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TEST REPORT AS 3100:2009 General requirements for

1. 29mm by 29mm Rating Input 500V 0 1A Output 12V 3A Switching Frequency 40kHz Core Ferrite El 28 20 JPP 4 or DMRAO or 2 or LP3 Coil Enamelled copper Magnet wire wound on Bobbin Bobbin BH B 2802 1 or P 2807 or SW 28A or TF 2801 BOEI280100 or T375J Insulation Tape NO 35660 by Symbio Inc Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity 1 6mm thickness Flame Class 94V 0 RTI 130 PCB Hung Chin 96 overall approx dimension ZPMV2 URus E211578 PVAP211 Electronic Co Ltd 133mm by 69mm by 1 6mm thickness Flame Class 94V 0 RTI 130 NTC THINKING NP19L Y1 4A 50hm 25 8 cURus 138827 NTC1 Electronic Industries Co Ltd Fuse CONQUER PTP A 3 6mm by 10mm JDYX cURus E82636 F1 250Vac 3A CSA C22 2 No 248 1 248 14 Capacitor Yi Shuo E tech PDF103M3A5T 1kV 01 Accepted C3 CY Capacitor Capxon KM 250Vac 471 105 C Accepted C2 C61 Electrolytic 2 in Series Capacitor HER MEI HT 250 471 105 C Accepted C2 C61 Electrolytic 2 in Series Capacitor LUXON SM 250Vac 47yF 105 C Accepted C2 C61 Electrolytic 2 in Series Capacitor Aishi RH 250Vac A7yF 105 C Accepted C2 C61 Electrolytic 2 in Series Capacitor Yi Shuo E tech PDB222K3A5T 1kV 2200pF Accepted C19 C22 CY Transistor Toshiba K4115 900Vdc 7A Accepted Q27 Transformer Cormex PVA H
2. me ti d 1 H MEUG SCALE IN CM Control Board bottom view _ ME oo E tits NI 31 25 959 om Aapan anm M TT 1 KILLI LLL 4444444444444 SCALE IN CM 0 162 167 Report No 09TH0459 AS3100 2 Workpower Board top side I Ima 3t y n w 1 3 4 Ss ed 7 8 9 10 11 12 13 14 15 4 5 SCALE IN Workpower Board bottom view 1 2 1 1 5 6 7 8 9 19 SCALE IN 163 of 167 Report 09TH0459 AS3100 2 BUREAU Zero Control Board top side 2008 08 05 1 OL LL 58 70 60 PEE cL el a 2 3 a y ii p SCALE oS Zero Control Board bottom view 4 OL I 3 1 m ji i a P BL SCALE IN CM Page 164 of 167 Report No 09TH0459 AS3100_2 Display Board top side IHH p p 9 tiaj 5 lew 11 2 3 SCALE IN Display Board bottom view 5 3 000000000000000000001 d 1 2 JI s ai w 16 SCALE 165 167 Report No 0
3. lt gp 2 oo ae UNS n 10 5 MIS x cmn z v w E My Mi on CNPT SS 9 op lt oud nm m um 1 a S we tm EN vom x Y uoa wm 1 wam S pp eu M CAI lt 53 Y agi we 9 E Ime C O Y 7 a 2 NAH nm COM com gt aL gt lt lt AA IE Iu S win gt Ne m O a w Lm ep vor 2 mu d T ate 2 T m 77 m 4 5 nD om BUREAU T 1 D Page 125 of 167 Report No 09TH0459 AS3100_2 ES2200 ES3300 Top Side PVAD010 LE HS Page 126 of 167 Bottom Side PVAD010 Report No 09TH0459 AS3100_2 Page 127 of 167 Report No 09TH0459 AS3100_2 ES4400 ES5000 Top Side PVBD020 Vat 128 of 167 Bottom Side 020 Report No 09TH0459 AS3100 2 129 167 Report 09TH0459 A83100 2 BUREAU ES2200 ES3300 ES4400 ES5000 EMI Board PVBF000 PV Inverter 4 5 EMI PCB y ABLEREX Electronice Co Ltd 2 T gt 1 ci
4. o w gt w 3 gt Inductor L4 Control Capacitor C41 Control Note The test specimens were pre conditioned in the laboratory environment One sample of each specimen was tested The needle flame was applied to one point at each specimen A wrapping tissue was used as burning indicator The needle flame test was conducted as consequential test to the glow wire testing in B3 3 108 of 167 Report 09TH0459 AS3100 2 BUREAU R U VERITAS Annex No 1 EMC Test Report The whole report is stored at Bureau Veritas Consumer Products Services Germany GmbH T rkheim Project 09TH0459 Page 109 of 167 Report No 09TH0459 AS3100_2 Product Name PV Inverter Main Model Number ES5000 Series Model Number ES4200 Applicant GE Industrial Belgium BVBA Address Nieuwevaart 51 B 9000 Gent Belgium Report Number 2C U030 0803 055 Issue Date May 15 2009 Applicable Standards EN 61000 6 3 2007 EN 61000 6 4 2007 EN 62040 2 2006 Category C2 EN 61000 6 1 2007 EN 55022 2006 Class B EN 61000 6 2 2005 IEC 61000 4 2 2001 IEC 61000 4 3 2006 IEC 61000 4 4 2004 IEC 61000 4 5 2005 IEC 61000 4 6 2006 IEC 61000 4 8 2001 IEC 61000 4 11 2004 Based on the EMC Directive 2004 108 EC and the specifications of the customer one sample of the designated product has been tested in our laboratory and found to be in compliance with the EMC sta
5. os se ae oom f waf wa te L3 insulation L3 insulation plate wire EMI wire L3 insulation plate wire EMI 750 C C 00 0cm NA N A 35 P EMI L4 L4 insulation plate wire L4 insulation plate wire EMI wire EMI 750 C C 0cm 30s P EMI Storage throttle isolation Storage throttle isolation oe C Storage totte wroce reoc oom NA NA P _ Rayvi oom 0s P oom 0s zom os 166 so P _ som P _ bobbin main na eswc oom so P _ T1 bobbin oom WAT so P _ ewe oom soo P Comment 1 the result is applicable all three storage trottles the result is applicable on CN2 CN4 CN5 CN6 CN11 CN12 CN13 3 the result is applicable on CN1 CN3 CN7 CN8 CN9 CN10 CN15 Only the listed connectors are tested in B 3 3 Male and female parts are of the same material thus they were not tested each 107 167 Report 09TH0459 AS3100 2 VERITAS poe Needle flame test EUN Part tested Duration of Application of Result flame t s flame t s X P Capacitor C34 C36 C7 C80 3
6. L3 136 5 2 54 1 C 54 1 C Ambient 25 defect hazard 32A 230V 4 Unit switched off OA 26 4A immediately L2 136 5 C L3 136 5 C CT2 54 1 C CT3 54 1 C Ambient 25 C No hazard no defect 32A 230V 4V Unit switched off OA 26 4A immediately L2 136 5 C L3 136 5 C CT2 54 1 C CT3 54 1 C b N O mes Page 102 of 167 5 Fault Test Test condition Test time fuse Fault condition No AC DC AC Short 230V 10 2 230 4V 16 OA 26 4 Transistor Short 230V pou 10min 32A 230V 4M Q10 16A OA 26 4 Diode D3 Short 230V E 10min 32A 230V 4V 16A OA 264A Diode D4 Short 230V pu 10min 32A 230V 4V 16A OA 26 4 Diode 05 Short 230V 10min 32A 230V 4V 16A OA 264A Diode D6 Short 230V e 10min 32A 230V 4V 16A OA 26 4 Current R180 open 230V 2h 32A 230V 500V Sensor 16A 16A 8A Current R152 short 230V E 2h 32A 230V 500V Sensor 16A 16A 8A 230V 7 10 32A 230 4V 26 short 16 OA 26 4 Short Pin1 to 230V 10min 32A 230V 500V Pin2 and 16 0 Pin3 to 4 Short Pin1 to 230V 5 10 32 230 500 2 16 Pin3 to 4 AC output 230V e 10min 32A 230V 4V Resistor 16A OA 26 4 AC output 230V 5 10 32A 230V 4V 16 OA
7. MD Oe ON Page 136 of 167 Report No 09TH0459 AS3100_2 L wa 6 1000 gt ABLEREX Electronice Co Ltd PV 2 5SKV A Communication ckt unit dominas Page 137 of 167 Report No 09TH0459 AS3100_2 VERITA Top Side PVAI032 9 BR N 94 1221 21292 Page 138 of 167 Report No 09TH0459 AS3100_2 BUREAU Workpower Board PVAP210 ll Ig 5 411 Page 139 of 167 Report No 09TH0459 AS3100_2 Top Side PVAP210 71002 Page 140 of 167 Report No 09TH0459 AS3100_2 Zero Control Board PVBH010 0 141 of 167 Report No 09TH0459 AS3100 2 Top Side 010 Page 142 of 167 Report No 09TH0459 AS3100_2 Display Board PVAM210 LRD PHLIESTRBT 1RD6 LIU 5 oper m Page 143 of 167 Report No 09TH0459 AS3100_2 Top Side PVAM210 144 of 167 Report 09TH0459 AS3100 2 Tramsformer T1 Datasheet SPECIFICATION FOR APPROVAL CUSTOMER iE ITEM EE IGX FMR Mechanical Assembly 175 m mns m sse 22 TEST INSTRUMENTS LH 1 HP 42844 DCR O HP 42841A 40KHZIV AT25C ZT 9072A Yi MAX REPORTED
8. Measurement of creepage distances and clearances The methods of measuring creepage distances and clearances to be used in interpreting the requirements of Clause 4 1 3 are indicated in Cases 1 to 10 of this Annex These cases do not differentiate between gaps and grooves or between types of insulation The following assumptions are made 8 A groove may have parallel converging or diverging sides b Any groove having diverging sides a min width exceeding 0 25mm a depth exceeding 1 5mm and a width at the bottom equal to or greater than 1mm is regarded as an air gap see Case 8 c Any corner including an angle less than 80 15 assumed to be bridged with an insulating link of 1mm width 0 25mm for dirt free situations moved into the most unfavourable position see Case 3 d Where the distance across the top of a groove is 1mm 0 25mm for dirt free situations or more no creepage distance exists across the air space see Case 2 e A creepage path is assumed not to exist if there is an air gap as defined in Item b exceeding 0 25mm f Creepage distances and clearances measured between parts moving relative to each other are measured when these parts are in their most unfavourable stationary positions g A computed creepage distance is never less than a measured clearance h Any air gap less than 1mm wide 0 25mm for dirt free situations is ignored in computing the total creepage distance Not
9. Noticed 5 3 4 Resistance of earthing connection The resistance between the earthing facility and any exposed metal parts shall not exceed 10 for readily accessible exposed metal parts that rotate reciprocate or oscillate continuously and 0 10 in all other cases when tested in accordance with Clause 8 4 See table 8 4 in Annex No 1 5 3 5 Printed conductors The printed conductors of printed circuit boards shall No hand held equipment N A VERITAS Page 33 of 167 Report No 09TH0459 AS3100_2 not be used to provide earthing continuity in hand held equipment They may be used to provide earthing continuity in other equipment if at least two tracks are used with independent soldering points and the equipment complies with the requirement of Clause 8 4 for each circuit 5 4 Equipment with double insulation 5 4 1 General Equipment may be accepted as having double insulation only if it complies with Clause 5 4 and is capable of passing the tests prescribed herein NOTE 1 See Annex D for information on the design of electrical equipment having double insulation NOTE 2 Sheathed type flexible cords that comply with AS NZS 3191 are regarded as affording double insulation between conductors and any metal in contact with the sheathing In addition the following forms of construction are considered as acceptable a Equipment having metal parts that can be touched and
10. Running overload test A running overload test is made on equipment incorporating motors that are either intended to be remotely or automatically controlled or liable to be operated continuously while unattended the equipment being operated under normal load at rated voltage or at the upper limit of the rated voltage range until steady conditions are established The load is then increased in appropriate steps so that the current through the motor windings is raised the supply voltage being maintained at its original value When new steady conditions are established the load is again increased This operation is repeated until the overload protection device operates or until the motor stalls The winding temperature is continuously measured and noted during each period of steady conditions and the maximum temperature value recorded shall not exceed for Class 105 A material 140 for Class 120 E material 155 for Class 130 B material 165 C for Class 155 F material 180 C for Class 180 H material 200 C for Class 200 material 220 C g for Class 220 material 240 C h for Class 250 material 270 C b c d e f Noticed N A 8 15 6 Equipment for short time or intermittent operation Equipment for short time or intermittent operation other than hand held equipment equipment that has to be kept switched on by hand equipment that is continuously loaded by hand or equipment
11. See table 8 3 1 in Annex No 1 8 3 2 Leakage current test The leakage current of equipment shall not be excessive when assessed according to the following test The leakage current is measured between any pole of the supply and accessible metal parts and metal foil having dimensions not exceeding 200mm x 100mm in contact with accessible surfaces of insulating material connected together After the equipment has been operated until steady state conditions are established the leakage current to accessible metal parts and metal foil shall not exceed the values given in the standard See table 8 3 2 in Annex No 1 8 4 High voltage electric strength test See table 8 4 in Annex No 1 8 4 1 Between live parts All equipment shall withstand the application between live parts of an a c voltage of the value indicated in Table 8 4 according to the working voltage between the parts to which the test is being applied Noticed 8 4 2 Equipment with earthing facilities All equipment with earthing facilities shall withstand the application between live parts and exposed metal or earth of an a c voltage of the value indicated in Table 8 4 according to the working voltage between the live parts and exposed metal or earth Noticed 8 4 3 Equipment with double insulation This test shall not apply to insulation that encloses only conductors or live parts operating at extra low voltage supplied
12. b The insulation after having been conditioned for 168 h in an oven maintained at a temperature equal to 75 in excess of the maximum temperature rise determined during the tests of Clause 8 15 withstands the electric strength test of Clause 8 4 this test being made on the insulation both at the temperature occurring in the oven and after cooling to approximately room temperature Compliance is checked by inspection and by test For optocouplers the conditioning procedure is carried out at a temperature of 50 C in excess of the maximum temperature rise measured on the optocoupler during the tests of Clauses 8 12 or 8 15 the optocoupler being operated under the most unfavourable conditions which occur during these tests 4 2 Mechanical protection of conductors and cables P 4 2 1 General P All conductors and cables shall be of such a type or be so located or protected that mechanical or electrical failure is not likely to occur under the conditions to which they may reasonably be subjected in service 4 2 2 Adjacent material P All material immediately adjacent to or in contact with a conductor shall be so shaped that it will not cause such abrasion of the conductor or its insulation braiding or sheathing as could lead to its mechanical or electrical failure 4 2 3 Passage for conductors P Where conductors and cables including flexible cables and flexible cords are to be threaded through tubes or channels or passe
13. DC terminal 2 AC Terminal 54 9 55 3 54 2 52 6 49 9 50 9 85 3 Diode D28 PCB 4 Terminal CN18 PCB 5 Coil L3 6 Condensator C51 T Q11 an PCB 8 Currentsensor CT2 9 Condensator C30 10 Condensator C26 11 Relay RY1 12 Condensator C61 13 Condensator C65 14 H1 PCB 15 Wiring Choke 16 Choke 17 Condensator C1 PB 18 Coil L2 PB 19 Condensator C3 PB 20 Transformer T1 CB 21 Housing 22 Housing near LCD 23 cooling fins 24 Transformator TX1 The above temperatures are recorded at The values measured are subtracted with tamb1 and tamb2 C added Therefore above measured temperatures are the absolute temperatures in C at maximum ambient The printed circuit board is rated 130 C applied test voltage and test current for each of the two DC strings reliability test heat resistance no evidence of mechanical damage shall occur after expose to 100 C for 96h VERITAS Page 96 of 167 Report No 09TH0459 AS3100_2 Nameplates transfers and paintings used to provide the information required in accordance with Clause 7 1 shall be checked by inspection and by rubbing by hand for 15 s with a piece of cloth soaked with water and again with a piece of cloth soaked with petroleum spirits Requirement Legible Yes Marking easily removable No Curling No U H U VERITAS Page 97 of 167 Report No
14. Distances through slots or openings in external parts of insulating material are measured to metal foil in contact with the accessible surface the foil is pushed into corners and the like by means of the standard test finger shown in Figure 8 10 but it is not pressed into openings If necessary a force is applied to any point on bare conductors other than those of heating elements on uninsulated capillary tubes of thermostats and similar devices and to the outside of metal enclosures in an endeavour to reduce the creepage distances and clearances while taking the measurements The force is applied by means of a test finger having a tip as shown in Figure 8 10 and has a value of a for bare conductors and for uninsulated capillary tubes of thermostats and similar devices 2 N and b for enclosures 30 N NOTE 1 If a barrier is interposed and if it is in two parts that are not cemented together the creepage distance is also measured through the joint NOTE 2 For appliances having parts with double insulation where there is no metal between basic insulation and supplementary insulation the measurements are made as though a metal foil were present between the two insulations See table 4 1 3 in Annex No 1 P VERITAS Page 16 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict NOT
15. The unit is permanently connected to mains and to DC photovoltaic The unit is specified for outdoor and indoor unconditioned use See IP report The magnetic device T1 has an electrical reinforced insulation system and is rated 100 C Compliance of T1 was checked by applying clause 4 1 3 Clearance and creepage and 8 4 Electric Strength of AS 3100 2009 An additional transformer winding analysis is included in Annex No 4 The product was evaluated for a maximum ambient of 50 C The temperature test was performed without forced air cooling EMC testing and IP testing was performed by an independent test house Marking The Unit needs the following marking Marking needed refer to user manual VERITAS Page 5 of 167 Report No 09TH0459 AS3100_2 Particulars test item vs test requirements Equipment mobility Fixed wall mounted wires detachable Operating Continuous Mains supply tolerance According to the specification Tested for IT power systems IT testing phase phase V Class of equipment Class Protection against ingress of water IP65 according to IEC 60529 Test case verdicts Test case does not apply to the
16. mm mm dcr mm mm DC to SELV reinforced 500 500 6 0 6 0 6 0 6 0 Layout PCB PVAI032 Top Side 1111111 995 Comment DC and AC are considered Hazard potential 87 of 167 Report 09TH0459 AS3100 2 BUREAU Insulation resistance Testing E A 500 voltage was applied to the two locations The current flowing was measured and the resistance was calculated Location from to Insulation type Potential used Insulation resistance AC to enclosure 500Vpc 7 8MQ DC to enclosure 500Vpc 2 5MO AC to secondary 500Vpc 180MQ DC to secondary 500Vpc 90MQ jua eae a Location from to Location from to Note The insulation resistance must be gt 1 in case of primary to enclosure and gt 10 in case of primary to secondary Secondary is grounded to enclosure So the primary to enclosure criterium applies AER Page 88 of 167 Report 09TH0459 AS3100 2 VERITAS 8 3 2 TABLE Leakage current and fault current P The outputs were loaded to the rated value The current measuring circuit according to Figure 4 of IEC 60990 was taken Star mains equipment Measured Calculated Parts tested voltage U2 current mA Comments L to PE N A 54 Normal condition N to PE N A 540yuA Normal condition Comments Where PCE has a continuous leakage current of more than 5 in normal
17. CT2 54 1 C CT3 54 1 C Ambient 25 C No hazard no defect 230V 4V Unit switched off OA 26 4A immediately L2 136 5 C L3 136 5 C CT2 54 1 CT3 54 1 Ambient 25 C No hazard no defect 230V 4 Unit switched off OA 26 4 immediately L2 136 5 C L3 136 5 C CT2 54 1 C CT3 54 1 C Ambient 25 C no defect No hazard N Page 101 of 167 Report No 09TH0459 AS3100 2 VERITAS Componen Fault Test Test condition Test time fuse Fault condition Result No AC DC Short 230V peu 32A 230V 4V Unit switched off 16A OA 26 44 immediately L2 136 5 L3 136 5 CT2 54 1 C Capacitor Short 230V pr 16A Capacitor Short 230V ped 16A Resistor Short 230V prd 16A Capacitor Short 230V pod 16A Ambient 25 No hazard no defect 54 1 C Ambient 25 Transistor Short 230V 2 10 32A 230V 4V switched off Q7 16A OA 26 44 immediately unit defect HiPot Test passed no hazard s Short 230V 2 10 32A 230V 4V Unit switched off 16 OA 26 4A immediately unit defect HiPot Test passed no hazard je No hazard no defect 32A 230V 4V Unit switched off OA 26 4 immediately L2 136 5 C L3 136 5 C CT2 54 1 C CT3 54 1 Ambient 25 C No hazard no defect 32A 230V 4V Unit switched off OA 26 4A immediately 12 136 5
18. Clause Requirement Test Result Remark Verdict 3 3 Selection of materials and parts Any material or part used in or in the construction of any equipment shall comply with any specific requirements set out in respect thereto in this Standard or in an individual Approval and test specification dealing with such materials or parts Where any standard prescribes for or in any equipment the use of a particular kind of material or part a material or part of another kind may be used instead provided that its use will not introduce any risk of electric shock or fire and will not render the equipment less resistant to mechanical or electrical failure than would the use of a material or part of the kind prescribed See list of critical components Annex No 1 Table 3 3 P 3 4 3 5 Selection of components Any component part that is used in or in the construction of any equipment and which is depended upon for safety shall comply with the appropriate requirements of any relevant individual Approval and test specification Workmanship All fabrication and construction shall be carried out in a thoroughly workmanlike fashion complying with the appropriate requirements of this Standard and the generally accepted principles of sound and safe practice See list of critical components Annex No 1 Table 3 3 3 6 Fuses N A 3 6 1 Accessibility and shrouding This Clause shall not ap
19. IGBT to enclosure heat sink provided with ceramic plate Transistor Infineon IKW75N60T 75 Tc 100 C 600V Accepted Q12 Screwed with metal clamp IGBT to enclosure heat sink enclosure heat sink Transistor Infineon IGW75N60T 75A Tc 100 C 600V Accepted Page 81 of 167 Report No 09TH0459 AS3100_2 Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Q12 Screwed with metal clamp IGBT to enclosure heat sink provided with ceramic plate Transistor IR IRG4PSC71KD 60 Tc 100 C 600V Accepted Q12 Screwed with metal clamp IGBT to enclosure heat sink provided with ceramic plate Comments 1 an asterisk indicates a mark which assures the agreed level of surveillance 2 means that components from other vendor and other model number but with the same rating and equivalent approvals are accepted IU Page 82 of 167 Report No 09TH0459 AS3100 2 BUREAU 3 14 Equipment connected to supply by a plug N A Measurement Initial voltage Measured voltage after 1s location peak V V Conditions Appliance inlet terminals Comments The voltage across the line capacitor decayed to less than 34V of it s original value after 1 second 83 of 167 Report 09 0459 53100 2 mmm 4 1 3 Creepage distances and
20. Stability test Freestanding equipment intended for use on a surface such as a floor or a table shall have adequate stability Compliance is checked by a stability test equipment provided with an appliance inlet being fitted with an appropriate connector and flexible cord The equipment is placed with the motor switched off in any normal position of use on a plane inclined at an angle of 10 C to the horizontal the cord resting on the inclined plane in the most unfavourable position If however the equipment is such that were it to be tilted through an angle of 10 C when standing on a horizontal plane a part of it not normally in contact with the supporting surface would touch the horizontal plane the equipment is placed on a horizontal support and tilted in the most unfavourable direction through an angle of 10 C Equipment with doors is tested with the doors open or closed whichever is the more unfavourable Equipment intended to be filled with liquid by the user in normal use is tested empty or filled with the most unfavourable quantity of water up to the rated capacity The equipment shall not overturn Abnormal operation General Equipment shall be so designed that the risk of fire mechanical damage impairing safety or the protection against electric shock as a result of abnormal or careless operation is obviated as far as is practicable Compliance is checked as follows and by the tests of Clauses 8 15 2 to 8 15 8 as appro
21. The object of the test is to draw into the enclosure by means of depression a volume of air 80 times the volume of the sample enclosure tested without exceeding the extraction rate of 60 volumes per hour In no event shall the depression exceed 2 kPa 20 mbar on the manometer shown in figure 2 5 extraction rate of 40 to 60 volumes per hour is obtained the duration of the test is 2 h If with a maximum depression of 2 kPa 20 mbar the extraction rate is less than 40 volumes per hour the test is continued until 80 volumes have been drawn through or a period of 8 h has elapsed 6 The enclosure under test is supported in its normal operating position inside the test chamber but is not connected to a vacuum pump Any drain hole normally open shall be left open for the duration of the test The test shall be continued for a period of 8 h 7 is impracticable to test the complete enclosure in the test chamber one of the following procedures shall be applied Testing of individually enclosed sections of the enclosure Testing of representative parts of the enclosure comprising components such as doors ventilation openings joints shaft seals etc in position during test Testing of a smaller enclosure having the same full scale design details In the last two cases the volume of air to be drawn through the enclosure under test shall be the same as for the whole enclosure in full scale Intertek Testing Services Ta
22. cord may be led in If in portable equipment the flexible cord is a two core cord sheathed with elastomer or PVC compound it might be thought that since the insulation around the conductors and that comprising the sheath were of mechanically and electrically different characteristics the conductor could pass through a hole in unearthed external metal without breaking the principle of double insulation However in view of the fact that the cord is particularly vulnerable at the point of entry into portable equipment because of the repeated bending that occurs there this is not considered to be safe and equipment may well fail to qualify for classification as double insulated unless the flexible cord enters either through a hole in insulating material as shown in Figure D1 g or through a properly secured insulating bush if the case is of metal as in Figure D1 h N A 07 Classification of the tests involved D 7 1 D 7 2 General To ensure that electrical equipment is safe when it leaves the factory tests are necessary to establish the following general requirements a The design is such that there is no likelihood of danger to the user or surroundings in normal use or in the event of such careless use as may occur in normal service and that the materials used will not deteriorate to such an extent that the equipment becomes unsafe see Paragraph 07 2 b During the course of production no unapproved changes in
23. flexible cord except that such flexible cord need not be provided for equipment intended for direct insertion into a socket outlet or incorporating a Group 3 appliance inlet or a Group 2 appliance inlet intended to accommodate a connector with thermal control The flexible cord shall a comply with AS NZS 3191 b unless varied in the individual Approval and test specification have a length of not less than i 0 9m for table top or bench mounted equipment or ii 1 8m for other equipment which length shall be measured from the body of the equipment at the point where the cord or appliance connector enters the body irrespective of the length of any cord protector to the centre of the live pins on the face of the plug c unless varied in the individual Approval and test specification be not less than i if elastomer insulated ordinary duty sheathed flexible cord or ii if polyvinyl chloride insulated A for equipment having a mass not exceeding 3 kg light duty sheathed flexible cord or Stationary equipment with industrial PV plug connection on DC side and fixed connection on AC side N A N A VERITAS Page 23 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict B for equipment having a mass exceeding 3 kg ordinary duty sheathed flexible cord d be of the appropriate current rating e be correctly wire
