kSIST FprEN IEC 61800-5-3:2021

Adjustable speed electrical power drive systems - Part 5-3: Safety requirements for encoders - Functional, Electrical and Environmental

IEC 61800-5-3:2021, which is a product standard, specifies requirements and makes recommendations for the design and development, integration and validation of safety-related encoder (Encoder(SR)) in terms of their functional safety considerations, electrical safety and environmental conditions. It applies to Encoder(SR), being sensors as part of a PDS(SR). This document can also be referred to and used for Encoder(SR) in any other safety-related application, for example safety-related position monitoring.
This document is applicable where functional safety of an encoder is claimed and the Encoder(SR) is operating mainly in the high demand or continuous mode. The requirements of IEC 61800-5-2:2016 for PDS(SR) apply to Encoder(SR) as applicable.
This document includes additional or different requirements for Encoder(SR). It sets out safety-related considerations of Encoder(SR) in terms of the framework of IEC 61508 (all parts), and introduces requirements for Encoder(SR) as subsystems of a safety-related system. It is intended to facilitate the realisation of the electrical/electronic/programmable electronic (E/E/PE) and mechanical parts of an Encoder(SR) in relation to the safety performance of safety sub-function(s) of an Encoder(SR).

Elektrische Leistungsantriebssysteme mit einstellbarer Drehzahl – Teil 5-3: Anforderungen an die Sicherheit von Encodern (Gebern) – Funktional, elektrisch und umwelttechnisch

Entraînements électriques de puissance à vitesse variable - Partie 5-3: Exigences de sécurité - Exigences fonctionnelle, électrique et environnementale pour codeurs

L'IEC 61800-5-3:2021, qui est une norme de produit, spécifie des exigences et donne des recommandations pour la conception et le développement, l'intégration et la validation des codeurs relatifs à la sécurité (codeurs(SR)), au regard de leur sécurité fonctionnelle, de leur sécurité électrique et des conditions d'environnement. Elle s'applique aux codeurs(SR) qui sont des capteurs qui font partie d'un PDS(SR). Le présent document peut également servir de référence et être utilisé pour les codeurs(SR) dans le cadre de toute autre application relative à la sécurité, par exemple la surveillance de position relative à la sécurité.
Le présent document est applicable lorsque la sécurité fonctionnelle d'un codeur est revendiquée et que le codeur(SR) fonctionne principalement en mode à sollicitation élevée ou en mode continu.
Les exigences de l'IEC 61800-5-2:2016 concernant les PDS(SR) s'appliquent aux codeurs(SR), selon le cas. Le présent document comprend des exigences supplémentaires ou différentes pour les codeurs(SR). Il expose des considérations relatives à la sécurité des codeurs(SR), prises dans le cadre de l'IEC 61508 (toutes les parties), et présente des exigences pour les codeurs(SR) en tant que sous-systèmes d'un système relatif à la sécurité. Il est destiné à faciliter la réalisation des parties électriques/électroniques/électroniques programmables (E/E/PE) d'un codeur(SR) en liaison avec la performance de sécurité d'une ou de plusieurs sous-fonctions de sécurité d'un codeurs(SR)

Električni pogonski sistemi z nastavljivo hitrostjo - 5-3. del: Varnostne zahteve za kodirnike - Funkcionalne, električne in okoljske

General Information

• Status: Not Published
• Public Enquiry End Date: 10-Mar-2020
• ICS: 29.200 - Rectifiers. Convertors. Stabilized power supply
• Technical Committee: MOV - Measuring equipment for electromagnetic quantities
• Current Stage: 5020 - Formal vote (FV) (Adopted Project)
• Start Date: 01-Dec-2020
• Due Date: 19-Jan-2021
• Completion Date: 29-Jan-2021
• Directive: 2006/42/EC - Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast)
• Mandate: M/396 - Mandate to CEN and Cenelec for standardisation in the field of machinery
• Ref Project: FprEN IEC 61800-5-3:2020 - Adjustable speed electrical power drive systems - Part 5-3: Safety requirements - Functional, electrical and environmental requirements for encoders

Standards Content (Sample)

SLOVENSKI STANDARD
oSIST prEN IEC 61800-5-3:2020
01-marec-2020
Električni pogonski sistemi z nastavljivo hitrostjo - 5-3. del: Varnostne zahteve za
kodirnike - Funkcionalne, električne in okoljske
Adjustable speed electrical power drive systems - Part 5-3: Safety requirements for
encoders - Functional, Electrical and Environmental
Ta slovenski standard je istoveten z: prEN IEC 61800-5-3:2019
ICS:
29.200 Usmerniki. Pretvorniki. Rectifiers. Convertors.
Stabilizirano električno Stabilized power supply
napajanje
oSIST prEN IEC 61800-5-3:2020 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN IEC 61800-5-3:2020

