IS 616 ( ELECTRONICS- DOMESTIC ELECTRONIC APPLIANCES & ACCESSORIES )

Industry Outlook

Indian Standard IS 616 provides information with respect to audio, video, and similar electronic apparatus. This standard is identical to IEC 60065: 2005 'Audio, video and similar electronic apparatus - Safety requirements' is published by International Electrotechnical Commission (IEC), which was adopted by Bureau of Indian Standards on the recommendation of of draft by Audio, Video, and Multimedia Systems and Equipment Sectional Committee, which had been approved by the Electronics and Information Technology Division Council. 

IS 616 was first issued in 1957, however, has been subsequently amended or revised in 1981, 1986 and 2003.

The electronic apparatus falls under this standard and is being widely used in places of public assembly such as schools, theaters, places of worship and the workplace professional apparatus. Due to the increased use of electronic apparatus in distinct fields, from school to workplace, it can be concluded that for the safety of the final consumer, it is essential to ensure conformance with compliance requirements. 

Even the statistical data indicates that it was over USD 1 trillion in 2020 and is estimated to grow at a CAGR of more than 8% from 2021 to 2027. From the given data, it is clear that the usage of electronic apparatus is constantly increasing.

Moreover, even India is one of the largest in the world with more than 1.5 million schools, 42 thousand colleges across India in 2020, and 1,989,777 companies. These numbers reflect the proximity of usage of audio and visual aids at the distinct place for distinct purposes. 

However, with the high usage of electronic apparatus, it is also essential to ensure that it must comply with the IS 616 standard to ensure the safety of consumers.

A tested and certified product, does not only achieve global market access seamlessly, but also ensures competitive advantage, so, more customer acceptance and wider market access. 

For a better understanding of why product testing is important and how it is beneficial for both, manufacturers and consumers, let’s move on to the next section.

Why is Product Testing Crucial | Importance of Product Testing

• One of the most important purposes of testing is quality assurance of a product that reflects high quality, safety, and reliability.
• Product testing allows the manufacturer to ensure the conformance with established technical standards to produce high quality and safe products.
• Build reputation and maximize the profit, considering that a tested product indicates quality assurance. 
• Helps in retaining customers, thus, providing a competitive edge.
• Helps in understanding distinct types of stress a product can endure, be it in case of weather, wear tear, and other conditions.
• In the initial prototyping stage, if you are trying to avail investment in order to manufacture your product in mass quantities, a tested product can allow you to achieve patent and investors as it shows the quality and functionality of the product.

With the benefits of product testing, we can clearly estimate how testing ensures quality assurance and product credibility. 

Since, it has been established how essential product testing is, now let’s move to the benefits of complying with standards.

What Are the Benefits of Complying With Standards?

Complying with standards offers numerous benefits to manufacturers and importers of the product, that further helps in building trustworthiness and reliability, thus retaining the customers.

Why, don’t we look at other benefits of the same -

• A certified product acts as a shield against penalties and fines which could be imposed for not certifying a product.
• A certified product serves as an evidence that a product has been tested and certified as per prescribed standards.
• A certified product provides a sense of security and safety to the consumers, thus ensuring easy acceptance.
• It provides a competitive advantage over competitors.
• Easy market acceptance as a product is tested and certified.
• Confirm the unmatched quality standards.
• Seamless to file government tenders.

With these benefits of ensuring conformance with IS 616 standards and specifications, a manufacturer can establish that a product is safe, reliable, and credible, thus, confirming to unmatched quality standards. 

Now, in the next section, we will learn about test requirements and product scope of the IS 616.

Scope of IS 616

IS 616 is applicable to electronic apparatus which are designed to use electricity from the supply apparatus using batteries or remote power feeding with the purpose for reception, generation, recording, or reproduction of audio, video, and associated signals, respectively. 

Moreover, it is also applicable to apparatus which are designed to be used exclusively in a combination of with the above mentioned apparatus. 

Below mentioned are some of the example of the apparatus falls under the scope of IS 616 -

• Receiving and amplifiers for sound and/ or vision.
• Independent load transductors and surface transductors.
• Supply apparatus which are intended to supply for other apparatus falls under the purview of this standard.
• Electronic musical instruments and accessories such as rhythm generators, tone generators, music tuner, and other instruments used for electronic or non-electronic music instruments.
• Audio and/ or video educational apparatus.
• Video projectors.
• Video camera and video educational apparatus.
• Video games and flipper games.
• Jukeboxes.
• Electronic gaming and scoring machines.

