Home

DA-EU-M - AutomationDirect

1. PLC Range Markings WV FeTalerel 05 AC 100 240V AC 100 240 10 15 05DC 12 24V DC 10 8 26 4 VDC O6AC 100 240VAC 50 60Hz 100 240 10 15 06DC 12 24V DC 20W 10 8 26 4 VDC 205 AC 100 240V AC 100 240 10 15 205 DC 1 24V DC 10 2 28 8 VDC 205 DC 2 125 240V 125 240V 10 15 305 AC 100 240V AC 100 240 10 15 305 DC O5BDC 24V DC 20 5 30 VDC lt 10 ripple and 10BDC 405 AC 100 120 and 196 240V 100 120 and 196 240 10 15 AC 405 DC 1 20 28V DC 20 29 VDC 24VDC less than 10 ripple 405 DC 2 100 132V 100 132V 10 15 lt 10 ripple Terminator AC 100 240V AC 100 240 10 15 Terminator DC 12 24V DC 10 8 26 4VDC FA 24PS 100 240V AC 100 240 10 15 Hold mode When the mains power to an ADC PLC turns off the internal power supply sends a PF power fail signal to the cpu Once the cpu receives the PF signal it stops accessing the memory enters the hold mode and waits for system reset The system reset is generated by a device which monitors the DAEUM Jan 2001 10 EN 60204 1 1992 4 2 4 3 2 EN 60204 1 1992 4 3 EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE voltage of the 5Vdc supply If the voltage drops to less than 4 25Vdc the device outputs a system reset signal If the mains power turns off for only a short time lt 900ms such as in a flicker of the mains the internal power supply sends the PF signal to the cpu However in this case th
2. Immunity tests are conducted with the PLC equipment mounted within an industry standard cubicle within the anechoic chamber This ensures there are no external EMC influences which would affect the products whilst undergoing testing A capacitive clamp is used to couple fast transients on I O control and comms lines whilst power inputs and outputs are injected directly or via capacitive networks as detailed in the emissions standard DAEUM Jan 2001 34 EUROPEAN DIRECTIVES THE EMC DIRECTIVE Radiated emissions This is a very important test as it produces more failures than any other Rf emissions in region of 30 1000MHz are observed The products are set up in a real life situation with appropriate cables industrial enclosure etc To the left is an example of a radiated A i pes emissions scan The two limit lines sM INK Le Vid p shown ate domestic and industrial Wa TE al AN hyf and are only relevant to a test distance of 3 metres Although the accuracy of a good anechoic chamber is high the standards still stipulate the use of an OATS open area test site Therefore once a scan is performed in the anechoic chamber the highest emissions are observed and individual measurements are taken on the OATS Emissions test equipment The emissions are measured with an EMCO hybrid conical log period antenna The test receiver is Rhode amp Schwarz which is the preferred choice of major test houses worldwide A
3. EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE The Machinery Directive Definition Applicable standards Essential reading This section should be read in conjunction with the standard EN 60204 1 1992 and relates directly to each section and clause within that standard while using the same nomenclature If an ADC programmable logic controller forms part of a system involving moving parts control and power circuits the machinery directive becomes the prime directive to be considered The term machinery also covers an assembly of machines or system arranged and controlled so that they function as an integral whole If an ADC PLC is integrated into a device such as an analyser system or data logging system which does not posses any powered moving parts then the EMC and low voltage directives become the prime directives covering the apparatus The machinery directive also includes a requirement for compliance to the EMC directive and the safety aspects of the product specific standard EN61131 which covers programmable logic controllers The standard listed in the machinery directive which covers PLCs and electrical components is EN 60204 1 1992 Safety of machinery Electrical equipment of machines part 1 General requirements The above standard is a category B1 application standard used in the production of group C product standards and includes a requirement for compliance to the EMC directive It also considers all th
4. EUROPEAN DIRECTIVES INTRODUCTION Directives and standards incorporating the May 2000 decision Manufacturers of PLCs and related products requiring CE Products designed Products designed before May 2000 after May 2000 You must satisfy both the low voltage and EMC directives You must satisfy both the low voltage and EMC directives EMC directive Radiated rf emissions Conducted rf emissions Electrostatic discharge immunity Radiated rf immunity Burst transients immunity Dips variations interruptions immunity Damped oscillitary waveimmunity Fluctuations and flicker emissions Harmonic emissions Standards EN50081 2 or EN55011class A EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN61000 4 11 EN 61000 4 12 EN61000 3 2 EN61000 3 3 Low voltage directive Standards EN61131 2 EMC directive Radiated rf emissions Conducted rf emissions Electrostatic discharge immunity Radiated rf field immunity Burst transients immunity Damped oscillatory wave immunity Voltage and frequency variations Harmonic immunity Supply interuptions and variations immunity Harmonic emissions Fluctuations and flicker emissions Standards EN50081 2 or EN55011class A EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 12 EN61131 2 EN61000 3 2 EN61000 3 3 Under consideration Surge immunity tests EN61000 4 5 DAEUM Jan 2001
5. circuit For compliance it will be necessary to choose complimentary sinking output and sourcing input module styles Many ADC input modules can be sink or source configured and it is the responsibility of the machine designer to ensure that any earthing requirements of loads or auxiliary equipment that are switched by the PLC output modules are complied with If a conflict occurs then separate isolation transformer windings must be used Requirements for the suppression of interference caused by the switching of inductive loads are detailed in each PLC user manual Switched output rates of less than 5 times per minute are outside the requirements of the EMC directive but if rates exceed 5 per minute then special consideration should be given to the suppression of electrical noise at source preferably using capacitive resistive and inductive components to avoid the fire hazard of un fused transient suppresserts DAEUM Jan 2001 18 EN 60204 1 1992 1012 EN 60204 1 1992 11 2 EN 60204 1 1992 TRAI EN 60204 151992 11 22 Electronic equipment EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE A 100 ohm resistor and 0 luf suppresser wired directly across the switching element is normally adequate suppression for most inductive PLC loads on 230vAC 50Hz supplies Servo drive interfaces Differential analogue outputs and inputs are required for signals between motor drive units ADC PLC systems offer opto isolated low s
6. not connected to that earth point of the system IT System which is not directly earthed 14 Is the electrical equipment to be connected to a neutral N supply conductor section 5 1 of EN60204 1 1992 Yes No 15 Does the user or the supplier provide the over current protection of the supply conductors section 7 2 lof ENGO204 11992 ies ci a n E aaa ERE att DAEUM Jan 2001 42 EUROPEAN DIRECTIVES ANNEX 16 17 18 19 20 21 22 23 24 25 Type and rating of over current protective devices c cee cece ences Supply disconnecting device Is the disconnection of the neutral N conductor required Yes No Is a link for the neutral N permissible Yes No Type of disconnecting device to be provided e cece eee eee ees Limit of power up to which 3 phase motors may be started directly across the incoming supply May the number of motor overloads on 3 phase motors be reduced to 2 section 7 3 of EN60204 1 1992 Yes No Where the machine is equipped with local lighting highest permissible voltage V if lighting circuit voltage is not obtained directly from the power supply state preferred voltage Functi nal identification ssesssessnrdcni soanen ien section 18 3 of EN60204 1 1992 Inscriptions Special markings necceccrecreecceserotanivarenni irai Mark of Certification Yes No If YES which one sseossseessereseeere On elec
7. of ADC equipment states that if access is required by operators or untrained personnel then the PLC equipment must be installed inside an internal cover or secondary enclosure Furthermore the safety requirements of the machinery directive standard EN60204 1 state that all control circuits and PLC power circuits must be via isolation transformers or an isolating power supply and one side of all AC or DC control circuits must be earthed This is the same as installation category 1 of the standard EN61010 1 low voltage directive For fire safety hazard reasons both power input connections to a PLC must be separately fused using 3 amp T type anti surge fuses Also a transient suppresser must be fitted to limit PLC supply and control circuit over voltages to 1500v maximum This ensures that the stipulations of over voltage category 1 are met PLC s are complex components that are mounted within enclosures The only accessible parts in a PLC system are the control circuit and power wiring and the braid of screened cables outside the control cubicle Operator interface MMI HMI products are mounted on enclosure fronts and hence accessible The thickness of membrane keypad overlays and the plastic cases has been considered when CE marking operator interface products DAEUM Jan 2001 23 Single fault test conditions EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Control and power circuits are required by the machinery directi
