IEC 62135-1:2015

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

IEC 62135-1:2015 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 second edition cancels and replaces the first edition published in 2008. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
- creepage distances for pollution degree 4 are no longer valid (see Table 2);
- insulation requirements for Class II equipment are defined (see Table 3);
- dielectric test voltage interpolation restriction lower limit is changed to 220 V and interpolation for control and welding circuit is clarified (see Table 4);
- maximum temperature for insulation systems are reviewed in accordance with current edition of IEC 60085 (see Table 7);
- marking of terminals is defined (see 10.3);
- table for nominal voltages of supply networks is changed adopting Table B.2 of IEC 60664-1:2007 in place of the Table B.1 values referenced in the previous edition to provide for equipment to be connected to both earthed and unearthed systems. The change impacts the creepage and clearance distance requirements for some supply voltage ratings (see Annex A);
- touch current in fault condition are measurement procedures are clarified (see 6.4.4 and Annex C);
- welding circuit touch current is defined (see 6.2.6);
- touch current in normal condition are clarified and moved in protection against electric shock in normal service (see 6.3.7);
- heating test conditions are clarified (see 7.1.1);
- external surface temperature rise limitation is changed (see 7.3.2). The contents of the corrigendum of February 2016 have been included in this copy.

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

L'IEC 62135-1:2015 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 deuxième édition annule et remplace la première édition parue en 2008. Cette édition constitue une résivion technique. Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
- les lignes de fuite pour le degré de pollution 4 ne sont plus valables (voir le Tableau 2);
- les exigences relatives à l'isolement pour le matériel de classe II sont définies (voir le Tableau 3);
- la limite inférieure de restriction d'interpolation de la tension d'essai diélectrique est modifiée à 220 V et l'interpolation des circuits de commande et de soudage est clarifiée (voir le Tableau 4);
- la température maximale pour les systèmes d'isolation est revue conformément à l'actuelle édition de l'IEC 60085 (voir le Tableau 7);
- le marquage des bornes est défini (voir 10.3);
- le tableau des tensions nominales des réseaux d'alimentation est modifié: les valeurs du Tableau B.2 de l'IEC 60664-1:2007 sont prises en compte à la place des valeurs du Tableau B.1, référencées dans la précédente édition pour le matériel à connecter aux systèmes mis à la terre et non mis à la terre. Cette modification influence les exigences relatives aux lignes de fuite et aux distances d'isolement dans l'air pour certaines caractéristiques assignées de tension d'alimentation (voir l'Annexe A);
- les informations relatives au courant de contact en cas de défaut et les procédures de mesure sont clarifiées (voir 6.4.4 et l'Annexe C);
- le courant de contact du circuit de soudage est défini (voir 6.2.6);
- les informations relatives au courant de contact en condition normale sont clarifiées et déplacées dans la partie protection contre les chocs électriques en service normal (voir 6.3.7);
- les conditions d'essai d'échauffement sont clarifiées (voir 7.1.1);
- la limite d'échauffement de la surface externe est modifiée (voir 7.3.2). Le contenu du corrigendum de février 2016 a été pris en considération dans cet exemplaire.

General Information

• Status: Published
• Publication Date: 06-May-2015
• ICS: 01 - GENERALITIES. TERMINOLOGY. STANDARDIZATION. DOCUMENTATION
• ICS: 25.160.30 - Welding equipment
• Technical Committee: TC 26 - Electric welding
• Drafting Committee: WG 1 - TC 26/WG 1
• Current Stage: PPUB - Publication issued
• Start Date: 31-May-2015
• Completion Date: 07-May-2015

Relations

• Corrected By: IEC 62135-1:2015/COR1:2016 - Corrigendum 1 - Resistance welding equipment - Part 1: Safety requirements for design, manufacture and installation
• Effective Date: 05-Sep-2023
• Revises: IEC 62135-1:2008 - Resistance welding equipment - Part 1: Safety requirements for design, manufacture and installation
• Effective Date: 05-Sep-2023

Standards Content (Sample)

