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SIThe European Standard EN 60974-4:2007 has the status of a
British Standard
ICS 25.160Arc welding equipment Part 4: In-service inspection
and testiBRITISH STANDARD BS EN 60974-4:2007
-
BS EN 60974-4:2007
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SIThis British Standard was published under the authority of the
Standards Policy and Strategy Committee on 30 March 2007
BSI 2007
ISBN 978 0 580 50304 7
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enseAmendments issued since publication
Amd. No. Date Commentscontract. Users are responsible for its
correct application.Compliance with a British Standard cannot
confer immunity from legal obligations. 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
-
EUROPEAN STANDARD EN 60974-4 NORME EUROPENNE EUROPISCHE NORM
February 2007
CENELEC European Committee for Electrotechnical
Standardization
Comit Europen de Normalisation Electrotechnique Europisches
Komitee fr 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) Matriel de soudage l'arc - Partie 4:
Inspection et essai en service (CEI 60974-4:2006)
Lichtbogenschweieinrichtungen - Teil 4: Instandhaltung und
Prfung (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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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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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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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 manufacturers 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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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 manufacturers
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 .
For cables longer than 5,0 m, the permissible value of the
protective conductor resistance is increased by 0,1 per additional
7,5 m cable. The maximum permissible value of the protective
conductor resistance is 1 .
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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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 M Welding circuit to
protective circuit 2,5 M Supply circuit to protective circuit 2,5
M
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 1 750 250
and be shunted by a capacitor so that the time constant of the
circuit will be 225 s 15 s.
In the case of 1 750 , the capacitor will be 130 nF.
mA
1 750
130 nF
IEC 1904/06
Figure 1 Measurement of leakage current of welding circuit
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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 F RS 1 500 R1 10 000 RB 500 C1 0,022
F
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 manufacturers
specification.
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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 manufacturers
instructions (see also instructions for use or manufacturers
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 k 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 k
0-5 k
10 nF 6,8 F
1
V
1 k
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 M.
The tolerance of the component values in the measurement circuit
shall not exceed 5 %. The minimum power for the resistor of 0,2 k
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 ;
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 [] 0,3
0,2 Insulation resistance --- - Input circuit/
Protective circuit (500 V) RI-P [M] 2,5 M N/A - Welding
circuit/
Protective circuit (500 V) RW-P [M] 2,5 M N/A - Input
circuit/
Welding circuit (1000 V) RI-W [M] 5 M 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
- -
IEC 60050-195 -1) International Electrotechnical Vocabulary
(IEV) - Chapter 195: Earthing and protection against electric
shock
- -
IEC 60050-851 -1) International electrotechnical vocabulary
(IEV) - Chapter 851: Electric welding
- -
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
- -
1) Undated reference. 2) Valid edition at date of issue.
15 EN 60974-4:2007
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BS EN
BSI
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B
SI389 Chiswick High RoadLondonW4 4AL60974-4:2007 BSI British
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60974-4e-ed1.copy.pdf1 Scope 2 Normative references 3 Terms and
definitions 4 General requirements 4.1 Qualification of test
personnel 4.2 Test conditions 4.3 Measuring instruments 4.4
Periodic inspection and test 4.5 Maintenance 4.6 Repair 4.7 Test
sequence 5 Protection against electrical shock 5.1 Visual
inspection 5.2 Continuity of the protective circuit 5.3 Insulation
resistance 5.4 Welding circuit leakage current 5.5 Primary leakage
current 5.6 No-load voltage (U0)
6 Functional test 6.1 Function 6.2 Supply-circuit on/off
switching device 6.3 Voltage-reducing device 6.4 Magnetic gas valve
6.5 Signal and control lamps
7 Documentation 7.1 Test report 7.2 Labelling
