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ANSI UL 458 User Manual

Power converters/inverters and power converter/inverter systems for land vehicles and marine crafts
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Power Converters/Inverters
and Power Converter/Inverter
Systems for Land Vehicles and
Marine Crafts
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR
DISTRIBUTION WITHOUT PERMISSION FROM UL
UL 458
ISBN 1-55989-212-9
UL COPYRIGHTED MATERIAL –

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Summary of Contents for ANSI UL 458

  • Page 1 UL 458 ISBN 1-55989-212-9 Power Converters/Inverters and Power Converter/Inverter Systems for Land Vehicles and Marine Crafts UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 2 UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 3 The revisions dated October 15, 2004 are being issued to incorporate requirements in accordance with: Responses to comments received on the Fourth Edition of UL 458, the Standard for Power Converter/Inverter Systems for Land Vehicles and Marine Crafts, balloted for ANSI...
  • Page 4 OCTOBER 15, 2004 − UL 458 UL’s Standards for Safety are copyrighted by UL. Neither a printed copy of a Standard, nor the distribution diskette for a Standard-on-Diskette and the file for the Standard on the distribution diskette should be altered in any way.
  • Page 5 OCTOBER 15, 2004 − UL 458 The requirements in this Standard are now in effect, except for those paragraphs, sections, tables, figures, and/or other elements of the Standard having future effective dates as indicated in the note following the affected item. The prior text for requirements that have been revised and that have a future effective date are located after the Standard, and are preceded by a ″SUPERSEDED REQUIREMENTS″...
  • Page 6 OCTOBER 15, 2004 − UL 458 This Standard consists of pages dated as shown in the following checklist: Page Date 1-12B ............... . October 15, 2004 13 .
  • Page 7 Pfingsten Road, Northbrook, IL 60062. An effective date included as a note immediately following certain requirements is one established by Underwriters Laboratories Inc. and is not part of the ANSI Standard. Revisions of this Standard will be made by issuing revised or additional pages bearing their date of issue.
  • Page 8 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 9: Table Of Contents

    OCTOBER 15, 2004 UL 458 CONTENTS INTRODUCTION 1 Scope ................7 2 Glossary .
  • Page 10 UL 458 OCTOBER 15, 2004 23 Inverter Output Circuits ............. .36 24 Lampholders .
  • Page 11 OCTOBER 15, 2004 UL 458 49.2 Relay and solenoid burnout ........... .67 49.3 Transformer burnout .
  • Page 12 UL 458 OCTOBER 15, 2004 CONSTRUCTION SA3 General ............... .SA1 SA4 Frame and Enclosure .
  • Page 13 OCTOBER 15, 2004 UL 458 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 14 UL 458 OCTOBER 15, 2004 This page intentionally left blank. UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 15: Introduction

    OCTOBER 15, 2004 UL 458 INTRODUCTION 1 Scope 1.1 These requirements cover fixed and stationary power converters, power-converter systems, and accessories having a rated nominal input of 120, 120/240, or 240 volts, alternating current and a nominal output of 24 volts or less, direct current. These converters are intended for use within land vehicles where not directly exposed to outdoor conditions, and are intended to be employed in accordance with the National Electrical Code, NFPA 70.

  • Page 16: Glossary

    UL 458 OCTOBER 15, 2004 specific requirements or provisions of this standard shall not be judged to comply with this standard. Where appropriate, revision of requirements shall be proposed and adopted in conformance with the methods employed for development, revision, and implementation of this standard.
  • Page 17 OCTOBER 15, 2004 UL 458 2.11 FLUSH-WALL-MOUNTED UNITS – Units that are intended to be recessed in a wall. 2.11 effective April 13, 1993 2.12 LIMITED-ENERGY CIRCUIT – A circuit having a voltage not exceeding 1000 volts and the energy limited to 100 volt-amperes by a secondary winding of a transformer, or a fixed impedance.
  • Page 18 UL 458 OCTOBER 15, 2004 2.18 PRESSURE TERMINAL CONNECTOR – A field wiring terminal that accomplishes the connection of one or more conductors by means of pressure without the use of solder. A pressure terminal connector may be the barrel and set screw type, crimp type barrel, or clamping plate and screw type.
  • Page 19 OCTOBER 15, 2004 UL 458 2.27 SAFETY CIRCUIT – Any primary or secondary circuit that is relied upon to reduce the risk of fire, electric shock, injury to persons, or electrical energy – high current levels. For example, in some applications, an interlock circuit is considered to be a safety circuit.

  • Page 20: Components

    UL 458 OCTOBER 15, 2004 3 Components 3.1 Except as indicated in 3.2, a component of a product covered by this standard shall comply with the requirements for that component. See Appendix A for a list of standards covering components generally used in the products covered by the standard.

