The Impact of Marking Requirements. on Design and Performance of Power Converters and Electrical Drives

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Colin Goodwin
6 years ago
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1 European The Impact of Marking Requirements on Design and Performance of Power Converters and Electrical Drives

2 Harmonization of Standards

3 The Key to the European Market C onfused E urope

4 EN BS... EU-Directive 89/336/EEC EMC-Law 1... Definitions Standards are documenting the technical state of the art might be part of delivery contracts. e.g. national BS, NP, VDE European EN international ISO, IEC, CISPR EU Directives are fixing basic safety requirements to be met by products within the European market e.g. EMC directive low voltage directive (LVD) safety of machinery directive EU directives usually refer to European standards Meeting these standards is one possibility to meet the directive - but not the only one. Laws are national realizations of EU directives e.g. EMC law, safety laws European governments are obliged to release laws according to the EU directives. They are not allowed to change the content.

5 -Marking - Purpose Passport -marking is an administrative process providing free commercial trade within the EU. The -mark on a product indicates, that this product meets all relevant EU directives and can be traded without restrictions within the whole EU. -mark shall enable national authorities to supervise the market. Nobody is allowed to use the -mark for commercial purposes (e.g. it is not permitted to advert: This product is -marked ) EG-Richtl. EG-Richtl. 89/336/EEC The -mark documents the compliance of a product with essential requirements of all relevant EU directives.

6 .... EU Directives medical equipment lifts safety of machinery low voltage EMC toys... all directives are safety related except the EMC directive!

7 CE -Marking - Relationships administration administration permission declaration of conformity manufacturer declaration delivery user manufacturer delivery user

CE -Marking Valuation of Conformity EG-Richtl. 90/683/EWG -1- EU Directive 90/683/EWG -1- valuation of conformity... is performed according to module A, B,..., or H.

8 CE -Marking Valuation of Conformity EG-Richtl. 90/683/EWG -1- EU Directive 90/683/EWG -1- valuation of conformity... is performed according to module A, B,..., or H. each EU directive defines by itself which module has to be used. declaration of conformity... is provided by the manufacturer including a description of the product, a reference to the product specification, an authorization of signature and the certified body (if applicable)... must be stored for 10 years from the delivery of the last product. each EU directive should explain the meaning of delivery. the mark... is the sign of conformity... is placed on the product or if this is impossible on the packaging or in the delivery documentation.

9 European Standards and Directives European Directive safety of machines safe insulation safe emergency stop safe standstill without energy switch-off (e.g. double channel supervision) safe limitation of motion European Directive low voltage safety against electrical shock European Directive EMC low harmonics in the mains new product standard EN (IEC )

10 Valuation of Conformity DIN VDE.. EN If design and production of a certain product are performed according to harmonized European standards (referenced by the directive), the manufacturer is allowed to mark the product in self responsibility according module A. In this case it is not necessary to involve an accredited laboratory! Prescription Dr. EMC -1- In the case of differences to harmonized European standards or non- existing harmonized European standards, a certified body has to confirm compliance of the product with EU directives. The confirmation has to be based on test reports of an accredited laboratory and allows the manufacturer to mark the product according module B. Conclusion: An accredited laboratory confirming that a product meets European Standards is nonsense with respect to EU directives.

11 Conformity Evaluation Modules A.(Internal Control of production) Manufacturer Keeps technical documentation at the disposal of national authorities A.a. Intervention of notified body B.(Type examination) Manufacturer submits to notified body - Technical documentation - (Proto)Type Notified body - Appores conformity with essential requirements - Performs out tests, if necessary - Issues EC type-examination certificate G.(unit verification) Manufacturer - Submits technical documentation H.(full quality assurance) EN Manufacturer - Operates an approved quality system (QS) for design Notified body - Performs surveillance of the QS - Verifies conformity of the design (*) - Issues EC design examination certificate (*) A. Manufacturer - Declares conformity with essential requirements - Affixes the CE mark A.a. Notified body - Tests on specific aspects of the product (*) - Product checks at random intervals (*) C. (conformity to type) Manufacturer - Declares conformity with approved type - Affixes the CE mark Notified body - Tests on specific aspects of the products (*) - Product checks at random intervals (*) D.(production quality assurance) En Manufacturer - Operates an approved quality system(qs)for production and testing - Declares conformity with approved type - Affixes the CE mark Notified body - Approves the QS - Performs surveillance of the QS E.(product quality assurance) En Manufacturer - Operates an approved quality system(qs)for inspection and testing - Declares conformity with approved type, or to essential requirements - Affixes the CE mark Notified body - Approves the QS - Performs surveillance of the QS F.(product verification) Manufacturer - Declares conformity with approved type, or to essential requirements - Affixes the CE mark Notified body -Verifies conformity - Issues certificate at conformity Manufacturer - Submits products - Declares conformity - Affixes the CE mark Notified body - Verifies conformity with essential requirements - Issues certificate of conformity Manufacturer - Operates an approved QS for production and testing - Declares conformity - Affixes the CE mark Notified body - Performs sureillance of the QS (*) supplementary requirements may be applied in specific directives

