Since UL61058-1 is based upon IEC 61058-1, a single test program can be used to achieve UL/cUL Recognition, CB Report, D Mark and ENEC Mark reducing test time and time to market. UL 1054 is in the process of being phased out and UL 61058-1 will completely replace UL1054 (Special-Use Switches) by June 2015. Many manufacturers are asking how to transfer their UL Recognized switches from UL1054 to UL61058-1, and about the differences between the two standards. The following provides high level information regarding these questions:
How do I transfer my UL 1054 (WOYR2) Certification to UL61058-1 (WKKY2)?
The two standards define the same level of safety. The methods each uses to arrive at that level of safety are different. Testing completed under one standard cannot be used to represent the other.
UL 1054 takes an empirical approach, depending heavily on demonstrated endurance cycles and measured results. UL 61058-1 takes a more academic approach with more detailed individual tests and equipment.
Switches presently certified under UL's product category of Special Use Switches (WOYR2, UL 1054) must be completely reevaluated to the requirements of UL 61058-1 (new category Appliance Switches -- WKKY2). A switch with a UL1054 recognition and a 61058-1 CB Test Report (TRF) may have a shorter evaluation based on testing that is applicable to the present edition of the standard and National Differences.
What are National Differences?
National differences document adaptations to harmonized requirements to meet country-specific needs. For example, North American (Canada and United States) national differences include simple clarifications and adjust selected technical requirements. The most important of these include:
Ratings -- Electrical Ratings associated with legacy North American loads, such as General Purpose ("GP"), television ("TV"), and horsepower ("hp", which is different from "motor load"). Testing for GP, TV, hp, T and TL is similar to UL1054. (188.8.131.52DV)
Cycles -- Minimum endurance cycles for recognition is 6,000, although 10,000 is suggested. Since many end product standards require more cycles, check the application before testing. (184.108.40.206DV)
Dielectric Tests -- Dielectric testing is completed for 60 seconds at the specified voltage. (15.3DV)
Thermal Compliance (Temperature Test after Normal Endurance) -- The maximum temperature rise is limited to 30°C to provide the same level of safety and historic benchmark performance required by legacy standards. The test is completed after the number of endurance cycles required by the application (usually 6,000, or 12,000 for lamps) under normal conditions. (220.127.116.11DV)
Plastics -- Acceptance is based on pre-select requirements (RTI and Flame ratings [see question 4 below]) as well as end product testing (ball pressure and glow-wire). (21 DV)
Test Frequency (Hz) -- The switch must be tested at the worst-case frequency for which it is rated. For example, a switch rated (50 - 60 Hz) would be tested using a 50 Hz supply. No calculation methods are permitted to test 60Hz amps to represent 50Hz amps. (UL1054 ;13.15)
What is the limit on temperature rise?
Under UL1054 and most UL legacy end product standards, the terminals of switches and similar devices are not permitted to rise above 30°C.
Under UL61058-1, the switch manufacturer has the choice of 30°C or 55°C according to the buyers market.
Switches evaluated to the 30°C rise are accepted in the widest market, UL legacy end products and end products harmonized to IEC standards.
Switches evaluated to 55°C rise are limited to acceptance in end products harmonized to IEC standards (where the 55°C rise is permitted).
The model card has a 30°C and 55°C column for endurance cycles allowing the same switch to have different cycles or electrical ratings for each market.
What changes were made for plastics requirements?
Two basic approaches to plastics exist: "pre-selection" and "end product" testing.
- Preselection is one of the more valuable tools available to the designer to assist with this task. Preselection is defined as the process of individually assessing and choosing materials and parts for particular applications based upon established criteria. For more than 40 years, the UL Preselection Program for plastics, has been successfully utilized by designers and safety steward engineers to select materials for their product applications that have demonstrated performance characteristics resulting in reduction of end-product tests and reduction in overall safety certification project turnaround time. The preselection criteria is available in UL's iQ Database. This database contains information on more than 50,000 plastic materials, can be used to assist manufacturers in the safety compliance analysis and merchandising of their plastics for use in both component and end-product parts in North American and Global (IEC) applications. The IEC continues to use "end-product" plastic test methods for each switch project.
- To satisfy both requirements, both methods are required for plastics used either in support of conductive parts, or relied upon for correct actuation. Many manufacturers use UL's Plastic on-line directory to identify plastics with acceptable pre-select ratings.
- End-product test limits must be provided for the glow wire test temperature based on the end product standard requirements and application. For example: Level 1 (650°C) attended use below 0.5A, Level 2 (750°C) attended use above 0.5A, or Level 3 (850°C) unattended use continuous load.
What are the differences between UL 61058-1 motor and hp rating test conditions?
North American "hp" rating and the European "Motor" rating are different based on historical testing of motor loads in end product and Building/ Electrical codes.
North America hp ratings have a required over CURRENT test to represent the Locked Rotor Amperage (LRA), power factor (PF) = 0.45 - 0.5, rated voltage and 50 cycles. Endurance cycles are completed for appliances, under more favorable start conditions: Full Load Amperage (FLA), rated voltage PF = 0.75 - 0.8 and 6,000 minimum cycles.
