Resistance welding equipment - Part 1: Safety requirements for design, manufacture and installation

IEC 62135:2008 applies to equipment for resistance welding and allied processes and includes single and multiple welding stations which may be manually or automatically loaded and/or started. This standard covers stationary and portable equipment and specifies safety requirements for design, manufacture and installation.

Widerstandsschweißeinrichtungen - Teil 1: Sicherheitsanforderungen für die Konstruktion, Herstellung und Errichtung

Matériels de soudage par résistance - Partie 1: Exigences de sécurité pour la conception, la fabrication et l’installation

La CEI 62135:2008 s'applique aux matériels de soudage par résistance et aux procédés connexes et comprend les stations de soudage simples et multiples qui peuvent être alimentées manuellement ou automatiquement et/ou mises en route. Cette norme s'applique aux matériels fixes et portables et spécifie les exigences de sécurité pour leur conception, fabrication et installation.

Oprema za uporovno varjenje - 1. del: Varnostne zahteve za zasnovo, izdelavo in inštalacijo (IEC 62135-1:2008)

General Information

Status
Withdrawn
Publication Date
12-Nov-2008
Technical Committee
Drafting Committee
Parallel Committee
Current Stage
6060 - Document made available
Due Date
13-Nov-2008
Completion Date
13-Nov-2008

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SLOVENSKI STANDARD
SIST EN 62135-1:2009
01-januar-2009
1DGRPHãþD
SIST EN 50063:1996
Oprema za uporovno varjenje - 1. del: Varnostne zahteve za zasnovo, izdelavo in
inštalacijo (IEC 62135-1:2008)

Resistance welding equipment -- Part 1: Safety requirements for the design, manufacture

and the installation
Widerstandsschweißeinrichtungen -- Teil 1: Sicherheitsanforderungen für Entwurf,
Herstellung und Errichtung
Matériels de soudage par résistance -- Partie 1: Exigences de sécurité pour la
conception, la fabrication et l’installation
Ta slovenski standard je istoveten z: EN 62135-1:2008
ICS:
25.160.30 Varilna oprema Welding equipment
SIST EN 62135-1:2009 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 62135-1:2009
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SIST EN 62135-1:2009
EUROPEAN STANDARD
EN 62135-1
NORME EUROPÉENNE
November 2008
EUROPÄISCHE NORM
ICS 25.160 Supersedes EN 50063:1989
English version
Resistance welding equipment -
Part 1: Safety requirements for design, manufacture and installation
(IEC 62135-1:2008)
Matériels de soudage par résistance - Widerstandsschweißeinrichtungen -
Partie 1: Exigences de sécurité Teil 1: Sicherheitsanforderungen
pour la conception, für die Konstruktion,
la fabrication et l’installation Herstellung und Errichtung
(CEI 62135-1:2008) (IEC 62135-1:2008)

This European Standard was approved by CENELEC on 2008-10-01. CENELEC members are bound to comply

with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard

the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on

application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other

language made by translation under the responsibility of a CENELEC member into its own language and notified

to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the

Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,

Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,

Sweden, Switzerland and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2008 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. EN 62135-1:2008 E
---------------------- Page: 3 ----------------------
SIST EN 62135-1:2009
EN 62135-1:2008 – 2 –
Foreword

The text of document 26/377/FDIS, future edition 1 of IEC 62135-1, prepared by IEC TC 26, Electric

welding, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as

EN 62135-1 on 2008-10-01.
This European standard supersedes EN 50063:1989 + corrigendum August 1990.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2009-01-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2011-10-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice

The text of the International Standard IEC 62135-1:2008 was approved by CENELEC as a European

Standard without any modification.

In the official version, for Bibliography, the following notes have to be added for the standards indicated:

IEC 60085 NOTE Harmonized as EN 60085:2008 (not modified).
IEC 60112 NOTE Harmonized as EN 60112:2003 (not modified).
IEC 60364 NOTE Harmonized in HD 384 / HD 60364 series (modified).
IEC 60990 NOTE Harmonized as EN 60990:1999 (not modified).
__________
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SIST EN 62135-1:2009
– 3 – EN 62135-1:2008
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications

The following referenced documents are indispensable for the application of this document. For dated

references, only the edition cited applies. For undated references, the latest edition of the referenced

document (including any amendments) applies.

NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD

applies.
Publication Year Title EN/HD Year
1) 2)
IEC 60204-1 - Safety of machinery - Electrical equipment EN 60204-1 2006
(mod) of machines -
Part 1: General requirements
IEC 60364-4-41 2005 Low-voltage electrical installations - HD 60364-4-41 2007
(mod) Part 4-41: Protection for safety - Protection + corr. July 2007
against electric shock
1) 2)
IEC 60364-6 - Low voltage electrical installations - HD 60364-6 2007
(mod) Part 6: Verification
1) 2)
IEC 60439-1 - Low-voltage switchgear and controlgear EN 60439-1 1999
assemblies -
Part 1: Type-tested and partially type-tested
assemblies
1) 2)
IEC 60529 - Degrees of protection provided by EN 60529 1991
enclosures (IP Code) + corr. May 1993
IEC 60664-1 2007 Insulation coordination for equipment within EN 60664-1 2007
low-voltage systems -
Part 1: Principles, requirements and tests
1) 2)
IEC 60664-3 - Insulation coordination for equipment within EN 60664-3 2003
low-voltage systems -
Part 3: Use of coating, potting or moulding for
protection against pollution
1) 2)
IEC 61140 - Protection against electric shock - Common EN 61140 2002
aspects for installation and equipment
ISO 669 - Resistance welding - Resistance welding - -
equipment - Mechanical and electrical
requirements
1) 2)
ISO 5828 - Resistance welding equipment - Secondary EN ISO 5828 2001
connecting cables with terminals connected to
water-cooled lugs - Dimensions and
characteristics
1) 2)
ISO 8205-1 - Water-cooled secondary connection cables EN ISO 8205-1 2002
for resistance welding -
Part 1: Dimensions and requirements for
double-conductor connection cables
Undated reference.
Valid edition at date of issue.
---------------------- Page: 5 ----------------------
SIST EN 62135-1:2009
EN 62135-1:2008 – 4 –
Publication Year Title EN/HD Year
1) 2)
ISO 8205-2 - Water-cooled secondary connection cables EN ISO 8205-2 2002
for resistance welding -
Part 2: Dimensions and requirements for
single-conductor connection cables
1) 2)
ISO 12100-1 - Safety of machinery - Basic concepts, EN ISO 12100-1 2003
general principles for design -
Part 1: Basic terminology, methodology
1) 2)
ISO 12100-2 - Safety of machinery - Basic concepts, EN ISO 12100-2 2003
general principles for design -
Part 2: Technical principles
1) 2)
ISO 13849-1 - Safety of machinery - Safety-related parts EN ISO 13849-1 2006
of control systems -
Part 1: General principles for design
1) 2)
ISO 14121-1 - Safety of machinery - Risk assessment - EN ISO 14121-1 2001
Part 1: Principles
---------------------- Page: 6 ----------------------
SIST EN 62135-1:2009
IEC 62135-1
Edition 1.0 2008-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Resistance welding equipment –
Part 1: Safety requirements for design, manufacture and installation
Matériels de soudage par résistance –

Partie 1: Exigences de sécurité pour la conception, la fabrication et l’installation

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX
ICS 25.160 ISBN 2-8318-9823-4
® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
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SIST EN 62135-1:2009
– 2 – 62135-1 © IEC:2008
CONTENTS

FOREWORD...........................................................................................................................5

1 Scope...............................................................................................................................7

2 Normative references .......................................................................................................7

3 Terms and definitions.........................................................................................................8

4 Environmental conditions................................................................................................10

5 Tests ..............................................................................................................................10

5.1 Test conditions......................................................................................................10

5.2 Measuring instruments ..........................................................................................10

5.3 Type tests .............................................................................................................11

5.4 Routine tests .........................................................................................................11

6 Protection against electric shock ....................................................................................11

6.1 General .................................................................................................................11

6.2 Insulation ..............................................................................................................12

6.2.1 General .....................................................................................................12

6.2.2 Clearances ................................................................................................12

6.2.3 Creepage distances...................................................................................13

6.2.4 Insulation resistance..................................................................................14

6.2.5 Dielectric strength .....................................................................................15

6.2.6 Liquid cooling ............................................................................................16

6.3 Protection against electric shock in normal service (direct contact) .......................16

6.3.1 General .....................................................................................................16

6.3.2 Rated no-load voltage at the output ...........................................................17

6.3.3 Protection provided by barriers or the enclosure........................................17

6.3.4 Capacitors .................................................................................................17

6.3.5 Automatic discharge of input capacitors.....................................................18

6.3.6 Protective conductor current under normal operation.................................18

6.4 Protection against electric shock in case of a fault condition (indirect contact) ......19

6.4.1 General .....................................................................................................19

6.4.2 Protective provisions for welding circuit .....................................................21

6.4.3 Internal conductors and connections..........................................................33

6.4.4 Touch current in fault condition..................................................................33

6.4.5 DC resistance welding equipment operating at mains frequency................34

6.4.6 DC resistance welding equipment operating at medium frequency.............34

6.4.7 Continuity of the protective bonding circuit ................................................35

6.5 Additional user requirements .................................................................................35

6.6 Supply voltage.......................................................................................................35

