Item-06-Electrical Hazards in Household Appliances - CMA Updated DRJ

INTERNATIONAL WORLDWIDE SYSTEM FOR CONFORMITY
ELECTROTECHNICAL TESTING AND CERIFICATION OF

COMMISSION ELECTRICAL EQUIPMENT AND COMPONENTS
Electrical hazards in household appliances

Reasons and means of reduction
Derek Johns
Chairman IEC Technical Committee 61:
Safety of household and similar electrical appliances
BAHRAIN 7-8 December 2009
Ministry of Industry and Commerce

Kingdom of Bahrain
Copyright IEC, Geneva,

Hazards covered by electrical safety legislation
Reasons and means of reduction
Introduction
Electric shock hazards
Thermal hazards
Abnormal operation
Mechanical hazards
Radiation, toxicity and similar hazards
Fire and heat hazards
Conclusions
Bahrain Workshop December 7-8 2009
2/63
Introduction
Legislation relating to household appliances is

enacted in many countries in order to protect the
health and safety of the consumer.
Enforcement of this legislation normally follows
one of two models.
Pre-market intervention
Performance based (post-market intervention)
In order to manage compliance with legislation
manufacturers use standards and government
regulators accept compliance with standards as
proof of compliance with legislation
3/63
Introduction - continued
Pre-market intervention as a legislation enforcement

tool makes compliance with standards mandatory in
order to obtain approval to sell.
The manufacturer must show proof of compliance with
appropriate standards before placing the product on
the market
Post-market intervention as a legislation enforcement

tool accepts compliance with standards as a deemed
to comply solution to the legislation
Prudent manufacturers hold proof of compliance with
appropriate standards to present in case of a regulatory
challenge that may arise due to market surveillance

4/63
1966
The formation of TC 61 was agreed at a
meeting of the IEC/COA in October 1966
1967
First meeting of TC 61 in New York city this
was also the first IEC technical meeting to be
held in the USA
Secretariat
Held by the US national committee since the
committee formation.
5/63
Secretaries
Mr S Hoffman, Mr C Guiges, Mr A Farquhar, Mr H Reimers, Mr K
Mitchell, Mr M Leimbeck, Mr A Brazauski, Mrs S Bird
Assistant Secretaries
Mrs J Dunlap, Mrs M Burk
Chairmen
Dr R C G Williams (UKNC) 1967 1973
Mr L Elfstrm (SENC) 1973 1978
Mr D Huisinger, (NLNC) 1978 1983
Mrs M C Bansse (FRNC) 1983 1994)
Mr D R Johns (NZNC) 1994 to Present

6/63
Hazards covered by electrical safety
legislation reasons and means of reduction
The safety standards in the IEC 60335 series include

requirements and test criteria to cover the following
hazards.
Electric shock
Thermal burns, overheated surrounds, insulation
Mechanical hazards cutting, crushing, explosion
Fire ignition of appliances due to internal faults
Radiation and toxicity non-ionising radiation
poisonous gases
These hazards are addressed during normal use and

abnormal operation of the appliance

7/63
Electric shock hazards
Special probes used to check for adequacy of protection against

access to live parts and for other than class O appliances, basic
insulation
Test pin
Test finger
8/63
Electric shock hazards - continued
Special probes
Special are
probes areused
usedwhere
wherechildren
children are
are likely to use
likely to usean
an
appliance without
appliance withoutadequate
adequateprior
prior training inits
training in itsuse
use
Child 3 -14 years
464,3 0,8 101,6 0,3 44 0,15
Axes of joints
A
Child up to 3 years 25,4 0,2 R 2,8 0,05
25,9 0,2
5,6 0,1
Hemispherical
Extension of handle
Collar
View A

9/63
Electric shock hazard - continued
A frequency compensated circuit weighted for

perception or reaction is used to check touch current
values these are then compared with the limits in
IEC 60479
Weighted touch current