24. having the lowest heat sink effect with the board orientated in its normal position of use and at a point if possible not less than 10mm from a corner B 3 3 Glow wire test For equipment that is operated while attended parts of insulating material supporting in contact with or within 3mm to current carrying connections other than those in low power circuits determined as described in Clause 19 11 1 of AS NZS 3350 1 are subject to the glow wire test of AS NZS 60695 2 10 the test being made at a temperature of 650 C However parts of insulating material supporting in contact with or within 3mm to screw connections that carry a current exceeding 0 5A during normal operation and which are likely to be made or remade during installation user maintenance or when replacing a supply cord assembled with the appliance by a Type X attachment are subject to the glow wire test of AS NZS 60695 2 10 the test being made ata temperature of 750 C For equipment that is operated while unattended parts of insulating material supporting in contact with or within 3 mm to current carrying connections other than those in low power circuits determined as described in Clause 19 11 1 of AS NZS 3350 1 are subject to the glow wire test of AS NZS 60695 2 10 the test being made at a temperature of 750 C However parts of insulating material supporting in contact with or within 3mm to screw connections which carry a current exceeding 0 5A du
25. of a strength sufficient to ensure that it cannot be deformed readily so as to come into contact with live parts Edison type screw lampholders incorporated equipment shall be provided with adequate shielding facilities appropriate to the type of lamp with which they may be used Guarantedd also due to IP65 5 1 1 Class construction Class appliances and class II constructions shall be constructed and enclosed so that there is adequate protection against accidental contact with basic insulation and metal parts separated from live parts by basic insulation only It shall only be possible to touch parts which are separated from live parts by double insulation or reinforced insulation Compliance is checked by inspection and by applying the test finger of figure 8 10 as described in clause 8 10 NOTE 1 This requirement applies for all positions of the appliance when it is operated as in normal use even after opening lids and doors and removal of detachable parts NOTE 2 Built in appliances and fixed appliances are tested after installation N A 5 2 Insulation of live parts 5 2 1 General See table 8 3 1 8 3 2 U R U VERITAS Page 30 of 167 Report No 09TH0459 AS3100_2 Live parts of electrical equipment shall be adequately insulated and supported and shall comply with the following a Clauses 8 3 and 8 4 of this Standard b Any specified requirements for
26. the use of tools shall not expose to personal contact a live parts b metal parts separated from live parts by basic insulation or c the surface of basic insulation Exposure of such parts due to the removal of a lamp from a lampholder shall not be a cause for rejection in terms of this requirement Accessible or external equipment wiring that complies with Clause 5 2 3 2 b is deemed to comply with this Clause No removal without the P use of tools 5 4 7 Arrangement of equipment wiring Precautions shall be taken in the support and fixing of equipment wiring to ensure compliance with the following requirements a Live parts including any one conductor that may become detached from its termination cannot come into contact with either supplementary insulation or external metal parts or become exposed to personal contact by protruding through an opening b Basic insulation cannot come into contact with external metal parts c Basic insulation cannot become exposed to personal contact by protruding through an opening Attachment of one conductor to another by tying lacing clipping or the like is regarded as a satisfactory means of fixing and support provided that any one conductor detached from its termination is thus so retained in position as to comply with this Clause Where a single layer of reinforced insulation is accepted as the equivalent of double insulation in accordance with Clause 5 4 4 a liv
27. wattage then the marked wattage shall correspond to the wattage measured at the highest marked voltage N A 7 4 Marking of earth connections The provisions of this Clause shall apply to all equipment except that which has a Type Z attachment The earthing terminal of any equipment shall be identified by means of the word earth or the letter E or the international earth symbol viz lt gt or any combination thereof marked in a legible and indelible manner on or adjacent to the terminal however for equipment arranged only for direct connection to fixed wiring of an installation a the earthing terminal need not be marked if its function is clearly evident for example where the earthing terminal stud or screw is obviously attached to a metal frame or enclosure or b if the earthing terminal is within a terminal box or enclosure any marking which is required may be effected in a durable manner by means such as painting or a suitable transfer Earthing is applied via screw connectior and is clearly marked with E on the enclosure VERITAS Page 40 of 167 Report No 09TH0459 AS3100_2 Lettering used for the marking of the earthing terminal shall be of such a size or so indented or embossed as to be conspicuous The marking required by this Clause may be supplemented by other identifying features such as plating or green colouring of earth connections or the word green In any e
28. 09TH0459 AS3100_2 814 Stability test Under conditions of normal use freestanding units and equipment shall not become physically unstable to the degree that they could become a hazard to operators and service personnel a The unit is tilted to an angle of 10 from its normal upright position Doors drawers etc are opened Result Equipment overbalanced Page 98 of 167 9 VERITAS 5 DC input 230V 500V 10min Diode 16 026 DC input 230V 500V DC input Short 230V 500V capacitor C50 DC input Short 230V 500V capacitor C51 A A A Current R189 open 230V 500V Sensor 16A 8A CT2 Current C64 short 230V 500V Sensor 16 8A CT2 A Transistor Short 230V 500V 2 Q11 8 DCinput Short 230V 500V 10min Diode 8A D28 DCinput Short 230V 500V 10min Diode 16A 8A D29 Diode 8 D27 2h 8 2h 8 2h 2h h o o 9 o o 8 8 a a l a l 84 38 AC CROMA DC 3x 300 40 Report No 09TH0459 AS3100 2 ps CROMA DC AC 10kW 300V 3x 15A DC 900V 40A Test condition Test time fuse C No AC Fault condition Result AC DC 230V 4V Unit switched off OA 26 4A immediately No hazard no defect 230V 4V Unit switched off OA 26 4A immediately No hazard no defect 230V 4 Unit switched off OA 26 4 immediately L3 136 5 Ambient 25 No hazard no defect 230V
29. 26 4 Report 09TH0459 AS3100 2 Result Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately Unit defect No hazard Unit switched off immediately unit defect HiPot Test passed no hazard No effect on function Output power limited No hazard no defect No effect on function Output power limited No hazard no defect Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit does not connect to grid Unit does not connect to grid Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard 9 VERITAS Componen Fault Test condition output Capacitor C2 C Short 230V 500 16 output Short 230V 500V Varistor 16A 8A RV1 AC output Short 230V 500V Capacitor 16A 8A C3 AC output Short 230V 500V Capacitor 16A 8A C4 Thermal Open 230V 500V Sensor 16A 8A Thermal Short 230V 500V Sensor 16A 8A Transformer short overload Power Pin1 to 5 230 500
30. 4V Unit switched off OA 26 4A immediately L3 136 5 Ambient 25 No hazard no defect 230V 500V No effect on function 16A 8A Output power limited No hazard no defect 230V 500V No effect on function 16A 8A Output power limited No hazard no defect 230V 4V Unit switched off OA 26 44 immediately L2 136 5 C L3 136 5 CT2 54 1 CT3 54 1 Ambient 25 No hazard no defect 230V 4V Unit switched off OA 26 44 immediately No hazard no defect 230V 4V Unit switched off OA 26 44 immediately No hazard no defect 0 i Page 99 of 167 L3 Test condition Test time input Short E ped 32A 230V capacitor 16A 0A C52 input Short 230V pri 32A 230V capacitor 16A C53 Current R178 open 230V pei 2h 32A 230V Sensor 16A 16A CT3 Current C61 short 230V pou 2h 32A 230V Sensor 16A 16A CT3 Transistor Short 230V pes 2h 32A 230V Q12 16A OA Capacitor Short 230V 2 2h 32A 230V C28 16A Short 230V Ed 2h 32A 230V C29 16A Fault condition Report No 09TH0459 AS3100_2 Result DC 4V 26 4 Unit switched off immediately L3 136 5 Ambient 25 C No hazard no defect Unit switched off immediately L3 136 5 Ambient 25 C No hazard no defect 4V 26 4 500V 8A No effect on function Output power limited No haz
31. 6A 22 14 7A 14 7 18 3A 18 3A Current IES Tracker 1 1 188 2 3 Rate Output 2K 3K 4K 5 Power Rate Voltage 230V 8 7A 230V 13A 230V 17 4A 230V 21 7 Current NI Intertek Testing Services Taiwan 144 5F No 423 Ruiguang Rd District Taipei 114 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 114 of 167 Report 09TH0459 AS3100 2 Intertek Report No TP10090079 ETS Date September 10 2010 Page 4 of 8 IP6X Test sub clause 13 4 and 13 6 of IEC 60529 Test Method 1 The test is made using a dust chamber incorporating the basic principles shown in figure 2 whereby the powder circulation pump may be replaced by other means suitable tomaintain the talcum powder in suspension in a closed test chamber The talcum powder used shall be able to pass through a square meshed sieve the nominal wire diameter of which is 50 um and the nominal width of a gap between wires 75 um The amount of talcum powder to be used is 2 kg per cubic metre of the test chamber volume It shall not have been used for more than 20 tests 2 Category 2 Enclosures where no pressure difference relative to the surrounding air is present 3 impracticable to make a special hole the suction connection shall be made to the cable inlet hole If there are other holes for example more cable inlet holes or drain holes these shall be treated as intended for normal use on site 4
32. BY Song Degen 18784000 CORMEX ELECTRONICS IND LTD A BUREAU Page 145 of 167 Report No 09 0459 53100 2 CUSTOMER PIN DIN 18784 DATE JUL 21 2010 XE18784000 GAP 0 1mm REF 1 CORE EE 16 NH2B EE 16 14 JPP4 FEE 16 NC 2H EE 16 DMR40 EE1614 LP3 EE16 ZP40 EE 16 M2 3K 2 BOBBIN BOEI160400 3 SCHEMATIC BOTTOM VIEW 8 10 4mm 0 5 PIN 5 CUT OFF 4 WINDING FIGURE PLOYESTER FILM TAPE LAYERS 10 9 CU 0 1 QUEW Y x IPx 44 5 j 9 8 CU 0 1 QUEW R x 1 2975 xx 7 6 CU 0 142UEW Y x IP x 52 Ts XX xx 4 3 CU 0 14 QUEW Y x IP x 55 Ts BOBBIN Teflon Tube gt 6mm MIN R44 3 0mm 5 CHARACTERISTICS 40KHZ IV 25 C Lp 4 3 300uH 5 DCR 4 3 220 MAX 6 HI POT TEST 1 3 TO SEC 7 10 3000Vac 60Hz 3mA IMIN 2 WINDING 3 TO CORE 1500Vac 60Hz 3mA IMIN 3 WINDING 7 10 TO CORE 1000Vac 60Hz 3mA IMIN 4 WINDING 7 TOWINDING 10 500 60Hz 3mA IMIN Page 146 of 167 Report No 09TH0459 AS3100_2 BUREAU MATERIAL _LIST ee asss A CORE ELECTRICAL CO LTD qasa YANG DMEGC MAGNETICS CO LTD INGILANG f Margin COMPANY ELECTRICAL MARKETS DIV YAHUA PRESSURE SENSITIVE GLUE CO LTD Epoxy DONGGUAN EATTO ELECTRONIC MATERIAL CO LTD DUC kno Vamishes JOHN C DOLPH CO 359
33. H j Page 130 of 167 Report No 09TH0459 AS3100 2 R T VERITAS Top Side Page 131 of 167 Report No 09TH0459 AS3100_2 Control Board PVA1032 wa t 25KVA Control Board System PVAK001 las i Page 132 of 167 Report No 09TH0459 AS3100_2 d 243 w PV 2 5 TMS320LF2407A Circuit _ Ay ABLEREX Electronice Co Ltd 2 25 L ku u uui E sm Report No 09TH0459 AS3100_2 N w e e k D A I nee Ad COOOEV priog awona Qj ml _ fun pp 3090003 VANSE Ad mis t b TTA _ i ho e lt E TM m w C Page 134 of 167 Report No 09TH0459 AS3100_2 BUREAU w PV AIDODA 1000 gt PV 2 5KVA Analog filter unit 1 ABLEREX Electronice Co Ltd ij Page 135 of 167 Report No 09TH0459 AS3100_2 w PV AIDOUS 1000 E ABLEREX Electronice Co Ltd PV 2 5KVA Analog filter unit 2 41
34. Inductor Top Coil T100 Open type construction Accepted 3 provided Technology 77439A7 3 with overall approx 700uH dimension 57mm by 57 by 57mm Rating 700uH 180 C Core Ferrite 77439 A7 by Magnetics Coil Enamelled copper Magnet wire with tubed outlets wound on Core Tubing RTI 125 C min 0 4mm thickness by DONGGUAN UL E209436 Mounted to Enclosure Heat sink Heat sink for Ablerex Steel overall approx dimension Accepted Inductor T100 82mm by 73mm by 66mm by min 1 2mm thickness Insulation PIONEER Silicone Molding Overall approx dimension QMFZ2 cURus E153203 between CONDUCTOR Resin 64mm by 60mm by min Inductor T100 RUBBER 4mm thickness and Heat sink INDUSTRY Flame Class 94V 0 RTI 150 Current sensor LEM HX15 P Galvanic isolation between NMTR2 cURus E189713 CT2 CT1 HX25 P primary and secondary Isolation voltage 3000V 75 of 167 Report 09TH0459 AS3100 2 Object Part Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Current rating 15 Transistor Fairchild HGTG30N60A4 60 Tc 110 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp Q9 Q10 to enclosure heat sink IGBT provided with ceramic plate Transistor Advanced APT50GN60BG 64A 110 600V Accepted Q11 Q7 Q8 Power Screwed with metal clamp Q9 Q10 Technology to enclosure heat sink IGBT provided with cera
35. a no load voltage not exceeding 12V and equal to 1 5 times rated current of the equipment or 25A whichever is the greater is passed between the earthing terminal or earthing contact and each of the accessible metal parts in turn The voltage drop between the earthing terminal of the equipment or the earthing contact of the appliance inlet and the accessible metal part is measured and the resistance calculated from the current and this voltage drop The resistance shall not exceed a for readily accessible exposed parts which rotate reciprocate or oscillate continuously 10 b in all other 0 10 table 8 5 in 1 VERITAS Page 45 of 167 Report No 09TH0459 AS3100_2 8 6 Cord anchorage For the purpose of testing the cord anchorage the equipment shall be wired in the normal manner with a flexible cord of the appropriate type If the equipment is provided with an earthing terminal the flexible cord shall include an earthing conductor For Type X attachment the conductors are introduced into the terminals the terminal screws if any being tightened just sufficiently to prevent the conductors from easily changing their position The cord anchorage is used in the normal way its clamping screws being tightened with a torque equal to two thirds of that specified in Table 8 7 The flexible cord shall be PVC sheathed
36. a Power Inverter for PV for use under dust tight and water jets conditions Testing Standard Sub clauses 13 4 13 6 and 14 2 5 14 3 of IEC 60529 1989 1 1999 degrees of protection provided by enclosures IP65 Conclusion From the results of our testing on the submitted sample s we are of the opinion that the submitted sample s COMPLY WITH the above testing standard Prepared by Reviewed by ez Godfrey Lee Gary Yunn Project Engineer Assistant Manager Intertek Testing Services Taiwan Ltd SF No 423 Ruiguang Rd Neihu District Taipei 114 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 XU VES 826 BUREAU VERITAS Page 112 of 167 Report 09TH0459 AS3100 2 Intertek Report No TP10090079 ETS Date September 10 2010 Page 2 of 8 Note 1 The testing results relate only to the items tested 2 The test report shall not be reproduced except in full without written approval of the laboratory 3 This test report only allows to be revised within three years from its original issued date unless further updating to the standard or requirement is noticed 4 This report is for the exclusive use of Intertek s Client and is provided pursuant to the agreement between Intertek and its Client Intertek s responsibility and liability are limited to the terms and conditions of the agreement Intertek assumes no liability to any party other than to the Client in accordance with the agreement for any
37. design have been made see Paragraph 07 3 Each of equipment has been assembled correctly and that no significant departure from the component or materials specifications has occurred see Paragraph 07 4 Type tests To ensure the first general requirement is being met a comprehensive series of tests is required These tests are known as type tests A type test is a test or a series of tests that is made on a sample of one or more specimens for the purpose of checking compliance of the design of a given product with the requirements of the Standard concerned It is not necessary to repeat this series of tests unless and until the manufacturer decides to make a change Such tests are contained in the main body of this Standard and in particular Approval and test specifications D 7 3 Surveillance tests To ensure that the second of the general requirements is being met manufacturers testing organizations or purchasers should select samples at random and at a frequency according to their own discretion Such samples should then be subjected to some or all of the tests specified in the relevant Standard as considered necessary VERITAS Page 68 of 167 Report No 09TH0459 AS3100_2 D 7 4 Production tests To satisfy the third of the general requirements it is necessary for the manufacturer to undertake production tests These tests will in general comprise routine tests but
38. equipment with fixed AC wiring and lockable DC connectors which are safe to touch P Page 14 of 167 Report 09TH0459 AS3100 2 VERITAS AS 3100 2009 Clause Requirement Test Result Remark Verdict SECTION 4 PROTECTION AGAINST MECHANICAL AND ELECTRICAL FAILURE 4 1 Prevention of short circuit and arcing P 4 1 1 General Noticed P All terminals contacts and other live parts shall be so arranged that short circuit or destructive arcing either between live parts or between any live part and other conductive material cannot take place and that no part other than an easily replaceable contact can be appreciably damaged by an arc or overheating arising from the normal operation of the equipment Holes for fixing screws shall be so placed that no such short circuit or arcing can occur when the screws are in position 4 1 2 Segregation of internal wiring Verified P Where extra low voltage see Clause 5 5 and low voltage equipment wiring is within the one enclosure and the extra low voltage wiring or parts connected thereto are accessible to the standard test finger without the use of tools either of the following requirements or a combination thereof shall apply a The extra low voltage wiring and associated connections shall be effectively separated from low voltage wiring by means of rigidly fixed screens or barriers or by other effective means such as lacing or enclosure in insula
39. from a transformer complying with AS NZS 61558 2 6 The insulation between live parts and external metal or live parts and a flexible electrode applied to the surface of the insulation shall withstand high voltages applied as follows a Across basic insulation 1250V b Across supplementary insulation 2500V Where it is not possible to test the basic and supplementary insulation separately or where a single layer of insulation is provided as the equivalent of separate layers of basic and supplementary insulation a test voltage of 3750V shall be applied between live parts and external metal or live parts and a flexible electrode applied to the outer surface of the insulation N A VERITAS Page 44 of 167 Report No 09TH0459 AS3100_2 8 4 4 Non conducting external parts An a c voltage of 3750V shall be applied between live parts and a flexible electrode applied to non conducting parts normally handled in service N A 8 4 5 Method of applying test Any radio interference suppression devices shall remain connected during the following high voltage test The test equipment and the test method shall be generally in accordance with AS 1931 1 and AS 1931 2 as detailed below To prevent overvoltages due to switching surges the initial voltage shall not exceed 30 of the full test voltage and shall be increased uniformly to the full voltage in a time of not mo
40. insulation thickness Unless otherwise specified in a particular clause herein or in an individual Approval and test specification any specified thickness of insulation shall be regarded as applicable at the thinnest point of the insulation for example at the bottom of a screwdriver slot in a brush holder cap and 8 4 in Annex No 1 below 5 2 2 Separation of live parts from non current carrying conductive parts The support and insulation of every live part shall be such as will ensure that no live part can make contact with any non current carrying conductive part exposed to personal contact In respect of terminals of components such as switches adequate clearances shall be maintained or insulation shall be provided to prevent contact of the terminals or loose strands of flexible cords intended to be terminated therein with exposed conductive parts Where necessary provision shall be made to ensure that conductors protruding through terminals when normally connected will not contact exposed conductive parts Noticed P 5 2 3 Equipment wiring NOTE This Clause deals only with requirements for electrical insulation In some instances further mechanical protection of equipment wiring may be necessary such as by providing a braiding covering sheathing or sleeving or by location of the wiring in order to comply with Clauses 3 1 3 2 and 4 2 5 2 3 1 General requirements Where equipment wiring is insul
41. its fixing shall not strip insulating material shall not crack nor shall there be any other failure which would render the screwed component non reusable Where a screw is intended to secure a conductor the test shall be carried out so that the stress is applied to the working section of the thread Where applicable the test shall be conducted with the appropriate conductor inserted in the terminal For terminals that may be used for looping purposes the test shall be conducted with the maximum and minimum number of conductors respectively which the terminal is intended to accommodate See table 8 7 in Annex No 1 8 7 2 8 8 Threaded fastenings with any component of thermoplastic material The length of thread engagement shall be measured and shall comply with Clause 4 7 The screwed components shall be tightened and loosened as described in Clause 8 7 1 except that the following procedure shall be used instead of the application of the specified torque values The tightening shall be effected by first taking the screw up to the point where it bottoms and then tightening by a further 180 C of turning or to the required torque in Table 8 7 whichever is reached first Threads of the fastening shall not jump or strip insulating material shall not crack nor shall there be any other failure which would render either component of the fastening non reusable Where a screw is intended to secure a conductor the test shall be
42. of a non self resetting protective device and it is necessary to remove a cover or to use a tool to reset it Before the test is started the test apparatus is brought to the temperature determined above After 1h the apparatus is removed and the part is immediately immersed in cold water so that it is cooled to approximately room temperature within 10s The diameter of the impression shall not exceed 2mm Resistance to fire tests See table B2 in Annex P No 1 B 3 1 General Unless varied in a particular specification compliance is checked by the tests of Paragraph B3 2 and the applicable parts of Paragraph B3 3 Guidance on the application of glow wire and needle flame tests is given in Figure B3 R U VERITAS Page 60 of 167 Report No 09TH0459 AS3100_2 B 3 2 Materials and tests Relevant parts of non metallic material are subjected to the glow wire test of AS NZS 60695 2 10 on the appropriate part of the equipment the test being made at a temperature of 550 C Insulating materials of winding bobbins and formers are subjected to the glow wire test of AS NZS 60695 2 10 the test being made at a temperature of 650 C Base material of printed wiring boards together with any coating or encapsulation shall comply with the needle flame test of Paragraph B3 4 however flames shall have extinguished within 15s of removal of the test flame The flame shall be applied to an edge of the board
43. of use All equipment shall be of a type design and construction that will enable it to be installed in accordance with the National Wiring Rules and will provide protection against mechanical and electrical failure which can reasonably be expected to result from mechanical failure or from exposure to weather water or dampness corrosive fumes dust steam oil high temperature or any other deleterious influences to which it will be exposed under the conditions of its use Non hygroscopic insulating materials shall be used where required in individual Standards In other cases hygroscopic materials may be used for insulation provided that the materials are suitably impregnated or treated if liable to exposure to dampness The position and fixing of the insulation shall be such as will maintain creepage distances and clearances during the normal life of the equipment In general timber shall not be acceptable as an insulating material except that may be recognized in special cases where particular grade is used for a specific purpose NOTE Non hygroscopic material is taken to be material that does not after being conditioned in an oven at 50 5 C for 24h 1h and then cooled in a desiccators absorb greater than 5 by weight of moisture during a 48 hour treatment in a humidity of 95 at a temperature of 20 C 5 C Noticed VERITAS Page 9 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009
44. one or other of the following procedures shall be adopted whichever is appropriate to the particular case a The bulb shall be surrounded by a single wrapping of tinfoil having a thickness of not less than 0 03mm The foil shall be turned up at the end to form a complete covering for the bulb which shall then be secured in contact with the surface under test The exposed part of the wrapped bulb shall be completely covered with a pad of heat insulating material without unduly shielding the test surface from normal cooling b The bulb except at the point of contact shall be covered with a pad of felt cotton wool or other non conducting material 3mm thick extending at least 19 0mm in every other direction from the bulb and pressed into contact with the surface to which it is applied to prevent loss of heat by radiation and convection from the bulb Any thermometers used shall be of marked immersion and known accuracy N A 8 11 3 Thermocouple method The two conductors between which the thermo electric effect is produced shall be welded or hard soldered at both the hot and the cold junctions care being taken to ensure that the wires at the junction make contact at one point only and are not twisted together The standard No 1 thermocouple shall be a base metal couple made up of wires not smaller than 0 213mm and not larger than 0 315mm The standard No 2 thermocouple shall be a base metal couple made up of wires no
45. open to view and is luminous when energized b If it controls only a portion of the element the whole of which is under the control of a switch opening all live conductors connected thereto and if the portion not controlled by the single pole switch is open to view and is luminous when energized N A 5 7 Temperature rises for components and insulating material The temperature rises of components and of electrical insulating materials used in the construction of electrical equipment shall not exceed the values specified in Table 5 7 when tested in accordance with Clause 8 12 The reference ambient temperature shall be as specified in Clause 8 1 See table 8 12 in Annex No 1 5 8 Fault indicating devices Any device other than a circuit interrupting device intended to indicate to the user that a fault exists in equipment shall be so designed and constructed that a defect in the fault indicating device itself shall not give rise to a false indication Fault indication just for grid conditions and DC insulation resistance N A 2 36 of 167 Report 09TH0459 AS3100 2 BUREAU R U VERITAS NOTE Defect in this context is intended to mean any fault or failure such as failure of a lamp or other component which may reasonably be anticipated in service see Clause 3 1 Any such device intended to indicate that a dangerous potential exists on any external metal parts of equi