12 Conformity Assessment (e.g. EMC Directive) Design and Development Module A Manufacturer - keeps technical documentation (compliance with harmonized EU standards) at the disposal of national authorities Notified bodies - intervention Manufacturer - declares conformity with essential requirements - affixes marking Notified bodies - supervision of the market Production - product tests and/or production checks (at random intervals) Module B Manufacturer submits to notified body: - technical documentation (from accredited test laboratory) - product sample Notified body - ascertains compliance with essential requirement - carries out additional tests (if necessary) - issues EU type examination certificate Module D/E Production certified according to EN (ISO 9002) or EN29003 (ISO 9003) (only possible in combination with module B!!)

14 Valuation of Conformity according to the EMC Directive/Law meets harmonized EU standards listed in EMC directive (Module A) product does not meet harmonized EU standards (Module B) manufacturer confirms compliance with EMC directive/law by signing the declaration of conformity and by marking the product with CE accredited test laboratory performs tests and issues test report(s) delivery of product certified / notified body confirms conformity with goals of EMC directive/law Conclusion: Even if a certified body and/or an accredited test laboratory are involved, the full responsibility stays with the manufacturer.

15 -Marking - Application on Components 89/392/EU safety of machinery manufacturer s declaration (without CE-marking) optional! 89/392/EU changed by 93/44/EWG safety related equipment declaration of conformity (with CE-marking) obligation! 72/23/EU LVD (low voltage directive) declaration of conformity (with CE-marking) obligation! heute : Einbauerklärung Caution! only machinery directive makes a difference between these types of declarations 89/336/EU EMC directive not applicable! (of course, this is not really helpful!)

20 Isolation Requirements mains DC link motor cable temp. sensor V~ EN V EN V V ss ss VDE V~ V~ V~ Capacitor V~ V~ VDE v~ VDE 0884 xxx V~ 750 V= 400 V~ V ss VDE v~ VDE 0884 xxx V~ 750 V= 400 V~ V ss Controller Controller overvoltage category I : VDE / 0 1 / 0 overvoltage category II : VDE 0110 overvoltage category III : VDE 0110 pulse voltage L --> L up = 750 V L --> PE up = 1500 V Isolation voltage L --> PE U = 800 V~ test voltage L --> PE U = 640 V~ pulse voltage L --> L up = 1200 V L --> PE up = 2500 V Isolation voltage L --> PE U = 1400 V~ test voltage L --> PE U = 1200 V~ pulse voltage L --> L up = 2000 V L --> PE up = 4000 V Isolation voltage L --> PE U = 2200 V~ test voltage L --> PE U = 1800 V~

21 Electrical Drives (PDS-Power Drive Systems) and the Most Relevant EU Directives Directive official requirements with respect to the EU directive practical problems Low voltage mark on product + Declaration of Conformity none practical solutions

22 Safe Operation

23 Mains mains supervision Usual Safety Concept delayed contacts emergency switch-off three-level confirmation Frequency Inverter 2 3 standstill supervision Motor encoder T motion supervision

24 Three-phase current system Standard cabinet configuration for Servodyn-D Mains Connection Module (NA) incl. current limitation and radio interference suppression filter mains contactor control Supply Module (VM) with sinusoidal currents during supply and regeneration - Integration of EMERGENCY-STOP - Connection and monitoring of a mode selector switch - Connection and monitoring of an enabling (control) device - Integrated mains monitoring for single- and multiple-phase system failures - Integrated control and monitoring of guard locking module cross-connection Inverter Module (DM) - Safe speed reduction in special operation - Safe standstill in special operation - Maximum speed monitoring motor measuring system Motor Safety guard locking Guard Safe Operation

25 Electrical Drives (PDS-Power Drive Systems) and the Most Relevant EU Directives Directive official requirements with respect to the EU directive Low Voltage -mark on product + Declaration of Conformity NO -mark Safety of Machinery but: manufacturer`s declaration Exception: safety related products: -mark on product + Declaration of Conformity Evaluation process according to module B mandatory practical problems none none practical solutions (for safety related products certified body & accredited test laboratory must be involved)

26 Electro Magnetic Compatibility E even M more C confusion

27 Why are EMC / Line Harmonics important for us? EMC Law is a legal basis defines safety requirements Standards define permissible values for emissions and noise immunity regulate the cooperation of different devices provide troublefree operation define measuring procedures for proofing of standard conformity Source: ZVEI-TK ½ - Workshop, 2. April 2001, Frankfurt (Möller)

28 Harmonics in the Mains without filtering with optimized filtering H1 H3 H5 H7 H9 H11 H13 H15 H17 H19 H21 0 H1 H3 H5 H7 H9 H11 H13 H15 H17 H19 H21

29 EMC standard cabinet configuration for modern servo drives signal electronics power equipment mains input motoring regeneration power supply unit with power regeneration at 200 A eff line current line voltage

30 EMC Directive Products NC SPS AN Components: integrated circuits, printed circuit boards, complex combinations of elements and circuits for exclusive use as parts integrated in an apparatus. PGS Apparatus: final product with specified function intended for an end user and traded as a function unit. Systems: several apparatuses for a certain purpose traded completely (as a whole). Plants: Several apparatuses or systems combined for a certain purpose at a certain place not traded as whole.

