I2PS

More than testing Worldwide market access for your future products

Testing | Certification | Consulting

2

Institute for International Product Safety The Institute for International Product Safety GmbH (I2PS) is an independent, according to ISO/ IEC 17025 accredited laboratory that provides testing services.

We are specialized in testing electrical and electronic components, systems, as well as running environmental simulations. At I2PS, we offer an extremely broad range of tests, with a spectrum ranging from materials testing and environmental load and stress simulations based on climatic, vibration/shock, IP degree of protection, and EMC tests all the way to short-circuit and arc fault tests with currents of up to 300,000 A. Moreover, we have a comprehensive array of state-ofthe-art analysis tools and equipment, including high-speed video, laser vibrometers, RoHS analyzers, and radiographic testing systems for more in-depth testing.

3 5

CONTENT TESTING According to national and international standards

CERTIFICATION Support for global market access

I2PS 02

CONSULTING Support in standards for your Global Market Access

High Current Tests

04 | 05

EMC 06 Environmental Tests Material Tests

07 08 | 09

Global Market Access

10

Shipping Classification

11

4

Short-circuit

Overload

Tests with extreme short-circuit currents are used to examine the behavior that switchgear and assemblies are being exposed to at the limits of their technical and physical capacity. The results achieved with these tests are extremely important and serve to reassure project developers, installers, and owners that a switchgear device or a power distribution system will be able to meet all applicable requirements.

An overload test is used to determine the tripping values for overload and short-circuit releases. The limits of the tripping values for the overload test are tested at various ambient temperatures.

Arc fault withstand capacity An arc fault is a short-circuit that can occur due to a fault between live parts with different potentials and/or between live parts and bodies and can be the type of a high-current arc discharge in air normally (ionized gas plasma with a temperature of approx.

10,000 °C or higher). These tests are used to verify safety for operating personnel and the public.

5

High Current Tests The term high-current tests summarizes types of tests which may need several kilo amps to be performed.

Tests are performed with a test voltage according to the appropriate standard, for example 115% of the rated voltage of the test object.

A requirement given by the standards is that the devices and power distribution systems have to fulfill their specified functions safely at these extreme short-circuit currents. The expanding energy density of the energy grid makes it necessary to provide extreme test currents far beyond 2 100,000 Amps for tests. I PS has

The following testing options are available for DC and within a frequency range of 16 2/3 Hz to 60 Hz: AC-High Current Tests Short circuit, Switching capacity 3phase, 50/60 Hz, 200 ms Test Voltage

Test current

240 V (60Hz) 253 V

AC-Short time withstand current 3phase, 50 Hz Test Voltage

Test current Current Flow Time

200 kA

440 V

65 kA

3000 ms

300 kA

525 V

80 kA

2000 ms

440 V

275 kA

525 V

120 kA

1000 ms

480 V (60Hz)

200 kA

525 V

250 kA

550 V

200 kA

600 V (60Hz)

200 kA

725 V

175 kA

770 V (60Hz)

175 kA

1100 V

100 kA

1500 V

85 kA

DC-High Current Tests Short circuit, Switching capacity 200ms

one of the world‘s most powerful testing systems.

The power for the relevant test is generated by one of the three surge generator systems.

The largest of these systems has a generator output of 298 MVA and, with a short-circuit power of 207 MVA, is one of the most powerful short-circuit testing systems in all of Europe.

An extensive control system makes it possible to precisely control all test procedures and to monitor system components. This ensures that a few seconds after completion of the test, the testing system is able to provide all the information required for a competent and comprehensive evaluation of the test results. Other special measuring techniques from the Test Laboratory Bonn, such as high-speed video, laser vibrometers, and x-ray analyses, can be used as well.

DC-Short time withstand current

Test Voltage

Test current

Test Voltage

Test current Current Flow Time

262 V

40 kA

48 - 1500 V

20 kA

550 V

50 kA

630 V

60 kA

788 V

70 kA

1500 V

70 kA

1575 V

70 kA

1000 ms

Temperature rise

Tripping behavior

Temperature rise tests on electrical equipment and switchgear assemblies are used to determine the thermal design of contacts and conductors, as well as the insulating material components of the current carrying parts. In addition, these tests are used to verify that the permitted temperature values are within the limits as required by national and international standards. In order to be able to analyze long-time temperature rise tests for the verification of suitability, 2 I PS measuring system has been specifically expanded to make it possible to record, analyze, and document physical variables.

