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Underwriters Laboratories

by:

Gary Di Troia

2Underwriters Laboratories

Overview

Underwriters Laboratories (UL)

The “LISTING” process.

UL Standards FCI Lists to.

General product “LIST” requirements.

UL Follow-Up Services.

UL486A for copper SERVITs

UL486B for aluminum SERVITs and UNITAP


UL - Who are they?

Independent, Not-for-profit Product Testing & Certification Organization

Established in 1874

Primary founders were Insurers

Product/Consumer safety orientation

NOT restricted to electrical industry!

Marine

Fire equipment

Environmental and Public Health

& Electrical and Electronics products/services


UL Activities - 1999

Estimated UL Marks appearing on new products 16,1 billion

Product evaluations 94 396

Follow-up Service visits to audit compliance 509 442

Consumers UL reached in the U.S. and Canada 110 million

Total number of current UL Standards 748

Countries with UL customers 89

UL Staff 5 644

UL Inspection Centers 193 in 71 countries

Laboratory testing and certification facilities 46

Number of product types UL evaluates 18 059

Total number of facilities registered by UL 4 089

Number of manufacturers producing UL certified products 58 684


UL “Listing”

The Listing defined:

A UL Listing allows a manufacturer to apply the UL symbol

to all products that have successfully been sample tested

to the appropriate standard (primarily a UL standard) for the product category. Product with the UL mark implies

continued compliance with Follow-Up inspections.


UL Listing Process (simplified)

Initial Request (IR)

Approval & Project #

Testing

Listing

The IR proposes a List program of testing.

UL reviews the IR, approves with changes,

estimates cost, and assigns project #.

Testing conducted in certified lab to UL

approved test program.

UL issues the product file listing all Listed

products reviewed. Manufacturer can

apply the UL mark to the products.

Follow-Up


UL Certified Labs

UL Labs

Northbrook, IL

Melville, NY

Camas, WA

Santa Clara, CA

Research Triangle Park, NC

UL Certified Labs - Many

FCI Manchester is one


UL Standards

FCI Manchester - Certified for:

UL 486 A - Cu Connectors

UL 486 B - AL to AL and Al to Cu

UL 486 C - Small disconnects

UL 486 D - Insulated connectors

UL 467 - Grounding


General Product List Requirements

Performance

Usually (but not restricted to) testing to UL Standard

Construction

List File contains product details

Product must remain as tested

Product changes must be reevaluated


Product List Requirements

Marking

Connector Product marking

Catalog Number

Company Identifier

Smallest unit packaging

Conductor

Tools

Dies

Stuffer sheet

Installation Instructions


Follow-Up Services

Follow-Up Services defined:

Follow-Up Services performs conformance audits to the

Manufacturers Report, ensuring proper use of UL Marking.


Follow-Up Services

Manufacturers File

The Manufacturers File contains the product description details. Auditors will use the file to inspect product at the manufacturing location to ensure products being shipped with the UL Mark conform to the File requirements.

UL486A Wire Connectors and Soldering Lugs

for Use With Copper Conductors


UL486A – Standard Scope

Scope

Terminal wire connectors and splices for #30 to #4 AWG or largercopper conductors with currents not exceeding the capacity of the insulated conductors.

Insulated connectors, insulating caps and covers intended for use at 600 Volts or less.

Exception: Uninsulated pressure wire connectors that are

compression tool applied may be used in circuits rated 35,000 Volts or less.


UL486A - Application

Areas of application:

UL 486A Listed products are appropriate for National Electric Code (NEC) applications.

NEC generally applies from the service entrance to throughout a facility.

UL 486A Listing NOT appropriate for distribution, transmission, or generation except for those facilities where the NEC applies by local law.


UL486A - Construction Requirements

All strands of conductor are contained.

The clamping action of a range taking connector shall not

require the permanent addition or removal of parts.

There shall be no sharp edges or corners that may damage

insulation that it may contact.


