Safety of machinery - Electro-sensitive protective equipment - Part 1: General requirements and tests

IEC 61496-1:2020 specifies general requirements for the design, construction and testing of non-contact electro-sensitive protective equipment (ESPE) designed specifically to detect persons or part of a person as part of a safety-related system. Special attention is directed to functional and design requirements that ensure an appropriate safety-related performance is achieved. An ESPE can include optional safety-related functions, the requirements for which are given in Annex A.
This document is intended to be used with a subsequent part of IEC 61496 that provides particular requirements based on the sensing technology.
Where a part covering the sensing technology does not exist, IEC TS 62998-1 is used.
Where the IEC 61496 series does not contain all necessary provisions, IEC TS 62998-1 is used.
It is an additional possibility to combine those aspects covered by the IEC 61496 series in addition to IEC TS 62998-1.
This document does not specify the dimensions or configuration of the detection zone and its disposition in relation to hazards in any particular application, nor what constitutes a hazardous state of any machine. It is restricted to the functioning of the ESPE and how it interfaces with the machine.
While a data interface can be used to control optional safety-related ESPE functions (Annex A), this document does not provide specific requirements. Requirements for these safety-related functions can be determined by consulting other standards (for example, IEC 61508 (all parts), IEC TS 62046, IEC 62061, and ISO 13849-1).
This document can be relevant to applications other than those for the protection of persons, for example for the protection of machinery or products from mechanical damage. In those applications, different requirements can be appropriate, for example when the materials that have to be recognized by the sensing function have different properties from those of persons.
This document does not deal with requirements for ESPE functions not related to the protection of persons (e.g. using sensing unit data for navigation).
This document does not deal with electromagnetic compatibility (EMC) emission requirements.
IEC 61496-1:2020 cancels and replaces the third edition published in 2012. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous edition:
a) It has been clarified that some requirements for ESPEs that are dependent on sensing technology are not included in IEC 61496-1. They are provided in a subsequent part of IEC 61496.
b) Requirements for protection against environmental influences from subsequent parts of IEC 61496 that are common to all ESPEs have been consolidated into IEC 61496-1.
c) Some test procedures in IEC 61496-1 were incomplete. They have been expanded with more detail and step by step procedures.
d) Some requirements and procedures in IEC 61496-1 are now covered by new generic machine safety standards. The requirements in IEC 61496-1 have been harmonized with references to the new generic standards.

Sécurité des machines - Equipements de protection électrosensibles - Partie 1: Exigences générales et essais

L'IEC 61496-1:2020 définit les exigences générales de conception, de construction et d'essai des équipements de protection électrosensibles (ESPE) sans contact spécifiquement conçus pour détecter des personnes au sein d’un système relatif à la sécurité. Une attention particulière est accordée aux exigences de fonctionnement et de conception assurant la satisfaction aux performances relatives à la sécurité appropriées. Un ESPE peut proposer des fonctions facultatives liées à la sécurité: les exigences relatives à celles-ci sont données à l’Annexe A.
L'IEC 61496-1:2020 est destiné à être utilisé avec une partie ultérieure de l’IEC 61496 qui définit des exigences particulières en fonction de la technologie de détection.
En l’absence d’une partie couvrant la technologie de détection, l’IEC TS 62998-1 est utilisée.
Dans le cas où la série IEC 61496 ne contient pas toutes les dispositions nécessaires, l’IEC TS 62998-1 est utilisée.
Il est en outre possible de combiner ces aspects couverts par la série IEC 61496 à l’IEC TS 62998-1.
Le présent document ne spécifie ni les dimensions ou la configuration de la zone de détection, ni sa disposition par rapport aux dangers dans toute application particulière, ni ce qui constitue un état dangereux pour toute machine donnée. Il se limite au fonctionnement de l’ESPE et à son interface avec la machine.
Bien qu’une interface de données puisse être utilisée pour commander des fonctions de l'ESPE relatives à la sécurité facultatives (Annexe A), le présent document ne fournit pas d’exigences particulières. Les exigences liées à ces fonctions relatives à la sécurité peuvent être déterminées en consultant d'autres normes (par exemple, l'IEC 61508 (toutes les parties), l’IEC 62046, l’IEC 62061, et l'ISO 13849-1).
Le présent document peut être pertinent pour des applications autres que la protection des personnes, par exemple la protection des machines ou des produits contre des dommages mécaniques. Dans ces applications, des exigences différentes peuvent être nécessaires, par exemple lorsque les matériaux qui doivent être reconnus par le dispositif de détection ont des caractéristiques différentes de celles des personnes.
Le présent document ne traite pas des exigences relatives aux fonctions de l’ESPE non liées à la protection des personnes (en utilisant, par exemple, les données de l’élément de détection en matière de navigation).
Le présent document ne traite pas des exigences d’émission relatives à la compatibilité électromagnétique (CEM).
L'IEC 61496-1:2020 annule et remplace la troisième édition parue en 2012. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
a) Il a été défini que certaines exigences relatives aux ESPE dépendant de la technologie de détection n’étaient pas incluses dans l’IEC 61496-1. Ces exigences sont fournies dans une partie ultérieure de l’IEC 61496.
b) Les exigences de protection contre les influences environnementales issues des parties ultérieures de l’IEC 61496 et qui sont communes à tous les ESPE ont été consolidées dans l’IEC 61496-1.
c) Certaines procédures d’essai de l’IEC 61496-1 étaient incomplètes. Elles ont été enrichies par des procédures plus détaillées et étape par étape.
d) Certaines exigences et procédures de l’IEC 61496-1 sont désormais couvertes par de nouvelles normes génériques relatives à la sécurité des machines. Les exigences de l’IEC 61496-1 ont été harmonisées avec des références à ces nouvelles normes génériques.