6.7 Conductors of the welding circuit...........................................................................35

7 Thermal requirements.....................................................................................................35

7.1 Heating test...........................................................................................................36

7.1.1 Test conditions ..........................................................................................36

7.1.2 Tolerances of the test parameters .............................................................36

7.1.3 Beginning of the heating test .....................................................................36

7.1.4 Duration of the test....................................................................................37

7.2 Temperature measurement....................................................................................37

7.2.1 Measurements conditions ..........................................................................37

7.2.2 Surface temperature sensor ......................................................................37

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SIST EN 62135-1:2009
62135-1 © IEC:2008 – 3 –

7.2.3 Resistance ................................................................................................37

7.2.4 Embedded temperature sensor..................................................................38

7.2.5 Determination of the ambient temperature (t )...........................................38

7.2.6 Determination of cooling liquid temperature (t ).........................................38

7.2.7 Recording of temperatures ........................................................................38

7.3 Limits of temperature rise......................................................................................38

7.3.1 Windings ...................................................................................................38

7.3.2 External surfaces.......................................................................................39

7.3.3 Other components .....................................................................................40

8 Abnormal operation ........................................................................................................40

8.1 General requirements............................................................................................40

8.2 Stalled fan test ......................................................................................................40

8.3 Cooling system failure ...........................................................................................40

8.4 Overload test.........................................................................................................41

9 Provisions against mechanical hazards ..........................................................................41

9.1 General .................................................................................................................41

9.2 Risk analysis .........................................................................................................41

9.2.1 General .....................................................................................................41

9.2.2 Ready to use equipment as in delivery state..............................................41

9.2.3 Equipment not ready to use as in delivery state.........................................41

9.2.4 Equipment not ready to use and designed to be incorporated in a

more complex equipment...........................................................................42

9.3 Measures ..............................................................................................................42

9.3.1 Minimum measures....................................................................................42

9.3.2 Additional measures ..................................................................................42

9.4 Conformity of components.....................................................................................43

9.5 Starting for manual operated equipment ................................................................43

10 Instructions and markings...............................................................................................44

10.1 Instructions ...........................................................................................................44

10.2 Markings ...............................................................................................................44

Annex A (informative) Nominal voltages of supply networks.................................................45

Annex B (normative) Construction of supply circuit terminals .............................................46

Annex C (informative) Extrapolation of temperature to time of shutdown..............................48

Annex D (informative) Example of risk analysis and safety level requirement.......................49

Annex E (informative) Indirect contact protection in resistance welding equipment...............53

Bibliography..........................................................................................................................60

Figure 1 – Measurement of leakage current ..........................................................................22

Figure 2 – Example of metal screen between windings of the supply circuit and the

welding circuit.......................................................................................................................23

Figure 3 – Example of protective conductor connected directly to the welding circuit

(single-spot, a.c. current equipment).....................................................................................24

Figure 4 – Example of protective conductor connected directly to welding circuits

(multi-spot, a.c. current equipment) ......................................................................................24

Figure 5 – Example of protective conductor connected direct to welding circuits

(medium-frequency equipment).............................................................................................25

Figure 6 – Example of protective conductor connected to welding circuits through

impedances ..........................................................................................................................26

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SIST EN 62135-1:2009
– 4 – 62135-1 © IEC:2008

Figure 7 – Example of protective conductor connected to welding circuits through

auto-inductances ..................................................................................................................27

Figure 8 – Example of protective conductor connected to welding circuits through

auto-inductances ..................................................................................................................27

Figure 9 – Example of current operated residual current device (a.c. current

equipment) ...........................................................................................................................28

Figure 10 – Example of current operated residual current device (medium-frequency

equipment) ...........................................................................................................................29

Figure 11 – Example of current operated residual current device and voltage relay ..............30

Figure 12 – Example of current operated residual current device and safety voltage

operated relay.......................................................................................................................31

Figure 13 – Example of safety voltage operated relay ...........................................................32

Figure 14 – Measuring network for leakage current...............................................................34

Figure E.1 – Typical fault current ..........................................................................................57

Figure E.2 – Time-to-voltage reference curve .......................................................................59

Table 1 – Minimum clearances for overvoltage category III ...................................................12

Table 2 – Minimum creepage distances ................................................................................14

Table 3 – Insulation resistance .............................................................................................15

Table 4 – Dielectric test voltages ..........................................................................................15

Table 5 – Minimum distance through insulation.....................................................................21

Table 6 – Continuity of the protective bonding circuit ............................................................35

Table 7 – Limits of temperature rise for windings ..................................................................39

Table 8 – Limits of temperature rise for external surfaces .....................................................39