8. 23 EEC CE marking of machinery or electrical equipment reflects conformity of a product to all applicable directives Every piece of equipment bearing the CE mark must have a declaration of conformity that states which standards applicable to the CE mark it complies DAEUM Jan 2001 The CE mark Automation Direct com EUROPEAN DIRECTIVES INTRODUCTION with This document doesn t have to accompany the product however in most cases the manufacturer does so A typical situation for example in an industrial machine which is built of components from different manufacturers would be to have 1 A CE label as part of the nameplate relating to the complete machine and with the declaration of conformity specifying compliance with either fundamental safety standards type A or specific machinery group safety standards type C within the machinery directive 2 CE labels on individual safety components such as emergency stop or guards forming part of the machine with compliance indicated on the separate declarations of conformity to the specific group safety standards applying to the particular safety device type B 3 CE labels on electrical components which do not have an intrinsic function such as contactors transformers and motors which have their own declarations of conformity to the low voltage directive or to specific non generic standards 4 CE labels on complex components such as PLC s with declarations of confo
9. B Rf emissions for domestic environments Domestic accreditation is not normally necessaty as PLCs are industrial products Although a PLC may not pass rf emissions limits to domestic environments special external modifications and conditions can be made in certain circumstances EN50081 2 or EN55011 class A Rf emissions for heavy industrial environments EN61000 4 2 Electrostatic discharge immunity EN61000 4 3 Radiated electromagnetic field immunity EN61000 4 4 Fast transients immunity EN61000 4 12 Damped oscillatory wave immunity EN 61131 2 Programmable controllers product specific Voltage and frequency variations EN 61131 2 Programmable controllers product specific Third harmonic immunity EN 61131 2 Programmable controllers product specific Supply interruptions and variations immunity EN61000 3 2 Harmonic emissions EN61000 3 3 Voltage fluctuations and flicker emissions DAEUM Jan 2001 30 EN 61131 2 3000 EUROPEAN DIRECTIVES THE EMC DIRECTIVE Generic standards EN50081 1 EN50081 2 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 11 EN61000 4 12 EN61000 3 2 EN61000 3 3 ot EN55011class B Rf emissions for domestic environments Domestic accreditation is not normally necessary as PLCs are industrial products Although a PLC may not pass rf emissions limits to domestic environments special external modifications and conditions can be made in certain circumstances or EN55011c
10. THE MACHINERY DIRECTIVE Protection Many panel mounting operator interfaces are protected to IP65 and contain sealed membrane key pads however they are usually not sealed at the back and must always be mounted in an enclosure sealed to suit the environment The DV1000 operator terminal is not sealed to any specific standard and should only be used in control cubicles with protective sealed doors or in a suitable environment specified in the machinery technical manual Due to their complexity operator interfaces must not be used as emergency stop devices A choice of output module types are available in all ADC ranges where single channel outputs with individual commons or multiple output channels sharing commons can be selected to suit the application Where modules with shated commons ate used it is recommended that separate bus connected DIN rail mounting terminals be used to provide the single point control and common return connections Inputs All ADC PLC input modules utilise opto isolation with the exception of two modules in the DL 05 and DL 06 range FO 04AD 1 and FO 4AD2DA1 The standard requires that the common supply terminals of each input module circuit must be connected to the protective bonding circuit at the single common terminal point of the supply Outputs The standard requires that the common supply terminal of each output which is load switched by the PLC must be connected to the protective bonding
11. and testing is carried out in the range of 150KHz 30MHz The test is carried out within the anechoic chamber and a LISN line impedance stabilisation network is used to couple the product to the mains supply The LISN has an rf pickup socket which is used to output the rf signal to the test receiver where a scan is run Two scans are run one between line and gt earth and the other between neutral to earth To the left is an example of a conducted emissions scan between line and earth The green plot illustrates the plot for the average measurement and the blue represents the quasi peak measurement The two limit lines are average and quasi peak Guard band If the measured signals on the scan rise to 3dBuv below the industrial limit lines the product is considered to have failed this test Further tests will then be carried out including tests using in line power filters Radiated immunity This test is similar to tadiated emissions tests but the antenna is used to transmit a signal from 80 1000MHz with 80 amplitude modulation at a field strength of 10v m ADC outsoutces this test as it is fairly quick and it is very rare that further investigation is required or that failures occur Fast transients ESD surge and dips ADC uses a generator by Schaffner which is the preferred choice of major test houses worldwide The generator is fully compliant with current EU standards for test equi
12. be fitted They must be wired for continuous independent operation or with a time delayed start of several hours to allow for the drying out of all electronic apparatus Humidity Specified as 30 95 RH non condensing DL 05 DL 06 DL305 and DL405 PLC systems operate over a 5 95 RH range DL205 PLC systems operate over 30 95 RH range The standard suggests measures that should be applied if the equipment is operated outside the above humidity limits In the case of high humidity or early morning condensation as is very often found in northern climates small thermostatically controlled cubicle heaters are often used Alternatively a permanently wired light bulb typically 60 watt will often overcome early start failures due to condensation ADC DL 05 DL 06 DL405 and DL305 PLC systems are specified for operation at humidity levels as low as 5 RH and most problems experienced at this level are normally caused by static discharge All ADC PLCs have been tested for ESD up to 8Kv while mounted within a grounded standard industrial cubicle If operation in very low humidity is required the hazards associated with operation of the equipment by maintenance personnel while the cubicle door is open should be considered Either power to mechanical actuating equipment should be cut or total system shutdown or static wrist straps should be provided while the door is open Warnings on the outside of the control cubicle should also
13. design engineer can utilise good engineering judgement to decide whether testing is required before applying the CE label The EMC directive simply states that the equipment must not cause interference and must have a reasonable level of immunity to EMC phenomena In the case of a dispute however a design engineer or company that does not conduct any tests may find itself liable to civil or legal action Manufacturers of standard machinery placed on the open market OEMs Machinery or equipment containing PLC s placed on the open market must show compliance to the EMC directive The manufacturer can choose to self certify to harmonised standards or to use a test house to approve a TCF The results from the test report should provide sufficient information for the system to be approved by a test house DAEUM Jan 2001 28 Environments applicable to the PLC system under test EMC standards applicable to PLC manufacturers EUROPEAN DIRECTIVES THE EMC DIRECTIVE Manufacturers of special purpose machinery for a single end user s own use In this case the machine or product specification will have been constructed and approved by both the final end user and the special machine manufacturer Use should be made of the questionnaire in the standard EN60204 1 machinery directive to ensure that the EMC environment is consistent with the product or machine design Utilising the results obtained in this report and providing proo
14. greater than 50v RMS and modules which allow higher voltages may be inserted For this reason all items in the ranges are considered individually Installation category Electrical equipment may fall into one of three installation categories which declare the level of over voltage within an environment Likewise equipment may fall into one of two categories of pollution degree which stipulate allowable levels of environmental pollution in an environment If equipment is CE marked as suitable for a particular category then over voltages must be limited by suitable devices transient suppressers etc to the level specified in that category see the following table Category 3 equipment connected directly to the power distribution system within a factory or work place is closest to the source of over voltages caused by the switching of large inductive loads and motor over runs etc DAEUM Jan 2001 21 EN 61010 1 1993 EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Category 2 equipment connected to a local AC power outlet is deemed to experience a lower level of over voltage from the same sources as above due to natural damping in the electrical distribution system Category 1 equipment is deemed as being operated via an isolation transformer or isolating power supply within a control cubicle All ADC PLCs are rated as basic insulation This is the insulation offered by the manufacturer between the live side of the power sup
