DIN EN IEC 62368-1 VDE 0868-1:2025-01

• Purpose: Safety standard for electrical/electronic devices based on Hazard-Based Safety Engineering (HBSE) to minimize hazards from energy sources (electrical, thermal, mechanical).

• Area of application: Audio/video equipment, IT and telecommunications equipment (e.g. routers, monitors, servers). Outdoor devices, devices with wireless energy transmission (e.g. inductive charging systems).

• Energy classes: Class 1: Perceptible but not harmful. Class 2: Painful, but no injury. Class 3: Risk of injury or fire hazard.

• User categories: Lay persons: Without specialist knowledge (e.g. end user). Instructed persons: Basic knowledge (e.g. technicians). Qualified persons: Specialized training (e.g. electricians).

• Tests: Insulation tests (up to 3,000 V AC), thermal stress tests (≤95°C), mechanical fuses (e.g. tool requirements for battery compartments).

• New features (version 2025-01): A new table with requirements for external circuits has been added. The requirements for openings in fire protection enclosures have been revised. The requirements for liquid-filled components have been revised. The requirements for battery charging devices have been updated. Clause 4.1.1, which previously allowed the use of components according to the older IEC 60950-1 and IEC 60065 standards, is no longer included in this version

Content, scope and tests:

Content

DIN EN IEC 62368-1 is a harmonized standard that specifies safety requirements for information and communication technology (ICT) equipment and audio/video equipment. It replaces the older standards IEC 60065 (audio/video) and IEC 60950-1 (IT equipment) and introduces a risk-based approach based on Hazard-Based Safety Engineering (HBSE). Hazard-Based Safety Engineering (HBSE)

The HBSE methodology comprises four steps:

(1) Identification of energy sources:

• Electrical energy (e.g. high voltage components).

• Thermal energy (e.g. heating elements).

• Mechanical energy (e.g. rotating parts).

• Chemical energy (e.g. batteries).

• Radiant energy (e.g. lasers).

(2) Classification of energy sources:

• Class 1: Energy is not sufficient to cause pain or injury (e.g. low voltage circuits <60 V DC).

• Class 2: Energy can cause pain but no permanent damage (e.g. touch voltages up to 120 V DC)

• Class 3: Energy is sufficient to cause injury or fire (e.g. mains voltage).

(3) Evaluation of the transmission paths:

• Direct contact, arcing, heat conduction or radiation.

(4) Implementation of protective measures (safeguards):

• Insulation: separation of dangerous voltages by insulation materials (e.g. transformers).

• Mechanical safeguards: Tool requirements for opening battery compartments to prevent access by non-professionals.

Specific requirements:

• Outdoor devices: Resistance to environmental influences such as humidity, temperature cycles (-33°C to +40°C) and UV radiation. Enclosures must be designed in accordance with Annex Y of the standard (e.g. IP protection classes).

• Wireless power transmission: Limit heating of metallic foreign objects to ≤70°C during charging. Tests simulate typical everyday scenarios (e.g. coins or keys on charging pad).

• Battery safety: Battery compartment must require two independent movements or a tool to open.

Area of application:

• Covered devices: Consumer devices such as smartphones, televisions, speakers, routers. Professional devices such as servers, network switches, industrial controllers (if not covered by IEC 60204-1). Outdoor installations such as solar system controllers, WLAN access points.

• Devices not covered: Medical devices (regulated by IEC 60601-1). Industrial machine controls (regulated by IEC 60204-1). Domestic appliances such as washing machines (regulated by IEC 60335-1).

Tests:

Test conditions:

• Ambient conditions: Thermal tests under operation at extreme temperatures (-33°C to +40°C) for outdoor devices. Humidity tests under a relative humidity of 93% at +40°C for 48 hours.

• Operating conditions: Tests under maximum load (e.g. full load operation of a power supply unit). Simulation of faults (e.g. short circuit, overload).

Tests performed:

(1) Insulation test:

• Dielectric strength: application of 3,000 V AC between primary and secondary circuits for 1 minute (no breakdown allowed).

• Insulation resistance: Measurement with 500 V DC; minimum value ≥10 MΩ.

(2) Thermal test:

• Monitoring of surface temperatures of touchable parts (limit value: ≤95°C).

• Infrared thermography to identify hotspots.

(3) Mechanical safety:

• Battery compartment: Requires tool or two simultaneous hand movements to open.

• Stability test: Tilt tests for standing devices (e.g. monitors).

(4) Wireless power transmission:

• Placement of metal objects (diameter ≤32 mm) on the charging pad.

• Measurement of the surface temperature with thermocouples (≤70°C).

Evaluation:

• Energy classification: Classification of all identified hazards in class 1-3.

• Safeguard effectiveness: Proof that protective measures keep energy transmission below threshold values (e.g. insulation materials prevent touch voltages >60 V DC). Performance criteria are criterion B: Temporary malfunction that corrects itself and criterion C: Manual reset required.

Documentation:

• Technical documentation: Hazard analyses, test protocols, certificates for components used (e.g. transformers). Proof of conformity with all relevant clauses of the standard.

• Declaration of conformity: Must confirm the application of the latest version. Re-certification is required for design changes.

Alternative standards:

1. IEC 60065: Predecessor standard for audio/video equipment (valid until 2020).

2. IEC 60950-1: Predecessor standard for IT equipment (replaced by IEC 62368-1.

3. IEC 61010-1: Safety requirements for electrical measuring and laboratory equipment.

4. IEC 60601-1: Medical electrical equipment.

5. IEC 60335-1: Safety of household appliances (e.g. refrigerators, washing machines).