1、. c-1 Manufacturing Standards E ELECTRICAL MANuFAC!lTJRING STANDARD SAFETP OF MACHINERY- ELEC!l!RICALEQUIEMENTOFMACHINES FORD USER REQUIREMENTS TO EURONORM EN 60204-l: 1992 This Ford Manufacturing Standard shall be read in conjunction with the National versions of the European Standard EN 60204-1:19
2、92, which together with this Ford Manufacturing Standard describes all the requirements for the ?. Guarding is impractical or, Short movements are required, for example clamping fixtures, piercing or clinching tools etc., or, cl - Manual movements of inching/jogging movements are required. Use of tw
3、o-hand control shall only be allowed with prior approval of the appropriate Plant safety representative. Where approved for use, two-hand control shall be so arranged placed and protected, that they cannot be operated unintentionally or be easily defeated. It shall be impossible for the operator to
4、actuate both controls with one hand or one hand and another part of the body. Bridging both buttons with a tool shall not be easily possible. U-EXOOI Safety of Machinery - Page 6 of 14 Electrical Equipment of Machines September 1994 l m Manufacturing Standards E The distance of the controls from the
5、 nearest dangerous movements (point of danger) must be such that movements stop before the operator can reach them. The minimum safe distance from the point of danger shall be provided based on the calculation :- S = v.t where : v = 1.6 m/s (metres/second) : t= braking time (seconds) This safety dis
6、tance shall also apply to movable two-hand controls. . :. The timing relay shall be of a fixed delay of 0.5 seconds, or, if adjustable, shall have a maximum setting of 0.5 seconds. Where more than one operator works on the same machine which is safeguarded by two-hand controls, each operator shall b
7、e provided with two-hand controls. the concurrent operation of all separate two-hand-start stations shall be necessary to obtain a start command. Arrangements to enable lock-out of control stations if the number of operators is reduced shall be carried out in a fail-safe manner. Power presses that r
8、equire more than one two-hand control station, have to comply with other special safety requirements. (eg. lock-out proceedure for two-hand control) Only two-hand-start-relays shall be used to control this operation. Where National legislation calls for specially approved two-hand-start safety relay
9、s to be used, the machine shall be supplied with the appropriate safety certificates which cover the relays provided. 9.3.5 Reverse current braking, DC. injection braking and braking via drive controllers alone shall only be used if no danger to personnel or machines arises. 9.3.6 The safety related
10、 parts of a control system shall be designed in a way that the machine is safe during all intended use, forseeable misuse and forseeable human mistakes if faults occur. The selecting of safety measures shall be determined by a provable risk assessment according to EN 954. 9.4.1.4 Circuits switched o
11、ff for personnal protection shall not be connected on the isolated side to any other circuits, to avoid possible faults bypassing safety functions over parallel paths. 9.4.3.1 All control circuits shall have one side of the circuit connected to the protective bonding conductor. (see 8.4 ) This requi
12、rement also applies to the power supplies for programmable controller input and output groups. September 1994 Safety of Machinery - Electrical Equipment of Machines U-EXOOl Page 7 of 14 Manufacturing Standards 10.1 Command/control devices, such as motion sensors or manually operated control equipmen
13、t, shall not be used for direct control of magnets, clutches and brakes. Exceptions are the switching functions of safety circuits . The use of safety override switches shall only be used with the approval of the Ford specifying engineer. 10.1.1 Operator control devices shall be so placed that all m
14、ovements of the machine remain visible, if necessary, several control stations shall be provided 10.1.3 In the case of position and proximity switches, valves etc. the actuated condition shall be indicated by an LED on the unit or on the connector (excluding safety limit switches) Wherever possible
15、the electrical connections should be plugable. (this shall exclude safety switches) With the exception of safety circuits, sensing with proximity switches is preferred. 10.3.1 Operator indicator lights and displays shall be provided with a grouped means to test their functions using a single button
16、on each operator station or other interface point. Alternative means of indication for machine status and fault diagnostic information can be as follows :- * Indicator lamps * Alphanumeric text display * Visual display units * EDDI to the Ford specification The method shall be agreed with the Ford S
17、pecifying Engineer 11.2 Inputs and Outputs of programmable devices should be potential free, voltages being derived from the control circuit supply and not from the programmable controller. 11.2.1 Digital inputs shall only be loaded by a single input device eg. push button, position switch etc. 12.2
