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© B
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BRITISH STANDARD
BS EN 60974-4:2007Arc welding equipment —Part 4: In-service inspection and testing
The European Standard EN 60974-4:2007 has the status of a British Standard
ICS 25.160
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BS EN 60974-4:2007
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© B
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This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 March 2007
© BSI 2007
dist
ribu
ISBN 978 0 580 50304 7
National foreword
This British Standard was published by BSI. It is the UK implementation of EN 60974-4:2007. It is identical with IEC 60974-4:2006.The UK participation in its preparation was entrusted to Technical Committee WEE/6, Electric arc welding equipment.A list of organizations represented on WEE/6 can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal obligations.
Amendments issued since publication
Amd. No. Date Comments
EUROPEAN STANDARD EN 60974-4 NORME EUROPÉENNE
EUROPÄISCHE NORM February 2007
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
© 2007 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 60974-4:2007 E
ICS 25.160
English version
Arc welding equipment - Part 4: In-service inspection and testing
(IEC 60974-4:2006) Matériel de soudage à l'arc - Partie 4: Inspection et essai en service (CEI 60974-4:2006)
Lichtbogenschweißeinrichtungen - Teil 4: Instandhaltung und Prüfung (IEC 60974-4:2006)
This European Standard was approved by CENELEC on 2006-12-01. 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.
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© B
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EN 60974-4:2007 – 2 –
Foreword
This standard is to be used in conjunction with EN 60974-1.
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)
2007-09-01
– latest date by which the national standards conflicting with the EN have to be withdrawn
(dow)
2009-12-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
__________
The text of document 26/340/FDIS, future edition 1 of IEC 60974-4, prepared by IEC TC 26, Electricwelding, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as EN 60974-4 on 2006-12-01.
This European Standard covers the essential requirements given in Article 4 of Council Directive 89/655/EEC concerning the minimum safety and health requirements for the use of work equipment by workers at work, as amended by Directive 95/63/EC.
The text of the International Standard IEC 60974-4:2006 was approved by CENELEC as a European Standard without any modification.
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© B
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– 3 – EN 60974-4:2007
CONTENTS
1 Scope ............................................................................................................................4 2 Normative references .....................................................................................................4 3 Terms and definitions .....................................................................................................4 4 General requirements .....................................................................................................5
4.1 Qualification of test personnel ................................................................................5 4.2 Test conditions ......................................................................................................5 4.3 Measuring instruments...........................................................................................5 4.4 Periodic inspection and test ...................................................................................5 4.5 Maintenance..........................................................................................................5 4.6 Repair ...................................................................................................................5 4.7 Test sequence .......................................................................................................5
5 Protection against electrical shock ..................................................................................6 5.1 Visual inspection ...................................................................................................6 5.2 Continuity of the protective circuit ..........................................................................6 5.3 Insulation resistance..............................................................................................7 5.4 Welding circuit leakage current ..............................................................................7 5.5 Primary leakage current .........................................................................................8 5.6 No-load voltage (U0) ..............................................................................................9
6 Functional test..............................................................................................................10 6.1 Function ..............................................................................................................10 6.2 Supply-circuit on/off switching device ...................................................................10 6.3 Voltage-reducing device ......................................................................................10 6.4 Magnetic gas valve ..............................................................................................11 6.5 Signal and control lamps......................................................................................11
7 Documentation .............................................................................................................11 7.1 Test report ..........................................................................................................11 7.2 Labelling .............................................................................................................11
Annex A (informative) Check-list for the visual inspection ...................................................12 Annex B (informative) Example of a test report after repair .................................................13 Annex C (informative) Equipment not built in accordance with IEC 60974-1 ........................14 Annex ZA (normative) Normative references to international publications with their
corresponding European publications............................................................................15 Figure 1 – Measurement of leakage current of welding circuit ................................................7 Figure 2 – Measuring network for primary leakage current .....................................................8 Figure 3 – Principles of primary leakage current measurement for single phase equipment ...9 Figure 4 – Measurement of peak values ..............................................................................10
Table 1 – Test sequence on used arc welding equipment.......................................................6 Table 2 – Insulation resistance..............................................................................................7
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© B
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EN 60974-4:2007 – 4 –
ARC WELDING EQUIPMENT –
Part 4: In-service inspection and testing
1 Scope
This part of IEC 60974 specifies test procedures for in-service inspection and, after repair, to ensure electrical safety. These test procedures are also applicable for maintenance.