  • Page 21: Part I - Power Converters And Inverters

    OCTOBER 15, 2004 UL 458 PART I – POWER CONVERTERS AND INVERTERS CONSTRUCTION 5 General 5.1 A converter or inverter shall employ materials that are acceptable for the intended use. 5.1 effective April 13, 1993 6 Frame and Enclosure 6.1 A converter or inverter shall be so formed and assembled that it will have the strength and rigidity necessary to resist the abuses to which it may be subjected without increasing the risk of fire, electric...
  • Page 22 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 23 DECEMBER 14, 1993 UL 458 Table 6.1 Minimum acceptable thicknesses of enclosure metal At small, flat, unreinforced At surfaces to which a At relatively large surfaces and at surfaces of wiring system is to be unreinforced flat surfaces, a shape or size to ensure connected in the field,...
  • Page 24 UL 458 SEPTEMBER 11, 1998 6.6 A nonmetallic part (such as a reset knob, a lever, or a button) protruding through a hole in the enclosure, shall be made of a material classed as V-0, V-1, or V-2 in accordance with the Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances, UL 94, if the area of the hole is 0.6 inch...
  • Page 25 OCTOBER 15, 2004 UL 458 6.12 Material supporting terminals or used as internal electrical insulation of an electrical instrument shall comply with the requirements in Section 16, Insulating Materials. Exception: An electrical instrument connected in a secondary circuit need not comply with this requirement if damage to or deterioration of the materials will not result in a risk of electric shock or fire.

  • Page 26: Enclosures Used For Protected Environments

    UL 458 OCTOBER 15, 2004 7 Enclosures Used For Protected Environments 7.1 A protected environment enclosure provided for compliance with 28.1.1 shall be constructed so as to protect the internal parts of the appliance against conductive contaminants and shall comply with the Atomized Water Test, Section 51.

  • Page 27: Accessibility Of Uninsulated Live Parts, Film-Coated Wire, And Moving Parts

    DECEMBER 14, 1993 UL 458 c) Welded, sonically welded, solvent cemented, or provided with tongue and groove joints and seams; or d) Encapsulated (potted); or e) Conformally coated with a compound that complies with the Standard for Polymeric Materials – Use in Electrical Evaluations, UL 746C, and with the intended application.
  • Page 28 UL 458 DECEMBER 14, 1993 This is generated text for figtxt. Figure 8.1 Accessibility probe UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 29: User Servicing

    DECEMBER 14, 1993 UL 458 8.1.3 Perforated sheet metal shall not be less than 0.042 inch (1.07 mm) thick if the perforations are 1/2 square inch (3.2 cm ) or less in area, and shall not be less than 0.080 inch (2.03 mm) thick for larger openings.

  • Page 30: Serviceman Servicing

    UL 458 OCTOBER 15, 2004 8.3 Serviceman servicing 8.3.1 An electrical component that may require adjustment, servicing, or maintenance not specified in the operator’s manual shall be located and mounted with respect to other components and with respect to grounded metal parts so that it is accessible for electrical service functions without subjecting the serviceman to the likelihood of electric shock or injury to persons.

  • Page 31: Protection Against Corrosion

    OCTOBER 15, 2004 UL 458 10 Protection Against Corrosion 10.1 Iron and steel parts shall be protected against corrosion by enameling, painting, galvanizing, plating, or an equivalent means. Exception No. 1: Bearings, laminations, other parts of iron or steel such as washers and screws, need not comply with this requirement.
  • Page 32 UL 458 OCTOBER 15, 2004 Table 11.1 Knockout or hole sizes and dimensions of bushings Table 6.2 relocated as Table 11.1 October 15, 2004 Bushing dimensions Trade size of conduit Knockout or hole diameter Overall diameter Height Inches Inches (mm)
  • Page 33 OCTOBER 15, 2004 UL 458 11.1.1.9 To determine whether wiring is prevented from being forced against live parts or sharp edges, a trial installation is to be made using only ordinary care. The system used for the test is to be representative of the various constructions and installation methods that may be employed.
  • Page 34 UL 458 OCTOBER 15, 2004 11.1.2.9 Upturned lugs, a cupped washer, or the equivalent shall be capable of retaining a conductor of the size specified in 11.1.2.2 under the head of the screw or washer. 11.1.2.10 The free length of a lead inside an outlet box or wiring compartment shall be 6 inches (152 mm) or more if the lead is intended for field connection to an external circuit.

  • Page 35: Cord Connection

    OCTOBER 15, 2004 UL 458 11.2 Cord connection 11.2.1 General 11.2.1.1 Other than a flush-wall mounted converter or a converter or inverter for which specific installation instructions are required, a converter or inverter requiring provision for connection to a source of supply...

  • Page 36: Bushings

    UL 458 OCTOBER 15, 2004 11.3 Bushings 11.3.1 A bushing or the equivalent shall be provided at a point where a flexible cord passes through an opening in a wall, barrier, or enclosing case. The bushing shall be substantial, reliably secured in place, and shall have a smooth, rounded surface against which the cord may bear.

  • Page 37: Low-Voltage Output Connections And Wiring

    DECEMBER 14, 1993 UL 458 12 Low-Voltage Output Connections and Wiring 12.1 General 12.1.1 A converter shall have one of the following provisions for output connections: a) A wiring compartment and terminals complying with the requirements in 12.1.2 – 12.1.5, b) A receptacle or attachment plug complying with the requirements in 12.1.6 –...

