As we are getting ready to move into prototype mode, we've identified another set of requirements that we need to keep in mind as we move forward. Nationally Recognized Test Labs (NRTLs, sometimes pronounced "Nurtles") have explicit requirements for product safety and we'll need to find what category we fit in. The fact that we are an AC mains powered device makes NRTLs especially restrictive in order to limit the potential for electrocution or fire.
At first glance, it looks like we fit best under UL 508 - Motor Controllers. Unfortunately, it seems that the standard we need to meet is nearly a thousand dollars to purchase and hundreds of pages, not to mention the myriad of other standards it references. Ugh.
Excerpts I've found online list lots of conductor spacing and thermal testing requirements. We'll also want to make use of UL recognized components whenever we can. More soon!