Tests To Be Performed and Parameters Tested

1. Marking And Instructions

Marking on the product must be permanent, comprehensive and seamlessly discernible on the apparatus when ready to use and the information must be provided on the exterior of the apparatus, excluding the bottom. 

Although, it can be provided to the area which is accessible by the hand, for instance could be under a lid, or on the exterior of the bottom of a portable apparatus or an apparatus with a mass not above 7 kg, provided that the location of the marking is given in the instructions for use.

Moreover, the compliance will be checked through inspection and rubbing the marking by hand for 15 seconds using a piece of cloth soaked with petroleum spirit. While in case of a second sample or distinct place, the mark will be rubbed again, using a soaked cloth with petroleum spirit for 15 seconds. 

2. Antenna Coaxial Sockets Mounted on Apparatus

The antenna coaxial sockets mounted on apparatus, including incorporating parts or components which isolate the hazardous live parts from accessible parts must be constructed in a way so that it can withstand the mechanical stress. 

This will be checked through conducting below mentioned test - 

1. Endurance test

A test plug will be inserted and withdrawn from the sockets 100 times, however, while doing this, a proper care must be taken to avoid damaging the socket intentionally during insertion and withdrawal of the plug.

2. Impact test

A test plug must be inserted into the socket and three excessive blows from the spring operated hammer which will be applied with the kinetic energy right before the impact of 0.5J at the same point in the plug in the most unfavorable direction.

3. Torque test

A test plug will be inserted into the socket with application of force of 50N for 10 seconds without any jerks at the right angles to the axis of the plugs and the radical direction of force being such that the stress will be applicable to the parts of socket which are weak.

3. Clearance And Creepage Distances

Clearance would be dimensioned in a way that overvoltage transients which might enter the apparatus and peak voltages, which might be generated within the apparatus must not break the clearance. 

While creepage distance must be dimensioned in a way that the given voltage operating voltage and degree of pollution, including no flashover or break of insulation occur. 

4. Components 

Below mentioned are the components included in the electric apparatus -

1. Isolating transformers 

These are the transformers with protective separation between input and output windings.

2. Separating transformers

A separating transformer are the ones which have inputs winding which are separated from the output winnings through basic insulation.

3. Thermal release 

It is a device that prevents the maintenance of excessive high temperatures in particular parts of apparatus through disconnecting these parts from supply. 

4. Thermal cut out

It is being referred to the thermal release being reset without having any provision of temperature setting for the user.

5. Thermal link

It refers to the thermal release without reset, which operates only once, then requires partial or complete replacement.

6.  Trip free

Typically, it is an automatic action with a reset actuating member, designed in a way that automatic action is independent of manipulation or position of reset mechanism. 

7. Micro disconnection

An appropriate contact separation which ensures functional security. 

8. PTC thermistor 

PTC thermistor is a thermally sensitive semiconductor device that reflects the step-like increase in the resistance, which occurs when increasing temperature reaches the particular value. Moreover, the change of temperature can be done through -

• By flow of current through a thermosensitive element.
• Change in ambient temperature.
• A combination of both.

9. Safety interlock

Safety interlocks refers to preventing access to hazardous areas until hazard is removed or removing the hazardous conditions when access is gained, automatically. 

10. Manually operated mechanical switch

It is referred to a hand operated device which does not contain semiconductor and located anywhere in the apparatus to interrupt the intended function by moving contacts, such as sound and/ or vision.

11. Mains switch

It is a manually operated switch which interrupts either one pole or all poles, excluding mains.

12. Printed board

Printed board is the base material cut of size, possessing all holes and containing at least one conductive pattern.

13. Conductive pattern

It is a configuration formed by electrically conductive material of a printed board.

14. Special battery

Special battery is referred to as the rechargeable battery which is identified by the manufacturer’s name and catalog number, which is provided or recommended by the manufacturer. 

5. Electrical Shocks Hazard Under Normal Operating Conditions

1. Outside testing

The accessible parts must not be hazardous live and when not contacted with another apparatus the inaccessible contacts terminals must not be hazardous live, excluding the below mentioned conditions -

• If the contact of the signal output terminals have to be hazardous for functional reasons, the provided contacts must be separated from the supply source as needed.