46. subjected to flexure and mechanical damage in service Twist on connectors with suitable metal inserts may be used for live conductors but shall not be used for earthing connections d Soldering may be used i for Type X attachments in equipment having a rated appliance inlet AC side b terminals terminal type Y VERITAS Page 19 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict input not exceeding 250W and ii for Type Y and Type Z attachments and shall comply with Clause 4 3 5 No portable equipment shall be provided with facilities for the connection of more than one supply flexible cord unless permitted in an individual Approval and test specification Any equipment intended for permanent connection to fixed wiring shall be provided with terminals as specified in 4 3 2 Design and consiruction of terminals All terminals shall be inherently corrosion resistant or suitably protected against corrosion and shall be so designed and proportioned that a connection made thereto will not loosen or overheat under normal conditions of use NOTE For equipment that will be subjected to severe vibration in service for example a percussion tool it is generally necessary for special precautions to be taken to ensure that the connections made to the terminals will not slacken off under normal conditions of
47. test c During the test temperatures of external surfaces of the insulating enclosure shall be measured and temperatures of surfaces of components or sub assemblies shall be measured within the equipment Where the test is applied to sub assemblies or components the temperature of the surfaces of the sub assembly or component shall be measured d The test specimen shall be allowed to remain in the oven for 7h after the measured temperature has reached the lower limit of the test temperature The test specimen shall then be carefully removed and allowed to cool to room temperature F5 Tests results After the tests inspection of the specimen shall be carried out The following shall apply a There shall be no exposure of live parts or bridging of live parts to accessible conductive parts b There shall be no change to the acceptable mechanical protection to internal parts of the equipment c There shall be no impairment of the normal operation of the equipment to the extent that the equipment fails the requirements of other tests of the appropriate Standard for example IR HV and tests of leakage current Page 72 of 167 Report No 09TH0459 AS3100_2 VERITAS 3 3 Selection of materials and parts p 3 4 Selection of components list of critical components Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Enclosu
48. test object Test item does meet the requirement Test item does not meet the requirement Testing N A P ass F ail Date of receipt of test item 2010 05 17 2010 01 10 2010 01 13 Date s of performance of test 2010 06 28 till 2010 08 31 The test result presented in this report relate only to the object s tested This report shall not be reproduced except in full without the written approval of the applicant Throughout this report a comma is used as the decimal separator This Test Report consists of the following documents 1 Test Report EMC Test Report Annex No 1 IP Test Report Annex No 2 Pictures of the unit Annex No 4 Test Equipment list Annex No 5 o N Schematics Layouts Transformer drawings Annex No 3 1 Page 6 of 167 Report No 09TH0459 AS3100_2 VERITAS General product information The Solar Inverter converts DC voltage into AC voltage The input and output are protected by Varistors to Earth The unit is providing EMC filtering at the output towards mains The unit does not provide galvanic separation from input to output The output is switched off redundantly by the high power switching bridge and two relays in series This assures that the opening of the output circuit will also operate in case of one error The voltage and frequency measurement is performed with resistors in serial wh
49. that a failure of either is unlikely to spread to the other If they have to be of the same material they should at least be mechanically distinct so that there is a surface of discontinuity to prevent the spread of deterioration from one to another Each section of insulation should be designed so that by itself it would be capable of withstanding the tests applicable to basic or supplementary insulation as appropriate d A variation of the type in Item c is shown in Figures D1 c and D1 e where the live conductors are not completely surrounded by solid basic insulation but are partly separated by air from the supplementary insulation The supplementary insulation may have a hole through it as in Figure 1 It is also possible that metal work connected to neither live conductors nor accessible metal is embedded in the supplementary insulation as shown in Figure D1 f Inspection and tests on the supplementary insulation as a whole should be made to ensure that the presence of the metal inclusions does not reduce the effectiveness of the supplementary insulation below the limit of acceptance N A VERITAS Page 67 of 167 Report No 09TH0459 AS3100_2 D 6 4 Connection to the power supply In designing double insulated equipment it is important to remember that the principle should be extended to auxiliary items such as switches plugs and sockets and also to any apertures through which the supply
50. that are separated from live parts by insulation that is considered to be the equivalent of double insulation NOTE 3 An example of this form of construction is the use of optocouplers b Equipment having metal parts that can be touched and which are intentionally connected to live parts through an impedance which is designed to preserve the appropriate level of safety Parts connected by protective impedances shall be separated by double insulation or reinforced insulation 5 4 2 Supplementary insulation Supplementary insulation shall consist of suitable non hygroscopic insulating materials possessing adequate mechanical strength and shall comply with the test requirements specified in Clause 8 4 3 Any supplementary insulation in the form of coverings linings and the like shall be securely fixed in position and shall be such as it will maintain its position and insulating properties under any conditions of normal wear and tear or other deteriorating factors that can be reasonably expected in service The arrangements of the supplementary insulation shall be such that in the event of failure of the basic insulation due to a fault condition the effectiveness of the supplementary insulation shall not be impaired N A 5 4 3 Basic insulation Basic insulation shall consist of suitable material possessing adequate mechanical strength and shall comply with the test requirements specified in Clause 8 4 3 Basic insu
51. that have no individual Approval and test specification the type of flexible cord permitted in published individual Approval and test specifications should be used as the basis for evaluating whether a particular type of cord is an appropriate type for the item in question In the selection of cords consideration should be given to the following conditions i Physical conditions ii Environment Exposure to oils grease or solvents ower supply cords shall have a nominal cross sectional area not less than those given in Table 4 4 4 4 2 Warning notice Any equipment with a current rating above 10A but not exceeding 20A and which is intended for connection by flexible cord and plug to a socket outlet shall have a prominent and durable notice affixed adjacent to the flexible cord entry of the equipment to indicate that it must be connected only to a socket outlet of appropriate current rating N A 4 5 Supply connection and external flexible cables and cords 4 5 1 General Where a supply flexible cord or supply flexible cable is to be connected directly to equipment that is not through a connector or the like the facilities for the connection of the supply flexible cord or cable shall in addition to complying with Clause 4 3 comply with this Noticed type Y attachment VERITAS Page 24 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Require
52. the circuit of an auxiliary winding is operated with the rotor locked the capacitors one at a time being short circuited or open circuited whichever is the more unfavourable unless the equipment is not intended for use unattended and the motor is provided with a capacitor complying with IEC 60252 1 For each of the tests the equipment starting from room temperature is operated at rated voltage or at the upper limit of the rated voltage range for a period of i 30s for A hand held equipment B equipment that has to be kept switched on by hand and C equipment that is continuously loaded by hand or ii 5 min or if a timer is provided equal to the max period allowed by the timer for other equipment that is not intended for use unattended or iii as long as necessary to establish steady conditions or if a timer is provided equal to the maximum period allowed by the timer for the remaining equipment At the end of the test period specified or at the instant of operation of fuses thermal cut outs motor protection devices and the like the temperature of the windings shall not exceed the values shown in Table 8 15 3 N A 8 15 4 Equipment with three phase motors Equipment incorporating three phase motors is operated under normal load with one phase disconnected for a period as specified in Clause 8 15 3 N A VERITAS Page 54 of 167 Report No 09TH0459 AS3100_2 8 15 5
53. the connection of current carrying parts unless they clamp these parts directly in contact with each other and are provided with a suitable means of locking Thread cutting self tapping screws shall not be used for the electrical connection of current carrying parts unless they generate a full form standard machine screw thread Unless the thread is formed by a swaging action such screws shall not however be used if they are likely to be removed or replaced during installation or servicing Thread cutting and space threaded screws may be used to provide earthing continuity provided that it is not necessary to disturb the connection in normal use and that at least two screws are used for each connection See table 8 7 in Annex No 1 Verified N A 4 9 Direct connection to fixed wiring Equipment designed for direct connection to the supply circuit wiring shall comply with the following a Provision shall be made for the entry of insulated conductors within their conduit sheathing or other protective covering b Terminals suitable for the connection of the supply conductors and an earthing conductor if required shall be provided the terminals shall be fixed in position and DC and AC inlets grouped PE terminal clearly marked VERITAS Page 28 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict shall be grouped togethe
54. the tests of Paragraph B3 Annex B This requirement does not apply to decorative trims knobs wiring insulation and other parts not likely to be ignited or to propagate flames originating from inside the equipment Alternatively compliance may be checked as specified in Clause 30 2 of AS NZS 60335 1 6 4 Resistance to tracking N A Insulating material across which a tracking path may occur shall have adequate resistance to tracking taking into account the severity of its duty conditions Compliance is checked by the tests of Paragraph B4 Annex B VERITAS Page 38 of 167 Report No 097 0459 83100 2 SECTION 7 MARKING 7 1 Information to be marked All equipment shall be marked with the following information a The name or registered trade name or mark of the manufacturer or of the responsible vendor NOTE In every state and territory of Australia and in New Zealand legislation has been enacted which requires that electrical equipment of a declared class or type should not be marketed unless approved by the relevant regulatory authority It may be essential in terms of the legislation that certain classes or types of article be marked with the approvals marking allotted by the relevant authority b The operating voltage and the rating in amperes or loading in watts or volt amperes For equipment other than class Ill equipment that is intended for connection to the supply mains the
55. tubing taping or the like on supply flexible cords shall not be accepted as providing insulation or protection on that flexible cord for equipment with Type X attachment Beads and similar ceramic insulators on live wires shall be so fixed or supported that they cannot change their position they shall not rest on sharp edges The equipment shall include provision for guarding the supply flexible cord against damage from internal moving parts and internal surfaces having normal operating temperatures in excess of that permissible for the supply flexible cord 4 5 5 Interconnection cables and cords Facilities for the connection of detachable and non N A VERITAS Page 26 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict detachable interconnection flexible cables or cords shall comply with the requirements for the supply cable or cord except that a connectors and appliance inlets used for the interconnection flexible cable or cord shall not be interchangeable with the connectors and appliance inlets used for the power supply cord if this might impair compliance with this Standard and b the cross sectional area of the conductors of the interconnection flexible cable or cord is determined on the basis of the maximum current carried by the conductor during the normal operation tests NOTE 1 An interconnection flexible c
56. use Devices such as self locking nuts self clamping terminals spring washers or reusable locking compounds are acceptable for the purpose All terminals shall be so designed that the conductors connected thereto can be rigidly effectively clamped between metal surfaces and shall comply with Clause 4 6 1 Connecting plates associated with terminals and forming internal connections shall be in effective electrical contact with the associated terminal in accordance with Clause 4 6 1 Terminals shall be either securely fixed in position within a terminal box or enclosure or so arranged that movement of the connections is limited by location in a suitable enclosure recess housing or the like provision being made for maintaining adequate clearance between live parts and exposed metal parts Other arrangements are not precluded provided that the terminals are suitably restrained Screws of tunnel type terminals and other clamping devices which are intended to clamp directly onto conductors shall be so shaped and finished that strands of the conductor are not likely to be severed when the screw is tightened to the extent necessary to provide a satisfactory termination The surfaces against which the terminated conductor is to be clamped shall have no sharp angles or projecting edges that would be likely to damage the conductor and for tunnel type terminals the hole for any pinching screw shall not extend through the conductor way be
57. use a fixed connection is required for protection this shall be stated in the installation manuals according to IEC 60950 1 Page 89 of 167 Report No 09TH0459 AS3100 2 VERITAS High voltage electric strength test voltage applied between Measured test voltage V breakdown working voltage Yes No AC to enclosure 230V 2000 to enclosure 500V 2000 to SELV 3800VAC DC to SELV 3800VAC No Note If a defect occurred during abnormal operation 8 15 the high voltage test was applied to assure that there is no hazard to the user Wy Page 90 of 167 Report No 09TH0459 AS3100 2 85 Test of earthing connection EE Using a maximum 12 Vac power source a current of 1 5 times rated current or 25A whichever is greater is passed between the equipment earthing terminal and the part in the equipment that is required by 8 5 to be earthed listed below The voltage drop from the earthing terminal to the accessible metal part required to be earthed was recorded and the resistance was calculated The resistance shall not exceed 0 10 ES3300 Accessible conductive part Test current in Measured Calculated Aac Voltage in Resistance in v terminal to enclosure cover 1 26 1 1 9V 72 terminal to enclosure cover 2 26 1A 2 1V termina
58. where there is true double insulation depends upon the relative impedance of basic insulation and supplementary insulation A decision should be made whether the test is to be made by applying the original test voltage for a shorter time by reducing the test voltage or by impulse testing the latter may involve higher voltages D 8 3 Continuity of earthing of Class equipment The continuity of earthing can be checked by the test described in the relevant Standard the check is to see that necessary connections have been made To avoid the possibility of deterioration due to local overheating a lower current than that called for in the type test may be passed for a shorter time D 8 4 Assembly of cord anchorage and terminal connections An inspection is necessary to ensure that all screws have been tightened and that snap on crimped or similar connections have been correctly assembled D8 5 Correct position of wiring and components The correct positioning and retention of wiring and components should be checked by inspection D 8 6 D 8 7 Correct functioning of the equipment The test program should include appropriate tests for the correct functioning of the equipment and safety devices Selection of tests It may not always be necessary to examine all of the criteria mentioned above For example it might be possible to dispense with the electric strength test in Paragraph 08 2 in favour of adequate in
59. with a timer is operated under normal load and at rated voltage or at the upper limit of the rated voltage range until steady conditions are established or until the thermal cut out operates When steady conditions are established or immediately before the operation of the thermal cut out the temperature of the windings shall not exceed the values specified in Clause 8 15 5 N A 8 15 7 Equipment with series motors Equipment incorporating series motors is operated at a voltage equal to 1 3 times rated voltage for 1min with the lowest possible load Any heating elements shall be disconnected for this test After this test the safety of the equipment shall not have been impaired in particular windings and connections shall not have worked loose N A VERITAS Page 55 of 167 Report No 09TH0459 AS3100_2 8 15 8 Equipment incorporating electronic components P The equipment is operated at a supply voltage so that the input is equal to rated input Components such as semiconductor devices capacitors resistors or inductors the failure of which might cause a hazard are short circuited or disconnected whichever is the more unfavourable If a non self resetting thermal cut out operates or if the current is otherwise interrupted in a non self resetting way before steady conditions are established the operating period is considered to be ended If interruption of the current does not occur t
60. 0 5mm if not protected against the deposition of dirt For peak voltages exceeding 50V the reduced creepage distances apply only if the proof tracking index PTI of the printed circuit board is greater than 175 when measured in accordance with Paragraph B4 Annex B These distances may be reduced further provided that the appliance complies with the requirements of Clause 8 15 when the distances are short circuited in turn NOTE When the limits specified above lead to higher values than those of Table 4 1 the values of the table apply Creepage distances clearances within optocouplers are not measured For live parts of different potential separated by basic insulation only creepage distances and clearances smaller than those specified in Table 4 1 are allowed provided the requirements of Clause 8 15 are met if these creepage distances and clearances are short circuited in turn No reduction on PCBs N A 4 1 4 3 Distances through insulation The distance through insulation between metal parts for working voltages up to an including 250V shall be not less than 1 0mm if they are separated by supplementary insulation and be not less than 2 0mm if they are separated by reinforced insulation Compliance is checked by inspection and by measurement NOTE 1 This does not imply that the distance has to be through solid insulation only The insulation may consist of solid material plus one or more air layers NOTE
61. 022885 Fax 886 2 66022415 o Page 118 of 167 Report No 09TH0459 AS3100_2 BUREAU Intertek APPENDIX 1 Report No TP10090079 ETS Date September 10 2010 Page 8 of 8 Z 8 f L 5 Flow meter gt ian 2222 28401 Dimensions in mifiimetres 6 3 for the test of 14 2 5 second characteristic numeral 5 12 5 for the test of 14 2 6 second characteristic numeral 6 Figure 6 Test device to verify protection against water jets hose nozzle Intertek Testing Services Taiwan Ltd SP No 423 Ruiguang Rd Neibu District Taipei 114 Taiwan Tel 886 2 66022885 Fax 886 2 66022415 qn Wy Page 119 of 167 Report No 09TH0459 AS3100_2 sureau Annex No 3 Schematics Layouts Transformer drawings Page 120 of 167 Report No 09TH0459 AS3100_2 ES2200 ES3300 ES4400 ES5000 Schematic Main Board E _ AV ABLEREX Electronice Co Ltd PV 25KVA Control Board System 9 qu 1 IH i pi Mil r 12 1 s L n ii mn AS3100_2 Report No 09TH0459 4 paver r M 121 of 167 om ws BUREAU Page 122 of 167 Report No 09TH0459 AS3100_2 BUREAU Page 123 of 167 Report No 09TH0459 AS3100_2 BUREAU q B
62. 05505 mus ff po E 4 L 1 1 1 1n 1 n j ww 3 o EES e ur l a KARAR M CR 1201 149 167 Report 09TH0459 AS3100_2 Construction Analysis Transformer Construction Analysis Form Verdict Date 49 5 AO Pass Project C97HO SS Fail Transformer Name RFN 48 Picture s filed Transformer No Mounted col Board Overall size 201 by AGS by 4 Ferrite size Aut by 465 by 46 Foild Pri Sec 5 Foil 1 Thickness 0006 Pin AO Foil 2 marga Sage Teil Thickness 2025 mm Br mim 0000000004 3 mine Thickness Pind Bobbin Min thickness mm Dind Tubing of wires muy Reaches _ MERO TERES into windings Pind Thickness OA mm Min Clearance 62 mm required mm Min Creepage 62 required _ mm Shortcuts PRI primary windings SEC secondary windings MEW multi extruded wire TUB wire tubed M margin tape 2L insulation foil 69 150 of 167 Report 09TH0459 AS3100 2 No 4 Pictures the unit Page 151 of 167 Report No 09TH0459 AS3
63. 100_2 ES2200 ES3300 f 152 of 167 Report 09TH0459 AS3100_2 ES2200 ES3300 inside 153 of 167 Report 09TH0459 AS3100 2 ES2200 ES3300 mainboard top ES2200 ES3300 mainboard bottom PR e Page 154 of 167 Report No 09TH0459 A83100 2 VERITAS ES4400 ES5000 155 of 167 Report 09 0459 53100 2 54400 55000 inside 156 167 Report No 09 459 53100 2 BUREAU a BUREAU Page 157 of 167 Report No 09 0459 53100 2 2 Page 158 of 167 Report No 09TH0459 AS3100_2 BUREAU M3 machine thread screw earth wire depth of impression 4 5mm lock washer thread bolt enclosure 159 of 167 Report 09TH0459 AS3100 2 54400 55000 mainboard top apt Page 160 of 167 Report No 09TH0459 AS3100_2 ES2200 ES3300 ES4400 ES5000 EMI Board top side z 21 3 4 5 1 9 io rr 12 129 94 15 16 12 19 20 21 22 33 24 20 SCALE IN EMI Board bottom view WO NI 37 5 Tam TERT Su S 4 to ii Y 105 320 st 30 25 37 39 SCALE IN WO NI 31 26 Page 161 of 167 Report No 09TH0459 AS3100_2 Control Board top side 1 EE WSA ne Ap 23
64. 2 For appliances having parts with double insulation where there is no metal between basic insulation and supplementary insulation the measurements are made as though there is a metal foil between the two insulations NOTE 3 The specified distances through insulation do not apply to Noticed 17 of 167 Report 09TH0459 AS3100 2 BUREAU VERITAS AS 3100 2009 Clause Requirement Test Result Remark Verdict the insulation of internal wiring 4 1 4 4 Insulation in sheet form Noticed P The requirement in Clause 4 1 4 3 does not apply if the insulation is applied in thin sheet form other than mica or similar scaly material and a for supplementary insulation consists of at least two layers provided that each of the layers withstands the electric strength test of Clause 8 4 for supplementary insulation or b for reinforced insulation consists of at least three layers provided that any two layers together withstand the electric strength test of Clause 8 4 for reinforced insulation Compliance is checked by inspection 4 1 4 5 Supplementary insulation and reinforced insulation Noticed P The requirement in Clause 4 1 4 3 does not apply if the supplementary insulation or the reinforced insulation is inaccessible and meets one of the following conditions a The maximum temperature rise determined during the tests of Clause 8 15 does not exceed the value specified in Table 5 7
65. 2103 EN to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEI 30 06 I 37A Tc 85 C 600V IEC Accepted D8 Screwed with metal clamp 62103 EN to enclosure heat sink 50178 provided with ceramic late Diode Fairchild RHRG5060 I 50A Tc 93 C 600V IEC Accepted D8 Screwed with metal clamp 62103 EN to enclosure heat sink 50178 provided with ceramic plate Diode Fairchild RURG8060 I 80A Tc 72 C 600V IEC Accepted D8 Screwed with metal clamp 62103 EN to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEP 60 06A 60A Tc 110 C 600V IEC Accepted D8 Screwed with metal clamp 62103 EN to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEI 60 06A 60A Tc 70 C 600V IEC Accepted D8 Screwed with metal clamp 62103 to enclosure heat sink 50178 provided with ceramic plate Transistor Fairchild HGTG30N60AA4 60A 110 600V Accepted Q12 Screwed with metal clamp IGBT to enclosure heat sink provided with ceramic plate Transistor Advanced APT50GN60BG 64 110 600V Accepted Q12 Power Screwed with metal clamp IGBT Technology to enclosure heat sink provided with ceramic plate Transistor Fairchild HGTG40N60A4 63 Tc 110 C 600V Accepted Q12 Screwed with metal clamp IGBT to enclosure heat sink provided with ceramic plate Transistor IRG4PSC71U 60A Tc 100 C 600V Accepted Q12 Screwed with metal clamp
66. 5 Switches Any switch incorporated in equipment shall be a Category 1 2 or 3 switches as appropriate or comply with AS NZS 61058 series in accordance with the conditions occurring in the appliance A Category 1 switch shall comply with the relevant requirements of AS NZS 3133 and its off position shall be marked in accordance with Clause 3 8 2 herein A Category 2 switch shall comply with the relevant requirements of AS NZS 3133 and its off position need not be marked A Category 3 switch shall satisfy the test requirements of Clauses 13 1 j 13 3 and 13 4 of AS NZS 3133 and its off position need not be marked In addition it shall be subjected to 50 operations of making and breaking the normal load current of the circuit it controls in accordance with Clause 13 5 4 and Table 3 of AS NZS 3133 except that where appropriate for circuits including motors the test current and power factor shall be the equivalent current and power factor of the circuit which the switch controls with the rotors locked The rate of operation shall be in accordance with Clause 13 3 of AS NZS 3133 In addition where Category 1 and 2 switches control circuits containing motors these switches shall be subjected to a further 50 operations The test current and power factor shall be equivalent to the current and power factor of the circuit with rotors locked and the rate of operation shall be in accordance with Clause 12 8 of AS NZS 3133 A Category 1
67. 9 459 53100 2 5232 Board top side LI LI S J Pa MU ai E SCALE IN RS232 Board bottom view SCALE IN CM bL 2 3 22 3 PLU UL UD UL ed a TT A 69 166 of 167 Report 09TH0459 AS3100 2 No 5 Test Equipment List 0 VERITAS Page 167 of 167 Report No 09TH0459 AS3100 2 Device Internal Manufacturer Serial No Last Next No Calibration Calibration Multimeter 329 Keithley 2701 E 1092554 Jun 2010 2011 Digital 663 METRAHit SF4220 Aug 2009 Aug 2010 Multimeter Gossen 29S Metrawatt GmbH Variable 49 Heine Spezial ESG 4 Resistor widerst 19 40 3A GmbH Insulation 61 Unitest 93406 IE 0167SE Aug 2009 Aug 2010 Tester Transformer 93 TTH ETR 250 V DC Power 224 Power Control AGKW 00084278 Supply eco 150 41 DC Power 225 Power Control A6KW Supply eco 150 41 DC Power 226 Power Control AGKW 00084297 Supply eco 150 41 DC Power 363 A12KW E00126314 Supply DC Power 364 A12KW E00126318 Supply 3 Phasen 446 Statron 5316 1 9507001 Trenntrafo 3 phase 596 Ruhstrat TIDMT a27468 transformer Oscilloscope 333 1620 91 424384 Jun 2008 2010 Die