This standard is applicable to power sources together with ancillary equipment for arc welding, cutting and allied processes built in conformity with IEC 60974-1.
This standard is not applicable to testing of new power sources or engine-driven power sources.
NOTE For a power source not built in accordance with IEC 60974-1, see Annex C.
2 Normative references
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.
IEC 60050-151, International Electrotechnical Vocabulary (IEV) – Part 151: Electrical and magnetic devices
IEC 60050-195, International Electrotechnical Vocabulary (IEV) – Part 195: Earthing and protection against electric shock
IEC 60050-851, International Electrotechnical Vocabulary (IEV) – Chapter 851: Electric welding
IEC 60974-1, Arc welding equipment – Part 1: Welding power sources
IEC 61557-4, Electrical safety in low voltage distribution systems up to 1000 V a.c. and 1500 V d.c. – Equipment for testing, measuring or monitoring of protective measures – Part 4: Resistance of earth connection and equipotential bonding
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-151, IEC 60050-195, IEC 60050-851, IEC 60974-1, as well as the following, apply.
3.1 periodic inspection and test examination carried out at specified intervals to reduce the risk of hazard
3.2 maintenance service carried out at specified intervals to reduce the risk of hazard and failure
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– 5 – EN 60974-4:2007
3.3 repair restore to a safe and intended operating condition
4 General requirements
4.1 Qualification of test personnel
Tests of welding power sources can be hazardous and shall be carried out by an expert in the field of electrical repair, preferably also familiar with welding, cutting and allied processes.
4.2 Test conditions
Tests shall be carried out at an ambient air temperature between 10 °C and 40 °C on a dry and cleaned welding power source.
4.3 Measuring instruments
The accuracy of measuring instruments shall be class 2.5 as a minimum, except for the measurement of insulation resistance, where the accuracy of the instruments is not specified but shall be taken into account for the measurement.
4.4 Periodic inspection and test
The periodic inspection and test specified in Table 1 shall be carried out.
Tests shall be documented in a test report in accordance with 7.1.
4.5 Maintenance
The manufacturer’s maintenance schedule and instructions shall be followed.
Tests shall be documented in a test report in accordance with 7.1.
4.6 Repair
After repair or replacement of a component which restores a welding or cutting function, an expert shall select appropriate tests to be carried out, as specified in Table 1.
NOTE After a minor repair such as replacement of a lamp, wheel or under carriage, the tests given in Table 1 may not be necessary.
Tests shall be documented in a test report in accordance with 7.1.
During the tests, complementary instructions from manufacturer included in repair manual shall be observed (for example, circuit diagrams, functional test, etc.).
4.7 Test sequence
The test sequence is given in Table 1.
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© B
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EN 60974-4:2007 – 6 –
Table 1 – Test sequence on used arc welding equipment
Periodic inspection and test After repair
a) Visual inspection in accordance with 5.1 a) Visual inspection in accordance with 5.1
b) Electrical test: – no-load voltage in accordance with 5.6
– insulation resistance in accordance with 5.3
– protective conductor resistance in accordance with 5.2
b) Electrical test: – no-load voltage in accordance with 5.6
– insulation resistance1 in accordance with 5.3
– protective conductor resistance in accordance with 5.2
c) Functional test: – no requirement
c) Functional test: – function in accordance with 6.1
– supply-circuit on/off switching device in accordance with 6.2
– voltage-reducing device in accordance with 6.3
– magnetic gas valve in accordance with 6.4
– signal and control lamps in accordance with 6.5
d) Documentation in accordance with Clause 7 d) Documentation in accordance with Clause 7
1 The insulation resistance test can be replaced by the primary and welding circuit leakage current tests in accordance with 5.4 and 5.5 .