2. Determination of hazardous live parts

To verify whether a part or contact of a terminal is hazardous live or not, below mentioned measurements will be carried out between any two parts or contacts then between any part or contact and either pole of the supply source used during the test -

• The open-circuit voltage exceeds 

1.  35 V (peak) a.c. or 60 V d.c., 
2. for audio signals of PROFESSIONAL APPARATUS, 120 V r.m.s., 
3. for audio signals of other than PROFESSIONAL APPARATUS, 71 V r.m.s.;

 If the voltage limits in a) are exceeded, provisions b) to d) apply. 

• The touch current, expressed as the corresponding voltages U1 and U2, and measured in accordance with IEC 60990, with the measuring network described in annex D of this standard, exceeds the following values: 

1. for a.c.: U1 = 35 V (peak) and U2 = 0,35 V (peak)
2. for d.c.: U1 = 1,0 V

• The charge increases 45 p.C for storage charges at the voltage between 60V DC and 15 kV DC.
• The energy of discharge increases 350mJ for stored charges at the voltage increase above 15kV DC.

c. Determination of accessible parts

To determine whether a part is accessible or not, the jointed test fingers as provided in the relevant specification will be pushed against the enclosure and inserted through any opening of the enclosure, including opening in the bottom, without appreciable force. 

Moreover, through opening the test finger will be applied to any depth a finger will allow and is rotated or angled before, during and after the insertion to any position. However, if the opening does not allow opening of the finger entry, the force in the finger in the straightened position will be increased to 20N +/- 2N and the test repeated with the finger in angled position. 

d. Shafts of operating knobs, handles, levers, and the like

The shafts of operating knobs, handles, levers, and the like must not be hazardous to live. 

6. Electrical Connections And Mechanical Fixings

The screw terminals providing electrical and screw fixings during the life of the apparatus should be tightened and loosened distinct times for the appropriate strength. Moreover, screws exerting contact pressure and screws with a nominal diameter below 3mm that forms the part of the screw fixings must screw into a metal nut or a metal insert. 

Although, screws possessing a nominal diameter below 3mm should not exert contact pressure and need not be screwed into metal, provided that the screw fixing withstands the torque for screws of 3 mm diameter as provided in the screws.

7. External Flexible Cords

The main supply of flexible cords should be of sheathed type for PVC cords or synthetic rubber cords. Non-detachable flexible cables and cords of CLASS I apparatus should be provided with a green/yellow core which is connected to the protective earthing terminal of the apparatus and, if a plug is provided, to the protective earthing contact of the plug.

8. Fault Conditions

• The short circuit across clearance and creepage distance, in case of use of values below specified in the standard for basic and supplementary insulation.
• The short circuit across parts of insulating material, could cause an infringement of requirements with respect to the protection against electric shock hazard or overheating.
• Short circuit or interruption of -

1. Heaters of electronic tube
2. Insulation between heaters and cathodes of electronic tube
3. Spacing in electronic tube
4. Semiconductor devices, one leat at a time interrupted or any two leads connected together as a pair

• short circuit or disconnection, whichever is much more favorable to resistors, capacitors, windings (for example transformers, degaussing coils), loudspeakers, optocouplers, varistors. or nonlinear passive components, the short-circuiting or disconnection of which might cause an infringement of the requirements regarding protection against electric shock or overheating.

9. Humidity Treatment

The safety of the apparatus should not be impaired by the conditions of the humidity. Moreover, the electrical components, covers, and other parts that can be removed by hand and are subjected to humidity treatment, if required. In that case, the humidity treatment which will be carried out in a humidity chamber with the relative air humidity of 93 to the power +3 and -2%. 

While the air temperature at the places where the apparatus is located should be maintained at 30 to the power 0 and -2%.

Moreover, in case of apparatus to be used in tropical climate would be subjected to temperature of 40% to the power +2 and -2 and relative humidity of 93% to the power +2 and -3. And prior to bringing the apparatus to the chamber, its temperature should be brought to provided temperature and 4k higher temperature.

Below mentioned is the duration for which the apparatus should be kept in chamber -

• 5 days (120 hours) in case of apparatus intended to be used in tropical climates.
• 2 days (48 hours) in case of other apparatus. 

10. Insulation Resistance And Dielectric Strength

The insulation of the insulating material must be appropriate, as follows -

 11. Marking And Instructions

The marking on the product should be permanent, comprehensible, and easily discernible when an apparatus is ready to be used. Moreover, the information provided on the apparatus should preferably be provided on the exterior of the apparatus, however, it can be provided on the area accessible by hand. 