IEC 62135-1 ®
Edition 2.0 2015-05
INTERNATIONAL
STANDARD
colour
inside
Resistance welding equipment –
Part 1: Safety requirements for design, manufacture and installation
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

IEC Central Office Tel.: [phone]
3, rue de Varembé Fax: [phone]
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Switzerland www.iec.ch
About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

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IEC 62135-1 ®
Edition 2.0 2015-05
INTERNATIONAL
STANDARD
colour
inside
Resistance welding equipment –

Part 1: Safety requirements for design, manufacture and installation

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 25.160 ISBN 978-2-8322-2664-3

– 2 – IEC 62135-1:2015 © IEC 2015
CONTENTS
FOREWORD . 6
1 Scope . 8
2 Normative references . 8
3 Terms and definitions . 9
4 Environmental conditions . 11
5 Tests . 11
5.1 Test condition . 11
5.2 Measuring instruments . 11
5.3 Type tests . 12
5.4 Routine tests. 12
6 Protection against electric shock . 12
6.1 General . 12
6.2 Insulation . 13
6.2.1 General . 13
6.2.2 Clearances . 13
6.2.3 Creepage distances . 14
6.2.4 Insulation resistance . 16
6.2.5 Dielectric strength . 16
6.2.6 Welding circuit touch current . 18
6.2.7 Liquid cooling . 18
6.3 Protection against electric shock in normal service (direct contact) . 19
6.3.1 General . 19
6.3.2 Rated no-load voltage at the output . 19
6.3.3 Protection provided by barriers or the enclosure . 20
6.3.4 Capacitors . 21
6.3.5 Automatic discharge of input capacitors . 21
6.3.6 Protective conductor current under normal condition. 22
6.3.7 Touch current in normal condition . 22
6.4 Protection against electric shock in case of a fault condition (indirect
contact) . 22
6.4.1 General . 22
6.4.2 Protective provisions for welding circuit . 24
6.4.3 Internal conductors and connections . 36
6.4.4 Touch current in fault condition . 36
6.4.5 DC resistance welding equipment operating at mains frequency . 37
6.4.6 DC resistance welding equipment operating at medium frequency . 37
6.4.7 Continuity of the protective bonding circuit . 37
6.5 Additional user requirements. 38
6.6 Supply voltage . 38
6.7 Conductors of the welding circuit . 38
7 Thermal requirements . 38
7.1 Heating test . 38
7.1.1 Test conditions . 38
7.1.2 Tolerances of the test parameters . 39
7.1.3 Beginning of the heating test . 40
7.1.4 Duration of the test . 40

7.2 Temperature measurement . 40
7.2.1 Measurements conditions . 40
7.2.2 Surface temperature sensor . 40
7.2.3 Resistance . 40
7.2.4 Embedded temperature sensor . 41
7.2.5 Determination of the ambient temperature (t ) . 41
a
7.2.6 Determination of cooling liquid temperature (t ) . 41
a
7.2.7 Recording of temperatures . 41
7.3 Limits of temperature rise . 42
7.3.1 Windings . 42
7.3.2 External surfaces . 42
7.3.3 Other components . 44
7.4 Protection from thermal hazards in normal service (direct contact) . 44
7.4.1 General . 44
7.4.2 Identification of hot surfaces . 44
7.4.3 Protection provided by insulation or other barriers . 45
7.4.4 Protection provided by supplemental cooling . 45
8 Abnormal operation . 45
8.1 General requirements . 45
8.2 Stalled fan test . 45
8.3 Cooling system failure . 45
8.4 Overload test . 46
9 Provisions against mechanical hazards . 46
9.1 General . 46
9.2 Risk analysis. 46
9.2.1 General . 46
9.2.2 Ready-to-use equipment as in delivery state . 46
9.2.3 Equipment not ready to use as in delivery state . 46
9.2.4 Equipment not ready for use and designed to be incorporated in more
complex equipment . 47
9.3 Measures . 47
9.3.1 Minimum measures . 47
9.3.2 Additional measures . 47
9.4 Conformity of components . 48
9.5 Starting for manual operated equipment . 48
10 Instructions and markings . 49
10.1 Instructions . 49
10.2 Markings . 49
10.3 Marking of terminals . 49
Annex A (informative) Nominal voltages of supply networks . 51
Annex B (normative) Construction of supply circuit terminals . 52
B.1 Size of terminals . 52
B.2 Spacings between supply circuit terminals . 52
B.3 Connections at the terminals . 53
B.4 Construction of the terminals . 53
B.5 Fixing of the terminals . 53
Annex C (normative) Touch current measurement in fault condition . 54
Annex D (informative) Extrapolation of temperature to time of shutdown . 56