15. insufficient power and under voltage detection may be necessary in these instances The requirements of this section are essential for the reliable operation of modern electronic control equipment Transformers Control circuit transformers are not mandatory in small fully enclosed machines or those having a rated power of less than 3Kw Control circuit isolation transformers however may be preferred for the reduction of voltage risk to personnel The practice of earthing the centre tap of 120v isolation transformers to provide a maximum voltage of 60vAC above earth is no DAEUM Jan 2001 16 EN 60204 1 1992 5 0 EN 60204 171992 6 0 EN 60204 1 1992 7 0 EN 60204 1 1992 7 2 9 EN 60204 1 1992 1a EN 60204 1 1992 8 0 EN 60204 1 1992 9 0 EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE longer allowable as one side of each input or output circuit must be connected to the protective bonding circuit ADC equipment is rated for installation over voltage category 1 as specified in EN 61010 1 provided an isolation transformer is used to supply the AC power to the control equipment Emergency stop Emergency stop functions should be wired so as to directly remove power from all actuators and an electromechanical drop out relay may be used for this function but the PLC power should not be removed The PLC should be informed of this action by using and input circuit via a secondary contact on the Emergency
16. systems are required for memory alteration DAEUM Jan 2001 19 EN 60204 1 1992 13d EN 60204 1 1992 11 3 2 3 EN 60204 1 1992 11 5 EN 60204 1 1992 12 2 1 EN 60204 1 1992 12 2 3 EN 60204 1 1992 12 3 EN 60204 1 1992 12 3 2 Testing EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE Programming equipment The machinery manufacturer can withhold access to control programs by password protection and fixing programs into UVPROM memory Operator interfaces and programming devices can operate without interaction on all CPUs with two or more serial ports Where communications networking or operator interfaces are required on a machine dual port CPUs only must be utilised Verification Software project titles and revision levels must be accurately maintained so that hard copies of a project s title page using the DirectSOFT programming software will ensure verification of documentation and software on disc Insulation resistance ADC PLC equipment has been tested to gt 10M ohm at 500v DC This is well in excess of the requirements Voltage test ADC PLC equipment has been tested to withstand in excess of 1000v AC for 1 minute Residual test There are no hazardous residual voltages as switched mode power supply capacitors ate discharged EMC ADC equipment complies with the generic heavy industrial requirements of the EMC directive including IEC 801 DAEUM Jan 2001 20
17. to suit the particular environment e g the wash down of machinery at night All of the above requirements preclude ventilation and therefore for the correct design of a control cubicle for operation in ambient temperatures up to 40 C the design engineer must assess or test for temperature rise at the top of the control cubicle This is to be no greater than 20 C above ambient to allow for the maximum PLC operating temperature of 60 C or 55 C for the DL 205 and DL 05 series DAEUM Jan 2001 13 EN 60204 1 1992 4 4 2 EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE All operator interfaces have a maximum operating temperature of 50 C and the FA UNICON has a maximum of 45 C when operating from 24vDC power This must be taken into account when measuring temperature rise above ambient in the enclosed fully loaded cubicle Therefore the cubicle size should allow sufficient cooling in free air and operator interfaces should not be mounted near the top of a cubicle where the heat rise is at a maximum Some FA UNICON signal converters should be mounted near the bottom of a cubicle preferably on an industry standard DIN rail mounting 25 pin D to terminal converter module This is due to the limited upper temperature limit ADC PLC equipment will operate at temperatures as low as 0 C which is ideal for indoor applications covered by the machinery directive Where the ambient temperature can drop below zero cubicle heaters must
18. 01 Enforcement agencies ADC s group policy EUROPEAN DIRECTIVES INTRODUCTION Minimum generic standard levels exist for EMC and safety of equipment The relevant EU directives are known as the EMC and low voltage directives The directives simply state that manufacturers and their agents must act responsibly using good engineering practice to ensure that CE marked equipment does not cause interference to other equipment exhibits a minimum specified level of EMC immunity and operates safely Each European country has translated the EU directives into national law and differences occur in the interpretation and implementation of these directives Local enforcement agencies are under increasing political pressure over and above their legal responsibilities to show that their country is actively enforcing the directives In the UK alone there are 182 local enforcement agencies each with their own interpretation of the law method of working local budget and political pressures for or against membership of the EU The UK and France utilise their own local trading standards departments to enforce the legislation who view this as a very small part of their responsibilities Activities in the UK started by identifying local electronic manufacturers and agents and judging the response by asking them if they are aware of the directives More recently local trading standards departments have identified manufacturers and importers and purcha
19. 6 EN61010 1 4 4 2 7 EN61010 1 4 4 2 8 EN61010 1 4 4 2 9 EN61010 1 4 4 2 10 Tests and other requirements EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Insulation Insulation between all circuits and accessible parts must be short circuited This is a test to ensure that any live control or power lines shorted to any other circuit or part will blow a fuse Alternatively the protection means can be demonstrated in the TCF Interlocks for the protection of operators must be high integrity components as detailed under sections 14 6 and 15 3 of the standard and type approved for the application under an IEC standard Compliance Compliance must be met as detailed in the standard EN61010 1 1993 or latest issue as released in the OJ All other aspects of the standard are also applicable and must be checked by the system designer Earthing PLC Direct equipment must be installed and operated with one side of all control and power circuits and the braid of screened cables adequately earthed This ensures that there are no unearthed parts or circuits accessible to operators and that basic insulation is adequate when used in external circuits of the control system as per table D1 in annex D of the standard Earth bond If both sides of the power supply are fused then the earth bond impedance of the control panel earth circuit must be checked by applying a test current of twice the fuse or circuit breaker rating for t
20. 61000 3 2 EN61000 3 3 after May 2000 You must satisfy both the low voltage and EMC directives SS OOOO Low voltage directive EMC directive Radiated rf emissions Additional safety te Remote IO Conducted rf emissions Electrostatic discharge immunity Radiated rf field immunity Burst transients immunity Damped oscillatory wave immunity Voltage and frequency variations Harmonic immunity Supply interuptions and variations immunity Harmonic emissions Fluctuations and flicker emissions Standards EN50081 2 or EN55011class A EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 12 EN61131 2 EN61000 3 2 EN61000 3 3 Standards EN61131 2 Under consideration Surge immunity tests EN61000 4 5 DAEUM Jan 2001 40 EUROPEAN DIRECTIVES ANNEX Annex C Extract of machinery directive questionnaire form EN60204 1 1993 Enquity form for the electrical equipment of machines The following information is required from the end user of the equipment to ensure proper design application and utilisation of the electrical equipment of the machine system or apparatus Name of Manufacturer or Supplier Nameof Bind User oreda EE EEE SHS Be Tendet Order No ccecccee essences Erra ENIN SENINE IITE Date Type of Machine Serial number 0 0 0 cece e ne a 1 Are there to be modifications as allowed for within EN60204 1 1992 Yes No Operating Conditions Special Requirements sec
21. C equipment can withstand storage and transportation temperatures as low as 25 C Provisions for handling No special provisions required Installation and operation Control cubicles should be accessible for maintenance and operator interfaces should be mounted at the eye level which is consistent with the average height of operators in the end users country This section deals with the requirements of equipment terminals and wiring associated with the PLC system inside the control cubicle The design engineer is responsible for the incorporation of these measures DAEUM Jan 2001 15 EN 60204 1 1992 4 4 4 EN 60204 1 1992 4 4 5 EN 60204 1 1992 4 4 6 EN 60204 1 1992 4 4 7 EN 60204 1 1992 4 5 EN 60204 1 1992 4 6 EN 60204 1 1992 4 7 Incoming supply terminations Protection against electric shock Protection of equipment Equi potential bonding Control circuits and control functions EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE If circuit breakers are used as the supply disconnection device then two CBs must be fitted one for each supply line in order to limit currents in unlimited supply circuits as required by the Low Voltage directive Protection by enclosure Over voltage surge suppressers that are wired to the power input terminals of each item of PLC equipment section 4 3 1 must be capable of withstanding the blow characteristics of the fuses or circuit breakers T
22. EN 60204 1 1992 1233 EN 60204 1 1992 12 3 4 EN 60204 1 1992 20 3 EN 60204 1 1992 20 4 EN 60204 1 1992 20 5 EN 60204 1 1992 20 6 EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE The Low Voltage Directive Introduction Classification for CE marking by the operating environment The low voltage directive simply states that electrical equipment must be safe It states that following the guidelines detailed in the applicable standards within the directive will in most cases satisfy the safety requirements Compliance with standards does not however exonerate all further responsibility and in the case of an accident or dispute enforcement agencies will look to the end user and manufacturing chain of the electrical apparatus for evidence of irresponsible design or use The most relevant generic safety standard under the low voltage directive is EN61010 1 1993 Safety requirements of electrical equipment for measurement control and laboratory use However the standard EN 61131 2 is a combined standard product specific which has a large section on safety and encompasses both the low voltage and the EMC directives Equipment that fully complies with EN 61131 2 is covered in the eyes of the low voltage directive as long as all the manufacturer s guidelines and the guidelines of this document are adhered to Confusion can arise as the low voltage directive applies only to equipment operating on voltages