31 Examples for Apparatus according to the EMC Law

32 Examples for Apparatus according to the EMC Law assembly units (complex components) set of devices for self assembly components if generally available! examples: PC Boards Ethernet Transceivers Interface Boards Switching Power Supplies

33 Special Situation: no Apparatus according to the EMC Law replacement and supply components exclusively for subsequent manufacturing by industry, handicraft or other expert (in the area of the EMC) not generally available not independently usable Do not have to meet the protection requirements! Examples: filters for integration in antenna amplifiers switching power supply for Hifi equipments controllers for washing machines

34 no Apparatus according to the EMC Law elementary devices Examples: Resistors Capacitors Transistors IC s cables, wires connectors, plugs batteries light bulbs or ballast circuits

35 Availability General Availability Channel of distribution is independant from the customer`s or user`s expert knowledge concerning EMC. Limited Availability Channel of distribution is limited to dealers, customers or users, who individually have technical EMC expert knowledge. Source: ZVEI-TK ½ - Workshop, 2. April 2001, Frankfurt (Möller)

36 EMC Directive Inverters According to EU directive 89/336/EU (EMC) an inverter is a component, no apparatus. In article 1, paragraph 1 of the EMC Directive an apparatus is defined with a specified function intended for an end user and to be traded as a whole (see enclosure 3 a). The EMC directive defines components as elements to be used for integration and not providing an own function. Components can be simple or complex devices as electrical motors, inverters

37 This Matrix is Harmonized with the BAPT (German Federal Administration for Mail and Telecommunication) product is sold to everyone product is sold only to specialists (not to everyone) components or replacement parts without independent operation EU declaration of conformity and mark are necessary. EU declaration and mark are not necessary. Replacement parts must be designed to avoid EMC disturbances after appropriate integration. plants to be set up at the place of operation EU declaration and mark are not necessary. The basic requirements of the EMC directive, however, must be met. devices with independent operation EU declaration and mark are necessary.

38 Specialists Not defined in directives! How can I transform my customer from everyone to a specialist? Offer him a training course!?!?

39 Electrical Drives ( PDS-Power Drive Systems) and the Most Relevant EU Diectives Directive Low Voltage Safety of Machinery EMC official requirements with respect to the EU directive mark on product + Declaration of Conformity NO -mark but: manufacturer`s declaration Exception: safety related products: NO -mark when sold to specialists -mark on product + Declaration of Conformity (evaluation process according to Module B uncendatory) practical problems none none (for safety related products certified body & accredited test laboratory must be involved) manufacturer of the final product is responsible for meeting the requirements of EMC directive usually no skills practical solutions marking based on EN (IEC )

40 Protection Requirements according to EMC Directive/Law Products as far as they are under EMC directive/law must limit the transmission of electromagnetic disturbances be robust in a reasonable way against electromagnetic disturbances

41 Basic Standards, Generic Standards and Product Standards If a product standard exists then it has priority to a product standard! A product family standard has priority to a generic standard! Example: concerning electrical drives the EN has priority to EN /-2 resp. EN /-2. Source: ZVEI-TK ½ - Workshop, 2. April 2001, Frankfurt (Möller)

42 Marking Product Product Product Product Harmonized product standard with EMC-requirements Harmonized product specific EMC-standard Harmonized generic standard No or only partial EMC-standard Competent Report (Module B) Technical Documentation Declaration of Conformity of the Manufacturer Records for Supervision Marking Source: CE-Kennzeichnung, ZVEI 04/1996, Frankfurt (Moeller)

43 First and Second Environment First Environment (Domestic Area, Business Areas) environment containing domestic areas and additionally facilities connected directly to a low-voltage system without seperation transformer. Second Environment (Industrial Areas, Private Grid) facilities not directly connected to domestic areas supplied by a low-voltage system. Source: ZVEI-TK 1/2 Workshop, 2.April 2001, Frankfurt (Moeller)

44 EMC Generic Standards high high Emission EN (Domestic) Immunity EN (Domestic) low low Source: ZVEI-FV1/MV 1996

45 Balanced EMC Valuation high high industrial emission immunity domestic low low Source: ZWEI-FV1/MV 1996

46 Imbalanced EMC Valuation high high emission cheap applicable everywhere immunity expensive technical nonsense low low Source: ZWEI-FV1/MV 1996

47 Conclusion refer to EU directives applicable to your product only (first choice: a product standard) offer support to your customer if he is legally responsible for technical issues of your product combine reasonable EU standards as a measure for your product use (expensive) accredited laboratories or certified bodies only if your product does not comply with harmonized EU standards

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