– 4 – IEC 62135-1:2015 © IEC 2015
Annex E (informative) Example of risk anal
...

IEC 62135-1 ®
Edition 2.0 2015-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
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

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
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copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

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About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigenda or an amendment might have been published.

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IEC 62135-1 ®
Edition 2.0 2015-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
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
INTERNATIONALE
ICS 25.160 ISBN 978-2-8322-3084-8

– 2 – IEC 62135-1:2015 © IEC 2015
CONTENTS
CONTENTS . 2
FOREWORD . 6
1 Scope . 8
2 Normative references . 8
3 Terms and definitions . 9
4 Environmental conditions . 11
5 Tests . 11
5.1 Test condition . 11
5.2 Measuring instruments . 11
5.3 Type tests . 12
5.4 Routine tests. 12
6 Protection against electric shock . 12
6.1 General . 12
6.2 Insulation . 13
6.2.1 General . 13
6.2.2 Clearances . 13
6.2.3 Creepage distances . 14
6.2.4 Insulation resistance . 16
6.2.5 Dielectric strength . 16
6.2.6 Welding circuit touch current . 18
6.2.7 Liquid cooling . 18
6.3 Protection against electric shock in normal service (direct contact) . 19
6.3.1 General . 19
6.3.2 Rated no-load voltage at the output . 19
6.3.3 Protection provided by barriers or the enclosure . 20
6.3.4 Capacitors . 21
6.3.5 Automatic discharge of input capacitors . 21
6.3.6 Protective conductor current under normal condition. 22
6.3.7 Touch current in normal condition . 22
6.4 Protection against electric shock in case of a fault condition (indirect
contact) . 22
6.4.1 General . 22
6.4.2 Protective provisions for welding circuit . 24
6.4.3 Internal conductors and connections . 36
6.4.4 Touch current in fault condition . 36
6.4.5 DC resistance welding equipment operating at mains frequency . 37
6.4.6 DC resistance welding equipment operating at medium frequency . 37
6.4.7 Continuity of the protective bonding circuit . 37
6.5 Additional user requirements. 38
6.6 Supply voltage . 38
6.7 Conductors of the welding circuit . 38
7 Thermal requirements . 38
7.1 Heating test . 38
7.1.1 Test conditions . 38
7.1.2 Tolerances of the test parameters . 39
7.1.3 Beginning of the heating test . 40

7.1.4 Duration of the test . 40
7.2 Temperature measurement . 40
7.2.1 Measurements conditions . 40
7.2.2 Surface temperature sensor . 40
7.2.3 Resistance . 40
7.2.4 Embedded temperature sensor . 41
7.2.5 Determination of the ambient temperature (t ) . 41
a
7.2.6 Determination of cooling liquid temperature (t ) . 41
a
7.2.7 Recording of temperatures . 41
7.3 Limits of temperature rise . 42
7.3.1 Windings . 42
7.3.2 External surfaces . 42
7.3.3 Other components . 44
7.4 Protection from thermal hazards in normal service (direct contact) . 44
7.4.1 General . 44
7.4.2 Identification of hot surfaces . 44
7.4.3 Protection provided by insulation or other barriers . 45
7.4.4 Protection provided by supplemental cooling . 45
8 Abnormal operation . 45
8.1 General requirements . 45
8.2 Stalled fan test . 45
8.3 Cooling system failure . 45
8.4 Overload test .
...