23. EUROPEAN DIRECTIVES Manual DA EU M Third edition Copyright 2000 This manual may be copied transmitted or reproduced without the permission of Automation Direct com as long as this copyright notice is included ADC retains the exclusive right to the information included within this document Contents INTRODUCTION 3 PURPOSE OF THIS MANUAL 3 THE DIRECTIVES 3 THE CE MARK 4 AUTOMATION DIRECT COM 4 ENFORCEMENT AGENCIES 5 ADC S GROUP POLICY 5 THE SITUATION ONSITE 6 DETERMINATION OF THE OPERATING ENVIRONMENT 6 DIRECTIVES AND STANDARDS INCORPORATING THE MAy 2000 DECISION 7 THE MACHINERY DIRECTIVE 8 DEFINITION 8 APPLICABLE STANDARDS 8 ESSENTIAL READING 8 HAZARD ANALYSIS 9 SELECTION OF EQUIPMENT 10 ELECTRICAL SUPPLY 10 Operational Requirements 10 Frequency 10 Harmonic Distortion 11 Voltage Impulses 11 Supply interruption 11 Voltage dips 12 DC voltage 12 Operation in vehicles Ertot Bookmatk not defined PHYSICAL ENVIRONMENT AND OPERATING CONDITIONS 12 EMC compatibility 12 Ambient air temperature 13 Humidity 14 Altitude 15 Contaminants 15 Radiation 15 Vibration shock and bump 15 Transportation and storage 15 Provisions for handling 15 Installation and operation 15 INCOMING SUPPLY TERMINATIONS 16 PROTECTION AGAINST ELECTRIC SHOCK 16 Protection by enclosure 16 PROTECTION OF EQUIPMENT 16 Under voltage protection 16 EQUI POTENTIAL BONDING 16 CONTROL CIRCUITS AND CONTROL FUNCTIONS 16 Transformers 16 Emergency stop 17 Circ
24. Stop See PLC installation manuals for suggested circuit arrangements Circuit redundancy and diversity Redundancy and diversity can be used in various ways to provide manual or automatic protection depending upon the hazards present The simple duplication of series or parallel connected output modules with a mixture of single channel relay and DC or AC output devices to provide diversity The addition of input channels to monitor output voltage application and limit switch detection of the operation of actuators within set times Change over relay contacts used to select duplicate output channels The use of manually selected duplicate duty standby systems with paralleled inputs and utilising standard diode isolation modules for parallel connection of DC output channels and power line selector Automatic duty standby parallel systems controlled by a third watchdog system of diverse design Emergency shutdown fail safe systems using a mixture of solid state and relay output devices All the above circuit arrangements can be constructed from within the ADC families with diversity of output control provided by a wide range of solid state and electro mechanical relay output modules All ADC PLC systems incorporate non volatile memory with the choice of battery backed CMOS RAM EEPROM or UVPROM DAEUM Jan 2001 17 EN 60204 1 1992 9 2 5 4 EN 60204 1 1992 9 4 2 2 Control interfaces EUROPEAN DIRECTIVES
25. and EN55014 quasi peak 56 46 dB uV average EN55022 Class B and EN55014 0 5 5 56 dB uV quasi peak EN55022 Class B and EN55014 46 dB uV average EN55022 Class B and EN55014 5 30 60 dB uV quasi peak EN55022 Class B and EN55014 50 dB uV average EN55022 Class B and EN55014 Generic heavy industrial environments emission Port Frequency Limits Basic Standard MHz Enclosure 30 230 30 dBuV 30m quasi peak EN55011 Class A 40dBuv m 10m 50 dBuV 3m 230 1000MHz 37dBuV 30m quasi peak 47dBuv m 10m 57 dBuV 3m AC mains 0 15 0 5MHz 79 dB uV quasi peak 66 dB uV average 0 5 30MHz 73 dB uV quasi peak 60 dB uV average Generic domestic and light industrial environments immunity Test Levels Basic Standard Enclosure RF field 27 500Mhz 3v m unmodulated EN 61000 4 3 ESD 8kv air discharge EN 61000 4 2 Signal and control lines and DC input output power ports Fast transients 500v peak 5 50nS 5khz EN 61000 4 4 AC power ports Fast transients 1kv peak 5 50nS 5khz EN 61000 4 4 32 DAEUM Jan 2001 EN50081 1 1995 EN50081 2 1994 EN50082 1 1992 EUROPEAN DIRECTIVES THE EMC DIRECTIVE Generic heavy industrial environment immunity gern 3 2 Test Levels Basic Standard Enclosure RF field 80 1000Mhz 10v m 80 AM at 1khz EN 61000 4 3 900Mhz 10v m 50 PM at 200hz ESD 8kv air discharge 4kv contact EN61000 4 2 Signal and bus lines 1kv peak 5 50nS 5khz Fast tr
26. ansients EN61000 4 4 criteria B Process measurement control lines AC and DC input and output power lines Fast transients Product specific N kv peak 5 50nS 5khz EN61000 4 4 criteria B For PLCs conforming to the product specific standard EN61131 1 the following immunity requirements are met Emissions for this category are covered by the generic standards as detailed above Noise tests Noise severity levels Maximum surge All power Digital I O Digital I O ext supply energy minimum supplies ext supply gt lt 24v analogue and source impedance 24v communication I O ESD 150 pf 150Q 15Kv 15Kv 15Kv Rf field 10v m 10v m 10v m Conducted noise Common mode fast mj spike at 2kv 2Kv 1Kv 0 25Kv transients on 50Q Damped oscillatory 2009 1Kv 1Kv wave series mode Other immunity tests within the product specific standard The following tests are specified by EN 61131 2 The standard does not reference any other standard but instead provides details for the these tests within e Voltage and frequency range e Third harmonic e Momentary interruption e Gradual and sudden shut down and start up e Gradual supply variation e Improper supply connection polarity and voltage level 33 DAEUM Jan 2001 Evaluation of EMC characteristics EUROPEAN DIRECTIVES THE EMC DIRECTIVE Future additions to standards Surge These tests simulate indirect lighting strikes The PLC produc
27. be considered DAEUM Jan 2001 14 EN 60204 1 1992 4 4 3 EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE Altitude Specified as operational up to 1000m above sea level ADC PLC equipment can operate at altitudes over 1000m above mean sea level Contaminants ADC PLC equipment contains IC sockets and electrical connectors The operational life of the PLC equipment can be shortened if corrosive gases etc are allowed to permeate into the cubicle Adequate measures must be taken by the machinery designer The corrosive atmosphere can be controlled either by filtering sealing out or locating the main control equipment in safer atmospheric conditions Distributed I O in sealed cubicles can also be considered Radiation Ionising or non ionising radiation could cause memory loss in ADC PLC systems Measures must be taken to eliminate this radiation by the design engineer Vibration shock and bump All PLC families are tested to MIL STD 810C Method 514 2 vibration MIL STD 810C Method 516 2 shock NEMA ICS3 304 noise Transportation and storage Specified as 25 C to 70 C transport and storage temperature range All PLC equipment and operator interfaces are specified for a storage range of 20 C to 70 C Programmer and operator interface devices with LCD displays must be removed from machinery during transportation and storage to avoid damage if temperatures as low as 25 C are to be encountered All other PL
28. d terminals or by mixing different circuits within the wiring of those connectors DAEUM Jan 2001 27 EUROPEAN DIRECTIVES THE EMC DIRECTIVE The EMC Directive Introduction Types of PLC user All PLC equipment supplied by ADC must be configured by competent engineers and the resultant control system must be housed in a steel enclosure to comply with the safety requirements of other directives The many possible configurations of control equipment and differing cable arrangements both inside and outside the control cubicle will always result in control systems with differing EMC characteristics The tests covered by this document ate conducted by ADC and have been designed to simulate actual operational configurations EMC compliance must be designed into control panels by all personnel associated with their manufacture The decision on whether to self certify the final product or system or to use an official test house to approve the product or a TCF technical construction file depends on the product produced There is no legal requirement in the directives which state that only an official test house can be used for official approval and there is also no such thing as a pre compliance test The end user OEM or system builder can conduct their own in house tests using purchased or hired equipment or hire time in a test laboratory to conduct their own tests If the product is designed to be EMC compliant the
29. e 5Vdc might not drop to less than 4 25Vdc The cpu then waits for system reset without accessing the memory and the PLC appears to freeze The cpu must be reset by removing the mains power Frequency All PLC ranges operate over the frequency range 47 63Hz Harmonic Distortion Range specified as lt 10 of total RMS value for 2nd through 5th lt 2 for 6th 30th Voltage Impulses Specified as 1 5mS pulses with 500nS 500uS rise fall time and peak value of 460v on top of nominal 230vAC mains It is the responsibility of the machinery designer to fit transient voltage suppressers such as metal oxide varistors of rating 275v AC working voltage and high energy capacity e g 140 joules across the power input connections of the PLC Transient suppressers must be protected by 3 amp anti surge long time lag fuses in both line and neutral circuits to comply with the requirements of the LV directive The capacity of the transient suppresser must be greater than the blow characteristics of the fuses or circuit breakers A recommended AC supply input arrangement for ADC PLCs is to use twin 3 amp anti surge fused terminals with fuse blown indication such as Klippon SAKSI An alternative arrangement would be to use two circuit breakers wired to a Schaffner FN 2070 or equivalent mains filter with a high energy transient suppresser soldered directly across the output terminals of the filter PLC system inputs should be protected from v
