In the realm of electrical systems, the importance of ensuring high-quality and reliable equipment cannot be overstated. To maintain safety and functionality, products such as low-voltage switchgear and control gear devices must undergo rigorous testing and certification processes. The Ministry of Heavy Industries has, through an order, outlined detailed product-related guidelines for manufacturers involved in the manufacture of control circuit devices and switching elements. These guidelines are designed to ensure that these devices comply with established standards, such as IS/IEC 60947-5-1: 2016, and the requirements laid down under the Electrical Equipment (Quality Control) Order, 2020.

Intoduction of Product Specific Guidelines for Low Voltage Switchgear and Controlgear

On March 10, 2025, the Ministry of Heavy Industries issued an order for low-voltage switchgear and control gear, specifically focusing on control circuit devices and switching elements. These devices are integral parts of the electrical system, and their quality must be verified and conform to certified standards. The guidelines focus on ensuring the safe and efficient operation of these devices as per Indian Standards (IS) and International Electrotechnical Commission (IEC) 60947-5-1: 2016.

These guidelines aim to provide a clear and standardized process for obtaining the necessary licenses and BIS certification, an important step for manufacturers who wish to market their products. By following these procedures, manufacturers can ensure that their products are tested, verified, and certified for safe use in compliance with national and international standards. This comprehensive framework also streamlines the product approval process, making it easier for manufacturers to expand their product ranges or make changes to their existing licenses while ensuring compliance with quality control standards.

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Purpose of Product Specific Guidelines

The guidelines provided here are specifically for manufacturers that seek BIS registration and certification for their low voltage switchgear and controlgear. These products must comply with IS/IEC 60947-5-1: 2016, which is an international standard for electromechanical control circuit equipment. The Electrical Equipment (Quality Control) Order, 2020, provides guidelines for granting a license for these equipment or changes in its scope.

Manufacturers are required to follow the procedures set by the Bureau of Indian Standards (BIS) to ensure that their products meet all technical requirements. The application for a license or change in scope must include technical files, which must contain test reports, certificates and other necessary documents as per BIS procedures. These reports must demonstrate compliance with the operational performance standards of the product.

Licensing Process and Submission of Technical File

To obtain a BIS license or to change the scope of an existing license, manufacturers have to apply to the Bureau of Indian Standards. The manufacturer must ascertain the scope of the license and submit a comprehensive technical file. This process ensures that products meet the required quality standards before being allowed for use in the market. This file should include:

• Test reports: Detailed reports demonstrating product compliance with applicable standards, particularly IS/IEC 60947-5-1: 2016.
• Certificates: Relevant certificates from accredited testing laboratories.
• Minimum sample requirements: The submission must also comply with the minimum number of sample products required for the product series or range.

Product Grouping

Product grouping refers to the classification of similar types of control circuit devices and switching elements. These products are for specific functions, such as controlling, signaling, interlocking, and other functions related to switchgear and control gear. The grouping of products should be in accordance with the classification of IS/IEC 60947-5-1: 2016, which provides a detailed breakdown of different types of control circuit devices and switching elements.

The product series can include a variety of devices, such as:

• Manual control switches: push buttons, rotary switches, and foot switches.
• Electromagnetic control switches: contactor relays, time-delay or instantaneous relays.
• Pilot switches: pressure-sensitive, temperature-sensitive switches, and programmers.
• Position switches: for detecting the position of mechanical components.
• Associated control equipment: indicator lights and other similar devices.

Sampling and Testing

Sampling and Testing Procedures

For each product series, a type test must be performed. Generally, spares, accessories, and sub-assemblies are considered an integral part of the product. Where possible, they should be tested together with the device. However, separate testing is not required unless otherwise specified. If the accessories meet the requirements of another standard, they must comply with that standard. This test will include:

• Maximum configurations and features: Type testing should be performed with the product configuration that has the highest number of features, such as the maximum number of switching elements.
• Test sequence: The test sequences follow those specified in IS/IEC 60947-5-1: 2016. Manufacturers may request additional tests on samples, but the tests must follow a specific sequence for each product type.

Type Test Reports

For each product series, a type test report should be provided. The test should cover the maximum number of switching elements for each product, which will help to cover all other configurations within that series. For example, a control circuit device with multiple configurations (e.g., 4NO, 3NO+1NC) will need to be tested with maximum intensity (i.e., all switching elements will be closed simultaneously).

Test Sequences

The types of tests are grouped into different sequences. Each sequence includes specific tests for operational performance. These tests are performed to ensure that the device performs as expected under various operational conditions. Some of the important sequence tests include:

• Making and breaking capabilities
• Short circuit test

Simplified Testing Procedure

To reduce the number of tests for similar devices, a simplified testing procedure is used. For devices with multiple rated operational voltages or currents, the highest rated value is used for testing. The key components of this procedure include:

• Testing the device with as many possible configurations of switching elements as possible to cover all possible configurations.
• Testing a single pole device for making and breaking capabilities, which would cover all poles if they were identical in design.

Testing for Different Terminal Designs

If a device has multiple terminal designs, additional tests should be performed as per Test Sequence I of IS/IEC 60947-5-1: 2016. This is particularly important to ensure accurate measurement of clearance and creepage distances.

Type Test for Indicator Lights and Indicating Towers

For devices such as indicator lights and indicating towers, the type test shall be carried out on the specimens with the highest rated power. This test shall cover all other ratings with lower or equal power.

Table A: Classification of Electromechanical Control Circuit Devices

This table presents the classification criteria for electromechanical control circuit devices based on various factors. Classification is essential for manufacturers seeking BIS registration and certification. Important aspects of classification include:

Table B: Electromechanical Control Circuit Devices and Testing Conditions

Table B specifies the conditions under which electromechanical control circuit devices may be included in the scope of the license without additional full type testing. The two main conditions under which this applies are:

Conclusion

The guidelines provided by the Ministry of Heavy Industries outline a structured approach for manufacturers seeking BIS registration and certification for Low Voltage Switchgear and Controlgear products. The key to obtaining BIS certification lies in adhering to the sampling, testing, and documentation requirements outlined by the Bureau of Indian Standards. By following these guidelines, manufacturers can ensure the quality and compliance of their products, thereby contributing to the safety and efficiency of electrical systems in India.