(perception/reaction)
A RS CS U2
= (peak value)
500
R1
Test terminals
B RB U1 U2
C1
IEC 1078/99
U2 is measured using an instrument with an

approximately flat frequency response 0 to 1 MHz
10/63

11/63
Adequate earthing is needed as a second level of

protection in class I appliances
The effectiveness of earthing circuits is checked
by measuring the earthing circuit resistances to
ensure that they do not exceed 0,1
Enhanced insulation is needed as a second level
of protection in class II appliances
Isolation from the supply mains and a voltage
limitation is needed as a second level protection
in class III appliances

12/63
Some other aspects that contribute to

reducing the electric shock hazard are:
Effects of heat, humidity and moisture on
insulation dielectric strength;
Effects of pollution on creepage distances over
insulated surfaces;
Effects of over-voltage on clearances between
live parts and accessible surfaces.

13/63
Pollution in a 4 slice toaster

14/63
Pollution in a bathroom 3-in-1

fan/heater/luminaire after 5 years of use
15/63
The temperature rise of a winding is normally obtained using the change in

resistance method. The temperature rise obtained depends on the K value of
the winding material (K = 234.5 for a copper winding and 225 for an aluminium
winding. In order to reduce material costs manufacturers are now using cooper
coated aluminium winding wires. The K value of such a winding material
depends on the ratio of area of copper/area of aluminium

16/63
Thermal hazards
Temperature limits on appliance surrounds are

selected to prevent pyrolysis of timber structures
Temperature limits for accessible surfaces are
based on touch times to avoid a superficial partial
thickness burn of the skin
Different materials give different temperature
spreads for the burn thresholds. The burn
thresholds are related to the thermal inertia of the
material in question.
Thermal inertia is the product of the density,
thermal conductivity and specific thermal capacity
of material
17/63
Thermal hazards - continued
For short contact periods the burn thresholds (contact temperature/time graphs) are not
drawn as lines but are drawn as spreads.
Illustration of relationship between the burn threshold and contact period when a hot
surface is touched by the skin 18/63
Burn hazards - continued
This takes into account the fact that for short contact
periods the knowledge of the temperature boundary
between non-burning and the onset of burning is not
complete.
The burn threshold depends on several factors which
include:
thickness of the skin at the touching point;
moisture of the skins surface (sweating);
contamination of the skin (e.g. grease);
touching force;
differences between the heat conductivity properties of
materials which have been combined in one group;
uncertainties of the scientific determination of the burn
threshold values.
19/63
Burn threshold spread when the skin is in contact with a hot

smooth surface made of bare (uncoated) metal
20/63
Rise in the burn threshold spread from Figure A2 for metals which are coated by (1)
porcelain enamel (160 m) / powder (60 m), (2) powder (90 m) and (3) polyamide 11
or 12 (thickness 400 m)
21/63
Burn threshold spread when the skin is in contact with a hot

smooth surface made of ceramics, glass and stone materials

22
22/63
When setting surface temperature limits,

touchable surfaces of an appliance are
generally considered to be one of the following:
Hot functional surfaces;
Adjacent surfaces;
Surfaces of handles, knobs, grips and similar
parts which are continuously held in normal use;
Surfaces of handles, knobs, grips and similar
parts which are held for short periods only in
normal use (e.g. switches);
Other touchable surfaces.
23/63
Burn threshold values for the contact of the skin

with water are derived from the lower limit of the
burn threshold spread established for bare metals
The temperature limits are selected based on the
use of individual appliances;
For example the existing temperature limit for the
glass in an oven door will be reduced based on a
touch time of 4 s. This will minimise the risk of
burns to the hands of very young children but will
not completely alleviate it without the additional
protection afforded by care giver supervision.

24/63
Right hand of an 18 month old child 11 days after prolonged

contact with the glass of an oven door
25/63
Abnormal operation
The electric shock hazard, certain aspects of the

thermal hazard and fire hazard are also assessed
during abnormal operation of the appliance
such as:
Failure of the normal temperature control;
Overloads and locking of moving parts such as the
rotor of a motor and the contacts of a relay;
Failure of electronic components;
Failure of safety related embedded software;
The effects of electromagnetic phenomena on stand-
by circuits and electronic disconnections.