30. e no effect on operation after resetting of fuses etc No hazardous live voltages or excessive temperatures that may cause fire are allowed Protective impedance If the system designer uses series resistors or voltage clamps to ensure that an accessible part does not become hazardous live then no hazard should be created when these are shorted out or removed under normal conditions This is not normally part of an industrial control system design Protective conductor The ground terminal of the PLC system must be open circuited and the system run for one hour to ensure that hazardous live situations cannot occur on accessible parts or the electrical noise from filters cause destruction and a fire hazard in sensitive electronics Actuators Actuators driven from output modules designed for short term or intermittent operation in the system must be operated continuously or it must be demonstrated in the TCF how this condition is protected DAEUM Jan 2001 24 EN61010 1 4 4 2 1 EN61010 1 4 4 2 2 EN61010 1 4 4 2 3 EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Motors Motors must be stalled for an hour while fully energised or it must be demonstrated in the TCF how this condition is protected Capacitors Capacitors in the auxiliary windings of motors except self healing capacitors must be short circuited for one hour while the motor is fully energised or it must be demonstrated in the TCF how this condition i
31. e requirements of the low voltage directive It is intended as the first part of a series of standards relating to the electrical equipment of machines The mechanical group of BSI British standards institute have produced an ovetview of the machinery directive which is essential reading for manufacturers wishing to sell machinery into Europe The part number of this publication is TH 42073 February 1996 8 DAEUM Jan 2001 Hazard analysis EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE All standards and the above publication are available from BSI Linford Wood Milton Keynes MK14 6LE England or your local BSI agent A hazard analysis must be performed by the machine builder or systems integrator It is a requirement in this standard that the PLC equipment must be installed in a standard industrial steel cabinet which must provide the required protection against shock Fuses must be fitted to power input lines weather AC or DC in order to limit the energy into all unlimited circuits even with power line reversal and thus providing electrical fire protection Control circuits can fail in any state which could conceivably cause a hazard and it is the responsibility of the machine designer to utilise redundancy and diversity in the design of output circuit arrangements that control hazardous actions Disruptions in external power to PLC systems should cause an output drive to be removed temporarily from all output sta
32. ection point to that used for the protective grounding see section 20 2 Furthermore equi potential bonding between machinery must be provided alongside serial data and signal lines with data and signal lines of screened twisted pair construction and where the cable screens are connected to the machinery frame at both ends End users must be made aware in the machinery technical manual that the extensive use of mains filters and screened cables within machinery will cause electrical interference to be channelled onto the protective earthing point of each machine Therefore if adequate site earthing is not provided interaction between control system components will occur and it will be the legal responsibility of the end user to improve site grounding Some factory sites situated on dry soils may be unsuitable for modern electronic equipment to operate reliably and safely See draft Installation guidelines IEC 1000 5 1 and IEC 1000 5 2 for site installation requirements Ambient air temperature Specified as 5 40 C in an enclosed cubicle or 35 C average over 24 hours The installation manuals for each PLC product series include details on the mounting orientation and spacing for each base in a control system for optimum heat dissipation The low voltage directive safety standard EN 61010 1 specifies the maximum size of openings allowed and the machinery directive standard EN60204 2 specifies that the enclosure must be sealed
33. es of operation dependant on manual control how often is it expected that cycles of operation will be repeated a a E nian ees aameten tuk eiteet hase per hour For what length of time is it expected that this maximum rate of repetition will be repeated without subsequent pause cece e eee eens minutes In the case of specially built machines is a certificate of operating type tests with the loaded machine to be supplied Yes No In the case of other machines is a certificate of operating type tests on a loaded prototype machine to be supplied Yes No DAEUM Jan 2001 44
34. f of EMC measures taken will assure compliance Integrators of individual machinery into systems for one end user A systems integrator must obtain from the final user adequate information regarding the operating environment usually by means of the questionnaire associated with EN60204 1 and these requirements must be included in the contract and project specification The systems integrator can then utilise the EMC test data contained in this report to configure EMC compliant systems with the EMC design measures documented in the technical manual for the product EMC compliant panels can be designed and manufactured in house or contracted out to a panel builder If however the end user specifically states in the purchase contract that CE approval is the responsibility of the systems integrator a TCF must be compiled This must include the data from this report and official approval for the TCF must be obtained from a test house Panel builders working to constructional drawings and end users constructing their own systems The panel designer must utilise this test report to determine EMC characteristics for each panel design This will normally control the layout of components power line filtering and cable style and layout with regard to other susceptible components within the same panel EMC compliant panels can then be built to order AC powered equipment for use in domestic light and heavy industrial environments DC po
35. he control and power circuit for 1 minute The voltage between the protective bond terminal on the PLC and eatth must not exceed 10vDC or AC RMS If only one side is fused then 25 amps test current is required and checked to 0 1 ohm impedance Double insulation If an external circuit controlled by the PLC equipment needs to be isolated from earth and hazardous voltages occur on this external circuit then double insulation must be provided This can be achieved by using a relay on the output circuit of the PLC system which will provide double insulation rating between adjacent output channels and to the logic supply powering the output device on the output module This requirement may be the main contributing factor when choosing a PLC range and output module type It is the responsibility of the system designer to assess the hazard and select the correct module for the task DAEUM Jan 2001 26 EN61010 1 4 4 2 11 EN61010 1 4 4 2 12 EN61010 1 4 4 3 EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Hazardous live parts in the form of terminals and sockets are permitted to be protected by basic insulation in the external circuits of the control system so long as the system designer ensures that terminal sockets and connectors have no accessible live parts by utilising good engineering practice The system designer must not compromise the basic insulation requirements of the PLC or system by using inferior quality connectors an
36. his section calls for all live parts to be located inside enclosures and the low voltage directive safety standard EN 61010 1 also specifies that enclosures should be metal but not magnesium for protection against fire All ADC output modules have their ratings indicated in the technical manual and on each module label Input module current requirements are indicated in the module specifications and the total input requirement should be estimated based on the percentage of inputs likely to be active so that adequate protective fusing can be determined AC and DC control citcuits to input and output modules should have both sides of the control circuit supply fused to EN 61010 1 for the low voltage directive and fuse values should never exceed the capacity of the circuit cabling used Fast blow fuses can also be used to protect individual DC transistor outputs and anti surge long time lag fuses can be used to protect individual relay and AC output channels Fuse ratings should be as low as possible to provide best protection and should never be greater than each output channel switching capacity Under voltage protection Controlled operation of the PLC by turning OFF outputs and storing machine operational status in non volatile memory ensures reliable operation in the event of under voltage conditions in all ADC PLCs The machine design engineer must consider hazardous operations that can occur if actuators fail to operate due to
