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Preparing a Sample for IEC 61010 Testing
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A test report describes the sample it received. If the sample differs from the production product in any way that affects safety, the report does not cover the product, and the difference is usually discovered by an auditor rather than by the manufacturer.
What to send
Production-representative units, from production tooling, with production firmware and the production bill of materials. Where the design has options, send the worst case for each assessment: the highest power option for thermal testing, the most crowded configuration for clearances, the largest enclosure for mechanical testing. Where the worst cases cannot be combined in one unit, send several and say which is which.
What to include with it
The rating plate artwork, the instructions for use in the final language, the circuit diagram, the bill of materials with component certificates for the safety-critical parts, and a description of the intended installation. Missing documents are the most common cause of a test campaign stalling.
What not to do
Do not send a hand-modified prototype and describe it as representative. Do not send a unit with a fuse fitted for the test that differs from production. Do not send a manual marked draft. Each of these is a small convenience that invalidates the result, and the correction costs more than the original test.