Devices such as electrical assemblies are protected from overcurrents by upstream protection devices. With our high-current test systems, we can determine trip values or potentially check if further to requirements from relevant product standards are being met.

To determine the tripping current the test object is operated with its rated current.

Then the current is increased until tripping occurs. Alternatively, the test object is loaded with a constant current, in which case the tripping characteristic is determined based on the time it takes for the device to trip.

Impulse withstand current The purpose of conducting an impulse withstand current test on current-carrying equipment such as switchgear or power distribution systems is to determine the mechanical stability of this equipment when subjected to large dynamic electromagnetic forces caused by the high currents.

Short-time withstand current testing is used to verify that a switchgear device or a distribution system is able to carry a short-circuit current for a specific time without being damaged.

6

EMC Electromagnetic Compatibility Interference immunity tests

EMC tests Power distribution and automation devices and systems must function as intended in their electrical and electromagnetic environment. At the same time, they are not allowed to disrupt other electronic devices or impermissibly influence their environment.

The corresponding requirements are defined by the term EMC, which stands for „electromagnetic compatibility“. State-of-the-art measuring and simulation systems provide information regarding emitted interference and interference immunity of the test object.

As an accredited EMC testing laboratory, we focus on the following: • Conformity tests for the CE marking according to EN and IEC standards • Tests according to technical standards, including for example medical devices, ISM devices, IT devices, domestic appliances, and tools • Rail engineering tests • Shipbuilding tests based on the guidelines from DNV-GL, ABS, BV, LR, and other shipping registers 2

I PS GmbH‘s EMC testing laboratory focuses on worldwide EMC requirements.

Therefore we are able to examine test requirements for multiple countries and special applications during testing.

Our expert EMC specialists can perform the following interference immunity tests: • Interference immunity to the discharge of static electricity (ESD), tests up to ±30 kV • Interference immunity to high-frequency electromagnetic fields within a frequency range of 80 MHz to 6 GHz • Interference immunity to fast transient electrical interference (burst) up to 4 kV • Interference immunity to surges up to 6.6 kV at 1.2/50 μs and up to 3.3 kA at 8/20 μs • Interference immunity to conducted interference induced by high-frequency fields (radiated RFI) within a frequency range of 150 kHz to 80 MHz • Interference immunity to magnetic fields with energy frequencies • Interference immunity to voltage dips, brief interruptions, and voltage fluctuations

• Interference immunity for residential environments, commercial and light industrial environments, and small businesses • Interference immunity for industrial environments Interference Tests Our expert EMC specialists can perform the following emitted interference tests • Radio interference properties, electromagnetic radiation • Harmonic currents • Flicker • Emitted interference for residential environments, commercial and light industrial environments, and small businesses • Emitted interference for industrial environments

IP degree of protection tests

7 5

In terms of enclosures and the components they contain, protection against: • access to hazardous parts • solid foreign objects • ingress of water is encompassed by the term „IP degree of protection.

Environmental simulations Throughout their daily use, assemblies, devices, and systems are subjected to an extremely wide range of natural and artificial environmental conditions. In order to 2 address this, I PS can conduct tests designed to evaluate the environmental resistance of products by using testing systems to simulate the corresponding conditions during shipping, storage, and operation even under extreme environmental conditions.

Shock and vibration tests

Environmental Tests IP degree of protection tests This degree of protection is indicated with the code „IP“ followed by two characteristic numerals.

The first characteristic numeral indicates the protection of persons against access to hazardous parts and simultaneously provided protection of equipment against the ingress of solid foreign objects, while the second characteristic numeral indicates the protection provided by enclosures with respect to harmful effects on the equipment due to the ingress of water. Additional letters either describe access to dangerous parts or provide special supplementary information. The testing systems 2 used by I PS for water and dust degree-of-protection tests are extremely spacious, making it possible to test large enclosures and distribution board systems.

Environmental Simulation The climatic environmental conditions under which technical devices are operated and which these devices must be able to withstand can vary enormously depending on the relevant application and location

of use. Examples include climatic conditions that vary geographically (e.g., humidity, temperature, etc.), industrial environments with specific corrosive loads (e.g., atmospheres containing sulfur), and „harsh“ production environments (resulting from high temperatures, exposure to fluids, and mechanical loads). In order to test whether your devices are able to withstand these adverse conditions, we can age them under an extremely wide range of climatic conditions in our testing systems. This makes it possible to examine the resistance of a product against damaging climatic conditions with the use of controlled and reproducible test conditions. More specifically, our test chambers can produce temperatures of -70 °C to 240 °C and a relative humidity of 4% to 100%.