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oSIST prEN IEC 61800-5-3:2020

22G/406/CDV

COMMITTEE DRAFT FOR VOTE (CDV)
PROJECT NUMBER:
IEC 61800-5-3 ED1
DATE OF CIRCULATION: CLOSING DATE FOR VOTING:
2019-12-20 2020-03-13
SUPERSEDES DOCUMENTS:
22G/383/CD,22G/400/CC

IEC SC 22G : ADJUSTABLE SPEED ELECTRIC DRIVE SYSTEMS INCORPORATING SEMICONDUCTOR POWER CONVERTERS
SECRETARIAT: SECRETARY:
United States of America Mr Christopher Johnson
OF INTEREST TO THE FOLLOWING COMMITTEES: PROPOSED HORIZONTAL STANDARD:


Other TC/SCs are requested to indicate their interest, if any,
in this CDV to the secretary.
FUNCTIONS CONCERNED:

EMC ENVIRONMENT QUALITY ASSURANCE SAFETY
SUBMITTED FOR CENELEC PARALLEL VOTING NOT SUBMITTED FOR CENELEC PARALLEL VOTING
Attention IEC-CENELEC parallel voting
The attention of IEC National Committees, members of
CENELEC, is drawn to the fact that this Committee Draft for
Vote (CDV) is submitted for parallel voting.
The CENELEC members are invited to vote through the
CENELEC online voting system.

This document is still under study and subject to change. It should not be used for reference purposes.
Recipients of this document are invited to submit, with their comments, notification of any relevant patent rights of which they
are aware and to provide supporting documentation.

TITLE:
Adjustable speed electrical power drive systems - Part 5-3: Safety requirements for encoders - Functional,
Electrical and Environmental

PROPOSED STABILITY DATE: 2022

NOTE FROM TC/SC OFFICERS:


Copyright © 2019 International Electrotechnical Commission, IEC. All rights reserved. It is permitted to download this
electronic file, to make a copy and to print out the content for the sole purpose of preparing National Committee positions.
You may not copy or "mirror" the file or printed version of the document, or any part of it, for any other purpose without
permission in writing from IEC.

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1
2
3 CONTENTS
4
5 FOREWORD . 7
6 INTRODUCTION . 9
7 1 Scope . 9
8 2 Normative references . 11
9 3 Terms and definitions . 12
10 4 Safety sub-functions . 18
11 4.1 General . 18
12 4.2 Safe incremental position (SIP) . 18
13 4.3 Safe absolute position (SAP) . 19
14 4.4 Safe speed value (SSV) . 19
15 4.5 Safe acceleration value (SAV) . 19
16 4.6 Safety sub-functions for evaluation and signalling . 19
17 5 Management of functional safety . 19
18 6 Requirements for design and development . 19
19 6.1 General requirements . 19
20 6.2 Design standards . 22
21 6.3 Fault detection . 22
22 6.4 Design requirements for specific types of Encoder(SR) . 23
23 6.4.1 Design requirements for Encoder(SR) with sine and cosine output signal . 23
24 6.4.2 Design requirements for Encoder(SR) with incremental and absolute output
25 signals . 23
26 6.4.3 Design requirements for Encoder(SR) with square wave signal interface . 24
27 6.4.4 Design requirements for Resolver . 24
28 6.5 Design requirements regarding Mechanics . 25
29 6.5.1 General . 25
30 6.5.2 Design requirements for mechanical fastenings . 25
31 6.5.3 Design requirements for mechanical connecting elements. 25
32 6.5.4 Bearings . 25
33 6.6 Design requirements for signal generation . 26
34 6.6.1 General . 26
35 6.6.2 Design requirements for signal generation of optical Encoder(SR) . 26
36 6.6.3 Design requirements for signal generation of magnetic Encoder(SR) . 26
37 6.7 Design requirements for signal processing . 26
38 6.8 Design requirements for internal evaluation and signaling . 26
39 6.9 Design requirements for software . 26
40 6.10 Pre-setting . 27
41 6.11 Parameterization . 27
42 6.12 Design requirements for thermal immunity . 27
43 6.13 Design requirements for mechanical immunity . 27
44 6.14 Design requirements for integrated connection cables . 27
45 7 Information for use . 27
46 7.1 General . 27
47 7.2 Labels . 27
48 7.3 Information and instructions for safe application of an Encoder(SR) . 27