68. C M dimension 33mm by 38mm by 18mm measured Rating 2 0mH Core Ferrite R 47x27x15A 055 Coil Enamelled copper Magnet wire wound on Core Base plate 26mm by 18mm by min 1 6mm thickness for 1PCB or 26mm by 18mm by min 0 8mm for 2PCB s 77 Flame Class 94V 0 Varistor Brightking Inc 621KD20 Climate Category XGPU2 VDE RT1 RT2 40 085 56 6500A max 1 61051 2 peak current 100A Class 61054 2 2 current Varistor Voltage CECC 42000 620Vdc CECC 42200 CECC 42201 Capacitor Nippon Chemi KMH 500V 47 105 C Accepted C28 C30 C31 Con C34 C35 C37 C50 C51 VERITAS Page 74 of 167 Report No 09TH0459 AS3100_2 circuit Hall effect measuring principle Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Electrolytic Bulk Capacitor Lelon LSG 500V 470uF 105 C Accepted C28 C30 C31 Electronics Corp C34 C35 C37 C50 C51 Electrolytic Bulk Capacitor Samwha SAMWHA 500V 4701 105 C Accepted C28 C30 C31 Electronic co C34 C35 C37 Ltd C50 C51 Electrolytic Bulk Capacitor Nichicon NICHICON 500V 47 105 C Accepted C28 C30 C31 Corporation C34 C35 C37 C50 C51 Electrolytic Bulk Capacitor Hitachi Hitachi 500V 4701 105 C Accepted C28 C30 C31 C34 C35 C37 C50 C51 Electrolytic Bulk
69. E 3 If a barrier is interposed clearances are measured over the barrier or if the barrier is in two parts with mating surfaces that are not connected together through the joint NOTE 4 When assessing creepage distances and clearances the effect of insulating linings of metal enclosures or covers is taken into consideration NOTE 5 Internal conductors are considered to be bare conductors unless their insulation withstands an electric strength test made between the conductor and metal foil wrapped round the insulation a test voltage of 2000Vbeing applied for 15 min NOTE 6 Means provided for fixing the equipment to a support are considered to be accessible NOTE 7 A component incorporated in an appliance and which may comply with an individual Approval and test specification is to also comply with the creepage distances and clearance specified in this Clause 4 1 4 Additional requirements for appliances 4 1 4 1 General The requirements in Clauses 4 1 4 2 to 4 1 4 5 are applicable only to appliances Noticed 4 1 4 2 Printed circuit boards For conductive patterns on printed circuit boards except at their edges the values in Table 4 1 between parts of different potential may be reduced as long as the peak value of the voltage stress does not exceed either a 150V per millimetre with a minimum distance of 0 2mm if protected against the deposition of dirt or b 100V per millimetre with a minimum distance of
70. Earthing facilities 5 3 1 Exposed metal parts to have means of earthing If equipment includes any exposed metal parts then all such exposed metal parts shall be in good electrical contact with each other and the equipment shall be provided with a common earthing facility by means of All exposed metal parts are earthed VERITAS Page 32 of 167 Report No 09TH0459 AS3100_2 which all the exposed metal parts may be effectively earthed For combination gas electric equipment the main metallic gas pipe of the equipment to which the incoming gas supply is to be directly connected shall be bonded to the earthing terminal of the equipment Metal parts that are coated with porcelain enamel paint or similar insulating finishes shall not be deemed to have been brought into good electrical contact with other parts merely by contact with the coated surface or by screws or bolts passing through those portions of the parts that are coated The coating of metal parts with porcelain enamel is not acceptable alone as justification of absence of earthing of such parts Flexible metallic conduit or tubing enclosing the conductors between movable component parts of an equipment shall not be relied upon for earthing purposes 5 3 2 Method of making the earth connection Facilities for earthing shall take one of the following forms a A terminal suitable for the attachment of an earthing conductor b The e
71. If the protective case is of metal a failure of the protection which might occur through breakdown of the insulating material or bridging of insulation such as the escape of a strand of flexible cord from under a clamping screw to bridge the gap to the case could raise the potential of the case to a hazardous voltage above earth This would be an extremely dangerous condition because persons touching the case would be likely to receive a dangerous shock if they were making partial contact with earth or a fatal shock if they were in good contact with earth through standing on a wet floor or touching water pipes gas pipes or other earthed metal It is therefore desirable in the interests of safety to provide a second line of defence and the National Wiring Rules requires generally that any metal in an electrical installation that can be touched shall be earthed that is to say electrically connected to the general mass of earth and to the earthed point of the supply system by conductors of low resistance So long as this condition is maintained there can be no danger in touching the metal for even in the event of failure of insulation no appreciable potential can exist between it and persons who are also making contact with earth If the failure of insulation is partial a small current will flow through the earth wire harmlessly to earth while if it is complete a heavy current will flow which will operate protective devices f
72. PTS 001 Open type construction Accepted TX1 Electronics Ind El 28 E 14177A with overall approx Co Ltd dimension 30mm by VERITAS Page 78 of 167 Report No 09TH0459 AS3100_2 Object Part No Manufacturer Tr ademark Type Model Technical data Standard Mark s of conformity or NO 1350F 1 by 3M Company or NO CT by Jingjiang Yahua Margin Tape NO 35661 by Symbio Inc or NO 44 by 3M Company or NO WF by Jingjiang Yahua Transistor U2 U3 U5 U10 STMicroelectroni cs L7805CV 5V 1 5 Screwed to Heat sink H1 H2 H3 H4 Accepted 15020035 PCB PVAI030 JIANGSU DIFEIDA DFD 2 overall approx dimension 215mm by 75mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C ZPMV2 cURus E213009 PCB PVAI030 Hung Chin Electronic Co Ltd 96 overall approx dimension 215mm by 75mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C ZPMV2 URus E211578 Transformer T1 Lion Electronics MSL HPTS 002 EE16 Open type construction with overall approx dimension 17 5mm by 15mm by 21 3mm Rating Input 12V 1A Output 12V 1A Switching Frequency 40KHz Core EE16 Ferrite Coil PACIFIC THAI ELECTRICWIRE amp CABLE CO LTD UL E142108 130 C Bobbin PHENOLIC T375J EE 16 10PIN CHANG CHUN PLASTICS CO LTD UL E59481 150 C Insulation System Insulation Class B 130 C Applicable par
73. RITAS Page 31 of 167 Report No 09TH0459 AS3100_2 shall comply with the relevant Approval and test specification except as provided in Clauses 5 2 3 2 and 5 2 3 3 5 2 3 2 Specific requirements PVC insulation Specific requirements for wiring with PVC insulation are as follows a For internal equipment wiring and accessible equipment wiring not subject to flexing or damage the following shall apply i General Insulation of internal equipment wiring of 250 V grade shall have an average aggregate thickness between any two live conductors and between any live conductor and exposed metal of not less than 0 5mm and in no case shall the minimum aggregate thickness at any point be less than 0 35mm Where insulating sleeving is used it shall be a close fit over the conductor or other sleeving or otherwise shall be securely fixed in position ii Maximum operating temperature Flexible cords with V60 V75 and V90 insulants may have a maximum operating temperature of 80 95 and 100 respectively when used as internal equipment wiring in such a manner as to be not subjected to flexing b For accessible equipment wiring subject to flexing or damage or external equipment wiring of 250V grade insulation shall have an average aggregate thickness of not less than 0 8mm and the minimum thickness at any point shall be not less than 0 6mm except as otherwise provided for a specific type of cable in the appropriate A
74. TEST REPORT AS 3100 2009 General requirements for electrical equipment Report reference No Tested by printed name and signature Approved by printed name and signature Date of issue 09TH0459 AS3100_2 Georg Loritz Geor lon k Frank Hesmer 2011 03 02 Testing Laboratory Name Bureau Veritas Consumer Products Services Germany GmbH Businesspark A96 86842 Tuerkheim Germany same as above pakks D PL 12024 03 01 Ablerex Electronics Co Ltd 1F No Lane 7 Paokao Road Hsintien 23114 Taiwan Test specification Standard Test procedure Non standard test method Test Report Form No Master TRF AS 3100 2009 Safety verification report None 53100 Bureau Veritas Consumer Products Services Germany GmbH Copyright 2009 Bureau Veritas Consumer Products Services Germany GmbH Test item description Solar Inverter Trademark Model and or type reference 51650 ES2200 ES3300 54200 55000 Ratings nr tt ES1650 ES2200 ES3300 ES4200 ES5000 Input Voltage 120 500V 150V 450V MPP Input current 10 5 14 6 22 14A 14A 17 6 17 6 A A Output Voltage 230V 50Hz Output current 6 5A 8 7A 13A 17 4A 21 7A Output power nom 1500W nom 2000W nom 3000W n
75. Terminal arrangements Except for equipment that is provided with a Type Y or Type Z attachment the following provisions shall apply a The arrangement of the terminals shall be such as will allow the supply flexible cord or flexible cable to be disconnected and replaced without removing any internal wiring or connections from the terminals b The clamping of the supply conductor at a terminal shall be independent of the clamping of any internal lead at that terminal This does not apply where the internal lead is effectively anchored to the terminal by means other than the terminal screw or where the replacement of the flexible cord or flexible cable by the user of the equipment is not intended or is unlikely having regard to the type of flexible cord and the Verified VERITAS Page 21 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict method of use of the equipment for example whether it is fixed or portable and the degree to which the supply cable or cord will be subjected to flexure and mechanical damage in service c Screwless terminals that require special preparation of the conductors shall not be acceptable for the connection of supply flexible cords 4 3 5 Soldered connections Where facilities for soldered connections are provided they shall comply with the following requirements a The soldering terminals lugs or
76. V Board short 16 8A Transform er TX1 Power Pin6 to Pin7 230 500V Board short 16 8A Transform er TX1 Power Pin8 to Ping 230 500V Board short 16A 8A Transform er TX1 Power Pin9 to Pin10 230V 500V Board short 16 8A Transform er TX1 Controlle Pin3 to Pina 230V 500V Board short 16A 8A Transform er T1 Page 103 of 167 Test time I i i I i i i i i i I Report No 09TH0459 AS3100_2 Fault condition Result Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit switched off immediately internal fuse F1 30A defect unit defect HiPot Test passed no hazard Unit switched off immediately display message Er18 no hazard no defect No effect on function no derating temperature rising on IBGT unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard Unit switched off immediately unit defect HiPot Test passed no hazard No effect T1 38 C Ambient 25 C no h
77. WU TAIHU INSULATING MATERIAL CO LTD ET 9a MW28 ET 90 a _MW24 THE LEADWIRE TENSILE STRENGTH OF THE PRODUCTS SHALL BE WITHSTAND THE STATIC FORCE OF 1 0 2 INSULATION RESISTANCE LR 500V DC 100M OHM MIN BETWEEN WINDING TO CORE 3 ISSECTION 1 BOBBIN 2 INSULATING 3 4 MAGNET WIRE 5 COPPER FOIL Page 147 of 167 Report No 09TH0459 AS3100_2 100 MIRRI IET LIRO x wem oe warm a mum secs mom m n ve ros ves tu seme paaa ocn ocnaen m peers mam asa a assis REF MAX MAX MAX 1 Bx ferr E gt 1271 1320 4 2 16 2 3 BOBBIN BOE1160400 4 WIRE CU 0 16 0 H9 9UEW Y 0 H42UEW R my CORMEX B 1201 Page 148 of 167 Report No 09TH0459 AS3100_2 Hoge EN LARG manm oon m rum se 77 aal ao gt H Am Cm Emm Gm 15 15 3stos 104505 325205 06505 ferme wax 99409
78. able or cord is considered to be a flexible cable or cord provided as part of the complete equipment for purposes other than supply for example a remote hand held switching device an exposed interconnection between two parts of the equipment or a separate signalling circuit NOTE 2 Socket outlets that are not accessible to the user and which are used for the interconnection of various parts of equipment are not considered to be general purpose outlets 4 6 Joints and connections N A 4 6 1 Joints and insulation Where insulation is required on joints or connections in equipment wiring the thickness need only be equivalent to that required by Clause 5 2 3 All joints and connections the failure of which could cause a hazard shall utilize materials and forms of construction that will avoid deterioration or loss of contact pressure in service Insulating materials which may shrink or deform in service in such a manner as to cause loss of contact pressure at a joint or connection shall not be used unless they are suitably treated or proofed to prevent such shrinkage or deformation or unless the metallic parts of the joint or connection have sufficient resiliency to compensate for any such shrinkage or deformation and to retain adequate contact pressure in service Stranded conductors shall not be consolidated by lead tin soldering where they are subject to contact pressure unless the clamping means is so designed that ther
79. ached they may readily touch live parts or bridge insulation Nameplates incorporating a durable surface finish including those with particulars printed photographically in conjunction with anodizing shall be regarded as indelible Where marking is by adhesive non metallic labels surface transfers painting silk screening printing with etching dyes or similar means the marking shall be sufficiently durable for its purpose and located where it will not be subjected to conditions that may lead to its deterioration having regard to the quality of marking the surface to which it is applied and service conditions such as temperature moisture abrasion and handling The marking of fixed equipment shall be clearly discernible from the outside after the equipment has been fixed as in normal use but if necessary after removal of a cover The marking of other equipment shall be clearly discernible from the outside if necessary after removal of a cover for portable equipment the removal of this cover shall not require the use of a tool Indications for switches thermostats thermal cut outs and other control devices shall be placed in the vicinity of these components they shall not be placed on removable parts if these parts can be replaced in such a way that the marking is misleading Verified 7 3 Double marking If any equipment is to be marked with its load in watts and is marked with more than one voltage but only one
80. ain Board Internal wiring Wonderful 1015 10 AWG 600Vac 105 AVLV2 cURus E77981 from AC Tech Provided with Ferrite Core terminal to AC Board and from AC Board to 73 of 167 Report No 09TH0459 AS3100 2 Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Main Board Internal wiring Sin Yu 1015 10 AWG 600Vac 105 AVLV2 cURus E191346 from DC Technology Inc terminal to Main Board Tubing shrink Shenzhen RSFR Temp Class YDPU2 cURus E203950 for 125 C VW 1 min 0 8mm DC wires thickness Tubing shrink Shenzhen RSFR Temp Class YDPU2 cURus E203950 for internal 125 VW 1 min 0 25mm wiring control thickness panel and internal wiring display Tubing shrink Shenzhen RSFR Temp Class YDPU2 cURus E203950 for internal 125 VW 1 min 0 3mm wiring between thickness the terminals AC DC power and EMI Board PCB JIANGSU DFD 2 overall approx dimension ZPMV2 cURus E213009 010 DIFEIDA 330mm by 270mm by 1 6mm Flame Class 94V 0 RTI 130 C PCB Hung Chin 96 overall approx dimension ZPMV2 URus E211578 PVAD010 Electronic Co Ltd 330mm by 270mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 Diode Diotec P1000J 10 600V Accepted D26 D27 Semiconductors Inductor Lion Electronics 106501 06 Open type construction Accepted L2 with overall approx
81. ard no defect 500V 8A No effect on function Output power limited No hazard no defect Unit switched off immediately L2 136 5 C L3 136 5 C 4V 26 4 2 54 1 54 1 Ambient 25 No hazard defect 4V 26 4 Unit switched off immediately L2 136 5 L3 136 5 CT2 54 1 C CT3 54 1 Ambient 25 C No hazard no defect Unit switched off immediately L2 136 5 L3 136 5 CT2 54 1 C CT3 54 1 Ambient 25 C No hazard no defect 4V 26 4 Page 100 of 167 Report No 09TH0459 AS3100 2 je VERITAS Componen Fault Test Test condition Test time fuse Fault condition Result 2h Capacitor Short 230V pe 230V 4V Unit switched off 16A OA 26 44 immediately L2 136 5 L3 136 5 CT2 54 1 C CT3 54 1 C Capacitor Short 230V pr 16A Capacitor Short 230V ped 16A Capacitor Short 230V prd 16A Capacitor Short 230V pod C34 16A Capacitor Short 230V pou C35 16A Ambient 25 No hazard no defect 230V 4 Unit switched off OA 26 44 immediately L2 136 5 L3 136 5 2 54 1 CT3 54 1 Ambient 25 C No hazard no defect AC 32 230V 4V Unit switched off OA 26 4A immediately 12 136 5 L3 136 5 C CT2 54 1 C CT3 54 1 C Ambient 25 No hazard no defect 230V 4 Unit switched off 26 4A immediately L2 136 5 C L3 136 5 C
82. arthing contact of an appliance inlet c Other approved means A constructional bolt stud or screw may be used as the earthing terminal on equipment having exposed metal parts only if all the following conditions are observed i The earthing conductor can be removed from the terminal without in any way reducing the effectiveness of the bolt stud or screw as a constructional medium or causing any parts of the equipment to lose their relative rigidity NOTE This provision does not preclude the use as an earthing terminal of a stud which also serves for securing a terminal cover provided that it complies with Items ii and iii 1 The removal of any covers or parts of which are likely to be removed in obtaining access to terminals or in adjusting the equipment or parts thereof shall not disturb or reduce the effectiveness of the earthing connection iii The bolt stud or screw is not used for fixing the equipment in position or for adjusting the position of the equipment or any part of it Earthing terminal provided and clearly marked 5 3 3 Design and construction of earthing terminal The earthing terminal provided on any equipment shall be capable of accommodating an appropriate internal earthing conductor and a supply earthing conductor of the size required by the National Wiring Rules The current carrying capacity of any earthing terminal shall be not less than that of the earthing conductors to be connected
83. at an axial pull is likely to be applied the force is i 30 N for actuating members of electrical components and ii 50 N in other cases NOTE Sealing compounds and the like other than self hardening resins are not considered to be adequate to prevent loosening 2 J Page 37 of 167 Report No 09TH0459 AS3100_2 VERITAS SECTION 6 RESISTANCE TO HEAT FIRE AND TRACKING 6 1 General Noticed P This Section applies only to equipment designated attended or unattended in a particular Approval and test specification For particular Approval and test specifications that do not designate equipment as attended or unattended the requirements of Annex A apply 6 2 Resistance to heat See list of critical P External parts of non metallic material parts of components Table insulating material supporting live parts including 2 in Annex No 1 connections and parts of thermoplastic material providing supplementary or reinforced insulation the deterioration of which might cause the equipment to fail to comply with this Standard shall be sufficiently resistant to heat Compliance is checked if required by Footnote to Table 5 7 and by Footnote to Table 8 15 9 using the test of Paragraph B2 Annex B 6 3 Resistance to fire Noticed see Table B3 3 P Parts of non metallic material shall be resistant to B3 4 in Annex No 1 ignition and spread of fire Compliance is checked by
84. ated in order to comply with Clauses 5 1 5 2 1 and 5 2 2 such insulation shall be of a grade appropriate to the voltage to which it will be subjected in ordinary use Insulants covered by this Standard shall comply with a the thickness requirements of Clauses 5 2 3 2 or 5 2 3 3 or b the thickness requirements of AS NZS 3191 However for other insulation the suitability of the insulant is assessed and an electric strength test shall be made between the conductor and metal foil wrapped around the insulation a test voltage of 2000V being applied for 15 min NOTE Where the insulant is adequately specified and compliance with this test is obvious the test need not be conducted Where equipment incorporates a component such as a pilot lamp which is connected to the supply terminals of the equipment but operates at a lower voltage than at those terminals the wiring to such component shall have a grade of insulation appropriate to the rated voltage of the equipment If however the reduced voltage is obtained from the potential drop across a shunt other than a section of an element or winding and if the conductors are separated from exposed metal parts by adequate spacing or by effective insulating means appropriate to the rated voltage of the equipment then the insulation between the conductors need only be appropriate for the voltage of the component Where the equipment wiring is in the form of a cable it VE
85. azard no defect 9 VERITAS Componen t No Controlle Board Transform er T1 Controlle Board Transform er T1 Controlle Board Transform er T1 Controlle Board Transform T1 Controlle Board Transform er T1 Controlle Board Transform er T1 Misuse Input DC voltage Output AC voltage Comment Page 104 of 167 Test condition Test time fuse AC N 3 3 3 Pin6 to Pin7 short Pin8 to Pin9 short Pin9 to Pin10 short 230V 500V 16 230 500 16 230V 500 16 230 500 16 8 230V 500 16 8 230V 500 16 Pin6 to Pin7 overload Pin8 to Pin9 overload 2h 2h 2h 2h 2h h Pin9 to Pin10 overload 8A before startup 0 32A 2A 32A 2A 2A 32A 32A 32A Mismatch before startup Report No 09TH0459 AS3100_2 Fault condition Result Unit switched off immediately T1 116 C Ambient 25 C unit defect HiPot Test passed no hazard No effect 1 95 Ambient 25 no hazard defect No effect 1 95 Ambient 25 no hazard no defect Unit switched off immediately T1 116 C Ambient 25 C unit defect HiPot Test passed no hazard No effect T1 95 C Ambient 25 C no hazard no defect No effect T1 95 C Ambient 25 C no hazard no defect Unit defect HiPot Test passed no hazard Unit does not connect to gri
86. bstantial insulating bush shall be securely fixed in the opening and shall comply with the test requirements specified in Clause 8 4 3 for supplementary insulation Strain relieves provided 5 4 10 Radio interference suppression devices No radio interference suppression device shall be connected between live parts and external metal parts of double insulated equipment Any radio interference suppression capacitor connected between live parts and internal metal parts for example in parallel with the basic insulation shall have a capacitance not exceeding 0 051 N A 5 5 Extra low voltage equipment Clauses 5 1 5 2 and 5 3 shall not apply to equipment rated at extra low voltage except that DC equipment rated above 50V shall be capable of withstanding the high voltage test specified in Clause 8 4 If extra low voltage wiring or parts connected thereto are accessibleto the standard test finger without the use of tools they shall be connected to a safety extra low voltage supply N A 5 6 Switches in portable heating appliances For portable heating appliances any switch controlling an element that is accessible to personal contact see Clause 8 10 shall open all live conductors connected to the element however a single pole switch may be used under the following conditions a If it controls only a portion of the element the remaining portion of which is not controlled by any switch on the appliance and is
87. by Bureau Veritas Ground Continuity Testing 25A 1 Min from PE to Enclosure VERITAS Page 8 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict SECTION 3 DESIGN AND CONSTRUCTION 3 1 General All equipment shall comply with the provisions of this Standard in respect of selection of materials design and construction and with the tests specified herein The selection and application of materials and the design and construction of all equipment shall be such as will ensure as far as is reasonably possible and economically practicable that when the equipment is standing supported or fixed in a normal position and operating in a normal manner and account being taken of ordinary wear and tear and other depreciating factors that can reasonably be anticipated no person will be exposed to risk of injury or electric shock and there will be no unwarrantable risk of fire either a through the functioning of the equipment under conditions required by its use at rated loading or b through the mechanical or electrical failure of any material or of the equipment itself or of any part thereof This Standard does not in general take into account the use of equipment by young children or infirm persons without supervision or playing with the equipment by young children Noticed P 3 2 Equipment to be suitable for conditions
88. carried out so that the stress is applied to the working section of the thread Mechanical strength test N A 8 8 1 General Equipment shall be subjected to blows with an impact energy of 0 5 0 05Nm by any means having the same performances as the spring operated impact test apparatus described in Clauses 8 8 2 to 8 8 4 See table 8 8 in Annex No 1 VERITAS Page 47 of 167 Report No 09TH0459 AS3100_2 8 8 2 Spring operated impact test apparatus The apparatus consists of three main parts the body the striking elements and the spring loaded release cone as shown in Figure 8 8 2 The body comprises the housing the striking element guide the release mechanism and all parts rigidly fixed thereto The mass of this assembly is 1250g The striking element comprises the hammer head the hammer shaft and the cocking knob The mass of this assembly is 250g The hammer head has a hemispherical face of polyamide having a Rockwell hardness of HR 100 with a radius of 10mm it is fixed to the hammer shaft in such a way that the distance from its tip to the plane of the front of the cone when the striking element is on the point of release is 20mm The cone has a mass of 60g and the cone spring is such that it exerts a force of 20N when the release jaws are on the point of releasing the striking element The hammer spring is adjusted so that the product of the compression in millimetres and the fo
89. ch the principle of double insulation can be incorporated a A continuous and substantial layer of metal is interposed between basic and supplementary insulation illustrated diagrammatically in Figure D1 a A defect starting in the basic insulation whether it be an electrical puncture or a mechanical fracture may grow until it reaches the metal layer but is unlikely to spread into the supplementary insulation It is necessary to arrange that the supplementary insulation has electric strength and insulation resistance substantially greater than the minimum required for the basic insulation The required degree of safety is proved by testing the insulation between live metal and the metal layer and the insulation between the metal layer and exposed metal and ensuring that each is adequate by itself b There is a metal layer interposed between the basic insulation and the supplementary insulation but this layer and the basic insulation are not complete and some bare live conductors are left separated only by air from the supplementary insulation This is shown in Figure D1 b c The live parts are completely enclosed in basic insulation which is itself enclosed in supplementary insulation without the interposition of any metal layer as shown in Figure D1 d In this case in order to comply with the principle of double improbability the supplementary and basic insulations should be of such mechanical and electrical characteristics