26/63
Abnormal operation - continued
Protection against the effects of abnormal

operation is usually provided by the use of
electromechanical devices or protective electronic
circuits (PECs)
If the PEC is programmable the software must
contain measures to control stuck-at faults and
for certain appliances DC faults
PECs must be designed so that electromagnetic
phenomena does not affect the ability of the PEC
to perform its safety function

27/63
Mechanical hazards
Some typical mechanical hazards resulting from

operation of the appliance are:
Crushing due to:
operation of drives for doors, gates etc,
pinch points in amusement machines such as kiddie
rides;
Injury due to access to moving parts of appliances

such as blades in kitchen machines, the blades in a
fan, the drum in spin extractors, the interface
mechanism between drives for gates etc and the
driven part;
Explosion due to excessive pressure in closed
containers.
28/63
Mechanical hazards - continued
The effect of these types of hazards are minimized

by the use of:
Non-contact presence sensors (infrared detectors) and
contact presence sensors (pressure pads);
Increasing the dimensions of potential pinch points
based on the physical size of body parts such as
the head;
Restricting finger access to moving parts or placing
them out of reach;
Restricting the rotational energy and hardness of
fan blades;
Use of pressure relief devices and enhanced
mechanical strength requirements.
29/63
Explosion caused by leakage of flammable refrigerant

30/63
Explosion caused by leakage of flammable refrigerant

31/63
Some typical mechanical hazards resulting

from the normal construction of an
appliance are:
Child entrapment in appliances with enclosed
cavities such as refrigerators, tumble dryers,
drying cabinets;
Presence of sharp edges excluding functional
sharp edges;
Toppling due to inadequate stability.

32/63
Hazardous substances cannot be used in

the construction of an appliance:
Asbestos and oils containing polychlorinated
biphenyl are specifically prohibited in IEC
60335-1;
The presence of substances such as Lead,
Mercury, Cadmium, Hexavalent Chromium,
Polybrominated Biphenyls, Polybrominated
Diphenyl Ethers is controlled by legislation
(RHoS) in various countries.

33/63
- continued
Some appliances produce toxic

substances as a result of their operation
and limits based on WHO guidelines are
specified:
Pyrolytic self cleaning ovens produce CO;
Air-cleaning appliances produce 0 . 3

34/63
- continued
Appliances are available that use non-ionizing

radiation to perform their function.
Microwaves are used in cooking appliances;
Ultraviolet radiation (UV and UV ) is used in skin
a b
treatment appliances;
Ultraviolet radiation (UV c ) is used in water treatment
appliances;
Infrared radiation is used in heating appliances.
Radiation limits based on ICNIRP guidelines are
specified.

35/63
Fire and heat hazards
An electric shock hazard or fire hazard

exists if an appliance with non-metallic
parts is affected by the heat generated
during either normal or abnormal
operation.
A ball pressure test is applied to non-metallic
parts
Forming the enclosure; or
Supporting live parts; or
Providing supplementary or reinforced insulation.
36/63
Fire and heat hazards - continued
Ball pressure apparatus
The apparatus is applied to the sample at a

temperature related to the temperature rise
values obtained during normal and abnormal
operation of the appliance
37/63
Base of a cordless kettle after exposure to

heat from abnormal operation
38/63
Terminal cover in wall oven after exposure to heat

from normal operation
39/63
Fires related to appliances have many causes

some of which are:
Failure of components;
Mechanical failure of heating element supports;
High resistance joints in current carrying
connections;
Careless use of an appliance such as:
Leaving an unattended pot of cooking oil on an energized
hob;
Incorrect installation of appliances such as electrically
heated bedding;
Inadvertent covering or placement of portable room heaters.
40/63
Some results
Mechanical failure of heating element

supports
41/63
High resistance joints in current carrying

connections
42/63
Tracking in pollution degree 3 environment

43/63
Design solutions to address these

problems are assessed by:
Abnormal operation tests for component failure;
Drop tests and impact tests for mechanical
support failure;
Fire simulation tests for bad connections
Review of user instructions for careless use.