General Information

Status
Published
Publication Date
13-Jul-2020
Current Stage
PPUB - Publication issued
Completion Date
14-Jul-2020
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IEC 61496-1
Edition 4.0 2020-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety of machinery – Electro-sensitive protective equipment –
Part 1: General requirements and tests
Sécurité des machines – Équipements de protection électrosensibles –
Partie 1: Exigences générales et essais
IEC 61496-1:2020-07(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 61496-1
Edition 4.0 2020-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety of machinery – Electro-sensitive protective equipment –
Part 1: General requirements and tests
Sécurité des machines – Équipements de protection électrosensibles –
Partie 1: Exigences générales et essais
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 13.110; 29.260.99 ISBN 978-2-8322-8435-3

Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 61496-1:2020 © IEC 2020
CONTENTS

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

INTRODUCTION ..................................................................................................................... 7

1 Scope .............................................................................................................................. 8

2 Normative references ...................................................................................................... 9

3 Terms and definitions .................................................................................................... 10

4 Functional, design and environmental requirements ...................................................... 14

4.1 Functional requirements ........................................................................................ 14

4.1.1 Normal operation ......................................................................................... 14

4.1.2 Sensing function .......................................................................................... 15

4.1.3 Types of ESPE ............................................................................................ 15

4.1.4 Types and required safety performance ....................................................... 15

4.1.5 Required PL or SIL and corresponding ESPE type ...................................... 16

4.2 Design requirements ............................................................................................. 16

4.2.1 Electrical supply .......................................................................................... 16

4.2.2 Fault detection requirements ........................................................................ 17

4.2.3 Electrical equipment of the ESPE................................................................. 18

4.2.4 Output signal switching devices (OSSDs) .................................................... 19

4.2.5 Indicator lights and displays ......................................................................... 21

4.2.6 Adjustment means ....................................................................................... 22

4.2.7 Disconnection of electrical assemblies ......................................................... 22

4.2.8 Non-electrical components ........................................................................... 22

4.2.9 Common cause failures ............................................................................... 22

4.2.10 Programmable or complex integrated circuits ............................................... 22

4.2.11 Software, programming, functional design of integrated circuits ................... 22

4.2.12 Integrity of the ESPE detection capability..................................................... 23

4.2.13 Test piece .................................................................................................... 23

4.3 Environmental requirements ................................................................................. 23

4.3.1 Ambient air temperature range and humidity ................................................ 23

4.3.2 Electrical disturbances ................................................................................. 23

4.3.3 Mechanical environment .............................................................................. 26

4.3.4 Enclosures ................................................................................................... 27

4.3.5 Light interference ......................................................................................... 27

5 Testing .......................................................................................................................... 28

5.1 General ................................................................................................................. 28

5.1.1 Type tests .................................................................................................... 28

5.1.2 Test conditions ............................................................................................ 29

5.1.3 Test results .................................................................................................. 30

5.2 Functional tests .................................................................................................... 30