  • Page 38: Cigarette Lighter Inputs

    UL 458 OCTOBER 15, 2004 12.1.13 Unenclosed individual leads intended for connection external to the converter shall employ insulated copper conductors. A positive lead shall extend outside the converter not more than 18 inches (457 mm). The insulation may be 0.030-inch (0.76-mm) thick thermoplastic or the equivalent.
  • Page 39 OCTOBER 15, 2004 UL 458 2) 150/V max amperes for 30-60 volts dc, when measured in accordance with 36.1 and 36.2. UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 40 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 41: Live Parts

    DECEMBER 14, 1993 UL 458 13.6 The power supply of a circuit as mentioned in 13.5 that is not limited to available energy in accordance with 13.5(b), but the circuit includes either one or more resistors, a fuse, a non-adjustable manual-reset circuit protective device, or a regulating network –...

  • Page 42: Internal Wiring

    UL 458 DECEMBER 14, 1993 14.4 Friction between surfaces is not acceptable as a means to prevent shifting or turning of a live part, but a lock washer properly applied is acceptable. 15 Internal Wiring 15.1 General 15.1.1 The internal wiring of a converter or inverter shall be of a type and size acceptable for the application as specified in this section.

  • Page 43: Protection Of Wiring

    OCTOBER 15, 2004 UL 458 15.3 Protection of wiring 15.3.1 Internal wiring shall be protected if, when judged in accordance with 8.1.2, it is accessible. Exception: Internal wiring need not be protected if it is located and secured within the enclosure so that it is not likely to be subjected to stress or mechanical damage.

  • Page 44: Separation Of Circuits

    UL 458 OCTOBER 15, 2004 15.4.6 When determining whether splice insulation consisting of coated-fabric, thermoplastic, or other tubing is acceptable, consideration is to be given to such factors as dielectric properties, heat-resistant and moisture-resistant characteristics, and the like. Thermoplastic tape wrapped over a sharp edge is not acceptable.

  • Page 45: Barriers

    OCTOBER 15, 2004 UL 458 15.6 Barriers 15.6.1 A barrier used to separate or segregate internal wiring shall have adequate mechanical strength, and shall be reliably held in place. 15.6.2 A barrier of metal shall be at least as thick as specified in 6.3. A barrier of insulating material shall not be less than 0.028 inch (0.71 mm) thick and shall be supported so that it cannot be readily deformed...
  • Page 46 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 47: Insulating Materials

    DECEMBER 14, 1993 UL 458 16 Insulating Materials 16.1 An insulating washer, a bushing, or the like, and a base or a support for mounting a live part, shall be moisture-resistant material that will not be adversely affected by the temperatures and stresses to which it will be subjected under conditions of use.
  • Page 48 UL 458 OCTOBER 15, 2004 17.2.3 A flanged bobbin-wound transformer shall be constructed so as to maintain physical separation between the primary and secondary windings. Physical separation may be accomplished by employing a 3-flange bobbin for winding the primary and secondary windings adjacent to each other. As an alternative,...
  • Page 49 DECEMBER 14, 1993 UL 458 Table 17.1 Transformer insulation Insulation required Type of insulation Insulation between the primary wires of opposite polarity and between a, b, c or d secondary wires of opposite polarity having a potential greater than 30 volts rms (42.4 volts peak)

  • Page 50: Resistors

    UL 458 DECEMBER 14, 1993 Table 17.2 Spacings within a transformer Potential involved, volts Minimum spacing through air and over surface, inch (mm) between any uninsulated live part and an uninsulated live part of opposite polarity, or the core 0 – 50 3/64 (1.2)

  • Page 51: Overcurrent-Overtemperature Protection

    OCTOBER 15, 2004 UL 458 20.2 Overcurrent-overtemperature protection 20.2.1 Integral overtemperature or overcurrent protection for all secondary circuits shall be provided. See 6.6 – 6.7. 20.2.2 An automatically reset protective device installed in a secondary circuit shall comply with the requirements for such devices and shall have a current and voltage rating acceptable for its intended use.

  • Page 52: Receptacles

    UL 458 OCTOBER 15, 2004 21.5 A fuse connected in an output circuit of a power inverter shall comply with the requirements for line-voltage fuses and fuseholders. 21.5 effective April 13, 1993 21.6 An uninsulated live part of a fuseholder that can result in a risk of electric shock, other than the screw shell or clips, shall not be exposed to contact by a person removing or replacing the fuse.

  • Page 53: Lampholders

    OCTOBER 15, 2004 UL 458 24 Lampholders 24.1 The screw shell of an Edison-base lampholder in a converter shall be connected to a conductor that is intended to be connected to the grounded conductor of the power-supply circuit. 24.1 effective April 13, 1993 24.2 A lampholder shall be designed or installed so that uninsulated live parts, other than a screw shell,...
  • Page 54 UL 458 JULY 8, 1996 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 55: Spacings

    DECEMBER 14, 1993 UL 458 27.2 A resistor, capacitor, inductor, or other part that is mounted on a printed-circuit board to form a printed-circuit assembly shall be secured so that it cannot be displaced to result in a risk of electric shock or fire by a force likely to be exerted on it during assembly, normal operation, or servicing of the converter...
  • Page 56 UL 458 DECEMBER 14, 1993 28.1.2 With reference to Exception No. 1 to 28.1.1 and with reference to UL 840, reduced through-air spacings are based on the use of insulating materials that resist arc tracking and the degree of conductive pollution present in the environment of use.
  • Page 57 DECEMBER 14, 1993 UL 458 Table 28.1 Spacings for converters or inverters intended for use in a general environment Table 28.1 revised September 11, 1998 Involved in V Minimum spacings, inch (mm) RMS (peak) Between any uninsulated live part and an uninsulated live part of...
  • Page 58 UL 458 DECEMBER 14, 1993 Table 28.2 Spacings for converters or inverters intended for use within a protected environment Table 28.2 effective April 13, 1993 Involved in V Minimum spacings, inch (mm) RMS (Peak) Between any uninsulated live part and an uninsulated live part of...
  • Page 59 DECEMBER 14, 1993 UL 458 28.1.8 If an uninsulated live part is not rigidly secured in position by means other than friction between surfaces, or if a movable dead metal part is in proximity to an uninsulated live part, the construction shall be such that, for any position resulting from turning or other movement of the parts in question, at least the minimum acceptable spacings will be maintained.