37. l system EUROPEAN DIRECTIVES THE LOW VOLTAGE DIRECTIVE Safety requirements for installations All ADC PLC equipment designed after May 2000 is compliant with the product specific standard EN61131 2 All PLC equipment designed before this date complies with the generic standards as outlined earlier on in this document and in the chart in the annex Therefore the DL 05 DL 06 DL 205 DL 305 and DL 405 PLC ranges all comply with the generic standards but not to the product specific standard EN 61131 2 In the case of future modules for existing PLC ranges they will be certified to the generic standards EN61131 2 stipulates a minimum installation over voltage category of 2 and that over voltages are controlled to less than 1500vDC by suitable devices transient suppressers etc It also stipulates minimum creepage and clearance distances across PCBs that are larger than those required by EN61010 1 the low voltage directive safety standard All ADC equipment is suitable for installation over voltage category 1 and to pollution degree 1 when the safety requirements of the manufacturer the low voltage directive and the machinery directives are met They state that PLC equipment must be housed in a protective steel enclosure sealed against the ingress of moisture and polluting gases and that with access by operators is limited for safety reasons by lock and power breaker The declaration of conformity associated with CE marking
38. lass A Rf emissions for heavy industrial environments Electrostatic discharge immunity Radiated electromagnetic field immunity Fast transients immunity Voltage dips interruptions and variations immunity Damped oscillatory wave immunity Harmonic emissions Voltage fluctuations and flicker emissions With regards to immunity for industrial environments the new standard EN61000 6 2 Generic immunity standard for industrial environments replaces for earlier generic standard EN 50082 2 1995 This new standard includes new tests which are not necessarily directly applicable to PLCs as the product specific standard EN61131 2 does not call them up Although at ADC we ate only certifying all new products to this standard we also intend to lean toward it with the when testing and retesting the existing equipment We have therefore also included the standard EN 61000 4 12 Damped oscillatory wave immunity that EN61131 2 calls up for use on equipment designed before May 2000 see May 2000 decision in annex DAEUM Jan 2001 31 EUROPEAN DIRECTIVES THE EMC DIREC TIVE Tests limits Generic domestic and light industrial environments emission applicable to the EMC directive Port Frequency Limits Basic Standard MHz Enclosure 30 230 30dBuV 10m peak EN55022 Class B 40dBuV 3m 230 1000 37dBuV 10m peak EN55022 Class B 47dBuV 3m AC mains 0 15 0 5 66 56 dB uV EN55022 Class B
39. lerance DC Supplies From batteries Voltage 0 85 to 1 15 of nominal voltage 10 2 13 8v and 20 4 27 6v 0 7 to 1 2 of nominal voltage in the case of battery operated vehicles Voltage interruption Not exceeding 5ms From converting equipment Voltage 0 9 to 1 1 of nominal voltage 10 8 13 2v and 21 6 26 4v Voltage interruption Not exceeding 20ms There shall be more than 1 second between successive interruptions Ripple peak to peak must not exceed 0 05 of nominal voltage EMC compatibility All ADC PLCs comply with the requirements of the EMC directive for use in industrial environments The following standards are applicable to the 05 06 205 305 and 405 PLC ranges however please refer to the chapter on EMC for further details DAEUM Jan 2001 12 EN60204 1 1992 4 3 2 EN 60204 1 1992 44 EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE EN50081 2 1994 Generic emissions standard for industrial environments EN 50082 2 1995 Generic immunity standard for industrial environments The products comply with the above standards only when the equipment is installed to the requirements of the individual product installation manuals It should be stressed in the machinery installation manual that it is the responsibility of the end user to provide adequate earthing of the framework of individual machinery and that earth continuity must be lt 0 1 ohms when tested at 10 amps AC to an adjacent earth rod or matrix earth conn
40. nechoic chamber Testing is carried out initially in the anechoic chamber This performs two main tasks Firstly it reduces ambient signals by 100dB to negligible levels across the range of 30 1000MHz and secondly it virtually eliminates internal reflections from rf signals from the product under test This means that the signal received at the antenna is the direct signal only as there is negligible influence from reflected signals Guard band If the measured signals on the scan rise to 15dBuv m below the industrial limit line the product is taken to the outside test site or OATS At the OATS a guard band of 5dBuV m is used Any emission falling 5dBuV m below the limit line is considered a failure The OATS is the final word in accuracy and ADC have built theirs very closely around the ideal as specified in CISPR 16 which is the EU standard covering requirements for official test sites OATS At the OATS the normal EU EMC procedure is utilised The antenna is raised from 1 4 metres and the product is rotated through 360 degrees An automated antenna mast and recessed turntable are used to do this The test distance is 10m and the product is placed 0 8m in height over the turntable DAEUM Jan 2001 35 EUROPEAN DIRECTIVES THE EMC DIRECTIVE The galvanised steel ground plane is 10m x 3 m and is perforated so as to avoid buckling with temperature change Conducted emissions This is applicable to ac powered units only
41. oltage impulses by deriving their power from the same fused filtered and surge suppressed supply All AC output modules in the DL305 and DL405 ranges contain internal transient suppressers and fuses with the exceptions of DL305 series D3 16TR suppressers but no fuses F3 08TRS 1 F3 08TRS 2 DL405 series F4 08TRS 1 F4 O08TRS 2 Supply interruption Specified as 3mS random total interruption of power DAEUM Jan 2001 11 Physical environment and operating conditions EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE All ADC AC powered bases PSUs or system assemblies can withstand a full half cycle 10mS power interruption without effect Response times of individual AC input modules are detailed in the main product catalogue and all AC input modules comply with this requirement Voltage dips Specified as 20 of nominal supply for one cycle All AC powered PLC systems and I O modules meet this requirement DC voltage DL 05 series 10 2 28 8v DC lt 10 max ripple DL 06 series 10 2 28 8v DC lt 10 max ripple DL 205 series 10 2 28 8vDC lt 10 max ripple DL 305 series 20 5 30vDC lt 10 max ripple DL 405 series 20 29vDC lt 10 max ripple All four PLC ranges are suitable for use on machinery with 24v DC supplies in Europe while the DL 205 DL 05 and DL 06 series are also suitable for use on 12v DC supplies Care must be taken to ensure that the chosen analogue modules accept the power supply to
42. ource impedance current loop input and output modules in several configurations and combinations Opto isolation ensures immunity to common mode signals between I O lines and frame The low impedance of current loop signals ensures good overall noise immunity Hydraulic servo and velocity drives All industrial standard current and voltage interface levels including 10v are available in each range Communications A key operated switch with a label marked isolate communications if operating machinery during maintenance must be provided in any networked PLC control cubicle Special products are under development VO status All ADC PLC input and output channels contain LED indication of their operational state Equi potential bonding As per the requirements of this section all control cubicles in a network utilising communications or remote I O must be equi potentially bonded by cables in excess of 6mm Communication cables must have twisted pairs with foil and 60 braid screening with the braiding connected to the machinery frame at both cable ends See draft Installation guidelines IEC 1000 5 1 and IEC 1000 5 2 for site installation requirements PLCs ADC programmable controllers comply with the sections of EN 61131 2 1995 that are applicable to the machinery directive Memory retention and protection Non volatile memory is provided Programs may be password protected and special programming devices or software
43. ply and the I O and comms ports Installation Category Overvoltage Category Level Description Peak impulse withstand voltage from 230vac power Basic Insulation Double Insulation 1 Signal level special equipment 1500v 2550v or parts of equipment telecommunications electronics etc 2 Local AC power level 2500v 4250v appliances portable equipment etc 3 Distribution power level fixed 4000v 6800v installations etc Pollution level Two levels of pollution are specified across terminals and printed circuit boards Pollution degree 1 No pollution or only dry non conductive pollution occurs The pollution has no influence Pollution degree 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation must be expected Classification with regard to protection against electric shock The definition of Class which designates the means by which electric shock protection is maintained in normal use and likely fault conditions Class 1 All accessible parts of the PLC equipment are earthed to a protective earth terminal so that only basic insulation is required in the external circuits of the installation Class 2 Accessible parts of the PLC equipment are not earthed so that double or reinforced insulation will be required in the external circuits of the installation DAEUM Jan 2001 22 Accessible parts that may become hazardous live in a contro
44. pment specification DAEUM Jan 2001 36 EUROPEAN DIRECTIVES THE EMC DIRECTIVE Fast transients are injected up to 4 4kv ESD to 16kv surge to 4 4kv and simulated voltage dips and dropouts at various specifications and levels are applied Harmonics voltage fluctuations and flicker These tests come under the emissions category not immunity as one might expect These tests are outsourced as they are quick and it is unusual for a failure to occur DAEUM Jan 2001 37 EUROPEAN DIRECTIVES ANNEX Appendices Certifications department May 2000 statement A ADC standards chart B Extract of questioner from the machinery directive C DAEUM Jan 2001 38 EUROPEAN DIRECTIVES ANNEX Annex A Statement on May 2000 decision DAEUM Jan 2001 39 EUROPEAN DIRECTIVES ANNEX Annex B ADC standards chart Manufacturers of PLCs and related products requiring CE Products designed Products designed before May 2000 You must satisfy both the low voltage and EMC directives Low voltage directive EMC directive Radiated rf emissions Conducted rf emissions Electrostatic discharge immunity Radiated rf immunity Burst transients immunity Dips variations interruptions immunity Damped oscillitary waveimmunity Fluctuations and flicker emissions Harmonic emissions Standards EN50081 2 or EN55011class A EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN61000 4 11 EN 61000 4 12 EN