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49 8 Verification and validation . 27
50 8.1 General . 27
51 8.2 Verification of hardware fault tolerance . 28
52 8.3 Additional verification for Encoder(SR) with sine and cosine output signal . 28
53 8.3.1 Verification of diagnostic measures for Encoder(SR) with sine and cosine
54 output signal with HFT=0 . 28
55 8.3.2 Suitability for interpolation . 28
56 8.4 Qualitative FMEDA . 28
57 8.5 Quantification . 29
58 9 Test requirements . 29
59 9.1 General . 29
60 9.2 Planning of tests . 29
61 9.3 Functional testing . 29
62 9.4 Electromagnetic (EM) and electrical immunity testing . 29
63 9.4.1 Electrical tests . 29
64 9.4.2 Electromagnetic (EM) immunity testing . 30
65 9.5 Thermal immunity testing . 30
66 9.5.1 General . 30
67 9.5.2 Dry cold . 30
68 9.5.3 Dry heat . 30
69 9.5.4 Damp heat . 30
70 9.5.5 Temperature rise test . 31
71 9.6 Mechanical immunity testing . 31
72 9.6.1 Clearances and creepage distances . 31
73 9.6.2 Short-circuit testing of printed wiring boards . 31
74 9.6.3 Mechanical fastenings . 31
75 9.6.4 Mechanical connecting elements . 31
76 9.6.5 Vibration and shock test . 32
77 9.6.6 Mechanical properties of electrical connections . 32
78 9.6.7 Testing the non-touchability . 32
79 9.6.8 Deformation testing . 32
80 9.7 Material tests . 32
81 9.8 Suitability of the components and materials used . 33
82 9.9 Integrated connection cables . 33
83 9.10 Contamination of solid measure . 33
84 9.11 Labels . 33
85 9.12 Instructions . 34
86 9.13 Test documentation . 34
87 10 Modification . 34
88 Annex A (informative) Types of Encoder(SR) . 35
89 Annex B (informative) Universal architecture of Encoder(SR) . 38
90 B.1 General . 38
91 B.2 The Universal Encoder(SR) architecture . 38
92 Annex C (informative) Examples of suitable mechanical tests for rotary Encoder(SR) . 40
93 C.1 General . 40
94 C.2 Mechanical Fastening of the Encoder(SR) . 40
95 C.2.1 Force-locked connection (e.g. by bolted joints) . 40
96 C.2.2 Form-locked connection (e.g. by feather key) . 40

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97 C.3 Mechanical connecting elements of the Encoder (SR) - Stator coupling (torque
98 support) or shaft-rotor coupling . 40
99 C.3.1 General . 40
100 C.3.2 Axial loads . 41
101 C.3.3 Radial loads . 41
102 Annex D (informative) Extended shock testing for rotary Encoder(SR) mounted to motors. 42
103 D.1 General . 42
104 D.2 Pseudo-Velocity Shock-Response Spectrum (PVSRS) . 42
105 D.3 Verification of resilience . 42
106 D.4 Testing machine . 43
107 Annex E (informative) Dimensioning of clearances and creepage distances on printed wiring
108 boards - Example . 45
109 E.1 General . 45
110 E.2 Assumptions. 45
111 E.3 Application of IEC 61800-5-1:2016 CSV, Clause 5.2.2.1 . 45
112 Annex F (normative) Information and instructions – detailed list . 46
113 Annex G (informative) Encoder(SR) fault lists and fault exclusions . 49
114 Annex H (informative) Quantification . 53
115 H.1 General . 53
116 H.2 Safety architecture and safety-related block diagram. 53
117 H.3 Failure rates . 54
118 H.4 Failure rates at realistic working temperatures . 55
119 H.5 Quantitative FMEDA and assessment of diagnostic measures . 56
120 H.6 Estimation of the common cause factor β (only in case of redundancy) . 57
121 H.7 Estimation of the PFH . 57
122 H.8 Safe failure fraction (SFF) . 57
123 H.9 Determination of the quantitative SIL capability . 58
124 H.9.1 SIL limit by architectural constraints . 58
125 H.9.2 SIL limit by PFH . 58
126 H.10 Additional considerations to comply with ISO 13849-1 . 59
127 H.10.1 General . 59
128 H.10.2 MTTF of a channel . 59
D
129 H.10.3 Determination of the quantitative category capability . 59
130 H.10.4 Determination of the quantitative PL-capability . 59
131 Annex I (informative) Digital processing of sine/cosine signals . 60
132 I.1 General . 60
133 I.2 Sampling of sine and cosine signals . 60
134 I.3 Consequences . 61
135 I.4 Measures to improve DC . 61
136 Annex J (informative) Single channel architecture with ideal fault detection . 63
137 J.1 General . 63
138 J.2 Ideal fault detection for Encoder(SR) with sine and cosine output signal . 63
139 Annex K (informative) Quantification - Specifics for single channel incremental Encoder(SR)
140 with sine and cosine output signal . 65
141 K.1 General . 65
142 K.2 Single-fault tolerance . 65
143 K.3 Undetectable faults . 65
144 K.4 Fault detection (DC) . 65