  • Page 60: Insulation Barriers

    UL 458 DECEMBER 14, 1993 28.1.14 Spacings between uninsulated live parts of different potential and between such parts and dead metal that are grounded in service are not specified for parts of isolated limited-energy circuits in accordance with 2.12. Spacings in circuits that exceed 30 volts (42.4 peak) are to be investigated by the applicable dielectric voltage-withstand test specified in Section 39, Dielectric Voltage-Withstand Test.

  • Page 61: Grounding

    OCTOBER 15, 2004 UL 458 29 Grounding 29.1 A converter or inverter having a metal enclosure shall have a terminal or lead for connecting the metal enclosure and enclosure parts to ground. Exception: This requirement does not apply to a portable inverter: a) Intended to be connected to the cigarette lighter outlet of a vehicle, and b) Having no direct electrical connection between the input and output circuits.
  • Page 62 UL 458 OCTOBER 15, 2004 29.10 A terminal shall be provided on the outside of a converter or inverter solely for connection of the enclosure to the chassis of a land vehicle. The terminal shall be of a size that will secure an 8 AWG copper bonding conductor, and shall be marked in accordance with Section 56, Details (plainly identified...

  • Page 63: Bonding Of Internal Parts

    OCTOBER 15, 2004 UL 458 30 Bonding of Internal Parts 30.1 General 30.1.1 An exposed dead metal part that is likely to become energized by an electrical fault shall be reliably bonded to the point of connection of the field-equipment-grounding means.
  • Page 64 UL 458 SEPTEMBER 11, 1998 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 65: Bonding Conductor

    DECEMBER 14, 1993 UL 458 30.2 Bonding conductor 30.2.1 Bonding shall be accomplished by metal-to-metal contact between parts or by a separate bonding conductor as specified in 30.2.2 – 30.2.4. 30.2.2 A bonding conductor shall be copper, a copper alloy, or other acceptable material.
  • Page 66 UL 458 DECEMBER 14, 1993 32.2 All exposed conductive surfaces are to be tested for leakage currents. The leakage currents from these surfaces are to be measured to the grounded supply conductor individually as well as collectively if simultaneously accessible, and from one surface to another if simultaneously accessible. Parts are considered to be exposed surfaces unless protected against electric shock as defined in 8.1.2.
  • Page 67 OCTOBER 15, 2004 UL 458 This is generated text for figtxt. Figure 32.1 Leakage-current measurement circuit UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 68 UL 458 OCTOBER 15, 2004 32.5 A sample of the converter or inverter is to be tested for leakage current starting with the as-received condition – the as-received condition is to be without prior energization except as may occur as part of the production-line testing –...

  • Page 69: Power Input Test

    JANUARY 27, 1995 UL 458 32.6 Normally, the complete leakage current test program as described in 32.5 is to be conducted without interruption for other tests. With the concurrence of those concerned, the leakage current tests may be interrupted to conduct other nondestructive tests.

  • Page 70: Output Voltage And Current Test

    UL 458 DECEMBER 14, 1993 36 Output Voltage and Current Test Section 36 effective April 13, 1993 36.1 With respect to 13.5, the measurement is to be made with all loading circuits disconnected from the transformer or power supply being tested. Measurements may be made at the output terminals of the transformer or power supply.
  • Page 71 JANUARY 27, 1995 UL 458 Table 37.1 Maximum acceptable temperatures Table 37.1 revised January 27, 1995 Material and component parts Degrees Any point on or within a terminal box or compartment of a converter in which field- installed conductors are to be connected including such conductors themselves...
  • Page 72 UL 458 JANUARY 27, 1995 Table 37.1 Continued Material and component parts Degrees Class 220 (R) insulation systems on coil windings of a transformer Thermocouple method Resistance method Class 105 (A) motor coil insulation systems In an open motor Thermocouple method...
  • Page 73 DECEMBER 14, 1993 UL 458 37.1.2 A protective device shall not operate during the normal temperature test. 37.1.3 With reference to 37.1.1, the load shall be subdivided between the output circuits so that at least one circuit of each rating is loaded to 80 percent of its rating and the remainder of the load is distributed equally among the other circuits.
  • Page 74 The thermocouple wire is to conform with the requirements for special thermocouples as listed in the table of limits of error of thermocouples in Temperature Measurement Thermocouples, ANSI MC96.1-1982. 37.1.9 revised October 15, 2004 37.1.10 A thermocouple junction and the adjacent thermocouple lead wires are to be held securely in...