European IEC motor ratings involve testing with a make current (motor start-up) power factor (0.6) and a break current (steady state) power factor resistive on each cycle. Typical test program:
a. (TE2) 100 cycles at 1.10 or 1.15 x rated voltage, Make 6xFLA, PF = 0.6 - 0.65, Break FLA, PF = 0.9 - 1.0.
b. (TE1) 100 cycles at rated voltage, Make 6xFLA, PF = 0.6 - 0.65, Break FLA, PF = 0.9 - 1.0.
c. (TE4) 5800 minimum cycles at rated voltage, Make 6xFLA, PF = 0.6 - 0.65, Break FLA, PF = 0.9 - 1.0
Can WOYR2 (UL 1054) switches with North American loads (such as hp, GP, VT, VL or TV) be transferred without re-testing to WKKY2?
No, although the electrical loads are similar, the test method of 61058-1 is different. In order to have all switches compliant to the new standard, UL made the decision to re-evaluate all switches entering the WKKY2 category. There is no method of "grandfathering" switches, all switches must demonstrate compliance to UL 61058-1 or be withdrawn in year 2015.
For switches certified against the new standard “UL 61058”, apart from acquiring UL/CUL certifications, could UL Demko certification be obtained?
Yes, the "D" mark (Demko), certification can be bundled with the evaluation for UL/ cUL certification. Be sure to ask for this in your opening request and UL Customer Service can provide you details.
Would UL accept European Lab approval test report for UL 61058-1 switches certification?
Yes, UL is a member of the CB Scheme and accepts reports completed by other members with authorization to issue the report. However, the National Differences still apply and must be included in the CB report; or a small amount of additional testing is required - mainly a limited number of endurance cycles to demonstrate the 30°C temperature rise. Cycles are limited to 6,000 except for Lamp loads (12,000) and TV loads (10,000).
Can UL complete one evaluation and testing to provide the UL, cUL, D, CB and ENEC service?
Yes, UL can complete the evaluation and provide the UL, cUL, and D, Certification as well as a CB Report.
What specific test method are required for switches used in Power Tools for IEC 60745?
- DC Cord Connected Switches Recognized to 61058-1 electrical test ratings - Switches for DC Cord Connected tools evaluated to 60745 are tested for suitable ratings using the following method. The switch should be tested to the requirements of 61058-1 as a simple DC rated switch. (voltage = tool rating, amps [resistive load]). Minimal cycles are 50,000. The end product tool evaluation will add the 50 cycles of locked rotor testing in the specific tool per the 60745 requirements.
- DC Battery Operated Tool Switches Recognized to 61058-1 electrical test ratings - DC Battery Operated tools evaluated to 60745 are tested for suitable ratings using the following method. The switch should be tested to the requirements of 61058-1 as a simple DC rated switch. (voltage = tool rating, amps = steady state, no mechanical load). At this time the minimum cycles is 6,000. The end product tool evaluation will add the 50 cycles of locked rotor testing in the specific tool per the 60745 requirements.
- AC Tool Switches Recognized to 61058-1 and used in 60745 electrical test ratings - AC tools evaluated to 60745 are tested for suitable ratings using the Resistive Motor (RM) electrical ratings or Specific Load (end product) rating as described in 61058-1 (Appliance Switches). At this time the minimum cycles is 50,000. General Purpose: The General Purpose classified in 61058-1; 18.104.22.168DV (National Difference) is not acceptable for 60745, since this load does not address the required inrush current.
Are Iron Core Coils electrical loads allowed for testing in 61058-1?
The standard allows both Air Core and Iron Core Coils. However, if you use an Iron Core, the wave form must be viewed and verified to be sinusoidal. This often results in a load being used at less than 70% of its marked value. A good reference is 61058-1, Table 17, footnote 3.
How has the test equipment changed from UL 1054 to UL 61058-1?
The test equipment in UL 1054 was beautifully simple. The test methods and equipment for 61058-1 are more complicated involving test ovens, and actuators with specific speed of actuations, on off times, and possible actuation at temperatures above 55°C. In addition, the dielectric tester can require larger capacities (Table 12, note 1). There are a number of requirements in the standard and they must be considered carefully.
When will UL publish a new standard harmonized to the new IEC publication of 61058-1, edition 3, amendment 2?
The IEC recently published a new corrigendum (correction) to the standard. UL nearly ready to publish a harmonized standard UL/CSA/IEC that will include the National differences and corrigendum information. We expect this work to be complete in July 2009. We do not expect the new publication to result in a file review. The major changes to the 61058-1 include Maximum Voltage 480V, Lamp markings update, Terminal Testing clarification, and Addition of a Test TC10 for specific constructions of mechanical DC rated switches.
How will the Follow-Up Testing Requirements change under WKKY2/8?
Follow-up process is very similar to UL1054. UL maintains ongoing surveillance over switches that bear the UL Recognition mark, including witnessed factory inspections and testing at the manufacturer's testing facility.
Test equipment required under UL61058-1 is more complicated than that required under UL1054. Manufacturers that want to become involved in this standard should review the test requirements, especially for the endurance test actuator (temperature of test cabinet, actuation velocity, and hold of the on- and off-time based on the ampere rating). In most cases this requires both an actuator that is uniquely programmable for the task, and specific control of the load conditions.
How can I buy a purchase copy of UL61058-1?
UL standards can be purchased on-line from comm-2000.com. The standard publication date is Sep. 30, 2005 and is harmonized to both IEC61058-1 edition 3.1, and CAN/CSA-C22.2 No. 61058-1-05.
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