45. rawings and end users constructing their own systems 29 ENVIRONMENTS APPLICABLE TO THE PLC SYSTEM UNDER TEST 29 EMC STANDARDS APPLICABLE TO PLC MANUFACTURERS 29 Product specific standard 30 Generic standards 31 TESTS LIMITS APPLICABLE TO THE EMC DIRECTIVE 32 Generic domestic and light industrial environments emission 32 Generic heavy industrial environments emission 32 Generic domestic and light industrial environments immunity Generic heavy industrial environment immunity Product specific Future additions to standards EVALUATION OF EMC CHARACTERISTICS Radiated emissions Emissions test equipment Anechoic chamber Guard band OATS Conducted emissions Guard band Radiated immunity Fast transients ESD surge and dips Harmonics voltage fluctuations and flicker APPENDICES Statement on May 2000 decision Standards chart 32 33 33 34 34 35 35 35 35 35 36 36 36 36 37 38 39 40 Extract of machinery directive questionnaire form EN60204 1 1993 41 EUROPEAN DIRECTIVES INTRODUCTION Introduction Purpose of this manual The directives Advanced programmable logic controllers are finding uses in an ever expanding range of applications While they fulfil their classical role as machinery controllers with advanced processing and operator facilities they are also to be found in instrumentation and analysis systems data logging systems and even on transport systems This manual deals with the new requi
46. rements for equipment sold into Europe that contains Automation Direct com ADC products and explains the requirements attached to the CE labelling of ADC equipment so that conformity can be assured to the now legally binding requirements of the EEC directives and their associated harmonised standards Where appropriate the reference to standard will be shown in the right hand margin Europe is in the process of harmonising all national standards in order to remove barriers to trade between EU countries and this process may easily take 10 20 years Each area of trade will eventually be controlled by a directive and within each directive is a set of applicable standards Directives and the standards within them are being constantly revised over this introductory period In order to determine which standard issues are applicable at any one time it is necessary to consult the official journal of the European community which lists all standards and directives as they become legally applicable Harmonised standards released in the OJ are prefixed by the letters EN Particular countries may still continue to insist on additional compliance to their own national standards and specific industries or particular customers may have their own specific requirements Three directives have been issued at present that relate to programmable logic controllers Machinery directive 89 392 EEC EMC directive 89 336 EEC Low voltage directive 73
47. rmity to EMC and low voltage directives with the applicable standards The standards directives and their amendments that legally apply are listed in the OJ official journal This manual is based on the current legal position with attention given to expected amendments that will effect the situation over the short to medium term future This is the second edition of the manual and there will be future issues plus amendment notices as legislation changes ADC are members of the ERA Electrical Research Association who inform of changes to current EMC and safety standards ADC has invested in its own certifications facility which is based in the UK and incorporates a premises dedicated solely for the purpose of CE and occasionally UL certification of ADC s products The premises is equipped with an extensive EMC testing facility as well as dedicated office space for management and procedures Programmable logic controllers have a product specific standard EN 61131 2 that became mandatory in mid 1998 Before this date ADC s s certifications department had been using appropriate generic standards To approve the existing product range to EN 61131 2 would have been economically unviable Therefore a decision was made in May 2000 to approve new products to the product specific standard while continuing to use the generic standards for existing products A formal department statement can be found in the appendix DAEUM Jan 20
48. s are mounted in explosion proof enclosures It is left to the design engineer to consider the hazards associated with each application All PLC CPUs contain super capacitors in order to maintain CMOS memory during battery change There ate no acoustic noise problems associated with PLCs DAEUM Jan 2001 EN 60204 1 1992 4 1 6 2 1 9 4 2 2 9 4 2 3 9 4 Selection of equipment Electrical supply EUROPEAN DIRECTIVES THE MACHINERY DIRECTIVE ADC PLCs are designed to be used in heavy industrial environments provided the equipment is installed correctly in a standard industrial steel enclosure maintaining the requirements of each individual product user manual Certain products can also be used in commercial and domestic environments see the product manual and declaration of conformity Equipment can be AC powered from all industrial or domestic mains supplies so long as appropriate filters are used where applicable and that isolation transformers are always used Consult the declaration of conformity for a particular product to find out these special requirements Operational Requirements The below table illustrates voltage requirements for the ADC product range Tolerance withstand of incoming voltage for AC powered models is stated in the manuals whilst the voltage markings on the product reflect this The standards do not require this tolerance to be included within the stated voltage range for DC powered models
49. s protected Transformers Mains and control voltage isolation transformers must have each winding short circuited or subjected to worst case overloads for one hour or it must be demonstrated in the TCF how this condition is protected Outputs Each output from the PLC must be short circuited one at a time for one hour on full output or it must be demonstrated in the TCF how this condition is protected The ADC product literature details which modules are fitted with safety fuses and their ratings Multiple supplies Equipment designed to operate from more than one supply must be connected to both supplies simultaneously for one hour or it must be demonstrated in the TCF how this condition is prevented Cooling Equipment cooling must be restricted as follows one fault at a time for one hour each e Air holes in cubicles with filters shall be closed e Forced cooling by motor driven fans must be stopped e Cooling by circulation of water or other coolant must be stopped Heating Equipment with heating devices must have the following faults applied one at a time e PLC timers that limit the heating shall be over ridden to run continuously e Temperature controllers except for over temperature control devices which have special requirements under section 14 3 of standard must be overridden to energise the heaters continuously DAEUM Jan 2001 25 EN61010 1 44 2 4 EN61010 1 4 4 2 5 EN61010 1 4 4 2
50. sed their products for the purpose of testing through approved bodies A number of prosecutions have already taken place Germany operates differently to the rest of Europe They have a dedicated CE marking enforcement agency that actively random tests electronic equipment Documentation is provided for systems builders and end users as to the standards classes and environments that suit each item in the PLC product ranges so that final product designs and systems may be constructed to comply with the requirements of the directives The ADC group has its own in house test facilities and has joined the ERA electrical research association in the UK who provides a consultation and approval of procedures applied within the group PLC equipment is designed and manufactured using good engineering practices to ensure safety and reliability The selection of ADC products for a particular application is the final responsibility of the system designer and end user and this document is only intended to provide awareness of possible working methods for system design departments Many industries have special hazards and it is the combined responsibility of the system designer and end user to ensure that equipment operates safely and within the law DAEUM Jan 2001 The situation onsite Determination of the operating environment EUROPEAN DIRECTIVES INTRODUCTION All end users within the EU must by law perform various basic electrical safe
51. t specific standatd EN 61131 2 in section 3 9 1 table 16 note 5 states Revision of these requirements is under consideration in order to take EN 61000 4 5 into account EN 61000 4 5 is about surge immunity tests Emissions None in the relatively near future When testing to the European standards three thinking methodigies are utilised Firstly the PLC equipment must be setup in as true to life a situation as reasonably possible secondly the procedures as detailed in the applied standards are followed as closely as reasonably possible Thirdly and because of the vast complexity of rf emissions and the possible combinations of system builds the product is tested at building block level Hence for emissions testing the system is separated down to each module and base and tested separately The rf emission characteristics of a modular PLC system are affected directly by control cubicle type layout quantity of orifices to the cubicle the equipment within the cubicle and the cabling arrangement utilised to mention but a few Therefore there is a virtually infinite number of possibilities and combinations of final system build in terms of rf emissions This is the reason that when testing for rf emissions each module base etc is tested individually The evaluation of the rf emissions of PLC components is conducted with the equipment mounted on an industry standard cubicle or enclosure This is placed on a 0 8m non conductive table
