input Input Process Output
Means Methods
• Review of requests, tenders and contracts

• Methods adequately defined
• Posses capability and resources
• Differences resolved before work begins
• Record of reviews maintained, including
discussion with clients
• Any subcontracted work

Manpower Machines
Output Input Process Output
Means Methods
• Reporting results
• Shall include all information requested by the client
and all information required by the method used
• Subcontracted results clearly identified

Manpower Machines
Output Input Process Output
Means Methods
• IECEE – TRF (test report form)

http://members.iecee.org/
• IECEE – TRF guide

• OD-2020
• http://www.iecee.org/Operational_documents/od-cb
_index.html

Vicky Zhang IECEE Workshop IEC SYSTEM OF CONFORMITY ASSESSMENT
Product Expert August 26 & 27 SCHEMES FOR ELECTROTECHNICAL

EQUIPMENT AND COMPONENTS
DEKRA Shanghai Nairobi - Kenya

Lite Vicky Zhang Ling Dekra Lite

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Principle/Testing of IEC

DEKRA Nairobi - Kenya EQUIPMENT AND COMPONENTS

2 IECEE Workshop August 26 & 27, Nairobi - Kenya

3 IECEE Workshop August 26 & 27, Nairobi - Kenya

6 IECEE Workshop August 26 & 27, Nairobi - Kenya

7 IECEE Workshop August 26 & 27, Nairobi - Kenya

8 IECEE Workshop August 26 & 27, Nairobi - Kenya

Mechanical Heat related

Representing market needs

Reducing risk, increasing quality, confidence

10 IECEE Workshop August 26 & 27, Nairobi - Kenya

11 IECEE Workshop August 26 & 27, Nairobi - Kenya

12 IECEE Workshop August 26 & 27, Nairobi - Kenya

13 IECEE Workshop August 26 & 27, Nairobi - Kenya

14 IECEE Workshop August 26 & 27, Nairobi - Kenya

15 IECEE Workshop August 26 & 27, Nairobi - Kenya

16 IECEE Workshop August 26 & 27, Nairobi - Kenya

• Class III luminaire:

Carried out by laboratory

Carried out by manufacturers after production

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Carried out by laboratory

Carried out by manufacturers after production

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• Suitable for use in the Luminaire

• Correct Classification and Ratings

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The height of symbol ≥ 5 mm

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Supply cable & Plug

Adaptor for track

• 0,75 mm2 for ordinary luminaires;

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min. 0,5 mm2 min. 0,4 mm2

Insulation thickness: min. Insulation thickness:

If current-carrying capacity and the mechanical

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