  • Page 75: Maximum Output Without Fan Operation

    JANUARY 27, 1995 UL 458 37.1.11 A temperature is considered to be constant when three successive readings taken at intervals of 10 percent of the previously elapsed duration of the test, but not less than 15 minutes, indicate no further increase.

  • Page 76: Maximum Overload Without Trip

    UL 458 DECEMBER 14, 1993 37.3.2 A converter or inverter is to be mounted in an enclosure consisting of four vertical side walls at right angles to each other, and a horizontal top and base of 1/2-inch-thick plywood or soft pine with a nominal thickness of 3/4 inch.

  • Page 77: Dielectric Voltage-Withstand Test

    OCTOBER 15, 2004 UL 458 Table 38.1 Maximum acceptable surface temperatures Table 38.1 effective April 13, 1993 Location Composition of surface Metal Nonmetallic °C °F °C °F A handle or knob and other surfaces subject to contact in operation and user maintenance A surface subject to casual contact Surfaces upon which a fixed or stationary...

  • Page 78: Induced Potential Test

    UL 458 OCTOBER 15, 2004 40 Induced Potential Test Section 40 effective April 13, 1993 40.1 If a 2-flange bobbin isolated power transformer is to be tested in accordance with (d) of the Exception to 17.2.3, the test specified in 40.2 – 40.4 shall be conducted without breakdown of insulation.

  • Page 79: Overload Test

    OCTOBER 15, 2004 UL 458 42.3 A wiring lead intended for field connection (see 11.1.2.11 and 62.4) shall withstand without damage or displacement a direct pull of: a) 20 pounds (89 N) for 1 minute applied to a lead extending from the enclosure (such as through a knockout);...
  • Page 80 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 81: Overcurrent Protection Calibration Test

    DECEMBER 14, 1993 UL 458 43.2 In a test to determine whether a switch or other control device complies with the requirements in 43.1, the converter or inverter is to be connected to a supply circuit of rated frequency and maximum test voltage –...

  • Page 82: Battery Charger Overcharge Test

    UL 458 OCTOBER 15, 2004 46 Battery Charger Overcharge Test 46.1 When connected to a supply circuit adjusted to 106 percent of the test voltage specified in 31.1, a battery supply of a converter or inverter is to be subjected to 7 hours of overcharging using a fully charged battery.
  • Page 83 OCTOBER 15, 2004 UL 458 47.1.3.2 During these tests the converter or inverter is to be placed on a softwood surface covered with a white tissue paper and a single layer of cheesecloth is to be draped loosely over the entire enclosure.

  • Page 84: Output Short-Circuit

    UL 458 OCTOBER 15, 2004 47.1.5 Each test is to be conducted on a separate sample unless the manufacturer requests that more than one test be conducted on the same sample. Exception: For the overload tests, one sample may be used provided it is subjected to the tests in the following order: 200 percent of rated current, followed by short-circuit current.

  • Page 85: Switch Position

    OCTOBER 15, 2004 UL 458 47.3 Switch position 47.3.1 A converter or inverter provided with a manual battery-to-converter transfer switch and a battery-charging circuit is to be operated as described in the input test except with the transfer switch in the battery position.
  • Page 86 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 87: Surge Protectors

    DECEMBER 14, 1993 UL 458 47.7 Surge protectors 47.7.1 A converter or inverter provided with a surge-protection device in the secondary circuit is to be subjected to the surge test described in 47.7.2. 47.7.1 effective April 13, 1993 47.7.2 A 1-microfarad capacitor is to be charged to 500 volts. The capacitor is to be discharged directly into the secondary output network with the transformer secondary leads disconnected.

  • Page 88: Blanketing Test

    UL 458 DECEMBER 14, 1993 47.9 Blanketing test 47.9.1 A converter or inverter that incorporates standoffs is to be subjected to a blanketing test. A double layer of blanket – see 47.9.3 – is to be loosely draped over the top and drawn in as close as possible against all sides of the converter or inverter.
  • Page 89 DECEMBER 14, 1993 UL 458 47.10.4 The abnormal tests may be conducted with a protective device built into the transformer or with an external protective device connected in either the primary or secondary circuit, or both. A protective device that is relied upon to open the circuit as a result of an abnormal test is to be one that has been investigated and found to be acceptable for the purpose.

  • Page 90: Blocked Fan

    UL 458 DECEMBER 14, 1993 47.10.11 For a transformer that is provided with a protective device built into the transformer or that is being tested in conjunction with an external protective device, a test described in 47.10.1 (a) – (c) is to be discontinued if the protective device opens the circuit and the next test in the sequence is to be started.