90. cified in AS NZS 60112 For parts of insulating material used under severe duty conditions the test voltage is 175V If the specimens do not withstand this test and there is no hazard other than fire surrounding parts are subjected to the needle flame test referred to in Clause 6 1 1 3 For parts of insulating material used under extra severe duty conditions the test voltage is 250V If the specimens do not withstand this test but withstand the test made with a test voltage of 175V and there is no hazard other than fire surrounding parts are subjected to the needle flame test referred to in Clause 6 1 1 3 The needle flame test is made on all parts of non metallic material positioned within a distance of 50mm from any place where a tracking path may occur unless these parts are shielded by a separate barrier or enclosure from that tracking path in which case the barrier or enclosure is subjected to the needle flame test NOTE 1 Guidelines for the duty conditions are given in Annex P of AS NZS 3350 1 NOTE 2 There are no tracking requirements for insulation considered to be subjected to normal duty conditions NOTE 3 Unless otherwise varied in the particular Standard the severity will be considered as normal duty N A VERITAS Page 59 of 167 Report No 09TH0459 AS3100_2 Annex B Normative Tests of resistance to heat fire and tracking B 1 Introduction The tests in this Annex shall be use
91. clearance distances for appliances P PCB EMI Clearance and creepage Up U r m s required cl cl required dcr distance V V mm mm dcr mm mm Hazard to earth basic 500 500 2 5 3 5 3 0 3 5 Layout PCB PVBFOOO Top Side Comment DC and AC are considered Hazard potential BUREAU Page 84 of 167 Report No 09TH0459 AS3100_2 PCB Mainboard PVAD010 ES2200 and ES3300 Clearance and creepage Up U r m s required cl cl required dcr distance V V mm mm dcr mm mm Hazard to earth basic 500 500 2 5 5 2 3 0 5 2 Comment DC and AC are considered Hazard potential Layout PCB PVAD010 Top Side 9 BUREAU Page 85 of 167 Report No 09TH0459 AS3100_2 PCB Mainboard PVBD020 ES4400 and ES5000 Clearance and creepage Up U r m s required cl cl required dcr distance V V mm mm dcr mm mm Hazard to earth basic 500 500 2 5 5 2 3 0 5 2 Layout PCB PVBD020 Side Comment DC and AC are considered Hazard potential lt E L NEA CHE an Cy 0 gt 2 3 Hi gt 20 pv cem NE 2 86 167 Report No 09TH0459 AS3100 2 BUREAU PVERITAS PCB Control Board PVAI032 Clearance and creepage Up 5 required cl cl required dcr distance V V
92. conductors or the terminals to which they are connected the AC wire 4 3 9 Temperature at terminals The terminals on all equipment shall be so placed arranged and ventilated that any conductors or cables connected thereto will not be liable to be exposed to temperatures in excess of those permissible for the conductor material and the class of insulation of the conductors or cables where such insulation is relied upon to prevent short circuit or contact with material through which leakage may occur Where temperature conditions are such as will require the use of connecting cables of heat resisting type prominent marking shall be provided adjacent to the terminals to indicate the type of connecting cable necessary For terminals for the connection of supply flexible cords to portable equipment the temperature rises in general shall not exceed 50 C to allow the connection of flexible cords having maximum operating temperature of 75 C except under the circumstances covered by Footnote nto Table 5 7 which allows a higher operating temperature See temperature test table 8 11 in Annex No 1 4 3 10 Access to terminal devices Terminal devices shall not be accessible without the aid of a tool even if their live parts are not accessible 4 4 4 4 1 When required Flexible cord and connecting plug Any portable equipment having a rating not exceeding 20A at low voltage shall be provided with a supply
93. ctors P All equipment shall be provided with facilities for the connection of supply conductors in one of the following forms a Terminals b Contact pins or spring contacts intended to engage with the corresponding contacts of a connector socket outlet or cord extension socket For socket outlets the requirements of Clause 3 10 shall apply c Connection of the conductors flexible cord or flexible cable to internal leads terminals lugs or the like by crimping or other similar suitable devices This form of connection shall be permitted only in the following cases i Where equipment is connected by a Type Y attachment ii A Type Z attachment where specifically allowed in an individual Approval and test specification However in the absence of an Approval and test specification a Type Z attachment may be permitted where it is used to provide an essential safety feature and where replacement during the economic life of the equipment is unlikely iii Where equipment has Type Y or Type Z attachments in accordance with Clause 4 5 1 of this Standard iv For equipment not covered by individual Approval and test specifications where the replacement of the flexible cord or cable by the user of the equipment is not intended or is unlikely having regard to the type of flexible cord and the method of use of the equipment for example whether it is fixed or portable and the degree to which the supply cable or cord will be
94. d 96 overall approx dimension 107mm by 75mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C Provided with Display ZPMV2 URus E211578 Diode D28 D29 Diotec Semiconductors P1000J 10A 600V Accepted Inductor L3 C M Lion Electronics L06S01 06 Open type construction with overall approx dimension 33mm by 38mm by 18mm measured Rating 2 0mH Core Ferrite R 47x27x15A 55 Coil Enamelled copper Magnet wire wound on Core Base plate 26mm by 18mm by min 1 6mm thickness for 1PCB or 26mm by 18mm by min 0 8mm for 2PCB s 77 Flame Class 94V 0 Accepted Varistor RT3 RT4 Brightking Inc 621KD20 Climate Category 40 085 56 6500A max peak current 100A Class current Varistor Voltage 560Vdc XGPU2 1 61643 331 URus 223465 80 of 167 Report No 09TH0459 AS3100 2 Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity Capacitor Nippon Chemi KMH 500V 470uF 105 C Accepted C53 C52 Con Electrolytic Bulk Current sensor LEM HX15 P Galvanic isolation between NMTR2 cURus E189713 CT3 HX25 P primary and secondary circuit Hall effect measuring principle Isolation voltage 3000V Current rating 15A Diode IXYS DSEP 30 06A 30A Tc 135 C 600V IEC Accepted D8 Screwed with metal clamp 6
95. d no hazard no defect Fault conditions are to be applied only one at a time and shall be applied in turn in any convenient order The equipment shall be operated until further change as a result of the applied fault is unlikely Each test is normally limited to 1 h since a HAZARD arising from the fault will usually manifest itself within that time If there is an indication that a HAZARD may result after the 1 h period the test shall be continued until the ultimate result is obtained or until temperatures stabilize whichever happens first The tests were performed on the unit mentioned in the bracket Only differences are the input voltage range and the power transformer The behaviour in case of a fault is identical 2 105 of 167 Report 09TH0459 AS3100 2 BUREAU VERITAS Resistance to heat test allowed impression diameter 5 Part Test temperature Impression diameter mm Bobbin T1 125 C 0 95mm Bobbin TX1 125 C 0 95mm 2 Page 106 of 167 Report No 097 0459 83100 2 BUREAU VERITAS 33 wire test p33 tested Temperature in C Flame height in cm Duration of flame in s of flame in s Result come ao roc os os 25m o oo housing many os ss oe Cms many
96. d through openings formed in metal work the tubes channels or openings shall be of ample size and if not bushed shall have no sharp angles or projecting edges which would be likely to damage a conductor or the insulation braiding or sheathing of a cable Conduit ends and other open ends through which cables pass shall be bushed or so VERITAS Page 18 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict shaped that they will not cause abrasion of conductors or the insulation braiding or sheathing of the cables Where bushes are used they shall be fixed securely in position 4 2 4 Protection near moving parts Cords are arranged P Equipment wiring near moving parts shall be so located accordingly or arranged as to guard against the possibility of abrasion of the conductor or its insulation braiding or sheathing 4 2 5 Unprotected conductors with fibrous insulation N A Fibrous insulated cables which are defined as unprotected in AS 3158 shall be used only where they can be installed without damage will not be subjected to undue bending and abrasion and are protected from mechanical damage and other deleterious effects by virtue of their location and the general design of the equipment in which they are incorporated 4 3 Terminals and connecting facilities for supply P conductors 4 3 1 Connecting facilities required DC side a Conne
97. d to a plug of appropriate type complying with AS NZS 3112 or alternatively for equipment with a rating not exceeding 600 W with a plug socket adaptor complying with AS NZS 3122 f be correctly connected to a connector of appropriate type if the equipment incorporates an appliance inlet or be correctly connected to terminals of the equipment g incorporate an earthing conductor where the equipment has earthing facilities and h not incorporate an earthing conductor where the equipment is of the double insulated type NOTE c refers to the provision of an appropriate type of flexible cord The permissible applications of the various types of flexible cord are specified in general terms in the National Wiring Rules Specific application requirements relating to equipment are specified within the individual Approval and test specifications Polyvinyl chloride insulated flexible cords shall not be used for equipment having external metal parts the temperature rise of which exceeds 75 K during the test of Clause 8 12 unless the design of the equipment is such that the power supply cord is not likely to touch such metal parts in normal use Tinsel flexible cords and flexible cords with conductors having a nominal cross sectional area of 0 5mmz shall not be used for earthing purposes Tinsel flexible cord is recognized only for the connection of equipment of small current rating where extreme flexibility is required For items
98. d to determine resistance to heat fire and tracking Noticed P B2 B3 Resistance to heat test Unless varied in a particular specification compliance is checked by subjecting the relevant part to the ball pressure test by means of the apparatus shown typically in Figure B2 Before starting the test the relevant part is maintained for 24h in an atmosphere having a temperature between 15 C and 35 C and a relative humidity between 45 and 7596 The part is supported so that its upper surface is horizontal and the spherical part of the apparatus is pressed against this surface with a force of 20 N The thickness of the part under test shall be at least 2 5mm NOTE If necessary the required thickness may be obtained by using two or more sections of the part The test is made in a heating cabinet at a temperature of 40 C x 2 C plus the maximum temperature rise determined during the test of Clause 8 12 but it shall be at least for external parts 75 C 2 C b for parts supporting live parts 125 C 2 C However for parts of thermoplastic material providing supplementary insulation or reinforced insulation the test is made at a temperature of 25 C 2 C plus the maximum temperature rise determined during the tests of Clause 8 15 if this is higher The temperature rises of Clause 8 15 1 are not taken into account if the test of Clause 8 15 is terminated by the operation
99. ds or by other metal it will not result in risk to the user who will be protected by the second set of insulation The accessible metal parts will become live only in the event of breakdown of both sets and the chances of this occurring are much less than the chances of the breakdown of either set alone N A R U VERITAS Page 65 of 167 Report No 09TH0459 AS3100_2 D 6 2 Design of metal encased Class Il equipment Metal encased equipment should be so designed that in general failure of two independent sections of insulation must occur before any external surface can become electrically connected with live conductors Each section of insulation should alone be amply sufficient to withstand the normal working voltage of the equipment without breakdown or appreciable leakage even under damp conditions so that if either section fails safety is assured by the second section The insulation adjacent to the live conductors is referred to as basic insulation and the second layer as supplementary insulation Alternatively the supplementary insulation may be in the form of a maintained air gap of adequate dimension It is not always possible or indeed necessary to comply fully with this ideal of two independent sections of insulation in order to achieve an adequate measure of safety In certain circumstances a single layer of insulation is sometimes used where the principles of two distinct laye
100. e appliance Where abbreviations or symbols are used in lieu of the appropriate wording the following shall apply however other abbreviations that clearly convey the intention may be accepted The numerical value of the frequency and the number of phases may be coupled with the alternating current abbreviation or symbol Notwithstanding the requirements of an_ individual Approval and test specification the following requirements shall apply i Th above marking viz alternating current or or shall be acceptable for designating equipment intended for operation on a c only In addition the presence of a marking that indicates the frequency of the supply voltage shall render the marking alternating current or unnecessary ii Any marking required shall be expressed in 5 units unless otherwise specified in individual Approval See type label P VERITAS Page 39 of 167 Report No 09TH0459 AS3100_2 and test specification 7 2 Method of marking Unless provision for a special form of marking is made in an individual specification marking required under Items a b c d e and f of Clause 7 1 shall be legible and except where permissible under Paragraph four below indelible and shall be made either on the equipment itself or on a nameplate securely fixed thereto Adhesive metallic labels shall not be fixed in locations where if they become det
101. e is no risk of bad contact due to cold flow of the solder NOTE 1 Some thermoplastic materials are regarded as liable to shrink or deform at temperatures normally associated with terminal block applications NOTE 2 Consolidation of stranded conductors by lead tin soldering is allowed if spring terminals are used securing the clamping screws alone is not considered adequate NOTE 3 Soldering of the tip of a stranded conductor is allowed N A 4 6 2 4 6 3 Soldered joints Soldered joints shall be made without the use of fluxes containing corrosive substances Limitations of soldered joints Soft soldered joints and soft soldering shall not be used for the connection of conductors or in the construction of any equipment where the temperature of the soldered joint is likely to exceed 120 C in normal operation NOTE It is recommended that the soft solder used in electrical work be that listed as 50 Sn in AS 1834 1 and AS 1834 2 this being the grade primarily intended for general electrical purposes N A N A 4 6 4 Joints and connections in lighting fittings N A VERITAS Page 27 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict No joint or connection shall be made within a lighting fitting except in a space incorporated therein for the purpose 4 6 5 Solderless joints The attachment of conductors by cr
102. e part in contact with the reinforced insulation is not precluded by the above requirements Verified P 5 4 8 Insulation of internal wiring The average aggregate thickness of basic insulation between any two live conductors and between any live conductor and supplementary insulation shall be not less than 0 5mm The average aggregate thickness of supplementary insulation shall be not less than 0 6mm The aggregate thickness of insulation at any point shall be not less than 0 35 mm and 0 44mm for basic and supplementary insulation respectively A regulatory authority may however accept a lesser aggregate thickness of certain types of insulation where satisfied that the insulation is superior to those that are generally used for similar applications and has Verified P VERITAS Page 35 of 167 Report No 09TH0459 AS3100_2 the requisite mechanical and electrical strength Where insulating sleeving is used it shall be a close fit over the conductor or other sleeving or otherwise shall be securely fixed in position Notwithstanding the requirements of this Clause insulation thickness complying with AS NZS 3191 is deemed to be satisfactory For appliances the requirements of Clause 4 1 4 3 are not applicable to the insulation of internal wiring complying with AS NZS 3191 5 4 9 Openings in external metal walls Where a flexible cord or other conductor passes through an external metal wall a su
103. e same pair of electrodes or two of the latter size may be used Standard test finger and protective impedance Noticed N A 8 10 1 8 10 2 General For the purpose of determining whether or not either live parts see Clause 5 1 or non current carrying conductive parts are exposed to personal contact use shall be made of the standard test finger Design and construction The standard test finger as shown in Figure 8 10 shall be so designed that each of the jointed sections can be turned through an angle of 90 with respect to the axis of the finger in the same direction only The tip of the finger shall be made of copper or copper alloy the handle shall be made of insulating material The finger shall be provided with two joints operating in the same plane and so constructed that they will remain in any desired position A terminal or other equivalent means shall be provided to permit attachment of a flexible wire lead to the finger Noticed Noticed N A N A VERITAS Page 49 of 167 Report No 09TH0459 AS3100_2 8 10 3 Method of use The standard test finger may be applied directly to the live or non current carrying conductive part in question and a visual examination made to determine whether or not the finger is in contact with the part under test The test finger shall be applied in every possible position making use of the joints incorporated provided that where bend
104. egulating devices and the different positions of switches may be indicated by figures letters or other visual means which clearly indicate the intent If figures are used for indicating the different positions the off position shall be indicated by the figure 0 or OFF and the position of any energized state shall be indicated by a higher figure The figure shall not be used for any other indication NOTE It is intended that individual Approval and test specifications be amended to line up with the requirements of the above paragraph as the opportunity arises Any marking provided to indicate the position of a regulating device or switch shall be visible when the device or switch is in the corresponding position 3 8 3 Voltage and current limitation N A No regulating device or switch shall control a normal operating Voltage or current when the Voltage with which the device or switch is supplied is more than 1596 in excess of the voltage at which the device or switch is rated 3 8 4 Switches for transportable machinery No transportable N A Transportable machinery with moving parts that may machinery cause injury to persons shall be fitted with a switch that operates in all live conductors so that it isolates the entire equipment from the supply U R T VERITAS Page 11 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict 3 8
105. enclosure surface area likely to be sprayed min minimum test duration 3 min distance from nozzle to enclosure surface between 2 5 m and 3 m Compliance criteria 1 After the test the enclosure shall comply with the requirements of sub clause 14 3 The enclosure shall be inspected for ingress of water If any water has entered it shall not Be sufficient to interfere with the correct operation of the equipment or impair safety Deposit on insulation parts where it could lead to tracking along the creepage distances Reach live parts or windings not designed to operate when wet Accumulate near the cable end or enter the cable if any Test Result 13 4 13 6 65 Test 14 2 5 14 3 After the test the function of the Sample is functioning as normal Intertek Testing Services Taiwan Ltd 5F No 423 Ruiguang Rd Neihu District Taipei 114 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 Page 117 of 167 Report No 09TH0459 AS3100_2 Intertek Report No TP10090079 ETS Date September 10 2010 Page 7 of 8 APPENDIX 1 Circulation pump or other suitable means to maintain the talcum powder in suspension NOTE See 60068 2 68 figure 2 valid for only Figure 2 Test device to verify protection against dust dust chamber Intertek Testing Services Taiwan Ltd SP No 423 Ruiguang Rd Neibu District Taipei 114 Taiwan Tel 886 2 66
106. equipment is suitable for conditions of use such as wet or dry conditions this is probably the safest form of construction The principles of design of insulation encased Class ll equipment are simple and should require no explanation Such equipment should not forfeit the description insulation encased because it has relatively small metal parts accessible from the outside of the enclosure such as screws name plates or guards separated from live parts by insulation that is thick and by visible creepage paths that are so long that the chance of their becoming live through failure of the insulating path is extremely remote Such insulation and creepage paths should as a minimum comply with the requirements for reinforced insulation Not all equipment can be manufactured using the insulation encased form of construction for example electric hair clippers hedge clippers and portable tools which require some external metal in order to perform their proper function Accordingly a form of construction known as double insulation has been devised N A D6 Metal encased class construction N A D 6 1 Principles of double insulation As its name implies double insulation involves the provision of two completely separate sets of insulation between the current carrying parts and any metal accessible to the user If either set of insulation breaks down or accidentally becomes short circuited by conductor stran
107. fety requirements on exposure to elevated temperatures for a specified time Where this is not practicable the test shall be applied to a sub assembly or component VERITAS Page 71 of 167 Report No 09TH0459 AS3100_2 F2 F3 Test specimen The test specimen shall be the complete equipment except that when this is not practicable for test purposes it shall be a complete sub assembly or component mounted in such a way as to simulate intended use If not otherwise specified the test specimen should be stored at 25 10 and a relative humidity of 6096 15 for 24h immediately before the test The test specimen shall be placed in an oven and heated at a predetermined temperature for a period of time Test apparatus The test apparatus shall consist of an air circulating oven capable of maintaining the temperature of its test space within 3 C of the test temperature specified in Paragraph F4 4 Test method The test method shall be as follows a The oven control shall be adjusted to a setting which produces a test temperature 10K higher than the highest temperature attained during conditions of normal use or 70 C whichever is the higher The oven shall be maintained at that setting for the duration of the test b The test specimen shall be positioned within the heated oven in the most unfavourable position likely to occur in normal use The test specimen shall not be energized during the
108. he equipment is operated until steady conditions are established For equipment for short term operation the duration of the test is equal to the rated operating time Positive temperature coefficient resistors PTCs negative temperature coefficient resistors NTCs and voltage dependent resistors VDRs are not short circuited if they are used within their manufacturer s declared Specification 8 15 9 Test results Noticed P During the tests of Clauses 8 15 2 to 8 15 8 the equipment shall not emit flames or molten metal or poisonous or ignitable gas in hazardous amounts enclosures shall not deform to such an extent as will impair compliance with this Specification and temperature rises shall not exceed the values shown in Table 8 15 9 After the tests the insulation of equipment other than that of Class when cooled down to approximately room temperature shall withstand an electric strength test as specified in Clause 8 4 the test voltage being a for basic insulation 1000V b for supplementary insulation 2750V c for reinforced insulation 3750V For equipment that is to be immersed in or filled with conducting liquid in normal use the sample is immersed in or filled with water as appropriate for 24h before the electric strength test is made Annex A Normative Requirements from the 1994 edition The following requirements taken from the 1994 edition of AS 3100 are applicable to equipment
109. he object under test For the purpose of the Standard ambient temperature shall be considered as the average of readings recorded at 10min intervals during the final 30min of the test N A 8 11 6 Maximum temperature rise The maximum temperature rise shall be taken to have been reached when for one 30min period the mean temperature curve for the object under test retains the same nominal temperature difference above ambient temperature 8 12 Temperature and fire risk test Any material or insulation of equipment and the surfaces of the test surroundings referred to below shall not attain excessive temperatures in normal use Except for hand held tools compliance shall be checked by determining the temperature of the surrounds and material or insulation where appropriate under the normal conditions as given in 8 12 8 13 Test of marking Nameplates transfers and paintings used to provide the information required in accordance with Clause 7 1 shall be checked by inspection and by rubbing by hand for 15 s with a piece of cloth soaked with water and again with a piece of cloth soaked with petroleum spirit At the completion of these tests the marking shall comply with Clause 7 2 This test does not apply to any marking provided on the container in which the article is supplied Verified VERITAS Page 52 of 167 Report No 09TH0459 AS3100_2 8 14 8 15 8 15 1 8 15 2
110. iced P Annex D Informative Information on the safety principles of the design and testing of electrical equipment including insulation encased and metal encased class II construction VERITAS Page 62 of 167 Report No 09TH0459 AS3100_2 D 1 The risk of electric shock Since the human body is to some extent a conductor of electricity a current will flow through the tissues when contact is made simultaneously with two objects that are at different potentials Thus if the two terminals of a source of electricity are grasped one in each hand current will flow through the body The current that flows may be imperceptible at very low voltages but lethal at higher voltages A similar effect will be produced if only one terminal of a supply is touched provided that as is usual the power supply is tied to earth and the person is standing on a floor that is not well insulated from earth Voltages below 32V are usually considered to be harmless to ordinarily healthy people under normal circumstances Consequently no precautions are taken generally to prevent a userfrom coming into contact with the conducting parts of a safety extra low voltage system Public supply systems however are of the order of 250V relative to earth potential and a shock from them can be dangerous Hence it is necessary to prevent the user of electrical equipment from making contact with any live part of the system that is