52. tes in a specified and controlled manner It is the responsibility of the design engineer to select a non hazardous restart mode after power failure in the program design Disturbances in common external power could in an extreme case cause complete destruction of all PLC systems so that even redundant diverse systems could fail The design engineer should consider alternative redundant diverse systems such as separate emergency shut down systems watchdog timers etc and with their own backup supplies where the hazards are extreme All ADC PLCs comply with the generic immunity requirements of the EMC directive when correctly installed to their individual installation manuals However it is the responsibility of the design engineer to ensure that adverse electrical interference which might cause destruction or disruption of the PLC will not give rise to a hazardous condition within the machine For example the stored electrical energy in the lithium CMOS memory backup batteries within each PLC can not cause a shock hazard but could cause a fire under adverse conditions outside the limits of this specification Only the replacement battery assemblies manufactured and approved by ADC should be fitted and note should be made to this effect in the spare parts or routine maintenance section of the machines technical manual For maintenance purposes PLCs may be operated without backup batteries in the case of hazardous environments and the PLC
53. tion 4 4 of EN60204 1 1992 2 Ambient Temperature Range ccc ecee eee eee ees 3 Humidity Range ocicsssavenisaeeassevesesamiaieageti nanan 4 Altitude 5 Environmental e g corrosive atmospheres particulate matter special EMC CharacteriSHCs cici lt sciccsiaieesestectesese nates nces 6 RAAT ON serem raa Gasman ein sanschs To Mibtationy SHOCK ssamen as E Ring iddededasagdadtnds ans soaedeats 8 Special installation and operation requirements cece eee eee eee eee ees DAEUM Jan 2001 41 EUROPEAN DIRECTIVES ANNEX Power Supply ies and Related Conditions section 4 3 of EN60204 1 1992 9 Anticipated voltage fluctuations if greater than 10 0065 10 Anticipated frequency fluctuations if greater than 1 oo cece eee e cece ee eee ee es Specification of the short time value c cece 11 Indicate possible future changes in electrical equipment that will require an increase in the electrical supply HEQuireMeENts 220i Metissutivaes aa ar n erii 12 Indicate for each source of electrical supply required nae Or If AC number of phases Pk Frequency If AC number of phases aa Frequency al ie If AC number of phases ae Frequency 13 Type of power supply earthing TN TT IT TN System with one point directly earthed with a protective conductor PE connected to that point TT System with one point directly earthed but the protective conductor PE
54. trical equipment 00 ee In which language 2 o c seciccinesdsis verdes se taees EEn rE ERRES Technical documentation section 19 1 of EN60204 1 1992 On what media cpc ookessdid veces duets avila wees AE E TEE Tn which language 2 isc ciceraianwekvrs eoetwtesaseaina vag tien He Senses Size location and purpose of ducts open cable trays or cable supports to be provided by the user section 19 5 of EN60204 1 1992 additional sheets to be provided where necessary DAEUM Jan 2001 43 EUROPEAN DIRECTIVES ANNEX 26 2T 28 29 30 31 32 33 For which of the following classes of persons is access to the interior of enclosures required during normal operation of the equipment Skilled persons sasstsiirisnoestoieieagensdeieistear sobs maser eapenonneys Iiistruct d PErSOS ironii niser ratakan ne a EA E Aai EaR Are locks with removable keys to be provided for fastening doors or covers 6005 If two hand control is to be provided state the type cece cece cece cece eee ee nena teens Indicate if special limitations on the size or weight may affect the transport of a particular machine or control gear assembly to the installation site Maximum dimensions cece ccc cece eee eee eee ee eens eet eeeeeaneneeees Maximum weights soeren nierien as S AEE E EEE REE eal se rdes In the case of machines with frequent repetitive cycl
55. ty checks before equipment is taken into service which are repeated annually These tests are designed to ensure continued reliability of the safety earth bond to any accessible metal parts and the integrity of the insulation Electrical safety and the EMC characteristics of equipment and installations rely heavily on good earthing and ADC equipment has been designed assuming that the installation recommendations detailed in IEC 1000 5 1 IEC 1000 5 2 and EN 61131 2 have been followed Some sites may not be suitable for modern electronic equipment and if a system design engineer is aware of this then subsequent accident or financial loss will be his or her direct responsibility The OEM panel designer or systems designer must always ensure that there are no special electrical requirements to be met within a particular project design and the questionnaire included within Annex B of the machinery directive electrical safety standard EN60204 1 1993 is a responsible method to ensure compliance Once the environment has been accurately specified in the contract or product design specification and the type of personnel identified who have access to the interior of the control enclosure an analysis must be performed by the system designer of each electrical circuit in the system to determine degrees of insulation required between hazardous circuits and accessible parts relative to installation categories pollution levels etc DAEUM Jan 2001
56. uit redundancy and diversity CONTROL INTERFACES Protection Inputs Outputs Servo drive interfaces Hydraulic servo and velocity drives Communications ELECTRONIC EQUIPMENT I O status Equi potential bonding PLCs Memory retention and protection Programming equipment Verification TESTING Insulation resistance Voltage test Residual test EMC THE LOW VOLTAGE DIRECTIVE INTRODUCTION CLASSIFICATION FOR CE MARKING BY THE OPERATING ENVIRONMENT Installation category Pollution level Classification with regard to protection against electric shock Safety requirements for installations 17 18 18 18 18 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 21 21 21 21 22 22 23 ACCESSIBLE PARTS THAT MAY BECOME HAZARDOUS LIVE IN A CONTROL SYSTEM SINGLE FAULT TEST CONDITIONS Protective impedance Protective conductor Actuators Motors Capacitors Transformers Outputs Multiple supplies Cooling Heating Insulation TESTS AND OTHER REQUIREMENTS Compliance Earthing Earth bond Double insulation THE EMC DIRECTIVE 23 24 24 24 24 25 25 25 25 25 25 25 26 26 26 26 26 26 28 INTRODUCTION 28 TYPES OF PLC USER 28 Manufacturers of standard machinery placed on the open market OEMs 28 Manufacturers of special purpose machinery for a single end user s own use 29 Integrators of individual machinery into systems for one end user 29 Panel builders working to constructional d
57. ve to be eatthed and ADC products have been CE marked on this basis and installation requirement The new installation standards IEC 1000 5 1 IEC 1000 5 2 and EN 61131 4 state that the braid of screened cables must not be used for connection of the signal Ov within networks Braiding must be earthed to the cubicle frame and substantial equi potential bond wires must be wired alongside serial cables between each node of a network purposely forming complex ground loops in order to reduce the overall impedance of a grid style ground plane in a factory ot office It is the responsibility of the system designer to ensure that control and power circuitry connected to the PLC is earthed as previously specified and that screened cable braiding is earthed with equi potential bonds between nodes of a network Correct observance of these requirements will ensure that there are no accessible un earthed citcuits or parts associated with a PLC system The system designer must also be aware of the further requirements of the low voltage directive safety standard EN 61010 1 section 4 4 which requires design of the control system to accommodate the following single fault test conditions to test for protection against the spread of fire A TCF technical construction file should be kept for each project or product that demonstrates how hazards have been avoided in the following sections Each test is applied one at a time for an hour and there must b
58. wered equipment for use in the domestic light and heavy industrial environments Battery powered equipment where the power leads are less than 3 metres in length Please see the May 2000 decision in the annex for explanation of the standards applied by ADC The standards chart also in the annex will give an overall guide to which standards ADC applies to which products DAEUM Jan 2001 29 EUROPEAN DIRECTIVES THE EMC DIRECTIVE Product specific standard EN 61131 2 1995 and amendment AMD 9441 Programmable controllers part 2 Equipment requirements and tests The standard EN 61131 2 is a combined product specific standard which encompasses both the low voltage and the EMC directives However equipment that complies with EN 61131 2 only is not fully covered in the eyes of the EMC directive as other EMC standards are required However in the eyes of the low voltage directive EN 61131 2 covers all aspects as it is recognised as a safety standard under the low voltage directive EN 61131 2 covers EMC immunity for which it calls up various standards from the EN 61000 series but it does not reference other standards for rf emissions It simply states Due to differing national regulations emission levels cannot be specified Equipment shall meet the levels specified in every country of concern Therefore ADC applies the generic rf emissions standard EN 50081 2 for industrial environments EN50081 1 or EN 55011 class

DA-EU-M - AutomationDirect

Contents

Download Pdf Manuals

Related Search

Related Contents