  • Page 91: Shorted Trace Test

    DECEMBER 14, 1993 UL 458 48.2.2 Power-dissipating parts, electronic devices, and capacitors connected between traces having reduced spacings are to be removed or disconnected in a manner that the spacings and insulations, rather than the component parts, are subjected to the full dielectric voltage-withstand test potential.
  • Page 92 UL 458 OCTOBER 15, 2004 49.3 Transformer burnout 49.3.1 A resistive load that will cause the input to draw three times the current obtained during normal operation – see 33.1 – is to be connected directly to the transformer secondary winding with the converter or inverter connected to 100 percent of the maximum test voltage specified in Table 31.1.
  • Page 93 OCTOBER 15, 2004 UL 458 50 Gasket Tests Section 50 effective April 13, 1993 50.1 The requirements in this section apply to a gasket that is required for protection against dust and other contaminants entering an enclosure described in Section 7, Enclosures Used for Protected Environments.
  • Page 94 UL 458 OCTOBER 15, 2004 Table 50.2 Gasket conditioning Table 50.2 revised July 8, 1996 Maximum gasket temperature Conditioning °C (°F) Rubber or neoprene Thermoplastic Air oven aging for 70 hours at 100 ±2°C Air oven aging for 168 hours at 87 ±2°C (140) (212 ±3.6°F)
  • Page 95 OCTOBER 15, 2004 UL 458 52 Label Adhesion Test 52.1 Unless known to be acceptable for the application, a pressure-sensitive label that is required to be permanent shall be tested as described in 52.2. 52.2 After being subjected to the conditions described in 52.3 – 52.6 a pressure-sensitive label or a label...
  • Page 96 UL 458 OCTOBER 15, 2004 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 97 JANUARY 27, 1995 UL 458 Table 52.1 Temperatures, oven-aging Maximum temperature during normal temperature test of Oven temperature surface to which applied °C °F °C °F 140 or less 176 or less 212 or less 257 or less 302 or less...
  • Page 98 UL 458 DECEMBER 14, 1993 Table 53.1 Production-line test conditions Converter rating Condition A Condition B Potential, volts Time, seconds Potential, volts Time, seconds 230 volts or less 1000 1200 53.3 The converter may be in a heated or unheated condition for the test.

  • Page 99: Grounding Continuity Test

    DECEMBER 14, 1993 UL 458 53.9 Test equipment, other than that described in 53.6 – 53.8 may be used if found acceptable to accomplish the intended factory control. 53.10 During the test, the primary switch is to be in the on position, both sides of the primary circuit of the converter are to be connected together and to one terminal of the test equipment, and the second test-equipment terminal is to be connected to the accessible dead metal.

  • Page 100: Marking

    UL 458 DECEMBER 14, 1993 MARKING 56 Details 56.1 Unless otherwise stated, all markings are required to be permanent, that is, either by being molded, die-stamped, paint-stenciled; stamped or etched metal that is permanently secured; or indelibly stamped on a pressure-sensitive label secured by adhesive that, upon investigation is found to comply with the applicable requirements for indoor use labels in the Standard for Marking and Labeling Systems, UL 969.
  • Page 101 OCTOBER 15, 2004 UL 458 57.2 Deleted October 15, 2004 57.3 Polarity identification shall be provided for output connections. The polarity is to be identified by: a) The words ″battery positive,″ ″converter positive,″ and ″negative;″ b) The words ″battery″ and ″converter″ followed by the signs ″+″ for positive and ″−″ for negative;...
  • Page 102 UL 458 OCTOBER 15, 2004 57.13 A cautionary marking shall be prefixed by the word ″CAUTION,″ ″WARNING,″ or ″DANGER″ in letters not less than 1/8 inch (3.2 mm) high. The remaining letters shall not be less than 1/16 inch (1.6 mm) high.
  • Page 103 OCTOBER 15, 2004 UL 458 No Text on This Page UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 104 UL 458 DECEMBER 14, 1993 57.15 In addition to the marking required in 57.14, a marking shall be provided adjacent to the fuseholder or fuseholders and shall consist of the word ″CAUTION″ and the following or the equivalent: ″For continued protection against risk of fire, or electric shock replace only with same type and ratings of fuse″.

  • Page 105: Instruction Manual

    OCTOBER 15, 2004 UL 458 58 Instruction Manual 58.1 The installation and operating instructions manual for inverter equipment provided with a marking in lieu of integral ground-fault circuit-interrupter protection shall indicate that ground-fault circuit-interrupters shall be installed in the recreational vehicle wiring system to protect all branch circuits. In addition, if a marking as specified in (b) of the Exception to 23.1 is used, the installation and operation instructions...

  • Page 106: Power-Supply Assembly

    UL 458 JULY 8, 1996 60.7 A component housing line-voltage circuit breakers shall be sufficiently deep to allow a door or cover to be closed with the handle of a circuit in any operating position. 60.8 The thickness of sheet-metal enclosures for compartments other than line-voltage circuit-breaker and field-wiring connection compartments shall comply with the requirements in 6.3.
  • Page 107 OCTOBER 15, 2004 UL 458 62.3 A pigtail lead employed for a remote line-voltage circuit shall be provided with a wire connector, on the end of the lead and taped, or the lead may be cut, folded over and taped. See 62.4.

  • Page 108: Overcurrent Protection

    UL 458 OCTOBER 15, 2004 63 Overcurrent Protection 63.1 A power-converter system shall be provided with overcurrent protection as specified in Table 61.1. The circuit breakers shall be rated 125 volts minimum. See 6.8 and 6.9. 63.1 revised October 15, 2004 63.2 With reference to 63.1, a power-converter system incorporating only one 15- or 20-ampere line...

  • Page 109: Transfer Switches

    OCTOBER 15, 2004 UL 458 64 Transfer Switches 64.1 A transfer switch or relay provided to change from inverter to line power shall disconnect both the grounded and ungrounded circuit conductors. 64.1 revised January 27, 1995 64.2 With reference to the requirement in 64.1 the rating of a transfer mechanism and associated wiring shall be acceptable for the higher of the inverter or line-supply ratings.