111. ich are connected directly to line and neutral Both controllers get these signals and analyze the data With the sensor the current is measured so that two independent signals are created These two signals are linked to both controllers The main controller and redundant controller communicate with each other There are two relays in serial on each path L1 and N Each controls one pair of relays one relay at each path In addition the power bridge can be stopped by both controller Before start up the inverter measures the insulation resistance of DC to GND If the value is smaller than the intern configured value the inverter will not connect to the grid The measurements had been performed with two Units one of each series The Series are devided in the ES5000 ES4400 and the ES3300 ES2200 ES1650 All the results are applicable to the other unit of the series Blockdiagramm DC EMI venice AC EMI Board Pana Soon or DSP Control OP System lower Supply Circuit 13201 F2407A Circuit 45V 15V LCD Display 4 Page 7 of 167 Report No 09TH0459 AS3100_2 BUREAU R U VERITAS Information for Production testing Visual Inspection Dielectric Testing AC to PE 1 1kVac or 1 6kVdc 1s AC DC to USER 1 35kVac or 1 9kVdc 1s DC to PE 1 35kVac or 1 9kVdc 1s AC to DC 1 35kVac or 1 9kVdc 1s Performance test Not required explicit by the standard but recommended
112. if it is not possible or practicable to carry out all the tests that might be considered desirable on each individual item of equipment reliance may be placed on sampling tests The frequency of sampling will depend upon the extent to which the production process is likely to vary Production tests are made as follows a Routine tests Routine tests are made on each item of equipment Details of routine tests are given in Paragraph D8 b Sampling tests Sampling tests are not made on each item of equipment but on a proportion diverted from the production line for this purpose If the manufacturer requires such tests or if they are specified the way in which the tests are to be applied and the action to be taken in the event of a departure from the requirements should be documented D8 Requirements for routine tests D 8 1 General To ascertain that the equipment has been correctly assembled routine tests should be made on every individual item usually at one or more suitable testing points on the production line Such tests should not therefore damage any product that is in accordance with the typetested sample in any way For this reason the tests may often have to be less stringent than the type tests Usually routine tests are made as part of the final inspection procedure It is not however always possible or practicable to apply the tests after complete assembly In these cases an intermediate test pos
113. imped or similar forms of solderless pressure joints shall be made only with the use of the appropriate attaching tools N A 4 6 6 4 7 4 8 Cascading of adaptors Two way quick connect tab and receptacle adaptors and the like shall not be cascaded Strength of screw threads and fixings Components that have screw threads and which will be removed or loosened with the aid of a tool for the purpose of connecting supply conductors to the equipment together with their fixings shall be capable of withstanding the test specified in Clause 8 7 Where a number of identical threaded components are involved tests may be conducted on a representative number at the discretion of the testing laboratory If one failure occurs and the omission of this component does not prevent the equipment from complying with the remaining requirements of the specification this shall not in itself constitute non compliance with this Clause but all of the remaining represented components shall withstand the test Where the screwed component or its fixing is of thermoplastic material the length of engagement of a thermoplastic screw into a tapped hole in metal or in plastic material shall be not less than the nominal diameter of such screw Testing to the requirements of this Clause shall not be required for equipment with Type Y or Type Z attachments Space threaded and thread cutting screws Space threaded sheet metal screws shall not be used for
114. ing takes place at both joints the direction of bending at each joint shall be the same either clockwise or anti clockwise Where however there is any doubt as to whether contact is made or whether a given part is live the flexible wire lead from the test finger shall be connected through a high resistance voltmeter having a resistance of not less than 1000Q V of the scale reading or other convenient indicator of equivalent current sensitivity to one pole of a battery 6V to 12V the other pole of which shall be connected to the supply terminals or points of the inner wiring of the equipment which shall be entirely disconnected from the supply mains during this test No openings in the enclosure IP65 protection N A 8 10 4 Protective impedance Protective impedance shall consist of at least two separate components the impedances of which are unlikely to change significantly throughout the life of the equipment If any one of the components is short circuited or open circuited the current between the part and the supply source shall not exceed 2mA for d c and its peak value shall not exceed 0 7mA for a c and also the following shall apply a For potentials not exceeding 450V peak the capacitance shall not exceed 0 11 b For potentials not exceeding 15 000V peak the quantity of electricity in the discharge shall not exceed 45 For potentials exceeding 15 000V peak the energy in the discharge shal
115. ion Where equipment is marked with a rated voltage of 230V a c or a voltage range that includes 230V a c for single phase equipment the rated voltage is equal to 240V a c in Australia and 230V a c in New Zealand or the highest marked voltage which ever is greater Where equipment is marked with a rated voltage of 400 V a c or a voltage range that includes 400V a c for polyphase equipment the rated voltage is equal to 415V a c in Australia and 400V a c in New Zealand or the highest marked voltage which ever is greater In all other cases such tests shall be carried out at the highest marked voltage In Australia for equipment other than class III equipment that is intended for connection to the supply mains and that is not marked with an operating voltage of at least 240V for singlephase equipment and at least 415V for three phase equipment for testing purposes the rating in amperes or loading in watts or volt amperes is equal to the calculated value corresponding to 240V for single phase equipment and 415V for three phase equipment as appropriate The frequency of the test supply voltage shall be 50Hz unless the equipment is intended for operation at some other particular frequency If any equipment incorporates provision for adjustment of loading about any marked voltage tests shall be conducted with the equipment adjusted so as to give maximum loading Where tests in this Standard or in any individual Approval and test
116. istances and clearances are measured is indicated in Annex C If a resonance voltage occurs between the point where a winding and a capacitor are connected together and metal parts separated from live parts by basic insulation only the creepage distance and clearance shall be not less than the values specified for the value of the voltage imposed by the resonance these values being increased by 4 mm in the case of reinforced insulation Compliance is checked by inspection and if necessary by measurement For appliances provided with an appliance inlet the measurements are made with an appropriate connector inserted for appliances with Type X attachment they are made with supply conductors of the appropriate current rating and also without conductors for otherequipment they are made on the equipment as delivered For appliances provided with belts the measurements are made with the belts in place and the devices intended for varying the belt tension adjusted to the most unfavourable position within their range of adjustment and also with the belts removed Movable parts are placed in the most unfavourable position nuts and screws with non circular heads are assumed to be tightened in the most unfavourable position The clearances between terminals and accessible metal parts are also measured with the screws or nuts unscrewed as far as possible but the clearances shall then be not less than 50 of the values shown in Table 4 1
117. ition VERITAS Page 25 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict the flexible cord when correctly applied nor shall it loosen in service The screw shall a be made of suitable insulating material b have a nominal diameter not less than that of the aperture for the flexible cord and c be so shaped as not to damage the flexible cord The method used for reducing the stress shall be such as will ensure that necessary insulation will not be damaged The knotting of a flexible cord shall not be deemed an acceptable means of cord anchorage A floating type cord anchorage shall not be acceptable unless it is suitably located in position within the terminal compartment independent of the flexible cord The cord anchorage shall be capable of accommodating a flexible cord of size and type appropriate to the equipment that is to be connected For equipment having an earthing terminal any cord anchorage designed to embrace the complete flexible cord shall be capable of accommodating a flexible cord that includes an earthing conductor See Note to Clause 4 4 1 Item h If the effectiveness of the cord anchorage of a connecting device is dependent on the relative location of component parts of the device the arrangement shall be such as will prevent inadvertent assembly of the component parts in the wrong position NOTE Wherever p
118. ition should be set up as near as is reasonable to the last point in the assembly line when access to the necessary parts can still be obtained No one series of tests will be universally applicable but tests to determine the following are suggested as a basis where specific tests are not laid down for particular equipment a The insulation is effective b The earthing of Class equipment has good continuity c Cord anchorage and terminal connections are properly assembled d Wiring and components are correctly fitted and positioned e The equipment functions correctly The tests necessary to check these items are described in Paragraphs D8 2 to D8 6 VERITAS Page 69 of 167 Report No 09TH0459 AS3100_2 D 8 2 Effectiveness of insulation The effectiveness of insulation is checked by an electric strength test However as the purpose of the test is mainly to check correctness of assembly it is not necessary to apply such high voltage for such times as are called for in the type test specified in the relevant Standard Indeed it is essential that there should be no risk of deterioration or premature failure due to overstress This is particularly important when applying the test voltage between live parts and accessible metal parts to test reinforced insulation in Class equipment The way in which the stress is apportioned between live parts intermediate metal parts and accessible metal
119. iwan Ltd 5F No 423 Ruiguang Rd District Taipei 114 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 0 Page 115 of 167 Report No 09TH0459 AS3100_2 BUREAU VERITAS Intertek Report No TP10090079 ETS Date September 10 2010 Page 5 of 8 IP6X Test sub clause 13 4 and 13 6 of IEC 60529 Test Method cont 8 The enclosure shall be deemed category 1 whether reductions in pressure below the atmospheric pressure are present or not Compliance criteria 1 The protection is satisfactory if no deposit of dust is observable inside the enclosure at the end of the test Intertek Testing Services Taiwan Ltd SF No 423 Ruiguang Rd Neihu District Taipei 114 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 116 167 Report 09TH0459 AS3100_2 BUREAU Intertek Report No TP10090079 ETS Date September 10 2010 Page 6 of 8 5 Test sub clause 14 2 5 and 14 3 of IEC 60529 Test Method 1 The test is made by spraying the enclosure from all practicable directions with a stream of water from a standard test nozzle as shown in figure 6 The conditions to be observed are as follows internal diameter of the nozzle 6 3 mm delivery rate 12 5 l min 5 96 water pressure to be adjusted to achieve the specified delivery rate core of the substantial stream circle of approximately 40 mm diameter at 2 5 m distance from nozzle test duration per square metre of
120. l A suitable circuit for measuring leakage currents in accordance with Clause 8 3 2 is shown in Figure E1 E2 Circuit components The circuit comprises two basic parts 8 a resistance capacitance shunt whose impedance changes with frequency and b a high impedance r m s responding a c voltmeter whose indication is virtually independent of frequency over the range 20Hz to 5000Hz The shunt consists of a parallel combination of a resistance of 17500 2500 and a capacitor such that the time constant of the circuit is 2255 151 The resistor has a tapping of 10000 from one end for connection to the voltmeter The voltmeter of internal resistance not less than 1 and an error of 5 or less over the frequency range of 20Hz to 5000Hz is to be connected across the 10000 portion of the shunt resistance so that its indication in volts r m s will be a direct measure of leakage current in milliamperes r m s at 50Hz Suitable overload protection may be provided for the voltmeter to prevent damage to the instrument due to excessive leakage current A resolution of at least 0 01V is required for the voltmeter A typical circuit of the arrangement is shown in Figure E1 Annex F Normative Heat behaviour test F 1 General Where required by a particular Standard the heat behaviour test shall be applied to the complete equipment to determine whether all insulating materials adequately maintain minimum sa
121. l not exceed 350mJ Voltage current and capacitance are measured between the relevant part and either pole ofthe supply source the equipment being supplied at rated voltage Discharge parameters are measured immediately after interruption of the supply ensuring that the method of interruption of the supply does not break the connection to earth of one of the poles of the supply source The circuit for measuring the steady state current shall have total resistance of 17500 2500 shunted capacitor such that the time constant of the circuit is 225 15 The quantity of electricity or energy in the discharge shall be measured into a load consisting of a non inductive resistor of 20000 Resistors or capacitors used as protective impedances shall comply with Clause 14 1 a or Clause 14 2 of AS NZS 60065 as appropriate N A 8 11 Temperature measurements See table 8 11 in No 1 VERITAS Page 50 of 167 Report No 09TH0459 AS3100_2 8 11 1 Methods of measurement Three methods of measuring temperatures are recognized a thermometer method b thermocouple method and c increase of resistance method Thermocouple method used 8 11 2 Thermometer method Three types of thermometer may be employed viz bulb thermometers containing either mercury or alcohol and resistance thermometers Where bulb thermometers are used to measure the temperature of a surface
122. l to enclosure heatsink 26 1A 1 9V 72 PE terminal to enclosure side 26 1A 2 0V 77 5 5000 Accessible conductive part Test current in Measured Calculated Voltage in Resistance in V 0 PE terminal to enclosure cover 1 32 5A 1 8V 55 PE terminal to enclosure cover 2 32 5A 2 1V 65mQ PE terminal to enclosure heatsink 32 5A 1 8V 55 terminal to enclosure side 32 5A 2 0V After 2 min applying the current the was measured 0 Page 91 of 167 Report 09TH0459 AS3100 2 8 6 cord is subjected 25 times to steady pull each time for a duration of 15 Force value m lt ikg 30N 0 1Nm lt lt 4 60N 0 25Nm x m gt 4kg 100N 0 35Nm ES5000 Power supply cord damaged P No effect on the cord Longitudinal displacement 1mm 1 3mm max 2mm AER Page 92 of 167 Report 09TH0459 AS3100 2 BUREAU Test for screw threads and fixings Screwed components shall be tightened and loosened in a steady and uniform manner the following number of times a where it operates in a thread in metal b where it operates in a thread in insulating material Torque dependent on the diameter see 8 7 2 Tested screw location Condition a or b Comment torque Screws for enclosure front panel side a P 0 25Nm Screws for enclosure upper
123. lation between live parts to PE 5 4 4 Reinforced insulation Instead of double insulation the use in equipment of a single layer of insulation may be accepted as affording equivalent protection under the following conditions a The single layer of reinforced insulation shall be of non hygroscopic X insulating material possessing adequate mechanical strength b The insulation shall be suitable for the particular application involved and shall not give rise to danger either i through the functioning of the equipment under conditions required by its use at rated loading or ii through the mechanical or electrical failure of the Reinforced insulation between live parts and accessible communication interface VERITAS Page 34 of 167 Report No 09TH0459 AS3100_2 equipment or of any part thereof c Precautions shall be taken to guard against the accidental bridging of the insulation by metal or partially conducting material such as carbon dust or moisture which can be reasonably anticipated to accumulate under normal conditions of use d The insulation shall comply with the test requirements specified in Clause 8 4 3 5 4 5 External metal parts The equipment shall have no external metal other than the parts listed in Items b to d of Clause 2 1 23 the definition for exposed metal 5 4 6 Detachable covers The removal of any covers that are detachable without
124. lectric 730 ISPS HA 2201G 04032304 Feb 2010 Feb 2011 tester electronic leakage 812 Kikusui TOS3200 NK003303 Dez 2009 Dez 2010 current meter Glow wire 75 LGA testapparatus Thermometer 223 Greisinger GMH3250 Aug 2010 2011 Needle flame 748 ED amp D Inc 01 tester Spring 63 PTL F 22 50 5001449 Jun 2008 2010 hammer Digital force 715 Chatillon 50LBF S N W00717 Aug 2009 Aug 2010 instrument Ametek Inc Dual channel 485 Greisinger GMH 2010 Jun 2011 digital multimeter Heating 580 Heraus UT6060 8903742 chamber Steel Ball 505 A Pfeifer 5009 Steel Ball 509 A Pfeifer 5009 Torquet 842 Proxxon II 2560 screwdriver Digital caliper 430 TESA 31172150 2 059206 Jun 2010 11 rule
125. loss expense or damage occasioned by the use of this report Only the Client is authorized to permit copying or distribution of this report and then only in its entirety Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material product or service must first be approved in writing by Intertek The observations and test results in this report are relevant only to the sample tested This report by itself does not imply that the material product or service is or has ever been under an Intertek certification program 5 When determining the test conclusion the Measurement Uncertainty of test has been considered Intertek Testing Services Taiwan Ltd SF No 423 Ruiguang Rd District Taipei 1 14 Taiwan Tel 886 2 66022888 Fax 886 2 66022415 j BUREAU Page 113 of 167 Report No 09TH0459 AS3100_2 Intertek Report No TP10090079 ETS Date September 10 2010 Page 3 of 8 Technical information Explanation of model designation of 52200 ES3300 ES4200 55000 Rating l T Model Name ES2200 ES3300 ES4200 L ES5000 Nominal DC 360Vdc 360 Vdc 360 Vdc 360 Vdc Voltage Max DC input 500 Vdc 500 Vdc 500 Vdc 500 Vdc Voltage Working range 120 500Vdc 120 500 120 500 Vdc 120 500 Vdc Range 150 450Vdc 150 450Vdc 150 500 150 450Vde Max DC input 14
126. marking of the operating voltage for single phase equipment shall be at least 230V and for polyphase equipment at least 400V or a rated voltage range that includes 230V for single phase equipment and 400V for polyphase equipment c Where the use of equipment is limited either by its own nature or by the nature of any component to a particular system it shall be marked with those details of the system such as DC AC phases frequency to which the use of the equipment or any component thereof is limited d Where a manufacturer or responsible vendor markets a number of different types of the same article each article shall be marked with the catalogue number type number or name or other marking that will distinguish it from any other type of the same article e If applicable designation for degree of protection against moisture including any pressure head or time NOTE Information on degrees of protection is contained in AS 60529 f If compliance with this Standard depends upon the operation of a replaceable thermal link or fuse link the reference number or other means for identifying the link shall be marked at a place so that it is clearly visible when the appliance has been dismantled to the extent necessary for replacing the link NOTE Marking on the link is allowed as long as the marking is legible after the link has failed This requirement does not apply to links that can only be replaced together with a part of th
127. ment Test Result Remark Verdict Clause Power supply cords shall be assembled with the equipment by one of the following methods a Type X attachment b Type Y attachment c Type Z attachment For equipment not covered by an individual Approval and test specification Type Y or Type Z attachments may be provided in the following circumstances i Where sealing or encapsulation provides essential safety feature such as waterproofing or avoidance of tampering with adjustments ii In all other cases where the replacement of the flexible cord or flexible cable by the user of the equipment is not intended or is unlikely having regard to the type of flexible cord and the method of use of the equipment for example whether it is fixed or portable and the degree to which the supply cable or cord will be subjected to flexure and mechanical damage in service Riveting or the use of special screws that are not removable or that are intended to be removed only with the aid of a special single purpose tool shall be regarded as an acceptable method of sealing screws of the conventional straight slot Phillips head Allen key type and the like are not acceptable unless access to their heads is prevented by a plug which is non removable without irreparable damage 4 5 2 Provision for entry of flexible cord The equipment shall include provision for entry of the flexible cord or cable within its protective c
128. mic plate Transistor Fairchild HGTG40N60A4 63 Tc 110 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp Q9 Q10 to enclosure heat sink IGBT provided with ceramic plate Transistor IR IRG4PSC71U 60A Tc 100 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp Q9 Q10 to enclosure heat sink IGBT provided with ceramic plate Transistor Infineon IKW75N60T 75 Tc 100 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp Q9 Q10 to enclosure heat sink IGBT enclosure heat sink Transistor Infineon IGW75N60T 75A Tc 100 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp 09 Q10 to enclosure heat sink IGBT provided with ceramic plate Transistor IR IRG4PSC71KD 60 Tc 100 C 600V Accepted Q11 Q7 Q8 Screwed with metal clamp Q9 Q10 to enclosure heat sink IGBT provided with ceramic plate Diode IXYS DSEP 30 06A 30A Tc 135 C 600V IEC Accepted D3 D4 D5 D6 Screwed with metal clamp 62103 EN D7 to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEI 30 06A 37 Tc 85 C 600V IEC Accepted D3 04 D5 D6 Screwed with metal clamp 62103 EN D7 to enclosure heat sink 50178 provided with ceramic plate Diode Fairchild RHRG5060 I 50A Tc 93 C 600V IEC Accepted D3 D4 D5 D6 Screwed with metal clamp 62103 EN D7 to enclosure heat sink 50178 provided with ceramic plate Diode Fairchild RURG8060 I 80A Tc 72 C 600V IEC Accepted D3 D4 D5 D6 Screwed with metal clam
129. ndards cited above 9 Central Research Technology TAPOS EMC Test Laboratory FCC CAB Code TW1053 11 Lane41 Fushuen St Jungshan Chiu y NVLAP Lab Code 200575 0 Taipei Taiwan 104 R O C Tel 886 2 25984568 Code 4699A Fax 886 2 25984546 VCCI No R 1527 C 1609 131 T 1441 A ENG Tsun Yu Shih General Manager 110 167 Report 09TH0459 AS3100 2 BUREAU R U VERITAS Annex No 2 IP Test Report The whole report is stored at Bureau Veritas Consumer Products Services Germany GmbH T rkheim Project 09TH0459 111 of 167 Report 09TH0459 AS3100 2 mmm Intertek Report No TP10090079 ETS Date September 10 2010 Page of 8 Applicant Ablerex Electronics Co Ltd IF No 3 Lane 7 Paokao Rd Hsintien 23114 Taipei Hsien Taiwan Product Power Inverter for PV Model ES2200 ES3300 ES4200 ES5000 Brand Name Ablerex Rating ES2200 Input 360Vdc Output 230V 8 7A ES3300 Input 360Vdc Output 230V 13A ES4200 Input 360Vdc Output 230V 17 4A ES5000 Input 360Vdc Output 230V 21 7A Model Similarity All models are identical except for the output rating difference the details see Page 3 Date of Receipt of Test September 3 2010 Date of Performance of Test September 3 2010 September 9 2010 Sample Description The product covered by this report is
130. neath the clamped conductor Aluminium conductors shall not be clamped directly by screws in tunnel type terminals other than special types designed to evenly distribute stress and to break the oxide film on the conductors Indirect clamping by means of suitable ferrules plates and the like shall be acceptable provided that the clamping means breaks the oxide film on the conductors In general a self tapping screw shall not be used as a terminal screw for conductors the acceptability of self Noticed VERITAS Page 20 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict tapping screws as terminal screws in any particular application will be judged on the circumstances of the case in accordance with Clause 4 8 Die cast terminal blocks made from zinc base alloy shall not be used Terminals provided for direct connection to fixed wiring of an installation shall be so designed and located as to permit the supply cables other than flexible cables and cables having fewer than seven strands to be connected in accordance with one of the following methods a Soldered into a cable socket of appropriate size b Clamped in a terminal or binding post c Terminated in an approved solderless tag or terminating device 4 3 3 Location of terminals The live terminals shall be within a terminal box or an enclosure and shall be grouped toge
131. o connections made in equipment with Type Y or Type Z attachment Verified 4 3 7 Earthing conductors Where the equipment includes an earthing terminal provision shall be made by means of space within the terminal enclosure the disposition of the terminals a separate conductor way suitable shielding or other suitable means to ensure that when correctly wired the connection is made without the earthing conductor of the flexible cord being held or pressed against live terminals or other live parts In addition where the equipment 15 intended to accommodate a supplementary earthing conductor of a supply flexible cord as part of an earth circuit monitoring arrangement provision shall be made for adequate basic insulation of the supplementary earthing conductor NOTE Earth monitoring equipment should be supplied with instructions describing how the equipment is to be correctly connected including reference to the provision of basic insulation for supplementary earthing conductors and a statement that the connection should be made by a suitably qualified person 4 3 8 Conductors and terminals not to be stressed Strain relief provided for VERITAS Page 22 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict All conductors shall be so supported and connected that there will be no undue mechanical stress on either the