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145 Annex L (normative) Static analysis of signal evaluation and fault detection . 67
146 L.1 General . 67
147 L.2 Motivation for the analysis of signal evaluation and fault detection . 67
148 L.3 What does “static analysis of signal processing” mean? . 67
149 L.4 Standard test signals . 70
150 L.4.1 Make test signal available (Step 1) . 70
151 L.5 Simulation of signal processing to specification . 75
152 L.5.1 General . 75
153 L.6 Assessment of the signal processing specification . 77
154 L.6.1 General . 77
155 L.6.2 Assessment concept for the signal processing specification . 79
156 L.7 FMEDA Encoder(SR) for verification of the diagnostic coverage . 81
157 L.7.1 General . 81
158 L.7.2 Explanation of the problem . 81
159 L.7.3 Procedure for FMEDA . 83
160 L.8 List of variables used for performing static analysis . 84
161 L.9 MS Excel tool for performance of static analysis . 86
162
163 Figure 1 – Context of Encoder(SR) . 11
164 Figure 2 – Example of an hardware architecture of Encoder(SR) with incremental and
165 absolute output signal . 24
166 Figure B.1 – Universal Encoder(SR) architecture . 38
167 Figure C.1 – Example of an additional ring for assembly with eccentricity x . 41
168 Figure D. 1 –Sample shock (a) and corresponding PVSRS on 4CP (b) . 42
169 Figure D.2 – Testing machine . 43
170 Figure I.1 – Digital sampling of sine and cosine signals - hardware architecture, example . 60
171 Figure I.2 – Lissajous figures of the sine and cosine signals A and B . 61
172 Figure K.1 – Static analysis of signal evaluation and fault detection . 66
173 Figure L.1 – Static analysis concept . 68
174 Figure L.2 – Static analysis procedure (for one test signal) with variable denominations . 70
175 Figure L.3 – Substitute circuit for Encoder(SR)’s outbound interface . 71
176 Figure L.4 – Example of a circuit for evaluation of the output signals and diagnostics of
177 Encoder(SR) faults . 76
178 Figure L.5 – Lissajous diagrams (representation of signal B over signal A) in the fault free
179 case (a) and in the event of a critical Encoder(SR) fault (b) . 83
180 Figure L.6 – Examples of the dual effect of a single component fault a) Differential amplifier
181 with operating point setting b) Inverting amplifier with operating point setting . 84
182
183 Table 1 – List of terms and definitions . 12
184 Table 2 – Applicable Clauses of IEC 61800-5-2:2016 for Encoder(SR) and respective
185 modifications . 19
186 Table 3 – Applicable Clauses of IEC 61800-5-1:2016 CSV for Encoder(SR) and respective
187 modifications . 21
188 Table A.1 – Types of Encoder(SR) . 35
189 Table B.1 – Function blocks of the Universal Encoder(SR) architecture . 38
190 Table G.1 – Encoder(SR) – mechanic fault list and fault exclusions . 50

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191 Table G.2 – Faults and fault exclusions for the selection, mounting and operation of rolling
192 bearings . 50
193 Table G.3 – Factors influencing the malfunctioning of rolling bearings – considerations for
194 selection, mounting and operation . 51
195 Table H.1 – Components for Encoder(SR) and their inclusion in quantification . 55
196
197
198

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199 INTERNATIONAL ELECTROTECHNICAL COMMISSION
200 ____________
201
202 IEC 61800 ADJUSTABLE SPEED ELECTRICAL
203 POWER DRIVE SYSTEMS –
204
205 Part 5-3: Safety requirements for encoders – functional, electrical and
206 environmental
207
208 FOREWORD
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239 International Standard IEC XXXXX has been prepared by subcommittee XX: TITLE, of IEC technical
240 committee XX:
241 The text of this International Standard is based on the following documents:
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242
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245 This document has b
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