5 Protection against electrical shock
5.1 Visual inspection
Visual inspection shall be carried out in accordance with the conditions of use of welding equipment and the manufacturer’s instructions.
An example of items for a visual inspection is given in Annex A.
5.2 Continuity of the protective circuit
For mains-powered welding equipment of protection class I, including ancillary equipment (for example, cooling system) having mains connecting cables up to a length of 5,0 m, the maximum measured protective conductor resistance shall not exceed 0,3 Ω.
For cables longer than 5,0 m, the permissible value of the protective conductor resistance is increased by 0,1 Ω per additional 7,5 m cable. The maximum permissible value of the protective conductor resistance is 1 Ω.
Conformity shall be checked by measuring the resistance between the protective conductor contact at the plug and exposed conductive parts with testing equipment according to IEC 61557-4.
During the measurement, the cables shall be bent, flexed or twisted along the whole length, especially in the vicinity of cable entries into the enclosure, in order to detect interruptions in the protective conductor.
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© B
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– 7 – EN 60974-4:2007
5.3 Insulation resistance
The insulation resistance shall be not less than the values given in Table 2.
Table 2 – Insulation resistance
Supply circuit to welding circuit 5,0 MΩ
Welding circuit to protective circuit 2,5 MΩ
Supply circuit to protective circuit 2,5 MΩ
Torches shall be disconnected during the measurement.
Welding power source including a liquid cooling unit shall be tested without liquid.
Conformity shall be checked by the stabilized measurement of the insulation resistance by application of a d.c. voltage of 500 V at room temperature.
5.4 Welding circuit leakage current
The leakage current between the welding outlets and the protective conductor terminal shall not exceed 10 mA a.c. r.m.s.
Conformity shall be checked by measurement of the leakage current with a circuit as shown in Figure 1 at the rated supply voltage and no-load condition.
The measuring circuit shall have a total resistance of 1 750 Ω ± 250 Ω and be shunted by a capacitor so that the time constant of the circuit will be 225 μs ± 15 μs.
In the case of 1 750 Ω, the capacitor will be 130 nF.
mA
1 750 Ω
130 nF
IEC 1904/06
Figure 1 – Measurement of leakage current of welding circuit
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© B
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EN 60974-4:2007 – 8 –
5.5 Primary leakage current
The primary leakage current in the external protective conductor shall not exceed
a) 5 mA for plug-connected equipment rated up to and including 32 A; b) 10 mA for plug-connected equipment rated more than 32 A; c) 10 mA for equipment for permanent connection, without special measures for the
protective conductor; d) 5 % of the rated input current per phase, for equipment for permanent connection with a
reinforced protective conductor.
Conformity shall be checked using the measuring circuit shown in Figure 2 under the following conditions:
a) the welding power source is – isolated from the ground plane; – supplied by the rated supply voltage; – not connected to the protective earth except through measurement components;
b) the output circuit is in the no-load condition; c) interference suppression capacitors shall not be disconnected.
NOTE The circuit given in Figure 2 is used to obtain reproducible results. The use of a conventional ammeter is not recommended because the value will be incorrect.
RS
RB
R1
C1 U2U1
A
B
CS
IEC 1905/06
Key
A, B Test terminals CS 0,22 μF
RS 1 500 Ω R1 10 000 Ω
RB 500 Ω C1 0,022 μF
Leakage current B
2PE R
UI =
Figure 2 – Measuring network for primary leakage current
The measurement of the primary leakage current may be made direct or in the form of a difference current measurement (see Figure 3). Instead of the ammeter shown in Figure 3, the measuring circuit in Figure 2 shall be used.
Equipment for permanent connection with a reinforced protective conductor shall be tested according to the manufacturer’s specification.
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© B
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– 9 – EN 60974-4:2007
Power source
IPE
PE N/L L
A
A
B
IOut IIn
Measuring instrument
IEC 1906/06
Power source
IOut
PE N/L L Measuring instrument
A
A
B
IIn IDif.
IEC 1907/06
Principle of direct measurement Principle of measurement according to the difference current procedure
Figure 3 – Principles of primary leakage current measurement for single phase equipment
NOTE Caution! A qualified person should perform this test. The protective conductor is disabled for this test.