132. obs and the like and to signal lamps and their covers but only if the lamps or covers protrude from the enclosure by more than 10mm or if their surface area exceeds 400mm Lamps within the equipment and their covers are only tested if they are likely to be damaged in normal use Noticed P VERITAS Page 48 of 167 Report No 09TH0459 AS3100_2 8 8 4 Criteria After the test the sample shall show no damage within the meaning of this Specification in particular live parts shall not have become exposed so as to impair compliance with Clauses 5 1 and 5 2 and there shall not have been such distortion as to impair compliance with Clause 4 1 3 In case of doubt supplementary insulation is subjected to an electric strength test as specified in Clause 8 4 3 If there is a doubt as to whether a defect has been promoted by the application of preceding blows this defect is neglected and the group of three blows which led to the defect is applied to the same place on a new sample which shall then withstand the test 8 9 8 10 Standard electrodes for electric strength tests Where the electric strength of a material in sheet form is to be tested the electrodes used shall be constructed of solid brass The electrodes shall be in the form of solid brass cylinders one of 75mm diameter by 25mm depth and the other of 38mm diameter by 38mm depth Where the electric strength over a surface is to be tested th
133. of application of the test flame is 30s 1s b for the purpose of Clause 8 2 of AS NZS 4695 2 2 the specimen is arranged so that the flame can be applied to a vertical or horizontal edge c for the purpose of Clause 8 4 of AS NZS 4695 2 2 the first paragraph of 8 4 does not apply If possible the flame is applied at least 10mm from a corner d for the purpose of Clause 8 5 of AS NZS 4695 2 2 the test is carried out on one specimen If the specimen does not withstand the test the test may be repeated on two further specimens both of which shall then withstand the test e for the purpose of Clause 10 of AS NZS 4695 2 2 the duration of burning tb shall not exceed 30s However for printed circuit boards it shall not exceed 15s Slight discolouration of the particle board is ignored A 6 2 Temperatures of surfaces to be handled The temperature rise of surfaces intended to be touched when tested in accordance with Clause 8 12 shall not exceed the values specified in Table 5 7 A 6 3 Resistance to tracking Insulating material across which a tracking path may occur between live parts of different polarity or between live parts and earthed metal parts and insulating material of commutators and brush caps shall have adequate resistance to tracking taking into account the severity of its duty conditions For parts of insulating material other than ceramic compliance is checked by the proof tracking test spe
134. of printed circuit boards is subjected to the needle flame test of A 6 1 7 The 12mm flame is applied to an edge of the board not less than 10mm from a corner If the board is horizontal in the normal position of use the board is tested in the horizontal position the flame being applied to the edge that has the lowest heat sink For all other board mounting positions the board shall be tested vertically with the flame applied to the lower edge The test is not carried out i on the printed circuit boards in a metal enclosure that confines flames or burning droplets ii if the material is classified as 0 according to AS NZS 60695 11 10 provided that the test sample was no thicker than the printed circuit board NOTE 1 For this test the printed circuit board may be tested without circuit components if the submitter wishes This is a more onerous test condition but this would permit a change of component without necessitating a retest NOTE 2 If the printed circuit board is tested with components mounted and a component ignites during the test this would not constitute a failure of the board unless the component ignites the board R U VERITAS Page 58 of 167 Report No 09TH0459 AS3100_2 A 6 1 7 Needle flame test method The needle flame test shall be carried out in accordance with AS NZS 4695 2 2 with the following modifications a for the purpose of Clause 5 of AS NZS 4695 2 2 the duration
135. om 4000W nom 5000W E9 Page 2 of 167 Report No 09TH0459 AS3100_2 Marking MODEL NO ES1650 DC INPUT 120 500V 10 5A Max NOMINAL 360V MPPT 150 450V 230V 50Hz 1500W 6 5 0126 1 1 AS NZS3100 amp AS4777 ENCLOSURE IP 65 HCE 9 6 VERITAS Page 3 of 167 Report 09TH0459 AS3100_2 History Sheet Georg Loritz 2010 09 14 Initial report was written Rev 0 Georg Loritz Georg Loritz Report reference number adapted Clarified temperature measurement 2010 09 28 in 8 11 Rev 1 Photos of cable entry glads and earth connection added New inverter model ES1650 2010 03 02 included Rev 2 Address of the manufacturer sites Ablerex Electronics SUZHOU Co Ltd No 36 Wangwu Road Wuzhong District Shuzhou City Jiangsu Province P R China 2 4 167 Report 09TH0459 AS3100 2 VERITAS Summary of testing The Product was tested to the standard AS 3100 2009 1 The 51650 ES2200 was tested on a 16 IEC branch circuit the ES 3300 ES4400 and the ES5000 on a 32A IEC branch circuit The safety of the unit relies on the branch circuit of building installation If used on a branch circuit greater than this additional testing may be necessary The input connector and output connector are fixed connected inside of the enclosure The solar inverters are rated class
136. ossible a device that provides for anchorage of the complete flexible cord within its braid or sheathing is to be used Such a device may take the form of a clamp or saddle type grip Where it is impracticable to anchor a flexible cord or flexible cable that includes an earthing conductor in this way the wiring facilities should be such as will permit sufficient slack to be left in the earthing conductor to ensure that any stress is taken up by the live conductors before the earthing conductor becomes taut Devices such as those in the form of a crimped on metal ring which are either not located in position or are incapable of being used more than once are not acceptable for equipment with Type X attachments Floating devices whether clamps or disks having holes for separate conductors may be used only where the design of the equipment provides a space in which such devices naturally fit and which locates them in position They may however be accepted without such location where space available is limited and there is little room for them to move in such a case the device shall not be of metal if there is a possibility of the clamp coming into contact with live terminals Split devices are acceptable only if they are of such a type that there is no possibility of damage to the flexible cord and they may be removed and replaced without undue difficulty 4 5 4 Protection of supply flexible cord Porcelain beads heat resistant sleeving
137. overing or sheath The opening through which the flexible cord or cable passes shall be bushed or shaped so as to minimize abrasion of the protective covering and insulation A sleeve guard or other device provided to prevent sharp bending of the supply flexible cord shall not be integral with the cord where a Type X attachment is used unless it forms part of a specially prepared cord available from the manufacturer or its service agent It shall be fixed in a reliable manner and not incorporated in the cord anchorage device unless the anchorage device will clamp the cord effectively with the sleeve removed Verified 4 5 3 Cord anchorage All equipment intended for connection by means of a flexible cord or flexible cable shall be provided with a saddle grip tortuous path or other suitable means so that when the device is connected in the correct manner the stress on the connecting terminals shall be definitely substantially reduced and the arrangement shall comply with the test specified in Clause 8 6 For Type X attachment where a tortuous path labyrinth is used it shall be clear how the cord is to be fitted and how the relief from strain and the prevention of twisting are obtained Where cord anchorage is obtained by means of a screw bearing on the sheathing of a flexible cord the assembly shall be such that in no way will it damage Cord anchorage or self locking inlet provide suitable location in pos
138. p 62103 EN D7 to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEP 60 06A 60A Tc 110 C 600V IEC Accepted D3 D4 D5 D6 Screwed with metal clamp 62103 D7 to enclosure heat sink 50178 provided with ceramic plate Diode IXYS DSEI 60 06A 60A Tc 70 C 600V IEC Accepted D3 D4 D5 D6 Screwed with metal clamp 62103 EN D7 to enclosure heat sink 50178 provided with ceramic plate Relay Song Chuan 841 P 2A C H Coil 12Vdc NLDX2 cURus E88991 76 of 167 Report No 09TH0459 AS3100 2 Object Part No Manufacturer Tr Type Model Technical data Standard Mark s of ademark conformity RY1 RY2 Contact 25A 250Vac EN60255 VDE Insulation Class F Capacitor Shihlin Electric RM 350Vac 10uF 105 C CZDS2 cURus E202431 C26 C90 AC Capacitor PCB JIANGSU DFD 2 overall approx dimension ZPMV2 cURus E213009 PVBF000 DIFEIDA 283mm by 82 5mm by 1 6mm Flame Class 94V 0 RTI 130 PCB Hung Chin 96 overall approx dimension ZPMV2 URus E211578 PVBF000 Electronic Co Ltd 283mm by 82 5mm by 1 6mm Flame Class 94V 0 RTI 130 C Fuse Conquer AFE 6 35mm 31 8mm JDYX2 URus E82636 F1 Electronics 250Vac 30A Fast Acting Fuse Littelfuse 314 6 35mm by 31 8mm JDYX2 E10480 F1 250Vac 30A Fast Acting Capacitor Cheng Tung CTX 300V max 100 C X FOKY2 cURus E211230 C4 Industrial Co L
139. ply cord is damaged it shall be replaced by the manufacturer or its service agent or similarly qualified person in order to avoid a hazard c For equipment with Type Z attachment the supply cord cannot be replaced If the cord is damaged the equipment should be scrapped 7 9 Legibility of marking See table 8 13 in Annex P The marking required by Section 7 shall comply with No 1 Clause 8 13 7 10 Instructions for installation and use Warning instructions are P If it is necessary to take special precautions when installing or using equipment details shall be given in an instruction sheet which shall accompany the equipment provided in the manual which is shipped with the units VERITAS Page 42 of 167 Report No 09TH0459 AS3100_2 SECTION 8 TESTS 8 1 General In general the tests specified in this Section shall be carried out on equipment as received A test of this Standard or any individual Approval and test specification that is not appropriate to any particular equipment because of the method of its construction or the technology of its design shall not be conducted In such cases a regulatory authority may substitute tests which it considers to be appropriate In any equipment a component that is not depended upon for safety and the failure or malfunction of which would not introduce a hazard need not be tested for compliance withany relevant Approval and test specificat
140. ply to internal fuses where the arrangement and enclosure of the fuses is such that they are not intended and are unlikely to be replaced other than by appropriate servicing personnel For all other fuses the following provisions shall apply a Every fuse incorporated in equipment shall be exposed to view or have its location clearly indicated by suitable visible marking or by instructional literature provided with the equipment b Every fuse shall be in an accessible position c Every fuse shall be so arranged that a person is not subject to the risk of inadvertent contact with i any part of a fuse that is mounted in a compartment accessible for normal routine cleaning or ii live parts when covers are removed to gain access to any fuse Fuse carriers shall remain in position for the purpose of assessing this requirement d Fuse links fuse contacts and fixed contacts shall be so shielded as to protect a person from accidental contact with live metal while the fuse carrier is being inserted or withdrawn in the normal manner Just internal fuses N A 3 6 2 Mounting A semi enclosed fuse that is incorporated in equipment and is marked with the letter R shall be mounted such a manner that no earthed metal is introduced in or adjacent to the fusing chamber N A 10 of 167 Report No 09TH0459 AS3100 2 BUREAU VERITAS AS 3100 2009 Clause Requirement Test Re
141. pment shall indicate when the potential difference between such external metal parts and earth or other reference point where an isolated system is used reaches a predetermined voltage which shall not exceed 32Vr m s Any external metal parts of such devices that are connected to internal wiring shall be so arranged that under no circumstances can they reach a potential exceeding 32Vr m s or shall be so arranged that under no circumstances can a leakage current in excess of 2mA flow when the external metal part is connected directly to earth or other reference point where an isolated system is used through a conductor having a negligible impedance Fixing of handles knobs or the like P Handles knobs grips levers or the like shall be fixed in a reliable manner so that they will not work loose in normal use if loosening might result in a hazard If handles knobs or the like are used to indicate the position of switches or similar components it shall not be possible to fix them in a wrong position if this might result in a hazard Compliance is checked by inspection by manual test and by trying to remove the handle knob grip or lever by applying for 1min an axial force of a value as follows a If the shape of these parts is such that an axial pull is unlikely to be applied in normal use the force is 15 N for actuating members of electrical components and ii 20 N in other cases b If the shape is such th
142. pproval and test specification for example parallel 2 core unsheathed 5 2 3 3 Specific requirements fibrous insulation The thickness of 250V grade fibrous insulation for internal accessible and external equipment wiring shall comply with AS 3158 or AS NZS 3191 as appropriate Fibrous insulation used for accessible or external equipment wiring shall be so treated or covered as to render it impervious to moisture a cable complying with AS 3158 shall be regarded as satisfactory in this respect N A 5 2 4 Arrangement of equipment wiring Precautions shall be taken in the support and fixing of equipment wiring to ensure that live parts including any one conductor that may become detached from its termination cannot become exposed to personal contact by protruding through an opening without coming into contact with exposed metal In the determination of compliance with this requirement the dimensions and disposition of the opening shall be taken into consideration Attachment of one conductor to another by tying lacing clipping or the like is regarded as a satisfactory means of fixing and support provided that any one conductor detached from its termination is so retained in position as to comply with this Clause External clip terminals on DC side AC side internal screw terminals external wiring is attached upon installation and secured via strain relief each exposed metal part is earthed 5 3
143. priate all thermostats and temperature limiters being short circuited or otherwise rendered inoperative and the equipment shall then comply with the tests of Clause 8 15 9 and the tests shall be conducted under the general test conditions specified in Clause 8 12 Heating equipment test Equipment with heating elements is tested under the conditions specified in Clause 8 12 the supply voltage being such that the input is equal to rated input If a non self resetting thermal cut out operates or if the current is otherwise interrupted in a non self resetting way before steady conditions are established the operating period is considered to be ended If interruption of the current does not occur the equipment is operated until steady conditions are established For equipment for short term operation the duration of the test is equal to the rated operating time Wall mounted equipment See table 8 15 in Annex No 1 Noticed N A N A U R U VERITAS Page 53 of 167 Report No 09TH0459 AS3100_2 8 15 3 Locked rotor test A locked rotor test is made by locking moving parts if the equipment a has moving parts liable to be jammed b has motors with a locked rotor torque smaller than the full load torque c has motors to be started by hand d is intended to be remotely or automatically controlled or e is liable to be operated while unattended Equipment incorporating motors having capacitors in
144. quipment the marking required by this Clause shall not be used to identify anything other than an earthing terminal or facility 7 5 Marking of class equipment All Class equipment other than accessories shall be identified by means of the international symbol for double insulated equipment viz 9 the words DOUBLE INSULATED Such markings shall be legible and indelible and shall be made either on the equipment itself or on a nameplate securely fixed thereto The dimensions of the symbol for Class II construction shall be such that the length of the sides of the outer square is about twice the length of the sides of the inner square The length of the sides of the outer square shall be not less than 5mm unless the largest dimension of the appliance does not exceed 150mm in which case the dimensions of the symbol may be reduced but the length of the sides of the outer square shall be not less than 3mm The symbol for Class construction shall be so placed that it will be obvious that it is a part of the technical information and is unlikely to be confused with any other marking N A 7 6 7 7 Marking of live supply connections Where it is necessary to mark and identify live supply connections the following system shall be used unless otherwise specified in an individual Approval and test specification a For active connections any marking or abbreviation which clearly indicates the inten
145. r either in a terminal box or within the equipment enclosure except that the earthing terminal may be located adjacent to the terminal box or enclosure c Where identification is necessary live terminals shall be marked in accordance with Clause 7 6 d Terminals of a heating element or thermostat shall not be used as a means for the connection of supply conductors 4 10 Mechanical strength Equipment shall have adequate mechanical strength and be so constructed as to withstand such rough handling as may be expected in normal use Compliance is checked by inspection and if necessary by the test of Clause 8 8 4 11 Degree of protection IP classification Where the equipment is marked to classify it as having a specified degree of protection the equipment shall comply with the appropriate requirements of AS 60529 The tests of AS 60529 shall be carried out after the test of Clause 4 10 if applicable For equipment assigned with a second characteristic numeral greater than 0 the equipment shall then withstand the tests of Clause 8 4 IP 65 see Annex no 3 VERITAS Page 29 of 167 Report 097 0459 83100 2 SECTION 5 PROTECTION AGAINST RISK OF ELECTRIC SHOCK 5 1 Guarding of live parts Except for equipment intended for use only in a position not accessible to unauthorized persons all equipment shall be so designed and constructed that when the equipment is standing suppo
146. rce exerted in newtons equals 1000 the compression being approximately 20mm With this adjustment the impact energy is 0 5 0 05Nm he release mechanism springs are adjusted so that they exert just sufficient pressure to keep the release jaws in the engaged position The apparatus is cocked by pulling the cocking knob until the release jaws engage with the groove in the hammer shaft The blows are applied by pushing the release cone against the sample in a direction perpendicular to the surface at the point to be tested The pressure is slowly increased so that the cone moves back until it is in contact with the release bars which then move to operate the release mechanism and allow the hammer to strike Noticed P 8 8 3 Procedure The sample as a whole is rigidly supported against a plane surface and three blows are applied to every point of the enclosure that is likely to be weak To ensure that the sample is rigidly supported it may be necessary to place it against a solid wall of brick concrete or the like covered by a sheet of polyamide which is tightly fixed to the wall care being taken that there is no appreciable air gap between the sheet and the wall The sheet shall have a Rockwell hardness of HR 100 a thickness of at least 8mm and a surface area such that no part of the sample is mechanically overstressed due to insufficient supporting area If necessary the blows are also applied to handles levers kn
147. re Ablerex ES1650 Steel cover one overall Accepted ES2200 approx dimension ES3300 430mm by 453mm by 170mm min 1 5mm thickness Provided with four 9mm holes for pushbuttons three 4mm holes for LEDs and a 68mm by 26mm opening on front for the display covered with plastic Steel cover two overall approx dimension 425mm by 450mm by 150mm min 1 5mm thickness Provided with four 9mm holes for pushbuttons three 4mm holes for LEDs and a 68mm by 26mm opening on front for the display covered with plastic Steel chassis overall approx dimension 429mm by 449mm by 164mm min 1 5mm thickness Gasket of main Shin Etsu KE 961U Flame Class 2 URus 48923 enclosure Silicone Taiwan RTI 150 C Class HB Enclosure Ablerex Aluminium overall approx dimension Accepted Heat sink 425mm by 300mm by 40mm mounted to enclosure chassis Case of control Grand Pacific D 1000 A Flame Class QMFZ2 cURus E88637 card Petrochemical 94V 0 RTI 60 C Corp Connector DC Multi Contact PV ADSP4 2 5 1000V 22 5A 90 ECBT2 URus E229145 Male AG Basel 3 provided Connector DC Multi Contact PV ADBP4 2 5 1000V 22 5A 90 ECBT2 URus E229145 Female AG Basel Connector AC Adels 1500 3DS 300V 40A 85 C FW2 XCFR2 URus E63492 CONTACT AWG18 8 Flame Class 94V 2 Internal wiring Ancheer Cable 1015 10 AWG 600Vac 105 AVLV2 cURus E328778 from AC Provided with Ferrite Core terminal to AC Board and from AC Board to M
148. re than 30s The full test voltage shall be maintained for 1 min after which the test voltage shall be diminished rapidly to 30 of its full value before switching off The specified test voltage shall be maintained for the 1 min duration of the test within 396 The test voltage shall be alternating of any frequency between 25Hz and 100Hz and approximately of sine waveform There shall be no disruptive discharges that is flashovers or insulation punctures during any high voltage tests The high voltage transformer used for the test shall be so designed that when the output terminals are short circuited after the output voltage has been adjusted to the appropriate test voltage the output current shall be greater than 180mA The overcurrent relay shall not trip when the output current is less than 100mA Noticed 8 4 6 Number of samples In cases where high voltage tests specified in any Specification would require the same insulation to be stressed more than once the person submitting the equipment may submit at the person s discretion a sufficient number of samples to permit each such test to be made on a separate sample Noticed 8 5 Test of earthing connection The connection between the earthing terminal or earthing contact and parts required to be connected thereto shall be of low resistance Compliance is checked by an earthing connection test whereby a current derived from an a c source having
149. ring normal operation and which are likely to be made or remade during installation user maintenance or when replacing a supply cord assembled with the appliance by a Type X attachment are subject to the glow wire test of AS NZS 60695 2 10 the test being made at a temperature of 850 C B 3 4 Needle flame test The needle flame test shall be carried out in accordance with AS NZS 4695 2 2 except that a accidentally applied ignition sources as referred to in Clause 8 4 of AS NZS 4695 2 2 are not applicable and b for the purpose of Clause 10 of AS NZS 4695 2 2 slight discolouration of the particle board is ignored VERITAS Page 61 of 167 Report No 09TH0459 AS3100_2 B4 Resistance to tracking test Insulating material across which a tracking path may occur shall have adequate resistance to tracking taking into account the severity of its duty condition A tracking path is considered likely to occur between live parts of different potential live parts and earthed metal parts and across insulating material of commutators and brush caps The needle flame test is made on all parts of non metallic material positioned within a distance of 50mm from any place where a tracking path may occur unless these parts are shielded by a separate barrier or enclosure from that tracking path in which case the barrier or enclosure is subjected to the needle flame test Annex C Normative
150. rs of insulation cannot be applied reasonably in equipment intended to be double insulated This single layer of insulation has to be of a special nature both in respect of quality and in the method of incorporation in the equipment to be accepted as affording protection equivalent to that provided by the two independent layers of insulation This single layer is referred to as reinforced insulation In addition to passing the test specified for double insulation the continued effectiveness of the single layer of insulation under normal conditions of use should be assessed having regard to such factors as a mechanical strength resistance to shrinking and warping and the like b resistance to moisture c security of mounting and fixing in the equipment d accidental bridging of the insulation by extraneous metal objects e resistance to tracking due to deposits of foreign matter for example carbon dust and the like see Clause 5 4 4 and f protection against heat and fire see Section 6 Failure of insulation in this context is taken to include the accidental bridging of an insulating gap by metal or partially conducting material such as carbon dust or moisture as well as electrical breakdown in the conventional sense N A VERITAS Page 66 of 167 Report No 09TH0459 AS3100_2 D 6 3 Methods of achieving double insulation The following are different forms of construction in whi
151. rted or fixed in a normal manner no person can inadvertently come into contact with any live part see also Clause 8 10 If a hole giving access to preset controls is marked as such on the enclosure or reference made to it in the instructions and the setting of this control requires a screwdriver or other tool the adjustment of the control shall not allow contact with any live parts A metal test pin having a diameter of 2 mm and a length of 100 mm shall not become live when it is inserted through the hole in every position with a force of 10 N Covers of equipment other than accessories relied upon to prevent inadvertent personal contact with live parts shall be fixed in position in such a manner that a tool is necessary to remove them wing nuts knurled nuts and the like are not deemed to comply with this requirement A slot that will accept a coin is regarded as intended to accommodate a tool for the purpose of this Clause In addition the opening or removal of any cover or component with or without tools where such opening or removal is necessary as a normal operation of the equipment as distinct from maintenance repairs or adjustment shall not expose live parts to inadvertent personal contact If a manufacturer instructs the user to remove any covers or components for maintenance repairs or adjustments this shall not expose live parts to inadvertent personal contact Any metal cover or casing enclosing live parts shall be
