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

IEC 61496-1:2012 specifies general requirements for the design, construction and testing of non-contact electro-sensitive protective equipment (ESPE) designed specifically to detect persons 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 may include optional safety-related functions, the requirements for which are given in Annex A. This third edition cancels and replaces the second edition published in 2004 and its amendment 1 (2007). The main changes with respect to the previous edition are as follows: The design, test and verification requirements have been updated to make them consistent with the latest standards for functional safety and EMC. The contents of the corrigendum of April 2015 have been included in this copy.

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

La CEI 61496-1:2012 définit les prescriptions générales de conception, de construction et d'essai des équipements de protection électro-sensibles (ESPE) sans contact spécifiquement conçus pour détecter des personnes au sein d'un système relatif à la sécurité. Une attention particulière est portée sur les prescriptions de fonctionnement et de conception assurant que le niveau de sécurité approprié est atteint. Un ESPE peut proposer des fonctions optionnelles, liées à la sécurité: les prescriptions pour celles-ci sont énumérées en Annexe A. Cette troisième édition de la CEI 61496-1 annule et remplace la deuxième édition parue en 2004 et son amendement 1 (2007). Par rapport à l'édition précédente, les changements majeurs sont les suivants: les exigences de conception, d'essai et de vérification ont été mises à jour pour les rendre cohérentes avec les normes les plus récentes relatives à la sécurité fonctionnelle et à la CEM (compatibilité électromagnétique). Le contenu du corrigendum d'avril 2015 a été pris en considération dans cet exemplaire.

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IEC 61496-1
Edition 3.0 2012-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety of machinery – Electro-sensitive protective equipment –
Part 1: General requirements and tests
Sécurité des machines – Equipements de protection électro-sensibles –
Partie 1: Prescriptions générales et essais
IEC 61496-1:2012
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 61496-1
Edition 3.0 2012-04
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Safety of machinery – Electro-sensitive protective equipment –
Part 1: General requirements and tests
Sécurité des machines – Equipements de protection électro-sensibles –
Partie 1: Prescriptions générales et essais
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX
ICS 13.110; 29.260.99 ISBN 978-2-8322-0061-2

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 – 61496-1 © IEC:2012
CONTENTS

FOREWORD ........................................................................................................................... 4

INTRODUCTION ..................................................................................................................... 6

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

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

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

4 Functional, design and environmental requirements ....................................................... 13

4.1 Functional requirements ........................................................................................ 13

4.1.1 Normal operation ....................................................................................... 13

4.1.2 Sensing function ........................................................................................ 13

4.1.3 Types of ESPE .......................................................................................... 13

4.1.4 Types and required safety performance ..................................................... 14

4.1.5 Required PL or SIL and corresponding ESPE type ................................... 14

4.2 Design requirements ............................................................................................. 14

4.2.1 Electrical supply ........................................................................................ 14

4.2.2 Fault detection requirements ..................................................................... 15

4.2.3 Electrical equipment of the ESPE .............................................................. 16

4.2.4 Output signal switching devices (OSSD) .................................................... 17

4.2.5 Indicator lights and displays ...................................................................... 19

4.2.6 Adjustment means ..................................................................................... 20

4.2.7 Disconnection of electrical assemblies ...................................................... 20

4.2.8 Non-electrical components ........................................................................ 20

4.2.9 Common cause failures ............................................................................. 20

4.2.10 Programmable or complex integrated circuits ............................................ 20

4.2.11 Software, programming, functional design of integrated circuits ................. 20

4.3 Environmental requirements .................................................................................. 21

4.3.1 Ambient air temperature range and humidity .............................................. 21

4.3.2 Electrical disturbances............................................................................... 21

4.3.3 Mechanical environment ............................................................................ 23

4.3.4 Enclosures ................................................................................................ 24

5 Testing ........................................................................................................................... 24

5.1 General ................................................................................................................. 24

5.1.1 Type tests ................................................................................................. 24

5.1.2 Test conditions .......................................................................................... 25

5.1.3 Test results ............................................................................................... 26

5.2 Functional tests ..................................................................................................... 26

5.2.1 Sensing function ........................................................................................ 26

5.2.2 Response time .......................................................................................... 26

5.2.3 Limited functional tests .............................................................................. 27

5.2.4 Periodic test .............................................................................................. 28

5.2.5 Indicator lights and displays ...................................................................... 28

5.2.6 Means of adjustment ................................................................................. 28

5.2.7 Rating of components ................................................................................ 28

5.2.8 Output signal switching devices (OSSD) .................................................... 28

5.3 Performance testing under fault conditions ............................................................ 29

5.3.1 General ..................................................................................................... 29

5.3.2 Type 1 ESPE ............................................................................................. 29

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61496-1 © IEC:2012 – 3 –

5.3.3 Type 2 ESPE ............................................................................................. 29

5.3.4 Type 3 ESPE ............................................................................................. 29

5.3.5 Type 4 ESPE ............................................................................................. 30

5.4 Environmental tests ............................................................................................... 30