5.6 No-load voltage (U0)
The peak values of the maximum no-load voltage at all possible settings shall not exceed the values given in the rating plate when the power source is supplied at rated supply voltage and frequency.
Before testing, arc striking and stabilizing devices shall, if necessary, be removed or by-passed according to the manufacturer’s instructions (see also instructions for use or manufacturer’s testing instructions).
The no-load voltage is measured between welding output terminals. If this is not possible for safety or control reasons (for example, with welding power sources for plasma cutting), the no-load voltage is measured between torch and welding return cable connection.
If UR or US are defined on the rating plate, UR or US shall be measured instead of U0.
Conformity shall be checked by measurement of
a) r.m.s. values
A true r.m.s. meter is used with a resistance of the external welding circuit of 5 kΩ with a maximum tolerance of ±5 %.
b) peak values To obtain reproducible measurements of peak values, omitting impulses which are not
dangerous, a circuit is used as shown in Figure 3 and Figure 4.
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EN 60974-4:2007 – 10 –
1 = Diode 1N4007 or similar
U0
0,2 kΩ
0-5 kΩ
10 nF 6,8 μF
1
V
1 kΩ
IEC 1908/06
Figure 4 – Measurement of peak values
The voltmeter shall indicate mean values. The measurement range chosen shall be as near as possible to the actual value of the no-load voltage. The voltmeter shall have an internal resistance of at least 1 MΩ.
The tolerance of the component values in the measurement circuit shall not exceed ±5 %. The minimum power for the resistor of 0,2 kΩ is 65 W. The rheostat shall withstand a current value of 0,6 A. The capacitor shall have a minimum voltage rating of 200 V.
6 Functional test
6.1 Function
Each safety-related function judged as relevant by the test personnel shall be checked for correct operation.
Conformity shall be checked by operating the device and by checking whether the welding power source operates correctly.
6.2 Supply-circuit on/off switching device
Where an integral supply-circuit on/off switching device (for example, switch, contactor or circuit-breaker) is fitted, this shall
a) open or close all ungrounded mains conductors; b) clearly indicate whether the circuit is open or closed.
Conformity shall be checked by visual inspection and measurement.
6.3 Voltage-reducing device
Where a voltage-reducing device is fitted, this shall
a) reduce the rated no-load voltage when the resistance of the external welding circuit exceeds 200 Ω;
b) indicate satisfactory operation.
Conformity shall be checked by connecting a variable load resistor across the welding output connections of the welding power source. Voltage value shall be measured in accordance with 5.6.
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– 11 – EN 60974-4:2007
6.4 Magnetic gas valve
Each magnetic gas valve (for example, TIG, MIG/MAG, PLASMA power sources), shall be checked for correct operation.
Conformity shall be checked by visual inspection and the following operations or by a test specified by the manufacturer.
a) Function Operate the trigger of the torch and check by means of the gas flow whether the magnetic
gas valve operates. b) Leakage Pressurize the system and verify there is no leak, for example, there is no pressure drop.
NOTE Attention should be paid to the fact that also flexible gas tubes and their connections may leak.
6.5 Signal and control lamps
Each signal or control lamp fitted shall be checked for correct operation.
Conformity shall be checked by visual inspection.
7 Documentation
7.1 Test report
The test report shall include
a) identification of tested arc welding equipment;
b) date of testing;
c) test results;
d) signature, identification of the technician and his organization;
e) identification of test equipment.
The test report, after repair, shall include all the tests given in Table 1 and an indication shall be made if a particular test has not been carried out.
An example of a test report is given in Annex B.
7.2 Labelling
A label shall be attached to the equipment to indicate that it has passed the test.
The label shall state the date of testing.