In addition, we have high-temperature ovens (muffle furnaces) that can be operated at temperatures higher than 1,000 °C for special tests at high temperatures (e.g., ashing, residue on ignition, determination of filler content, heat treatments, etc.). Meanwhile, the effect of atmospheres containing sulfur

The purpose of mechanical shock and vibration tests is to simulate conditions that can occur during the transport or operation of parts, devices, and/or equipment.

can be tested with a Kesternich test, in which acid rain conditions are simulated with an alternating sulfur dioxide atmosphere to which DUTs are exposed. The effect of „pure“ condensate can also be tested, as well as icing on DUTs with an icing test. Furthermore, openair weathering tests can also be performed following consultation.

Shock and vibration During these tests, the important aspect is how the structure reacts to excitation displacements and accelerations. In fact, the ability of the structure to transmit and damping vibrations, as well as its resistance to them, can be determined. In addition, these tests can be used to identify a system‘s normal modes and natural frequencies.

We also offer online monitoring services that provide additional information on the DUT during testing. We conduct shock and bump tests and vibration tests in conformity with international standards as well as customer-specific standards and specifications.

8

Thermal tests (fire tests) The behavior exhibited by materials when subjected to abnormal heat or fire is crucial when it comes to the operational reliability and safety of a product, especially in the case of electrical products. Accordingly, a large number of methods that can be used to test the flammability properties of materials can be found in IEC, DIN EN, ASTM, and UL standards.

Mechanical tests In addition to the electrical suitability and the resistance to environmental conditions, the mechanical properties of both devices and their components are crucial when it comes to operation and service life. A device can be subjected to an extremely wide variety of mechanical loads throughout its 2 lifecycle. I PS offers a variety of testing methods that make it possible to determine mechanical characteristic values or to check the mechanical strength of components, devices, and material specimens.

Scanning electron microscope (SEM) with X-ray spectrometer (EDX) Our scanning electron microscope uses electron beams for imaging analyses, and we have various detectors available depending on the specific application at hand (SE, BSE, VPSE detector).

9 5

Materials tests Thermal tests The behavior exhibited by materials when subjected to abnor2 mal heat can be tested by I PS according to defined test methods.

We can perform glow wire tests (GWT), GWFI, GWIT, GWEPT, needle flame tests (NFT), and horizontal and vertical flame tests in conformity with IEC/UL classifications HB, V0, V1, V2, 5VA, and 5VB. Abrasion tests Plates, labels, and markings are often subjected to special abrasive loads throughout a device‘s lifecycle. It goes without saying that these markings and labels need to remain legible throughout the entire lifecycle. Accordingly, we offer standardized manual and automated abrasion tests for labels, markings, and prints. Upon request, these tests can be combined with the application of cleaning agents and other solvents.

Torque testing Our test stand is able to accurately measure and set torques of 0 to 200 Nm and enables us to measure torques and angles of torsion. This test can be used, for example, to determine screw-in torques, tightening torques, and overtightening torques for fasteners; actuation torques for switches; and torques that will lead to the failure of control elements or mounts.

Hardness testing Hardness is one of the defining properties of a material and its

Tensile / compression / bend tests Within the context of mechanical testing, tensile, compression, and bend tests make it possible to determine important mechanical characteristic values of materials, components, and devices relatively quickly.

treatment, and can be determined with suitable hardness tests such as Vickers (HV0.1 to HV10), Brinell, Knoop, or Shore A, D. After the appropriate metallographic specimen preparation, we are also able to examine core hardnesses, hardness penetration depths, weld hardnesses, heat-affected zones, hardness profiles, and other aspects related to hardness.

Scanning electron microscope (SEM) with energy dispersive X-ray spectrometer (EDX) With magnifications of 20x to 300,000x and an extremely great depth of field, our SEM makes it possible to obtain highly detailed and accurate images of surfaces from an extremely wide variety of specimens and materials. Accordingly, our SEM is very flexible and can be used for an extremely broad range of applications going from analyzing the fracture grain structure of a hardened steel component (hydrogen embrittlement), to the links between the glass fibers in a polymer matrix, to the microstructure in semiconductor ele2 ments. At I PS, we often use our SEM for failure analyses, materials analyses, and surface analyses in combination with metallographic structure analysis methods.

Finally, our energy dispersive X-ray spectrometer (EDX) can be used simultaneously with a SEM analysis in order to perform a materials analysis, i.e., to measure element compositions and distributions.