5.4.1 Rated supply voltage ................................................................................. 30

5.4.2 Ambient temperature variation and humidity .............................................. 30

5.4.3 Effects of electrical disturbances ............................................................... 31

5.4.4 Mechanical influences ............................................................................... 33

5.4.5 Enclosures ................................................................................................ 33

5.5 Validation of programmable or complex integrated circuits .................................... 33

5.5.1 General ..................................................................................................... 33

5.5.2 Complex or programmable integrated circuits ............................................ 34

5.5.3 Software, programming, functional design of integrated circuits ................. 34

5.5.4 Test results analysis statement .................................................................. 34

6 Marking for identification and for safe use ...................................................................... 34

6.1 General ................................................................................................................. 34

6.2 ESPE supplied from a dedicated power supply ...................................................... 35

6.3 ESPE supplied from an internal electrical power source ........................................ 35

6.4 Adjustment ............................................................................................................ 35

6.5 Enclosures ............................................................................................................ 35

6.6 Control devices ..................................................................................................... 35

6.7 Terminal markings ................................................................................................. 35

6.8 Marking durability .................................................................................................. 36

7 Accompanying documents .............................................................................................. 36

Annex A (normative) Optional functions of the ESPE .......................................................... 39

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

the ESPE, to be applied as specified in 5.3 ........................................................................... 46

Annex C (informative) Conformity assessment ..................................................................... 47

Bibliography .......................................................................................................................... 48

Index .................................................................................................................................... 49

Figure 1 – Examples of ESPEs using safety-related communication interfaces ..................... 19

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

interfaces .............................................................................................................................. 26

Table 1 – Types and required safety performance ................................................................. 14

Table 2 – Required PL or SIL and corresponding ESPE type ............................................... 14

Table 4 – Supply voltage interruptions .................................................................................. 21

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– 4 – 61496-1 © IEC:2012
INTERNATIONAL ELECTROTECHNICAL COMMISSION
___________
SAFETY OF MACHINERY –
ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT –
Part 1: General requirements and tests
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

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5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity

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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

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

Safety of machinery – Electrotechnical aspects.

This third edition cancels and replaces the second edition published in 2004 and its

amendment 1 (2007). The document 44/615/CDV, circulated to the National Committees as

amendment 2, led to the publication of this new edition.

The main changes with respect to the previous edition are as follows: The design, test and

verification requirements have been updated to make them consistent with the latest

standards for functional safety and EMC.
---------------------- Page: 6 ----------------------
61496-1 © IEC:2012 – 5 –
The text of this standard is based on the following documents:
CDV Report on voting
44/615/CDV 44/641/RVC

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.

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.

A vertical line in the margin shows where the base publication has been modified by

amendment 2.

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

the stability 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.
The contents of the corrigendum of April 2015 have been included in this copy.
---------------------- Page: 7 ----------------------
– 6 – 61496-1 © IEC:2012
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 part of IEC 61496 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 standard 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

standard to recommend the manner of application of the ESPE to any particular machine. The

application of the ESPE should be 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 part of IEC 61496 specifies technical requirements of electro-sensitive protective

equipment. The application of this standard may require the use of substances and/or test

procedures that could be injurious to health unless adequate precautions are taken.

Conformance with this standard 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 standard.

Due to the complexity of the technology used to implement ESPEs, there are many issues

that are highly dependent on analysis and expertise in specific test and measurement

techniques. In order to provide a high level of confidence, independent review by relevant

experts is recommended.
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61496-1 © IEC:2012 – 7 –
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 design, construction and testing

of non-contact electro-sensitive protective equipment (ESPE) designed specifically to detect

persons 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 may include optional safety-related functions, the requirements for which are given in

Annex A.

The particular requirements for specific types of sensing function are given in other parts of

this standard.

This standard 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 standard does not provide specific requirements. Requirements for these

safety-related functions can be determined by consulting other standards (for example,

IEC 61508, IEC/TS 62046, IEC 62061, and ISO13849-1).

This standard may 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 necessary, for example when the materials that

have to be recognized by the sensing function have different properties from those of

persons.

This standard does not deal with electromagnetic compatibility (EMC) emission requirements.