And the compliance of the marking and instructions will be checked through rubbing the marking using a soaked cloth for 15 seconds, while in case if marking is done on a distinct place other than exterior of the apparatus, a cloth soaked with petroleum spirit will be used to rub the marking. 

12. Mechanical Strength

To check the mechanical strength of an apparatus, below mentioned test will be conducted -

1. Bump test

A bump test will be carried out only if the mass of the apparatus is above 7kg. Under this test, an apparatus will be placed on the horizontal wooden surface and will be allowed to fall for 500 times from the height of 5cm. 

Thereafter, the conformance with compliance will be established if the apparatus reflects no damage. 

2. Vibration test

A vibration test will be conducted on -

• Transportable apparatus used for audio amplification of musical instruments
• Portable apparatus
• An apparatus containing metal enclosures

Below mentioned are the direction of vibration is vertical and severity as follows -

• Duration should be 30 minutes.
• Amplitude should be 0.35mm.
• The frequency range should be 10Hz, 55Hz, and 10Hz.
• The sweep rate should be 1 octave per minute, approximately.

3. Impact test

The apparatus should be held firmly against a rigid support and is subjected to 3 blows from spring operated impact with the kinetic energy right before the impact 0.5J to every point of enclosure which protects hazardous parts and which is probably weaken, including ventilation areas, drawers in pulled out position, handle levers, and switch knobs.

13. Non-separable Thin Sheet Materials

Below mentioned are the test specifications for non-separable thin sheet materials -

• For testing, three test samples will be withdrawn which possess 3-4 layers of non-separable thin sheet materials, forming an reinforced insulation. At a time, one sample will be fixed on the mandrel of the test fixture. 
• The downward force of 150N +/- 10N would be applicable to the free end of the sample using the appropriate clamping device. 

14. Resistance to Fire

The apparatus should be designed in a way that it could prevent the start and spread of fire as far as possible and must not invite any danger of fire to the surrounding of an apparatus. That can be achieved as mentioned below -

• Use of a good engineering practice in design and production of apparatus with the purpose to avoid potential ignition sources.
• Using low flammability materials for the internal parts in the vicinity of possible ignition sources.
• Using fire enclosures to restrict the spread of fire.

15. Surge Test

The insulation of class - II apparatus between the accessible parts or connected parts to them and hazardous live parts which must withstand the surge due to transient causes.

16. Telescoping or Rod Antennas

It basically should have the diameter button of 6.0mm or the ball on the end and should be provided with guard or barrier which prevents any part of the antenna or any part of the mounting hardware from falling into the apparatus and contacting hazardous live parts in the situation when the antenna or any part of it breaks.

How We Help Ensuring Conformance With IS 616 Specifications?

• We will educate you concerning every aspect of IS 616.
• We will check whether a product falls under the purview of BIS or not, including whether a product complies with the BIS standards or not, then, after mutual understanding, the project will move forward. 
• There is no better place to obtain it than JR Compliance because IS 616 is applicable to electronic apparatus which are designed to use electricity from the supply apparatus using batteries or remote power feeding
• JR Compliance has experienced expert professionals, who can assist you in the documentation, evaluation, and examination.
• We are equipped with the necessary resources to conduct a virtual pre-audit to confirm whether your manufacturing unit and production process are complying with provided specifications or not. 
• JR Compliance will schedule a meeting with the BIS officer for a factory audit.
• If you lack an in-house testing facility, we will help you in setting up one.
• We will coordinate with a BIS accredited laboratory for product testing.
• You can expect reliable and punctual service delivery as we will also visit the BIS office on your behalf if required.
• We invest our sustained efforts to meet the startled queries or demands of BIS.
• In case of any concern, we assure to provide the finest solution.

Conclusion

IS 616, an Indian Standard applicable to electrical cables, which are usually used in the Mining industry and metro industries, is one of the major contributors to our economic development. Considering that, it is not only mandatory but necessary to ensure conformance with specifications mentioned in IS 616 with the purpose to introduce your product in the Indian market.

Keeping the importance of conformance with compliance in mind, we - JR Compliance, a leading compliance service provider are equipped with experts and resources to provide you with above and beyond support to obtain a BIS certificate.

Till now, we have experience in providing compliance assistance to over 10,000+ global leaders such as Toray, Bombay Dyeing, Softbank, and others.

For details, get in touch with our experts.