152. s given in Annex A of AS NZS 60695 2 11 If parts tested withstand the glow wire test but during the test produce a flame that persists for longer than 2s then the consequential needle flame test of A 6 1 5 applies U R T VERITAS Page 57 of 167 Report No 09TH0459 AS3100_2 A 6 1 5 Consequential needle flame test a The needle flame test of A 6 1 7 is applied to all parts of non metallic material including barriers and enclosures that are likely to be ignited by and are positioned within a distance of 50mm of those parts that flamed during the glow wire test of A 6 1 4 Note The needle flame test should be applied wherever possible from inside the enclosure b The needle flame test of A 6 1 7 is also applied to those parts outside the 50 mm specified above that were contacted by the flame subjected to burning droplets or glowing particles when the glow wire test was conducted in accordance with A 6 1 4 c The needle flame test of A 6 1 7 is also applied to those parts that were contacted by the flame or subjected to burning droplets or glowing particles when the needle flame test was conducted in accordance with A 6 1 5 b above The needle flame test is not carried out on parts of material classified as V 0 or V 1 according to AS NZS 60695 11 10 provided that the test sample was no thicker than the relevant part A 6 1 6 Needle flame tests on printed circuit boards The base material
153. side a P 0 25Nm Screws for fixing PCB a P 0 7Nm Screws for connector terminal a P 0 7Nm E ey Page 93 of 167 Report No 09TH0459 AS3100_2 PSUREAU Mechanical strength test Equipment shall be subjected to blows with an impact energy of 0 5 0 05Nm by the impact test apparatus see clause 8 8 2 AER Page 94 of 167 Report 09TH0459 AS3100 2 VERITAS 8 10 4 Protective Impedance A 2000 Ohms non inductive resistor and a switch were connected between the user accessible part of a limited current circuit and either pole of the limited current circuit or earth A storage oscilloscope was connected across the points under consideration The switch was closed and voltages on resistor were measured LLLI a LL mwa E 9 95 of 167 Report 09TH0459 AS3100 2 BUREAU 811 Temperature messurement 55000 Test voltage Vdc 180 180 184 4021 406 406 am Test current 1 1 22 135 1222 6 am Test voltage 218 230 252 219 230 246 p p p Test current lac 20 19 166 23 19 192 T24 29 288 28 225 so so 5 maximum temperature T of part at
154. specification are to be conducted with alternating current at a lagging power factor the test circuit shall unless otherwise specified be a series circuit of an inductor and resistor The reference ambient temperature shall be 25 C unless it is clear by virtue of the design application or marking that the equipment will usually operate in an ambient temperature higher than 25 C in which case it shall be 40 C Notwithstanding the foregoing where an individual specification requires a test to be conducted under specified temperature shall be required to withstand all tests relevant to the failure Noticed 8 2 Void N A 8 3 Insulation resistance and leakage current VERITAS Page 43 of 167 Report No 09TH0459 AS3100_2 8 3 1 Insulation resistance Insulation resistance shall be measured with a d c voltage of approximately 500V applied the measurement being made 1min after application of the voltage a between live parts and internal metal parts b between live parts and the case frame or exposed metal parts c between live parts and external metal parts d between live parts and a flexible electrode applied to non conductive parts normally handled in service and e through supplementary insulation The insulation resistance so measured shall not be less than 1 between parts as detailed above in Items a b c and not less than 10MO in all other cases
155. spection of creepage distances while inspection in Paragraph D8 5 would in general only be applied in cases where inadequate retention or incorrect positioning could lead to danger The tests in Paragraph D8 6 apply in general only to equipment such as motor operated appliances and heating appliances In some cases additional tests may be necessary A decision should be made whether the production tests are to be routine tests or sampling tests D 8 8 Segregation of defective products It is essential that all defective items are segregated from production until the items have been repaired and retested or destroyed VERITAS Page 70 of 167 Report No 09TH0459 AS3100_2 D9 Production test equipment The following applies to production test equipment a The manufacturer should be able to demonstrate i that the equipment apparatus and instruments for the tests are suitable for their purpose and ii that checks are made at sufficiently frequent intervals to ensure that their accuracy is maintained b Essential operating instructions for test equipment should be maintained and should be readily available to the operator c Adequate records should be maintained for the test equipment showing i means of identification where appropriate and ii frequency of check tests and details of repairs Annex E Informative Circuit for measuring leakage currents E1 Genera
156. sult Remark Verdict 3 7 Identification of wiring Verified P For equipment other than that having a Type Z attachment insulated or covered conductors used as earthing conductors shall be coloured 8 green or b green and yellow in the proportions specified in ASINZS 3191 The colour green in combination with colours other than yellow shall be acceptable for live conductors provided that the other colour covers not less than 3096 of the surface of the conductor in any 15 mm length The single colour green shall not be used to identify any live conductor except i at the discretion of a regulatory authority where the conductor forms portion of the complex wiring of equipment or ii where it is specified by an individual Approval and test specification 3 8 Regulating devices and switches P 3 8 1 Fixing and mounting Verified P All regulating devices and switches shall be securely fixed in position Rotary regulating devices and rotary switches shall be so fixed or located that they cannot turn bodily during operation No regulating device or switch shall be mounted in a position or be marked in such a manner as to incorrectly indicate the intended contact position NOTE See Clause 5 2 2 concerning clearances between terminals and exposed conductive parts 3 8 2 Visual indications of positions N A Notwithstanding the requirements of an individual Approval and test specification the different positions of r
157. switch shall be used when a the equipment is intended for connection to the supply by a plug and flexible cord b notwithstanding Clause 5 1 it is not usual or possible to guard live parts completely against personal contact because of the intended use and generally accepted practice with any particular equipment and c the equipment is of a type that is usually left connected to the outlet socket indefinitely and which has not been provided with a means to indicate whether it is energized or not NOTE 1 The specification of a particular category of switch in an individual Standard does not necessarily preclude the use of a switch with a lower category number NOTE 2 A Category 3 switch tested to the above requirements would not automatically qualify for an M rating in accordance with AS NZS 3133 N A 3 8 6 Electronic regulating devices and switches Electronic thermostats and electronic switches without a mechanical switch in the main circuit may not provide a reliable off state Therefore the circuit on the load side shall be considered to be live N A Page 12 of 167 Report 09TH0459 AS3100 2 BUREAU VERITAS AS 3100 2009 Clause Requirement Test Result Remark Verdict 3 9 Socket outlets No socket outlets N A Socket outlets shall not be permitted in equipment intended for connection by flexible cord except in the following circumstances a Where specificall
158. t b For neutral connections N or Neutral In any equipment marking as above shall not be used other than to indicate live connections Additional marking of multi rated equipment Where an equipment is provided with facilities for supply by flexible cord and plug and is designed for conversion to a rating which exceeds that at which the equipment is initially intended to operate the equipment shall be marked with the following information a Instructions which clearly indicate how the equipment is to be converted to any higher rating b Details for fitting the correct type of supply flexible cord and plug and the appropriate socket outlet to be used for each rating which exceeds 10A Such marking shall be legible and indelible and shall be made either on the equipment itself or on a nameplate securely fixed thereto L for line N for neutral used N A 7 8 Equipment with type X type Y and type Z attachments The instructions shall contain the substance of the following a For equipment with Type X attachment having a specially prepared cord if the supply cord is damaged Wiring defined in the manual The cords AC Y type is not provided by the manufacturer U R U VERITAS Page 41 of 167 Report No 09TH0459 AS3100_2 it shall be replaced by a special cord or assembly available from the manufacturer or its service agent b For equipment with Type Y attachment if the sup
159. t periods of time and for which the rated power input does not exceed 1200W NOTE Asymmetrical control means control by a device designed to operate in a different manner on the positive and negative half cycles of an alternating voltage or current Compliance is checked by inspection and by measurement 3 13 Stability Wall mounting N A Freestanding equipment intended to be used equipment surface such as a floor or a table shall have adequate stability and shall be tested in accordance with Clause 8 14 U H T VERITAS Page 13 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict 3 14 Equipment connected to supply by a plug Equipment intended to be connected to the supply mains by means of a plug shall be constructed so that in normal use there is no risk of electric shock from charged capacitors having rated capacitance exceeding 0 1 pF when the pins of the plug are touched Compliance is checked by the following test The equipment is supplied at rated voltage Any switch is then placed in the off position and the equipment is disconnected from the supply mains at the instant of voltage peak One second after disconnection the voltage between the pins of the plug is measured with an instrument that does not appreciably affect the value to be measured The voltage shall not exceed 34 V Permanetly connected
160. t smaller than 0 457mm and not larger than 0 559mm and with insulation suitable for use at 350 C Thermocouples shall be affixed in a manner appropriate to the case for example by tying clamping wedging or soldering Where a thermocouple is soldered to a portion of the article under test care shall be taken to avoid appreciable modification of the physical characteristics of the article by the temperature or the fluxes used in the soldering process Measurements of the thermal e m f should be made with suitable equipment potentiometer or direct reading instrument If the test equipment is not provided with cold junction compensation the cold junction should be contained in a vacuum flask containing crushed ice Noticed VERITAS Page 51 of 167 Report No 09TH0459 AS3100_2 8 11 4 8 11 5 Increase of resistance method he increase of resistance method is suitable for the measurement of the average temperature of coils or windings The appropriate equations to be used are contained in Note 2 to Table 5 7 An approximate method is to calculate the temperature rise of the conductor on the basis of 1 C for each 0 4 increase of resistance It should be noted that this method provides no indication of any points of temperature higher than average Measurement of ambient temperature The temperature of the ambient air shall be measured by at least two thermometers protected against radiation from t
161. td IEC60384 14 VDE Line to Line Induction Cormex E 13447 Open type construction Accepted L1 L2 L3 L4 Electronics with overall approx C M Industry Co Ltd dimension 60mm by 40mm by 55mm Rating 2mH 15A Core Ferrite Coil Enamelled copper Magnet wire wound on Core Base Plate 26mm by 18mm by min 1 6mm thickness for 1PCB or 26mm by 18mm by min 0 8mm for 2PCB s NF 77 Flame Class 94V 0 Capacitor Cheng Tung CTX 300V max 0 681 FOKY2 cURus E211230 C3 Industrial Co Ltd 100 X IEC60384 14 VDE Varistor Brightking Inc 471KD20 Diameter 20mm XGPU2 URus E244500 RV1 RV2 300Vac 385Vdc IEC61643 19280010 RV3 6500A max peak current 331 100A Class current Varistor Voltage 470Vdc Tubing shrink EVREFAME HST 2 Temp Class CSA LR97595 for RV1 RTI 125 C min 0 4mm thickness Capacitor Success SE 250Vac 4700pF 125 FOWX2 URus E114280 C5 C6 Electronics Co Y2 IEC60384 14 VDE Line to Ground Ltd Capacitor Shantou High CE 250Vac 4700pF 125 C FOWX2 URus 208107 C5 C6 New Technology Y2 IEC60384 14 VDE Line to Ground Capacitor Cheng Tung CTX 300Vac 3 3nF 100 X FOKY2 cURus E211230 C1 C2 Industrial Co Ltd IEC60384 14 VDE Line to Line PCB JIANGSU DFD 2 overall approx dimension ZPMV2 cURus E213009 PVAP211 DIFEIDA 133mm by 69mm by VERITAS Page 77 of 167 Report 09TH0459 AS3100_2
162. that is not designated as attended or unattended SECTION 5 PROTECTION AGAINST RISK OF ELECTRIC SHOCK FOOTNOTES TO TABLE 5 7 There is no specific limit for thermoplastic material SECTION 6 PROTECTION AGAINST HEAT AND FIRE A 6 1 Resistance to fire P U R U VERITAS Page 56 of 167 Report No 09TH0459 AS3100_2 A 6 1 1 A 6 1 2 General requirements for compliance of solid insulating materials and non metallic enclosures Compliance of solid insulating materials and non metallic materials of electrical accessories is checked by the tests detailed in A 6 1 2 to A 6 1 7 Guidance for the selection and sequence of tests is given in the flow chart figure A1 Glow wire test apparatus and common test procedure is given in AS NZS 60695 2 10 Glow wire flammability test method for end products is given in AS NZS 60695 2 11 This includes guidance for the test temperature a definition of small parts and evaluation of test results In addition to the evaluation requirements of AS NZS 60695 2 11 the complete product has failed to comply with the glow wire tests if burning droplets or glowing particles escape from the equipment and ignite the tissue paper or scorch the particle board underlay beneath the specimen The glow wire test temperature T is required to be specified in each product specification The test method for Needle Flame Test is given in AS NZS 4695 2 2 This includes an e
163. the like shall be so designed that the conductors are held position independently of the soldering b They shall be so located and arranged as to minimize the likelihood of insulation being bridged by excess solder and so that essential insulation will not be damaged during soldering NOTE See Clause 4 5 3 and Clause 4 6 N A 4 3 6 Prevention of slipping or spreading of conductors All terminals shall be of a form that will prevent slipping or spreading of conductors or conductor strands for example by providing for the clamping of conductors either in a cylindrical hole by means of a suitable binding screw or screws or between the head of a screw and a base so arranged that it will prevent the conductors from slipping or spreading or by providing solderless tags or washers or other suitable devices to prevent such slipping or spreading Except for equipment with Type Y or Type Z attachments a device shall not be acceptable as a means of preventing spreading of conductor strands on the terminals of portable equipment unless it can be readily re used when connection of the supply flexible cord is renewed NOTE Terminal washers and lugs having sections such as claws that are intended to fold over and contain strands of a flexible cord or conductor or a device in which the conductors are held by clinching the shank of a solderless terminal lug are not deemed to be readily re usable The requirement is not applicable t
164. ther The earthing terminal if any shall be either within the terminal box or enclosure or on the external surface of the equipment adjacent to the terminal box or enclosure If the earthing terminal is on the external surface of the equipment provision shall be made for the earthing conductor of the supply flexible cord or cable to pass through an opening in the terminal box or enclosure to the earthing terminal An earthing terminal of the quick connect type shall not be acceptable on the external surface of the equipment In equipment except for those which have Type Y or Type Z attachments in accordance with Clause 4 5 1 the terminal box or enclosure shall be such as will allow access to the terminals and replacement of the flexible cord without dismantling the equipment to such an extent as will disturb the assembly of internal wiring and internal live parts This does not preclude the terminals of a switch being used as the supply terminals of an equipment provided that if it is necessary to move the switch for the purpose of connecting the supply flexible cord the equipment shall incorporate a suitable recess channel or space so that the switch and any associated internal wiring will readily return to their correct positions NOTE See Clause 5 2 2 concerning clearances between terminals and exposed conductive parts DC terminals grouped together AC terminals grouped together PE terminal clearly marked 4 3 4
165. ting sleeving b The extra low voltage wiring and exposed parts shall be insulated for the highest voltage present in any low voltage conductor and shall be so arranged or fixed that in the event of a conductor breaking away or becoming detached from a terminal bare extra low voltage parts cannot come into contact with uninsulated low voltage parts or vice versa Parts of one voltage system provided with basic insulation shall not come into contact with live parts of other systems The requirements of Clauses 5 1 5 2 and 5 3 shall not be applicable to extra low voltage wiring complying with the requirements of this Clause Where separate external equipment operating at extra low voltage is supplied from the enclosure in which cables and wiring of different systems are terminated the extra low voltage wiring and connections shall be effectively separated from low voltage wiring as in a unless all parts of external equipment and associated wiring are installed and protected in accordance with the low voltage requirements of the National Wiring Rules U R T VERITAS Page 15 of 167 Report No 09TH0459 AS3100_2 AS 3100 2009 Clause Requirement Test Result Remark Verdict 4 1 3 Creepage distances and clearances for appliances Creepage distances and clearances for appliances shall be not less than the values in millimetres shown in Table 4 1 The way in which creepage d
166. to say any part whose potential is or may become different from earth potential It might be thought that safety would be ensured if no part of the supply system were connected to earth while this would be so as long as the insulation were adequately maintained the system would not in practice be safe because the potential might fortuitously rise to any value above earth By deliberately earthing one point of the system the maximum potential to earth that can occur is limited to a value that is known and can be guarded against In Australia and New Zealand all low voltage supply systems are required to be earthed and the most commonly used method of earthing electrical installations is the multiple earthed neutral MEN system This system is a variant of the TN C S system used in some other parts of the world D2 Protection of live parts In the interests of safety no equipment for connection to electricity supply mains should have any live parts accessible to the user The protective screen or case may be of insulating material or of metal if it is insulated from the current carrying parts Any such apertures should be so arranged in the form of baffled louvers or the like so that there is no possibility of a finger passing through them and coming into contact with live parts or unearthed metal U R U VERITAS Page 63 of 167 Report No 09TH0459 AS3100_2 D3 Earthing of class equipment
167. tors shall not have moved over a distance of more than 1 mm in the terminals nor shall there be appreciable strain at the connection For the measurement of the longitudinal displacement a mark is made on the cord while it is subjected to the pull at a distance of approximately 20mm from the cord anchorage or other suitable point before starting the tests After the tests the displacement of the mark on the cord in relation to the cord anchorage or other point is measured while the cord is subjected to the pull See table 8 6 in Annex P No 1 8 7 Test for screw threads and fixings See Clause 4 7 VERITAS Page 46 of 167 Report No 09TH0459 AS3100_2 8 7 1 Threaded fastenings of metal in metal or thermosetting plastic or wood or the like The screwed component shall be tightened and loosened in a steady and uniform manner the following number of times by means of a suitable test screwdriver or other appropriate device applying a torque of appropriate value given in Table 8 7 a Where it operates in a thread in metal 5 times b Where it operates in a thread in insulating material 10 times Screwed components operating in a thread in insulating material shall be completely removed and re inserted for each operation The shape of the blade of any test screwdriver shall be compatible with the slot of the screw to be tested Threads of the screwed component and
168. ts of IEC 62103 EN 50178 Accepted Optical Isolator U1 U15 U16 U17 U20 Cosmo Electronic K1010 Diameter Clamping Voltage 5000Vac FPQU2 VDE 0884 cURus E169586 VDE PCB 010 JIANGSU DIFEIDA DFD 2 overall approx dimension 50 5mm by 72mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C ZPMV2 cURus E213009 VERITAS Page 79 of 167 Report 09TH0459 AS3100_2 Object Part No Manufacturer Tr ademark Type Model Technical data Standard Mark s of conformity Provided with Ferrite Core PCB 010 Hung Electronic Co Ltd 96 overall approx dimension 50 5mm by 75mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C Provided with Ferrite Core ZPMV2 URus E211578 PCB PVAN210 JIANGSU DIFEIDA DFD 2 overall approx dimension 31mm by 35mm by min 1 6mm thickness Flame Class 94 0 RTI 130 ZPMV2 cURus E213009 PCB PVAN210 PCB PVAM210 Hung Chin Electronic Co Ltd JIANGSU DIFEIDA 96 DFD 2 overall approx dimension 31mm by 35mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 overall approx dimension 107mm by 75mm by min 1 6mm thickness Flame Class 94V 0 RTI 130 C Provided with Display ZPMV2 ZPMV2 URus E211578 cURus E213009 PCB PVAM210 Hung Chin Electronic Co Lt
169. unless otherwise specified in an individual Approval and test specification Any sleeving or packing around the cord where it passes through the cord anchorage device shall be removed before the test is applied The equipment is tested with the cord as delivered It shall not be possible to push the cord into the equipment to such an extent that the cable or cord or internal parts of the equipment could be damaged After the equipment has been correctly wired with all the strands intact it shall be held fixed in position The cord shall then be subjected 25 times to a pull of the value shown in Table 8 6 The pulls are applied in the most unfavourable direction without jerks each time for 1s Unless varied in an individual specification accessories shall be subjected to a pull of 65 N Immediately afterwards the cord is subjected for 1 min to a torque of the value shown in Table 8 6 For Type X attachments having a specially prepared cord and Type Y and Z attachments any additional sleeving used for cord protection purposes shall not be totally displaced from its anchorage point when tested The sleeving shall be tested separately after the cord anchorage test in accordance with the method specified in this Clause however the pull shall be 30 N and the torque test shall not be applied During the tests the cord shall not be damaged After the tests the cord shall not have been longitudinally displaced by more than 2mm and the conduc
170. uses or circuit breakers in the live conductors and disconnect the power supply If earthing is to be relied upon for protection it is essential that portable equipment should be connected to the mains by means of plugs and sockets that incorporate an earthing connection If two pin plugs and sockets or lampholder adaptors are used no such protection is afforded Equipment having metal cases that are not earthed are not allowed in Australia or New Zealand Class 0 and Class 01 equipment unless the equipment is of Class 11 construction as described in Paragraphs D5 and D6 D4 Monitored earthing connections There are in existence systems for detecting the presence of leakage current to earth or a rise in potential of accessible metal and which disconnects the supply to minimize the risk of electric shock Other systems may activate alarms or switch off the power supply to the equipment unless the earth circuit is complete VERITAS Page 64 of 167 Report No 09TH0459 AS3100_2 D5 Insulation encased class construction In this form of Class Il construction the equipment is totally enclosed in a casing made of insulating material having no external metal whatever and having no apertures through which a probe can be inserted to touch live metal or basic insulation Where the insulating case is made strong enough to withstand service conditions without fracture or deterioration and when the
171. valuation of test results Materials and tests The tests are carried out on solid insulating materials and non metallic enclosure whilst assembled on a complete end product The tests are not carried out on decorative trims insulation of wires knobs and other small parts unlikely to be ignited or to propagate flames originating from inside the equipment A 6 1 3 Glow wire tests on relevant parts Relevant parts other than those in A 6 1 4 are subjected to the glow wire test of AS NZS 60695 2 11 which is carried out at 650 C unless otherwise specified in the relevant product standard Note The majority of thermoplastic materials are capable of complying with the 5500C GWT and consequently where the material is adequately specified and certified this test may be waived with the agreement of the test authority The glow wire test is not carried out on parts of material classified at least HB40 according to AS NZS 60695 11 10 provided that the test sample was no thicker than the relevant part A 6 1 4 Glow wire tests on retaining parts Parts of insulating material retaining current carrying parts carrying more than 0 2amps in position are subjected to the glow wire test of AS NZS 60695 2 11 which is carried out at the glow wire test temperature T specified in the product standard NOTE Where no product standard exists the appropriate test temperature may be obtained from the guidance for glow wire test
172. y accepted by an approvals authority in those cases where there is little likelihood of cascading of similar equipment which could result in circuit overloading and extension of fault conditions b Where permitted by an individual Approval and test specification or by National Wiring Rules c Where the equipment is basically providing a switching or control function This does not preclude the use of socket outlets or other facilities for connections within the equipment 3 10 Equipment intended to be supported by contacts of N A socket outlets Appliances having integral pins for insertion into socket outlets shall comply with Appendix J of AS NZS 3112 1 3 11 Static charge in equipment N A Attention is drawn to the hazard of shocks caused by the build up of electrostatic charge in equipment such as hand held tools AS NZS 1020 gives guidance on the control of undesirable static electricity 3 12 Control methods Unit intended for feeding P For equipment suitable for connection to the supply in to the public low mains asymmetrical control of the input current is voltage mains prohibited in normal use However half wave Asymetrical abnormal rectification directly on the supply mains may be used operation causes a where the controlled active input power does disconnection of the unit exceed 100W or where the controlled equipment is class portable equipment which in normal use is only operated for shor

TEST REPORT AS 3100:2009 General requirements for

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