How to Prepare for Luminaire Certification
Product safety certificates like CB and ENEC are a competitive edge for lighting brands.
These certificates are not only proof that a product has been deemed safe by a third party, but they also show that the manufacturer truly invests in product safety.
With the rapid development of LED lighting, the certification process needs to be quick and straightforward. The launch of a product should not be delayed by a cumbersome testing and certification process.
In this blog post, we discuss the common challenges in product testing and certification and their impact on the overall process. We also explain how to prepare for luminaire certification to avoid these common challenges.
Key takeaways
Product safety certifications provide a competitive edge for luminaire manufacturers, indicating a commitment to product safety.
Challenges in the certification process, such as non-compliance with standards and incomplete product information, can delay product launches.
Careful preparation for certification reduces delays and costs, ensuring faster market entry.
Knowledge of standards and assessment of critical components and materials are crucial for successful certification.
Common Challenges in Luminaire Certification
Based on our experience, challenges during the certification process typically arise from three areas:
The product and documentation do not comply with standards.
Essential information is missing from product details.
The testing party lacks a thorough understanding of the product.
These challenges can lead to wasted time, money, and resources.
Product and Documentation Compliance
It is obvious that the product must meet all the requirements of applicable standards to be certified. In addition to the product, its documentation must also meet these standards. Compliance is ensured through:
Installation instructions
User manuals
Maintenance guides
It is quite common to find deficiencies in the product or documentation during testing.
Deficiencies in the product often send it back to the drawing board.
At worst, these deficiencies result in a cycle where the product and documentation are bounced back and forth between the testing laboratory and the manufacturer.
Furthermore, the testing laboratory cannot give concrete advice on how to correct deficiencies in the product due to ISO/IEC 17025 standard, which prohibit the laboratory from participating in product development.
Deficiencies in the product and documentation always delay the testing and certification schedule. Re-testing and inspections invariably result in additional costs.
Incomplete Product Information
The most important details needed for testing and certification of a luminare include:
Technical specifications
Used materials and their properties
Information on critical components
While some of this information is required for conducting the tests, some must be included in the product test report.
Missing technical specifications can delay the start of testing.
Without material information, testing could technically begin, but incomplete or missing material data can later prove to be a significant obstacle.
A comprehensive list of critical components, including details and certificates of components, should be already available during the testing inquiry phase. Critical components have a direct impact on the extent of testing and product compliance.
Understanding of the Product by the Testing Laboratory
Although not as apparent to the certificate applicant as the previous two points, the testing laboratory's understanding of the product is also crucial for project success.
The better the testing laboratory understands the product's features, the more accurate and detailed their testing offer can be.
A good product understanding also reduces additional requests for information during testing and minimizes testing errors and uncertainties that can delay the process.
Certification Path rethought.
Find out how Complite can make the certification process easier and faster.
Preparing for Luminaire Certification
As with all projects, good groundwork is key to success.
It is important to remember that each product is unique, and readiness for certification should be assessed individually for each product.
However, there are certain fundamental principles that generally apply to all luminaires.
1. Ensuring Compliance with Standards
Ideally, the need for certification is considered during the design phase, ensuring the luminaire is designed to meet all the requirements of applicable standards.
Sometimes, the need for certification arises later in the product's lifecycle, making it essential to assess compliance with standards. Product safety and compliance, while related, are distinct factors.
As mentioned, each product is unique, making it impossible to create an all-encompassing checklist. However, the following areas are generally applicable to all luminaires:
Product markings. Ensure all standard-required markings are present, considering their location and the size of letters and symbols. Note that not all marking requirements may be listed in a single section of the standard.
Visual construction inspection. This includes not only the clause “construction” of the standard but also things like wiring (external and internal) and protection against electric shock.
Critical creepage distances and clearances. These are physical distances between different parts and circuits. When the luminaire's controlgear is certified separately, the critical creepage distances and clearances are found between mains-voltage parts and the body, as well as between the LED module and the body.
Temperature checks / risk analysis. Ensure that the components in the luminaire do not overheat. The most critical components include the controlgear and the LED module, which must not exceed their tc temperature. Use K or T type thermocouples for these checks. Measure the temperatures of components and the surrounding environment, and make temperature corrections as necessary. Consider also the alternative components.
IP rating risk analysis. Verifying the IP rating without standard testing is challenging. The higher the IP rating, the greater the risk. Conduct a visual risk analysis of the product. If necessary, consider pre-testing the IP rating, which can be taken into account in the certification process.