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EN 60974-4:2007 – 12 –
Annex A (informative)
Check-list for the visual inspection
During visual inspection, the following listed items should be checked.
a) Torch/electrode holder, welding current return clamp missing or defective insulation defective connections defective, damaged switches other damage
b) Mains supply defective, damaged cable deformed, faulty plug broken or thermally damaged plug pins ineffective cable anchorage cables and plugs unsuitable for the intended use and performance
c) Welding circuit defective, damaged cable deformed, faulty or thermally damaged coupler/sockets ineffective cable anchorage cables and couplers unsuitable for the intended use and performance
d) Enclosure missing or damaged parts unauthorised modifications cooling openings blocked or missing air filters signs of overload and improper use missing or defective protective devices, for example, gas cylinder holder missing or defective wheels, lifting means, holder, etc. defective wire reel mounting means conductive objects placed in the enclosure
e) Controls and indicators defective switches, meters and lamps defective pressure regulator or flowmeter incorrect fuses accessible from outside the enclosure
f) General condition cooling liquid circuit leaking or incorrect cooling liquid level defective gas hoses and connections poor legibility of markings and labelling other damage or signs of improper use
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– 13 – EN 60974-4:2007
Annex B (informative)
Example of a test report after repair
Test report Company: Sample Ltd. Location: London Torchham WH15 B4
Equipment: Arc welding power source Type: Freefried S/N:
Manufacturer: Freefried Electric Ltd. Protection class:
Testing equipment: Multimeter D6, Metaframe, measuring circuits as given
Date 2005-10-20
Test point: Limit Measured values Visual inspection --- OK
Protective conductor resistance ---
RPE [Ω] ≤ 0,3 Ω 0,2
Insulation resistance ---
- Input circuit/ Protective circuit (500 V) RI-P [MΩ] ≥ 2,5 MΩ N/A
- Welding circuit/ Protective circuit (500 V) RW-P [MΩ] ≥ 2,5 MΩ N/A
- Input circuit/ Welding circuit (1000 V) RI-W [MΩ] ≥ 5 MΩ N/A
Primary leakage current ---
- Plug-connected equipment rated up to 32 A (500 V) IPE [mA] ≤ 5 mA
2
- Plug-connected equipment rated more than 32 A (500 V) IPE [mA] ≤ 10 mA
- Permanent connection without special measures (500 V) IPE [mA] ≤ 10 mA
- Equipment with reinforced protective conductor (500 V) IPE [mA] ≤ 5 %
Welding circuit leakage current ---
IPE [mA] ≤ 10 mA 0,568
No-load voltage ---
U0 [VAC] ≤… Vpeak N/A
U0 [VDC] ≤113 Vpeak 110
Functional test --- ok
Test passed Investigator name --- Myself
Investigator signature --- Me
Remarks (result of visual inspection or functional test): None __________________________
Testing company: Checkmates Limited____________________________________________
Address: London Weldshire WG3 A7 _____________________________________________
Repair: replacement of broken main switch ________________________________________ N/A: Not applicable to the repair according to the investigator
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EN 60974-4:2007 – 14 –
Annex C (informative)
Equipment not built in accordance with IEC 60974-1
Welding equipment not built in accordance with IEC 60974-1 (for example, built prior to the publication date of edition 1) may not meet all requirements of this standard.
In this case, the investigator should state in his report as follows:
– the requirements which have not been met; – the extend to which the requirement has not been met; – the assessment of the risk deriving there of; – the corrective measures when necessary.
The report should enable the owner to take the right decision. In some cases the equipment will need to be taken out of service.
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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
IEC 60050-151 -1) International Electrotechnical Vocabulary (IEV) - Part 151: Electrical and magnetic devices
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IEC 60050-195 -1) International Electrotechnical Vocabulary (IEV) - Chapter 195: Earthing and protection against electric shock
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IEC 60050-851 -1) International electrotechnical vocabulary (IEV) - Chapter 851: Electric welding
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IEC 60974-1 -1) Arc welding equipment - Part 1: Welding power sources
EN 60974-1 20052)
IEC 61557-4 -1) Electrical safety in low voltage distribution systems up to 1 000 V a.c. and 1 500 V d.c. - Equipment for testing, measuring or monitoring of protective measures - Part 4: Resistance of earth connection and equipotential bonding
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1) Undated reference. 2) Valid edition at date of issue.
– 15 – EN 60974-4:2007
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© B
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