5.2.1 Sensing function .......................................................................................... 30

5.2.2 Response time ............................................................................................. 30

5.2.3 Limited functional tests ................................................................................ 31

5.2.4 Periodic test................................................................................................. 31

5.2.5 Indicator lights and displays ......................................................................... 32

5.2.6 Means of adjustment .................................................................................... 32

5.2.7 Rating of components .................................................................................. 32

5.2.8 Output signal switching devices (OSSD) ...................................................... 32

---------------------- Page: 4 ----------------------
IEC 61496-1:2020 © IEC 2020 – 3 –

5.3 Performance testing under fault conditions ........................................................... 33

5.3.1 General........................................................................................................ 33

5.3.2 Type 1 ESPE ............................................................................................... 33

5.3.3 Type 2 ESPE ............................................................................................... 33

5.3.4 Type 3 ESPE ............................................................................................... 33

5.3.5 Type 4 ESPE ............................................................................................... 33

5.4 Environmental tests .............................................................................................. 34

5.4.1 Rated supply voltage ................................................................................... 34

5.4.2 Ambient temperature variation and humidity ................................................ 34

5.4.3 Effects of electrical disturbances ................................................................. 35

5.4.4 Mechanical influences .................................................................................. 40

5.4.5 Enclosures ................................................................................................... 42

5.4.6 Light interference ......................................................................................... 42

5.5 Validation of programmable or complex integrated circuits .................................... 44

5.5.1 General........................................................................................................ 44

5.5.2 Complex or programmable integrated circuits .............................................. 44

5.5.3 Software, programming, functional design of integrated circuits ................... 44

5.5.4 Test results analysis statement .................................................................... 44

6 Marking for identification and for safe use ..................................................................... 44

6.1 General ................................................................................................................. 44

6.2 ESPE supplied from a dedicated power supply ..................................................... 45

6.3 ESPE supplied from an internal electrical power source ........................................ 45

6.4 Adjustment ............................................................................................................ 45

6.5 Enclosures ............................................................................................................ 45

6.6 Control devices ..................................................................................................... 46

6.7 Terminal markings ................................................................................................ 46

6.8 Marking durability ................................................................................................. 46

7 Accompanying documents ............................................................................................. 46

Annex A (normative) Optional functions of the ESPE ........................................................... 49

A.1 General ................................................................................................................. 49

A.2 External device monitoring (EDM) ......................................................................... 49

A.2.1 Functional requirements .............................................................................. 49

A.2.2 Fault condition requirements ........................................................................ 49

A.2.3 Verification .................................................................................................. 49

A.2.4 Information for use ....................................................................................... 50

A.3 Stopping performance monitor (SPM) ................................................................... 50

A.3.1 Functional requirements .............................................................................. 50

A.3.2 Fault condition requirements ........................................................................ 50

A.3.3 Verification .................................................................................................. 50

A.3.4 Marking........................................................................................................ 51

A.4 Secondary switching device (SSD) ........................................................................ 51

A.4.1 Functional requirements .............................................................................. 51

A.4.2 Fault condition requirements ........................................................................ 51

A.4.3 Verification .................................................................................................. 51

A.5 Start interlock ....................................................................................................... 51

A.5.1 Functional requirements .............................................................................. 51

A.5.2 Fault condition requirements ........................................................................ 52

A.5.3 Verification .................................................................................................. 52

A.5.4 Indication ..................................................................................................... 52

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– 4 – IEC 61496-1:2020 © IEC 2020

A.6 Restart interlock .................................................................................................... 52

A.6.1 Functional requirements .............................................................................. 52

A.6.2 Fault condition requirements ........................................................................ 52

A.6.3 Verification .................................................................................................. 52

A.6.4 Indication ..................................................................................................... 53

A.7 Muting................................................................................................................... 53

A.7.1 General........................................................................................................ 53

A.7.2 Functional requirements .............................................................................. 53

A.7.3 Fault condition requirements ........................................................................ 53

A.7.4 Verification .................................................................................................. 53

A.7.5 Indication ..................................................................................................... 54

A.8 Reinitiation of machine operation facility ............................................................... 54

A.8.1 General........................................................................................................ 54

A.8.2 Functional requirements .............................................................................. 54

A.8.3 Fault condition requirements ........................................................................ 54

A.8.4 Verification .................................................................................................. 54

A.9 Setting the detection zone and/or other safety-related parameters ........................ 55

A.9.1 Functional requirements .............................................................................. 55

A.9.2 Verification .................................................................................................. 55

Annex B (normative) Catalogue of single faults affecting the electrical equipment of

the ESPE, to be applied as specified in 5.3 ........................................................................... 56