Table B.1 – Range of conductor dimensions to be accepted by the supply circuit

terminals...............................................................................................................................46

Table B.2 – Spacing between supply circuit terminals ...........................................................47

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SIST EN 62135-1:2009
62135-1 © IEC:2008 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
RESISTANCE WELDING EQUIPMENT –
Part 1: Safety requirements for design,
manufacture and installation
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

all national electrotechnical committees (IEC National Committees). The object of IEC is to promote

international co-operation on all questions concerning standardization in the electrical and electronic fields. To

this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,

Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC

Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested

in the subject dealt with may participate in this preparatory work. International, governmental and non-

governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely

with the International Organization for Standardization (ISO) in accordance with conditions determined by

agreement between the two organizations.

2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

consensus of opinion on the relevant subjects since each technical committee has representation from all

interested IEC National Committees.

3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

misinterpretation by any end user.

4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

transparently to the maximum extent possible in their national and regional publications. Any divergence

between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in

the latter.

5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any

equipment declared to be in conformity with an IEC Publication.

6) All users should ensure that they have the latest edition of this publication.

7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and

members of its technical committees and IEC National Committees for any personal injury, property damage or

other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and

expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC

Publications.

8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of

patent rights. IEC shall not be held responsible for identifying any or all such patent rights.

International Standard IEC 62135-1 has been prepared by IEC technical committee 26:

Electric welding.
The text of this standard is based on the following documents:
FDIS Report on voting
26/377/FDIS 26/383/RVD

Full information on the voting for the approval of this standard can be found in the report on

voting indicated in the above table.

This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

---------------------- Page: 11 ----------------------
SIST EN 62135-1:2009
– 6 – 62135-1 © IEC:2008

The list of all the parts of the IEC 62135 series, under the general title Resistance welding

equipment, can be found on the IEC website.

The committee has decided that the contents of this publication will remain unchanged until

the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in

the data related to the specific publication. At this date, the publication will be

• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 12 ----------------------
SIST EN 62135-1:2009
62135-1 © IEC:2008 – 7 –
RESISTANCE WELDING EQUIPMENT –
Part 1: Safety requirements for design,
manufacture and installation
1 Scope

This part of IEC 62135 applies to equipment for resistance welding and allied processes and

includes single and multiple welding stations which may be manually or automatically loaded

and/or started.
This standard covers stationary and portable equipment.
It specifies safety requirements for design, manufacture and installation.

To comply with this standard, all safety risks involved in loading, feeding, operating and

unloading the equipment, where applicable, should be assessed and the requirements of

related standards should be observed.
2 Normative references

The following normative documents contain provisions which, through reference in this text,

constitute provisions of this part of IEC 62135. For dated references, only the edition cited

applies. For undated references, the latest edition of the referenced document (including any

amendments) applies.

IEC 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General

requirements

IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –

Protection against electric shock
IEC 60364-6, Low-voltage electrical installations – Part 6: Verification

IEC 60439-1, Low-voltage switchgear and controlgear assemblies – Part 1: Type-tested and

partially type-tested assemblies
IEC 60529, Degrees of protection provided by enclosures (IP code)

IEC 60664-1:2007, Insulation coordination for equipment within low-voltage systems – Part 1:

Principles, requirements and tests

IEC 60664-3, Insulation coordination for equipment within low-voltage systems – Part 3: Use

of coating, potting or moulding for protection against pollution

IEC 61140, Protection against electric shock – Common aspects for installation and

equipment

ISO 669, Resistance welding – Resistance welding equipment – Mechanical and electrical

requirements
---------------------- Page: 13 ----------------------
SIST EN 62135-1:2009
– 8 – 62135-1 © IEC:2008

ISO 5828, Resistance welding equipment – Secondary connecting cables with terminals

connected to water-cooled lugs – Dimensions and characteristics

ISO 8205-1, Water-cooled secondary connection cables for resistance welding – Part 1:

Dimensions and requirements for double-conductor connection cables

ISO 8205-2, Water-cooled secondary connection cables for resistance welding – Part 2:

Dimensions and requirements for single-conductor connection cables

ISO 12100-1, Safety of machinery – Basic concepts, general principles for design – Part 1:

Basic terminology, methodology

ISO 12100-2, Safety of machinery – Basic concepts, general principles for design – Part 2:

Technical principles

ISO 13849-1, Safety of machinery – Safety-related parts of control systems – Part 1: General

principles for design
ISO 14121-1, Safety of machinery – Risk assessment – Part 1: Principles
3 Terms and definitions

For the purposes of this document, the following terms and definitions, together with those

given in ISO 669, IEC 60664-1 and IEC 60204-1, apply.
3.1
equipment for resistance welding and allied processes
equipme
...

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