This makes it possible, for instance, to identify structure inhomogeneities and impurities in specimens.

Tensile / compression / bend tests Within the context of mechanical testing, tensile, compression, and bend tests make it possible to determine important mechanical characteristic. The tests can be performed under laboratory conditions or in a test chamber that incorporates specific temperature conditions. We have universal testing machines that allow for loads up to a maximum force of 100 kN. Impact tests Drop hammer, spring-operated impact hammer, and pendulum impact tester being some examples to perform impact tests according to the relevant standard with.

In addition to impact tests, drop tests (e.g., ball drop tests) from a defined height onto products with and without outer packaging can be performed.

Electrical tests 2 I PS offers standardized methods which are used to measure the comparative tracking index (PTI/ CTI A/B) yielded by creepage paths being formed on solid insulating materials when drops of a test solution are dropped on these materials. Our testing system is able to perform the test for voltages of up to 600 V.

Impact tests

Electrical tests

Impact tests are used to test and classify the protection of a metal or plastic enclosure against dynamic mechanical loads (e.g., IK code). Within this context, the corresponding impact energy is transmitted in a variety of manners depending on the standard being used, with a drop hammer, spring-operated impact hammer, and pendulum impact tester being some examples.

When it comes to determining whether plastics are suitable for use as an insulating material in electrical devices, an important electrical property is their creepage resistance. This resistance is determined with a standardized method that is used to measure the comparative tracking index (PTI/CTI A/B).

10

International Market Access North America At the Institute for International Product Safety GmbH, we can help manufacturers who are interested in exporting their electrical products to North America. For most of these products, a certification is needed in order to gain access to the market.

Middle East 2

Test results of I PS are state-approved with the assistance of UL (Underwriters Laboratories) or directly by Middle East countries.

Testing for Middle Eastern countries is based on IEC standards, as well as additional requirements stipulated by the relevant national standards institutes and/or responsible utilities.

IEC markets For the majority of all countries worldwide IEC standards are the basis of technical test regulations. With the help of the IECEE certification system a global market acces is possible and 2 assisted. I PS as an independent certified test laboratory assist their clients to get the relevant certificates in combined partnership with UL.

North America The UL test mark stands for approved conformity according to safety regulations of the US and Canada. To launch technical products in public buildings and facilities of the USA and Canada a certification of a certified body is 2 absolutely demanded. I PS as a part of the UL DAP program (Data Acceptance Program) is well recognized by UL as an independent test laboratory.

We perform tests according to a big variety of UL- and CSA-standards, which results can be used for a general northern America certification. Common standards such as UL845 (Motor Control Centers), UL891 for power distributors, UL 489 for circuit switches, U67 for switchboards and distribution boards, UL508A for panelboards and UL891 / UL845 for control cabinets.

The Institute for International Product Safety GmbH offers all required tests, temperature tests, high voltage tests, and short circuit tests.

Middle East requirements Electrical and electronic devices, components and systems to be sold worldwide have to be constructed according to various different standards. Especially Middle East countries do have their own requirements regarding product tests.

It has to be stated that the regulatory environment in Middle East is fragmented. Meanwhile tests according to der IEC 61439-2 (switchboards) are usual for Abu Dhabi. Also different power frequencies, 60 Hz in Saudi-Arabia and 50 Hz in most Gulf countries, have to be considered. In addition to that many specific requirements of national authorities and energy providers have to be considered too.

The generation of test programs coming from one skilled hand can save time and costs and helps to realize a successful market entry. The combined partnership 2 of I PS and UL as an approved certified body offers qualified tests and regulation services for the whole Middle East area.

11 5

Shipping Classification Services

The Institute for International Product Safety GmbH assists ship suppliers in certifying their electrical and electronic devices, components and systems.

We offer a broad range of ser-

vices beginning with generation of test programs, the mandatory tests and the complete approval services. Our clients appreciate our rapid certification assistance for their products.

2

Meanwhile I PS is well recognized by all important ship classification authorities acting worldwide. This belongs especially to environmental and EMC tests.

Institute for International Product Safety GmbH Hein-Moeller-Strasse 7-11 53115 Bonn | Germany Telefon: +49 (0)228 748 708 - 0 Fax: +49 (0)228 748 708 - 1149 Email: prueflabor@i2ps.de DE-Mail: prueflabor@i2ps.de-mail.de

www.i2ps.de

Version No.: 03/2018 | Š Titel photo : Quanrong Huang/shutterstock.com - inside: pixabay, all other I2PS | text: I2PS