B.1 General ................................................................................................................. 56

B.2 Conductors and connectors .................................................................................. 56

B.3 Switches ............................................................................................................... 56

B.4 Discrete electrical components ............................................................................. 56

B.5 Solid-state electrical components .......................................................................... 56

B.6 Motors .................................................................................................................. 56

Annex C (informative) Design review ................................................................................... 57

Bibliography .......................................................................................................................... 58

Figure 1 – Examples of ESPEs using safety-related communication interfaces ..................... 21

Figure 2 – Test setup for the EMC test of ESPEs with safety-related communication

interfaces .............................................................................................................................. 30

Table 1 – Types and required safety performance ................................................................. 15

Table 2 – Required PL or SIL and corresponding ESPE type ............................................... 16

Table 3 – Supply voltage dips and interruptions for AC power ports ...................................... 24

Table 4 – Supply voltage dips and interruptions for DC power ports ...................................... 24

Table 5 – Vibration test for stationary use ............................................................................. 40

Table 6 – Sinusoidal vibration test for ground vehicle installations ........................................ 40

Table 7 – Broadband vibration test for ground vehicle installations ....................................... 41

Table 8 – Shock test for stationary use ................................................................................. 41

Table 9 – Shock test for ground vehicle installation............................................................... 42

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IEC 61496-1:2020 © IEC 2020 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
SAFETY OF MACHINERY –
ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT –
Part 1: General requirements and tests
FOREWORD

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International Standard IEC 61496-1 has been prepared by IEC technical committee 44: Safety

of machinery – Electrotechnical aspects.

This fourth edition cancels and replaces the third edition published in 2012. This edition

constitutes a technical revision.

This edition includes the following significant technical changes with respect to the previous

edition:

a) It has been clarified that some requirements for ESPEs that are dependent on sensing

technology are not included in IEC 61496-1. They are provided in a subsequent part of

IEC 61496.

b) Requirements for protection against environmental influences from subsequent parts of

IEC 61496 that are common to all ESPEs have been consolidated into IEC 61496-1.
---------------------- Page: 7 ----------------------
– 6 – IEC 61496-1:2020 © IEC 2020

c) Some test procedures in IEC 61496-1 were incomplete. They have been expanded with

more detail and step by step procedures.

d) Some requirements and procedures in IEC 61496-1 are now covered by new generic

machine safety standards. The requirements in IEC 61496-1 have been harmonized with

references to the new generic standards.
The text of this International Standard is based on the following documents:
FDIS Report on voting
44/874/FDIS 44/877/RVD

Full information on the voting for the approval of this International Standard can be found in

the report on voting indicated in the above table.

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

A list of all the parts in the IEC 61496 series, published under the general title Safety of

machinery – Electro-sensitive protective equipment, can be found on the IEC website.

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

stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to

the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 8 ----------------------
IEC 61496-1:2020 © IEC 2020 – 7 –
INTRODUCTION

An electro-sensitive protective equipment (ESPE) is applied to machinery presenting a risk of

personal injury. It provides protection by causing the machine to revert to a safe condition

before a person can be placed in a hazardous situation.

This document provides general design and performance requirements of ESPEs for use over

a broad range of applications. Essential features of equipment meeting the requirements of

this document are the appropriate level of safety-related performance provided and the

built-in periodic functional checks/self-checks that are specified to ensure that this level of

performance is maintained.

Each type of machine presents its own particular hazards and it is not the purpose of this

document to recommend the manner of application of the ESPE to any particular machine.

The application of the ESPE is a matter for agreement between the equipment supplier, the

machine user and the enforcing authority, and in this context attention is drawn to the relevant

guidance established internationally, for example ISO 12100.

This document specifies technical requirements of electro-sensitive protective equipment. The

application of this document may require the use of substances and/or test procedures that

could be injurious to health unless adequate precautions are taken. Conformance with this

document in no way absolves either the supplier or the user from statutory obligations relating

to the safety and health of persons during the use of the equipment covered by this document.

The requirements of this document are highly dependent on analysis and expertise in specific

test and measurement techniques. In order to provide a high level of confidence, independent

review is recommended.
---------------------- Page: 9 ----------------------
– 8 – IEC 61496-1:2020 © IEC 2020
SAFETY OF MACHINERY –
ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT –
Part 1: General requirements and tests
1 Scope
This part of IEC 61496 specifies general requirements for the de
...

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