44/63
The fire test used for simulating a current

carrying bad connection, is the glow-wire
end product test from IEC 60695-2-11
A heated wire tip is applied to the material
likely to be ignited by the bad connection
and the results are observed
The tip temperature (severity) applied is
selected according to the expected current
through the connection and typical use of
the appliance (attended, unattended, etc.)
45/63
Glow-wire test apparatus

46/63
Glow-wire test
47/63
Many materials flame during and after

application of the glow-wire tip.
This shows that this material may be
source of ignition for other non-metallic
materials in the vicinity.
In order to limit the spread of fire these
other materials are subject to a
consequential test using the needle flame
described in IEC 60695-11-5.

48/63
In order to aid with repeatability and

reproducibility the consequential needle flame
is applied to non-metallic material that falls
within a 20 mm x 50 mm (diameter x height)
hypothetical cylinder placed above the
connection being investigated and only in
instances where (te ti) > 2s.
Some time line diagrams that explain the

glow-wire test methodology that may lead
to a consequential test follow.

49/63
Time Lines
Glow-wire tip Glow-wire tip Compliance boundary
applied 0 s removed 30 s 60 s
Test No
50
Time Lines
Pass and no
Test No
consequential
1 assessment
No Ignition necessary
te-tI = 0 s since t e - t I = 0 s
51
Time Lines
Pass and no
Test No
consequential
1 assessment
Pass and no
consequential
Ignition but assessment
2 0 s < te-ti 2 s necessary
since t e - t i 2 s
ti te
52
Time Lines
Pass and no
Test No
consequential
1 assessment
Pass and no
consequential
since t e - t i 2 s
ti te
Pass and no
consequential
since t e - t i 2 s
ti te
53
Time Lines
Pass and no
Test No
consequential
1 assessment
Pass and no
consequential
since t e - t i 2 s
ti te
Pass and no
consequential
since t e - t i 2 s
ti te Pass and no
consequential
since t e - t i 2 s
ti te
54
Time Lines
Pass but
Test No consequential
assessment
5 necessary
since t e - t i > 2 s
Ignition
ti te
55
Time Lines
Pass but
assessment
5 necessary
Ignition
ti te Pass but
consequential
assessment
6 necessary
Ignition
ti te
56
Time Lines
Pass but
assessment
5 necessary
Ignition
ti te Pass but
consequential
assessment
6 necessary
Ignition
ti te Pass but
consequential
assessment
7 necessary
Ignition
ti te
57
Time Lines
Pass but
assessment
5 necessary
Ignition
ti te Pass but
consequential
assessment
6 necessary
Ignition
ti te Pass but
consequential
assessment
7 necessary
Ignition
Pass but
ti te consequential
assessment
8 necessary
Ignition
ti te
58
Time Lines
Pass but
assessment
5 necessary
Ignition
ti te Pass but
consequential
assessment
6 necessary
Ignition
ti te Pass but
consequential
assessment
7 necessary
Ignition
Pass but
ti te consequential
assessment
8 necessary
Ignition
ti te Pass but
consequential
assessment
9 necessary
Ignition
59
ti te
Time Lines
Test No
10
Fail since
t e > 60 s
Ignition
ti te
60
Time Lines
Test No
10
Fail since
t e > 60 s
Ignition
ti te
11
Fail since
t e > 60 s
Ignition
ti te
61
Time Lines
Test No
10
Fail since
t e > 60 s
Ignition
ti te
11
Fail since
t e > 60 s
Ignition
ti te
12
Fail since
t e > 60 s
Ignition
tI te
62
Conclusions
The IEC 60335 series of standards are written in a