UL486A – Material Requirements

Main current carrying portion of the connector shall be copper

or a copper alloy.

Tin is an accepted coating. Others are acceptable upon

testing.

Brass shall be resistant to stress corrosion (>15% Zinc shall be tested to the Moist Ammonia-Air Stress Cracking Test).


UL486A – Performance Requirements

Two sets of sequential testing:

Set 1: Static Heating

Secureness

Static Heating

Pullout

Set 2: Mechanical

Secureness

Pullout


SET 1: Static Heating Sequence - Secureness


Secureness

Static Heating

Pullout


SET 1: Static Heating Sequence - SH


Secureness

Static Heating

Pullout


SET 1: Static Heating Sequence - Pullout


Secureness

Static Heating

Pullout conductor

connector

Pullout

Force


SET 2: Mechanical - Secureness

Set 2: Mechanical

Secureness

Pullout


SET 2: Mechanical - Pullout

Set 2: Mechanical

Secureness

Pullout


UL486A - Marking Requirements

Connector

Manufacturer’s name/tm/other

Catalog number

Conductor range

Container

“CU”

Class B or C

“Solid” (if tested and acceptable)



Instructions

Specific tool(s) required

Multiple crimping operations

Location of crimp points

Conductor strip length

Preliminary conductor preparation

UL486B Standard for Wire Connectors for Use

With Aluminum Conductors


UL486B – Standard Scope

Scope:Pressure wire connectors intended for use with aluminum or copper-clad aluminum conductor according to the National Electrical Code, NFPA 70. The connectors may be constructed so that they are also acceptable for use with copper conductor.

Terminal-type wire connectors intended for use with No. 12 AWG (3.3 mm 2 ) or larger aluminum or copper-clad aluminum conductor.

Splicing-type wire connectors intended for use with No. 4 AWG (21.2 mm 2 ) or larger conductors, with currents not exceeding the ampacity of insulated conductors rated 75°C or 90°C

Insulated connectors, insulating caps, and covers intended for use at 600 volts or less anduninsulated connectors for use in general-use circuits rated 2000 volts nominal or less.

Exception: Uninsulated pressure wire connectors that are compression tool applied may be used in circuits rated 35,000 volts or less.


UL486B - Application

Similar to UL486A – NEC type applications.


UL486B – Construction Requirements

The main current-carrying part of a connector shall be of aluminum, an aluminum alloy, copper, a copper alloy, or other material investigated and found to be acceptable for the purpose.

A connector body of copper, copper alloy, aluminum, or aluminum alloy shall be coated with an electrically conductive coating that will inhibit oxidation and corrosion.


UL486B – Installation Note

Note:

Split-bolt torque is specified by the standard based on the maximum conductor size accommodated.

Set screw torque is specified by the standard based on the maximum conductor size accommodated.

Manufacturer may provide instructions for alternate torque, but must be clearly identified in published literature and with the connector when shipped.


UL486B – Performance Requirements

Static Heating, Secureness & Heat Cycle:

Set 3: Heat Cycling

•500 cycles

•All combinations of

conductor

•125 °C max

connector temp rise

Set 1: Static

Heating

Secureness

Static Heating

Pullout

Set 2:

Mechanical

Secureness

Pullout +

As in UL486A


UL486B – Heat Cycle

Set 3: Heat Cycling

•500 cycles

•All combinations

of conductor

•125 °C max

connector temp

rise

Fully

Automated,

Digital Data

Acquisition

System for

Heat Cycle

Testing


UL486B - Marking Requirements

Connector

Manufacturer’s name/tm/other

Catalog number

Conductor range

“ALCU” or “AL7CU” for 75 °C applications

“AL9CU” for 90 °C applications

Container

Class B or C

“Solid” (if tested and acceptable)



Instructions

Specific tool(s) required

Torque

Multiple crimping operations

Location of crimp points

Conductor strip length

Preliminary conductor preparation

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