  • Page 110: Performance

    UL 458 OCTOBER 15, 2004 PERFORMANCE 66 Temperature Test 66.1 The temperature test shall be conducted as indicated in Section 37, Temperature Test, except as indicated in 66.2 and 66.3. 66.2 Direct-current secondary-output circuits are to be loaded as specified in Section 33, Power Input Test.

  • Page 111: Supplement Sa - Marine Power Converters/Inverters And Power Converter

    DECEMBER 14, 1993 UL 458 SUPPLEMENT SA - MARINE POWER CONVERTERS/INVERTERS AND POWER CONVERTER/ INVERTER SYSTEMS INTRODUCTION SA1 Scope Section SA1 effective April 13, 1993 SA1.1 These requirements cover marine power converters or inverters intended for permanent installation aboard vessels as covered by the Standard for Motor Craft (Pleasure and Commercial), NFPA 302-1972, the applicable publications of the American Boat and Yacht Council Inc., and Electrical...

  • Page 112: Sa4 Frame And Enclosure

    UL 458 JANUARY 27, 1995 SA3.3 With reference to SA3.2, a meter may be located in an area remote from the marine converter provided: a) The meter shunt is located within the marine converter enclosure. b) Overcurrent protection for external meter leads is provided within the marine converter or inverter enclosure.

  • Page 113: Sa5 Protection Against Corrosion

    JULY 8, 1996 UL 458 SA5 Protection Against Corrosion Section SA5 effective April 13, 1993 SA5.1 Iron and steel parts shall be protected against corrosion by enameling, painting, galvanizing, plating, or an equivalent means. Exception No. 1: Bearings, laminations, other parts of iron or steel such as washers and screws need not comply with this requirement.

  • Page 114: Sa6 Supply Connections

    UL 458 OCTOBER 15, 2004 d) A cadmium coating not less than 0.0010 inch (0.025 mm) thick on both surfaces. The thickness of coating shall be established in accordance with the Metallic-Coating-Thickness, Section SA22. e) A cadmium coating not less than 0.00075 inch (0.0191 mm) thick on both surfaces with one coat of outdoor paint on both surfaces;...

  • Page 115: Sa7 Internal Wiring And Grounding

    OCTOBER 15, 2004 UL 458 SA7 Internal Wiring And Grounding SA7.1 Internal wiring shall have stranded conductors. SA7.1 revised October 15, 2004 SA7.2 A permanent marine converter or inverter shall have a terminal or lead for connecting the metal enclosure and enclosure parts to ground.

  • Page 116: Sa10 Receptacles

    UL 458 OCTOBER 15, 2004 SA10 Receptacles Section SA10 effective April 13, 1993 SA10.1 An attachment plug receptacle shall not be employed in a marine converter or inverter intended for use in an area in which ignition-protected equipment is required.
  • Page 117 OCTOBER 15, 2004 UL 458 converter or inverter, except that consideration is to be given to the normal mounting position. If the marine converter or inverter employs a fan or other moving part, the operation of which is likely to facilitate the entrance of water, it is to be energized and operated as intended.
  • Page 118 1.52 6.35 3/32 2.38 Nylon Rain-Test Spray Heads are available from Underwriters Laboratories Inc. ANSI B94.11M Drill size. Optional – To serve as wrench grip. UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...
  • Page 119 OCTOBER 15, 2004 UL 458 Figure SA13A.2 Water spray head piping Figure SA14.2 revised and relocated as Figure SA13A.2 January 27, 1995 Item inch 1400 2-1/4 UL COPYRIGHTED MATERIAL – NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL...

  • Page 120: Sa13B Drip Test

    SA10 UL 458 OCTOBER 15, 2004 SA13A.3 The water to be used for the test is to have its resistivity adjusted, before the test is started, to 3500 ohm-centimeters ±5 percent when measured at 25°C (77°F). At the conclusion of the test, the resistivity of the water is not to be less than 3200 ohm-centimeters or more than 3800 ohm-centimeters at 25°C (77°F).

  • Page 121: Sa15 Salt Spray Corrosion Test

    OCTOBER 15, 2004 UL 458 SA11 Figure SA14.1 Rain test spray head Figure SA14.1 revised and relocated as Figure SA13A.1 January 27, 1995 Figure SA14.2 Rain-test spray head piping Figure SA14.2 revised and relocated as Figure SA13A.2 January 27, 1995...

  • Page 122: Sa17 Electrolyte Conditioning

    SA12 UL 458 OCTOBER 15, 2004 SA16.2 The test mentioned in SA16.1 is then to be repeated, with the input voltage adjusted to 127 volts (rms). A marine converter/inverter which incorporates a semiautomatic battery charging circuit is to be manually adjusted for this test.
  • Page 123 OCTOBER 15, 2004 UL 458 SA13 Exception: The test need not be conducted for a marine converter or inverter that is marked for use on a vessel more than 65 feet (19.8 m) long and marked in accordance with SA25.7.

  • Page 124: Sa20 Shock

    SA14 UL 458 OCTOBER 15, 2004 SA20 Shock Section SA20 effective April 13, 1993 SA20.1 A marine converter or inverter that has been subjected to the vibration test in Section SA19, Vibration, shall withstand 5000 impacts of 10 g peak with a duration of 20 – 25 milliseconds – measured at the zero reference line of the half-sine wave shock pulse –...