manner that is timely, efficient and which keeps pace
with modern technology.
They are written so as to set prudent and realistic
requirements
That facilitate international trade in electrical
appliances;
That minimise the need for national differences;
That enable certification bodies to issue test reports
containing repeatable and reproducible test results;
That manufacturers can apply to their designs;
That governments can confidently recognize in their
regulations;
That provide protection for consumers.
63/63
Conclusions - continued
In the time available it has only been

possible to give a brief selective overview
of the way in which the IEC 60335 series of
standards recognizes and reduces the risk
presented by hazards in electrical
appliances
Consequently the contents of this
presentation must not be taken as a
substitute for applying the full text of the
IEC 60335 series of standards

64/63
INTERNATIONAL WORLDWIDE SYSTEM FOR CONFORMITY
ELECTROTECHNICAL TESTING AND CERIFICATION OF
COMMISSION ELECTRICAL EQUIPMENT AND COMPONENTS
Thank you.
Any questions?
BAHRAIN 7-8 December 2009
Ministry of Industry and Commerce

Kingdom of Bahrain
Copyright IEC, Geneva,

Item-06-Electrical Hazards in Household Appliances - CMA Updated DRJ

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INTERNATIONAL WORLDWIDE SYSTEM FOR CONFORMITY

ELECTROTECHNICAL TESTING AND CERIFICATION OF

Electrical hazards in household appliances

BAHRAIN 7-8 December 2009

Ministry of Industry and Commerce

Copyright IEC, Geneva,

Legislation relating to household appliances is

Pre-market intervention as a legislation enforcement

Post-market intervention as a legislation enforcement

Bahrain Workshop December 7-8 2009

Bahrain Workshop December 7-8 2009

The safety standards in the IEC 60335 series include

These hazards are addressed during normal use and

Bahrain Workshop December 7-8 2009

Special probes used to check for adequacy of protection against

Child 3 -14 years

464,3 0,8 101,6 0,3 44 0,15

Child up to 3 years 25,4 0,2 R 2,8 0,05

Bahrain Workshop December 7-8 2009

A frequency compensated circuit weighted for

Weighted touch current

U2 is measured using an instrument with an

Bahrain Workshop December 7-8 2009

Adequate earthing is needed as a second level of

Bahrain Workshop December 7-8 2009

Some other aspects that contribute to

Bahrain Workshop December 7-8 2009

Pollution in a 4 slice toaster

Pollution in a bathroom 3-in-1

The temperature rise of a winding is normally obtained using the change in

Bahrain Workshop December 7-8 2009

Temperature limits on appliance surrounds are

Burn threshold spread when the skin is in contact with a hot

Burn threshold spread when the skin is in contact with a hot

Bahrain Workshop December 7-8 2009

When setting surface temperature limits,

Burn threshold values for the contact of the skin

Bahrain Workshop December 7-8 2009

Right hand of an 18 month old child 11 days after prolonged

The electric shock hazard, certain aspects of the

Bahrain Workshop December 7-8 2009

Protection against the effects of abnormal

Bahrain Workshop December 7-8 2009

Some typical mechanical hazards resulting from

Injury due to access to moving parts of appliances

The effect of these types of hazards are minimized

Explosion caused by leakage of flammable refrigerant

Bahrain Workshop December 7-8 2009

Explosion caused by leakage of flammable refrigerant

Some typical mechanical hazards resulting

Bahrain Workshop December 7-8 2009

Hazardous substances cannot be used in

Bahrain Workshop December 7-8 2009

Some appliances produce toxic

Bahrain Workshop December 7-8 2009

Appliances are available that use non-ionizing

Bahrain Workshop December 7-8 2009

An electric shock hazard or fire hazard

Ball pressure apparatus

The apparatus is applied to the sample at a

Base of a cordless kettle after exposure to

Terminal cover in wall oven after exposure to heat

Fires related to appliances have many causes