2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and

are indispensable for its application. For dated references, only the edition cited applies. For

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

IEC 60068-2-6, Environmental testing – Part 2-6: Tests – Test Fc: Vibration (sinusoidal)

IEC 60068-2-27, Environmental testing – Part 2-27: Tests – Test Ea and guidance: Shock

IEC 60204-1:2009, Safety of machinery – Electrical equipment of machines – Part 1: General

requirements

IEC 60445, Basic and safety principles for man-machine interface, marking and identification

– Identification of equipment terminals, conductor terminations and conductors

IEC 60447, Basic and safety principles for man-machine interface, marking and identification

– Actuating principles
---------------------- Page: 9 ----------------------
– 8 – 61496-1 © IEC:2012
IEC 60529, Degrees of protection provided by enclosures (IP code)
IEC 60947-1:2011, Low-voltage switchgear and controlgear – Part 1: General rules

IEC 61000-4-2, Electromagnetic compatibility (EMC) – Part 4-2: Testing and measurement

techniques – Electrostatic discharge immunity test

IEC 61000-4-3, Electromagnetic compatibility (EMC) – Part 4-3: Testing and measurement

techniques – Radiated, radio-frequency, electromagnetic field immunity test

IEC 61000-4-4:2004, Electromagnetic compatibility (EMC) – Part 4: Testing and measurement

techniques – Section 4: Electrical fast transient/burst immunity test
IEC 61000-4-5:2005, Electromagnetic compatibility (EMC) – Part 4-5: Testing and
measurement techniques – Surge immunity test

IEC 61000-4-6, Electromagnetic compatibility (EMC) – Part 4-6: Testing and measurement

techniques – Immunity to conducted disturbances, induced by radio-frequency fields

IEC 61000-6-2, Electromagnetic compatibility (EMC) – Part 6-2: Generic standards –

Immunity for industrial environments

IEC 61131-2:2007, Programmable controllers – Part 2: Equipment requirements and tests

IEC 61508 (all parts), Functional safety of electrical/electronic/programmable electronic

safety-related systems

IEC 62061, Safety of machinery – Functional safety of safety-related electrical, electronic and

programmable electronic control systems

IEC/TS 62046, Safety of machinery – Application of protective equipment to detect the

presence of persons
ISO 9001, Quality management systems – Requirements

ISO 12100:2010, Safety of machinery – General principles for design – Risk assessment and

risk reduction

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

principles for design

ISO 13849-2:2003, Safety of machinery – Safety-related parts of control systems – Part 2:

Validation
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

NOTE The index lists, in alphabetical order, the terms and acronyms defined in Clause 3 and indicates where

they are used in the text of this part.
3.1
blanking

optional function that permits an object of a size greater than the detection capability of the

ESPE to be located within the detection zone without causing an OFF-state of the OSSD(s)

Note 1 to entry: Fixed blanking is a technique wherein the locations of the blanked areas of the detection zone do

not change during operation. The detection capability of the other parts of the detection zone remains unchanged.

Note 2 to entry: Floating blanking is a technique wherein the blanked area of the detection zone follows the

location of a moving object(s) during operation. The detection capability of the other areas remains unchanged.

---------------------- Page: 10 ----------------------
61496-1 © IEC:2012 – 9 –
3.2
controlling/monitoring device
part of the electro-sensitive protective equipment (ESPE) that:

– receives and processes information from the sensing device and provides signals to the

output signal switching devices (OSSD),
– monitors the sensing device and the OSSD
3.3
detection capability

sensing function parameter limit specified by the supplier that will cause actuation of the

electro-sensitive protective equipment (ESPE)
3.4
detection zone

zone within which a specified test piece will be detected by the electro-sensitive protective

equipment (ESPE)
3.5
electro-sensitive protective equipment
ESPE

assembly of devices and/or components working together for protective tripping or presence-

sensing purposes and comprising as a minimum
– a sensing device;
– controlling/monitoring devices;
– output signal switching devices and/or a safety-related data interface

Note 1 to the entry: The safety-related control system associated with the ESPE, or the ESPE itself, may further

include a secondary switching device, muting functions, stopping performance monitor, etc. (see Annex A).

Note 2 to entry: A safety-related communication interface can be integrated in the same enclosure as the ESPE.

3.6
external device monitoring
EDM

means by which the electro-sensitive protective equipment (ESPE) monitors the state of

control devices which are external to the ESPE
3.7
failure
termination of the ability of an item to perform a required function
[SOURCE: IEC 60050-191:1990, 191-04-01, modified]
Note 1 to entry: After failure the item has a fault.

Note 2 to entry: 'Failure' is an event, as distinguished from 'fault', which is a state.

Note 3 to entry: This concept, as defined, does not apply to items consisting of software only.

Note 4 to entry: In practice, the t
...

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