18、.1 All Input and Output devices shall be short circuit protected Electronic devices with short circuit protected outputs shall be functional after removal of the short circuit. Removal of the short circuit shall not cause hazards to personnel, machines or products. The input/output modules shall be
19、removable without disconnection of the field wiring. Input/output modules shall be located as close as possible to the functional devices controlled and interconnecting wiring shall be arranged to facilitate this. U-EXOOl Safety of Machinery - Page 8 of 14 September Electrical Equipment of Machines
20、1994 o c-3 Manufacturing Standards E 12.3.1 12.3.2 12.3.3 12.3.4 Terminal reference and control device numbering shall be in accordance with the Input/Output addresses. Consideration shall be given to the provision of spare Input and Output capacity with the agreement of the Ford Specifying Engineer
21、. Configuration and installation of the programmable equipment shall be in accordance with the original manufacturers instructions. The Programmable controller internal watchdog device shall be arranged to switch off all hazardous machine functions in a controlled safe manner in the event of a malfu
22、nction within the Programmma ble controller. It is preferred that programme software shall be stored on non-volatile memory. In any event, data in programmable memory shall not be lost as a result of power failure. The Programmable controller executive software shall not be modified by the machine b
23、uilder or overwritten by the user programme. Suitable power sockets and data connection points for the programming equipment shall be provided within the enclosures of all the programmable devices and at other appropriate points. Memory capacities of the program memories (for user programmes) shall
24、be selected so that standard machines have at least lo%, special machines at least 20% spare capacity. The connection and disconnection of programming equipment shall be possible during machine operation and without disconnection of diagnostic displays. The user software shall be clear and serviceab
25、le. Structured programming shall be applied. Fault detection and fault signalling shall be part of the programme structure. All actions of the machine sequence shall be controlled and monitored. The status of all solenoids, circuit breakers etc. shall also be monitored in all operating modes eg. Aut
26、omatic, manual etc. The display of a single line of control logic shall not exceed the width of the programming device screen. If allowed by the production process, the programme shall be segregated into functional groups with sequential execution. The software design shall follow the requirements o
27、f the Ford Specifying Engineer. The programmable controller cycle and reaction times shall be taken into consideration when developing the user software to fulfil the process requirements. 0 September 1994 Safety of Machinery - Electrical Equipment of Machines U-EXOOl Page 9 of 14 Manufacturing Stan
28、dards 12.3.5 Programmable electronic equipment shall not be utilised for the following safety functions except where agreed with the Ford specifying engineer:- * emergency stop circuits * master control relay * guard door limit switches, solenoid operated locks and monitoring devices * Contactless s
29、afety circuits (eg. Electrosensitive safety systems ) * two hand controls * any other personnel safety devices 13.2 Control gear shall preferrably be mounted on the back plane of the enclosure. Consideration shall be given to mounting control gear in a logical numerical sequence rising from left to
30、right and top to bottom. Where environmental conditions exceed those stated in 4.4 the following cooling equipment may be provided :- * air to air dual circuit heat exchangers * air to water dual circuit heat exchangers * air to air dual circuit refrigerated coolers (refrigerant R134a is preferred,
31、proposals concerning any (alternative CFC free refigerant to be discussed with the (Ford specifying engineer) Where refrigerated cooling units are provided, controls shall be supplied to shut down the units when enclosure doors are opened, these shall include timers to delay restart of the units unt
32、il the refrigerant has fully evaporated, thus preventing overloads and improving the life of compressors. Filter fan systems shall not be provided 13.4 Control gear enclosures shall be provided with lifting eyebolts for transport and installation. The doors (maximum width 900 mm.) shall have an open
33、ing angle of at least 165O and shall be designed so that the control enclosures can be installed next to each other without intermediate space. The insides of the doors shall have metal pockets for the technical documentation. These pockets shall be configured so that all the required documents/manu