2. Checking Luminaire’s Documentation
Check the compliance of written documentation such as installation instructions, user manuals, maintenance guides, and other documentation with standards.
Consider all the requirements of the standards applicable to the product. Some luminaires may be covered by multiple second parts of the luminaire standard series.
Standards contain ready-made warning and instruction texts that are recommended for use. Using standard texts reduces misinterpretation and ambiguity during the testing phase.
3. Evaluating and Listing Used Plastic Materials
In terms of compliance with luminaire standards, critical materials include plastics that:
are part of protection against electric shock: such as luminaire housing, diffusers, and protective covers over LED modules
hold current-carrying parts in place: for instance, connectors and lampholders, and in some cases, the luminaire housing
are near light sources: the part's distance from the light source is less than 30 mm
In selecting materials, prefer those that are already approved somewhere, for example in North America. Such materials have an E-file listing their properties and tests conducted on them.
If the luminaire’s connectors or lampholders are separately tested according to applicable standards, there is no need to test these materials again in the context of the luminaire.
Note that not all IEC standards correspond directly to North American standards. E-files can provide a lot of information about a material, but the data may not cover all the requirements of IEC standards.
Luminaire material tests include:
Ball pressure test: applicable to practically all the above-mentioned materials
Glow wire test: for parts that are part of protection against electric shock and parts that are near heat sources
Needle flame test: for parts holding current-carrying parts in place
Tracking test: for parts holding current-carrying parts in place in luminaires with an IP rating better than IP20
List all critical plastic materials, including different color options and alternative materials.
Clearly define where each plastic material is used. For more complex cases, consider using an exploded view of the product and numbering parts / components.
4. Listing Critical Components of the Luminaire
Critical components include all components that affect the safety and compliance of the luminaire, such as:
Controlgears and power supplies
LED modules
Wires and conductors
Connectors
The component list consists of rows and columns. Each row is one component. The columns provide additional details about the component: description, manufacturer, model / type, technical specifications, applicable standards, and proof of compliance.
The unique aspect of the lighting product category regarding the component list is the component coding system. The coding system indicates the interchangeability of the component.
A* = The component is replaceable with another one according to ETF5-OSM-LUM/DSH 2057
A = The component is replaceable with another one, also certified, with equivalent characteristics
B = The component is replaceable if authorized by the test house
C = Integrated component tested together with the appliance
D = Alternative component
Most luminaire components are listed with code B and their alternative components with code D. Code A* can be used for LEDs and code A for wiring.
It is generally recommended that all critical components have been certified and tested according to IEC / EN standards. If a component has not been tested and certified, additional tests may be required for the component during the luminaire testing.
Provide as detailed technical information about components as possible. Regarding model markings, note the component's connectivity to the related certificate.
Also, ensure the suitability of alternative components for the luminaire. Pay particular attention to the controlgear’s tc temperature and maximum output voltage (Uout).
Certificates of certified components should be sent along with the component list for testing and certification. Make sure all necessary certificates are available and valid.
Note: The EU Declaration of Conformity (DoC) is not a certificate and is therefore not accepted as proof of a component's compliance with standards.
5. Assembling the Documentation Package for Certification
Once the product and instructions have been checked and other necessary documents created, these should be compiled into a documentation package for testing and certification.
The package should ideally include the following documents / information:
Basic information about the product
If a product family, a description of the different models and differences between them
Marking plate and other markings
Technical documentation and written instructions of the product
Material list
Material certificates or certificate numbers
Component list
Component certificates
Component data sheets
Test reports of any pre-tests conducted
Pay attention to how the documentation package is assembled. The clearer the documents are divided into folders and named, the easier it is for the testing laboratory to find the needed information. This speeds up the entire process.
The documentation package should be assembled by the time of the inquiry for a quote. This allows the laboratory to make a more accurate offer and start testing as quickly as possible.
It is beneficial to review the product and related documentation with the testing laboratory. This improves the laboratory's understanding of the product and allows any questions or ambiguities to be addressed early in the project.
Summary
Product safety certifications are a significant competitive advantage for luminaire manufacturers. In this article, we have explored the challenges of luminaire certification and presented how preparation is key to managing costs and minimizing delays.
Good preparation and understanding of standard requirements ensure a smoother process and faster market access, while also strengthening the brand's reliability and market position.