  • Page 125: Sa22 Metallic Coating Thickness

    OCTOBER 15, 2004 UL 458 SA15 d) A mixture of propane and air held as close to the maximum explosive proportions as possible is to be fed into the explosion chamber at a rate of approximately 1 cubic foot per minute (0.0005 m...
  • Page 126 SA16 UL 458 OCTOBER 15, 2004 SA22.5 Each sample is to be thoroughly cleaned before testing. All grease, lacquer, paint, and other nonmetallic coatings are to be removed completely by means of solvents. Samples are then to be thoroughly rinsed in water and dried with clean cheesecloth. Care should be exercised to avoid contact of the cleaned surface with the hands or any foreign material.

  • Page 127: Sa23 Accelerated Aging Of Gaskets, Sealing Compounds And Adhesives

    OCTOBER 15, 2004 UL 458 SA17 Table SA22.1 Continued Temperature Thickness factors, 0.00001 inch (0.0003 mm) per second °F °C Cadmium platings Zinc platings (30.6) 1.513 1.130 (31.1) 1.524 1.141 (31.7) 1.534 1.150 (32.2) 1.546 1.160 SA23 Accelerated Aging of Gaskets, Sealing Compounds and Adhesives Section SA23 effective April 13, 1993 SA23.1 SA23.1 and SA23.2 apply to gaskets and sealing compounds employed in marine converters or...
  • Page 128 SA18 UL 458 OCTOBER 15, 2004 Table SA23.2 Accelerated aging conditions Table SA23.2 revised July 8, 1996 Measured temperature rise Material Conditioning °C °F Air oven aging for 70 hours at 100 ±2°C (212 Rubber or neoprene ±3.6°F) Air oven aging for 168 hours of 87 ±2°C (189 Thermoplastic ±3.6°F)

  • Page 129: Sa24 Label Adhesion

    OCTOBER 15, 2004 UL 458 SA19 SA23.7 For a gasket secured by an adhesive and exposed to a temperature rise not exceeding 35°C (63°F), a sample of the gasket secured to the mounting surface by the adhesive shall be exposed for 72 hours to each of the following conditions: a) A temperature of 100.0 ±1.0°C (212.0 ±1.8°F),...

  • Page 130: Instructions

    SA20 UL 458 OCTOBER 15, 2004 SA25.4 A marine converter or inverter which incorporates a semiautomatic battery charging circuit shall be marked with the word ″CAUTION″ and the following or the equivalent: ″To reduce the risk of fire or explosion of the battery as a result of overcharging, compensate input voltage. See instructions.″...

  • Page 131: Sa27 Important Safety Instructions

    OCTOBER 15, 2004 UL 458 SA21 SA26.7 The text of the instructions required by SA27.4 and SA27.5 shall be verbatim, or in equally definitive terminology. Exception: If a specific conflict in the application to a marine converter or inverter exists, or if the wording would not be applicable, variations from the specified wording may be used.
  • Page 132 SA22 UL 458 OCTOBER 15, 2004 5) Do not disassemble marine converter or inverter; take it to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire. 6) To reduce risk of electric shock, unplug marine converter or inverter from outlet before attempting any maintenance or cleaning.
  • Page 133 OCTOBER 15, 2004 UL 458 SA23 ix) If necessary to remove battery from vessel, always remove grounded terminal from battery first. Make sure all accessories in the vessels are off, so as not to cause an arc. x) Be sure area around battery is well ventilated.
  • Page 134 SA24 UL 458 OCTOBER 15, 2004 DANGER – Never alter AC cord or plug provided – if it will not fit outlet, have proper outlet installed by a qualified electrician. Improper connection can result in a risk of an electric shock.

  • Page 135: Sa28 Assembly Instructions

    OCTOBER 15, 2004 UL 458 SA25 Figure SA27.1 Grounding method SA28 Assembly Instructions Section SA28 effective April 13, 1993 SA28.1 The assembly instructions, if applicable, shall contain all information needed for proper assembly of parts and shall be preceded by the heading ″ASSEMBLY INSTRUCTIONS,″ or the equivalent.

  • Page 136: Sa30 Maintenance Instructions

    SA26 UL 458 OCTOBER 15, 2004 SA30 Maintenance Instructions Section SA30 effective April 13, 1993 SA30.1 The instructions for user maintenance shall include explicit instructions for all cleaning and minor servicing – lubrication, external adjustments, and the like – that should be performed by the user; and shall warn the user that all other servicing should be performed by qualified service personnel.
  • Page 137 OCTOBER 15, 2004 UL 458 APPENDIX A Standards for Components Standards under which components of the products covered by this standard are evaluated include the following: Title of Standard − UL Standard Designation Analog Instruments – Panelboard Types, Electrical – UL 1437 Appliance Wiring Material –...
  • Page 138 UL 458 OCTOBER 15, 2004 Polymeric Materials – Short Term Property Evaluations – UL 746A Polymeric Materials – Use in Electrical Equipment Evaluations – UL 746C Positioning Devices – UL 1565 Printed-Wiring Boards – UL 796 Switches, Special-Use – UL 1054 Tape, Polyvinyl Chloride Polyethylene and Rubber Insulating –...

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