34、als size DIN A3 are completely enclosed and mounted with their longest sides vertical. Doors of height 800 mm. shall have door, closures with pushrods and handle. At 1600 mm. or more height an additional central fastening shall be provided. The doors shall be fastened with a lock having a detachable
35、 key with 7 mm. inside square in accordance with 7E DIN 7417 U-EXOOl Page 10 of 14 Safety of Machinery - Electrical Equipment of Machines September 1994 cm Manufacturing Standards E 14.2 15.1.1 All cable conductors shall be copper Screw-type terminals of all devices must have a pressure foot, clampi
36、ng bar or clamping shackle to protect the conductor, a direct contact between the screw and conductor is not permitted. Control wiring terminations shall be provided with crimped sleeves. Identification tags shall not be fixed to wiring by adhesives 15.2 All wires and cables shall be marked at each
37、end by a durable and secure label in accordance with the documentation in addition to the required colour coding (see also 19) 15.2.4 When using multicore cables for Low Voltage power supplies, the following colour coding shall be used :- Ll. - Black L2. - Brown L3. - Black N. - Blue PE. - Green/Yel
38、low PEN.- Green/Yellow 15.3 Motor circuit connections within enclosures, shall be made via separate terminals and not directly to devices. 15.4 Only multicore cables should be used outside enclosures. 15.5.6 Trunking systems and conduits shall be of metal type. 15.5.8 Connection and junction boxes i
39、f provided shall have a degree of protection of at least IP 54, where these boxes are exposed to liquids and dusts, the degree of protection shall be increased in accordance with EN 60529: 1991 The outer structure and internal members of the enclosure shall be fabricated in sheet steel of not 1eSS t
40、han 2 mm. thickness assembled for maximum rigidity of the whole unit, with all sharp corners removed. The colours of enclosures and associated trunking shall be in accordance with the requirements of the Ford specifying engineer. Connection and junction boxes shall only be used if :- - branching of
41、wires is necessary - a separation of cables is necessary or recommended for transport or for moving the machine - a transition between flexible and highly flexible cable is necessary - individual devices with encapsulated connecting wires (such as transducers, proximity switches) must be connected C
42、onnection and junction boxes shall be installed so that - the opening is in a vertical plane - the opening is accessible without disassembly of other l September Safety of Machinery - U-EXOOl 1994 Electrical Equipment of Machines Page 11 of 14 E Manufacturing Standards !llZB. 16.1 16.2 16.6 17.2.1 1
43、7.2.2 18.1 18.3 18.4 machine parts, switching-off the machine or removing guards - the bottom edge of the box is at least 400 nun. and the top edge of the box not more than 2200 mm. above the service level Control devices shall not be installed in connection or junction boxes. Requirements for distr
44、ibuted bus-systems shall be discussed with the Ford specifying engineer. Cable entries to boxes should be from the underside. With the exception of servo motors, only three phase AC motors shall be used. Forced cooled motors shall not be used unless previously agreed with the Ford specifying enginee
45、r. Motor enclosures shall have a degree of protection of at least IP54. Higher degrees of protection may be specified in special circumstances. The limit of power up to which 3- phase motors may be started directly across the incoming supply lines shall be 50 KW. unless previously agreed with the Fo
46、rd specifying engineer. Where fixed lighting is provided inside enclosures, it shall be controlled by a local position switch operated by the door AL1 lighting not obtained directly from the power supply shall be either 24 volts dc. or 230 volts ac. Inside the enclosure identification plates shall b
47、e of a material which is resistant to deformation and also the obliteration of the marking. Outside the enclosure, identification plates shall be of non- corrodible metal, a minimum of 1 mm. thick, or laminated plastic coloured in layers white/black/white All identification plates shall be fixed in
48、a durable manner (not adhesives). The suppliers name plate shall indicate the Ford drawing number of the master control schematic. All functional descriptions shall be in the language of the country where the machine is to be installed. For the main control enclosure, all information indicated shall
49、 be provided on an identification plate mounted as close as practicable to the main isolator. l U-EXOOl Safety of Machinery -. September l Page 12 Of 14 Electrical Equipment of Machines 1994 l cm Manufacturing Standards E 18.5 Identification plates shall not be fixed on the components and control devices, and shall not be lost when changing these. Where components are hidden by covers, the identification plates shall be repeated on the outside of the covers. Components mounted outside enclosures shall be marked with engraved plates adjacent to the component. 0 All programmable device gro
