Technical Delivery Instructions IDEAL Automotive GmbH · Last updated: 09/2016 Industrialisation division Page 4 T001/0/31.08.16/MH 1.1 Scope of Validity These technical instructions

Technical Delivery Instructions

IDEAL Automotive GmbH

Last updated:

09/2016

Industrialisation division Page 1 T001/0/31.08.16/MH



chapter… content………………………………………………………………………. page

1 ............ Instructions General ............................................................... 3

2 ............ Labour Safety, Environment Protection and Fire Safety ... 11

3 ............ Electrical Engineering .......................................................... 24

4 ............ Hydraulics ............................................................................. 47

5 ............ Pneumatics ........................................................................... 59

6 ............ Technical Documentation .................................................... 65



Last updated:

09/2016


Moreover, our

Conditions of purchase and

Packaging instructions for overseas transport

apply (as amended).

Always the latest version at hand – Homepage IDEAL Automotive GmbH/ Company/ Supplier portal/ Download centre

http://www.ideal-automotive.com/en/supplier-portal/download-centre/

IDEAL Automotive GmbH Kapellenfeld 1 D - 96138 Burgebrach

Administrative headquarters: Margaretendamm 34 D - 96052 Bamberg

How to contact us:

Phone: +49 (0)951 78-0 Fax: +49 (0)951 78-204 E-mail: [email protected] www.ideal-automotive.com

http://www.ideal-automotive.com/en/supplier-portal/download-centre/



Last updated:

09/2016


1 Instructions General

Amendments:

Revision

Page Description of Amendment and Name of the Person Responsible

Date

1 3-10 Original 2010-11-19

2 4-10 Cooling water distributor for tool cooling 2015-06-10

3 9 Energy Management System 2015-07-03

4 9 Energy Management System extended 2015-09-07

Table of contents:

1 .................. Instructions General ............................................................................................. 3

1.1 .............. Scope of Validity .................................................................................................. 4

1.2 .............. Connection/Supply ............................................................................................... 4

1.3 .............. Lubrication ........................................................................................................... 4

1.4 .............. Platforms And Means Of Access .......................................................................... 4

1.5 .............. Cooling-Water Supply .......................................................................................... 4

1.5.1 ........... General ................................................................................................................ 4

1.5.2 ........... Cooling water distributor at moulding machines for tool cooling ........................... 6

1.5.3 ........... Cooling water distributor at hand moulding plants for tool cooling ........................ 7

1.5.4 ........... Quick couplings at cooling water hoses ................................................................ 7

1.6 .............. Varnishing ............................................................................................................ 8

1.6.1 ........... Machinery: ........................................................................................................... 8

1.6.2 ........... Tools .................................................................................................................... 8

1.7 .............. Storage Compartment For Documentation ........................................................... 8

1.8 .............. Mobile Equipment ................................................................................................ 9

1.9 .............. Energy Management System ............................................................................... 9

1.10 ............ List Of Approved Suppliers ................................................................................. 10



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1.1 Scope of Validity

These technical instructions shall apply generally to the design of the machinery. They shall be applicable to all IA plants.

1.2 Connection/Supply

The energy supply provided by the customer for all installations must always come in from the top.

Pipes, hoses and cables must be bundled in vertical cross-rails and led downwards.

For this reason, all connections of the machinery must be joined in one place to the extent possible.

If several connections of one type of power are required, the supplier has to position them in one place as well. The internal piping/cabling is included in the contractor's scope of delivery.

1.3 Lubrication

Lubrication points shall be arranged on common strips. A note shall be made on the common strips as to what lubricating points are supplied by these strips. Using individual lubricating points shall only be admissible if this has been agreed with the client in writing. This will only be possible if there are strong technical or economic reasons for this.

If components have lubricating intervals shorter than 600 operating hours (or 1 month), they have to be lubricated by lubricators (e.g. Permatec Star Control) which provide lubricant amounts depending on the number of production hours. Here it should be ensured that the lubrication points are sufficiently lubricated already at the start.

1.4 Platforms And Means Of Access

Platforms have to comply with the valid safety instructions as a rule.

Means of access to platforms shall preferably be designed as stairs. If the available room does not allow for stairs or if platforms need not be accessed frequently, a ladder may be used as an alternative upon consultation with the orderer. Ladders must be fixed permanently though.

Vertical step ladders should not be used.

1.5 Cooling-Water Supply

1.5.1 General

The interface for flow and return of the cooling water shall be provided at the upper edge of the equipment.

Internal pipes between the interface and distributor to be provided with insulation (depending on temperature).

Cooling-water flow and return to be disconnected with a solenoid valve after the equipment has been at a standstill for 5 min. to avoid condensation of water on the cooled equipment or tools.



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Solenoid valve and electric control are part of the contractor's scope of delivery.

The exact position of feed and return and the position of the distribution pipes shall be determined jointly by the supplier, orderer and toolmaker during the engineering meeting. (following schematic sketch serves an overview only)

Cooling-water thermometers must be installed on the main cooling-water feed and return pipe of the equipment. The displays shall be designed to also be easily legible during machine operation. Because oft he sensetivity to contamination devices must not be used with Ballball balls.

Cooling water flow line IABU (Burgebrach) 5 bar / 5 °C IAOE (Oelsnitz) 6 bar / 3 °C

IAIN (Ingolstadt) 4 bar / 12 °C

IABO (Bor, CZ) 5-6 bar / 7 °C

Attention: For plants delivered to IABO there hast o bean internal cool water piping out of stainless steel because the whol piping in the production hall is out of stainless steel!

Components

Solenoid valve J.R. Sparenberg Memelstr.12

90518 Altdorf

Germany Tel.: +49 (0)9187/5160 Fax: +49 (0)9187/1788

(or other supplier)

2/2 ways solenoid valve series 40 G 2“ Type B4028/1001/. . . .



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1.5.2 Cooling water distributor at moulding machines for tool cooling

Elektromagnetventil 2"

(Standard) im Vor- und Rücklauf

G 1 1/2"

Kugelhahn 3/4"

G 2"

G 1 1/2"

Rohrnippel 3/4"x80

Kugelhahn 3/4"

Verschlußkappe

Rohr 1 1/2"

150150 150 150 150150150

Ball valve 3/4 "

Sealing cap Pipe nipple 3/4” x80

Pipe 1 1/2 "

Ball valve 3/4 "

Solenoid Valve 2 " (Default) in the flow and return



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1.5.3 Cooling water distributor at hand moulding plants for tool cooling

Elektromagnetventil 2"

(Standard) im Vor- und Rücklauf

Kugelhahn 3/4"

G 2"

G 1 1/2"

G 1 1/2"

Kugelhahn 3/4"

Verschlußkappe

Rohrnippel 3/4"x80

120

720

70 120 120120

Verschraubung 1 1/2"

Rohr 1 1/2"

1.5.4 Quick couplings at cooling water hoses

Cooling water connection hast o be equipped with couplings Type Walther Präzision LP-012-0-WR021-G1/2.

To avoide confusion every circle is signed like circle 1VL, circle1 RL,...

Solenoid Valve 2 " (Default) in the flow and return

Ball valve 3/4"

Pipe nipple 3/4” x80

Sealing cap

Pipe 1 1/2 "

Ball valve 3/4"

Screwing



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1.6 Varnishing

1.6.1 Machinery:

Parts which will have contact with water/humidity: stainless

1.6.2 Tools

1.7 Storage Compartment For Documentation

Documentation/operating instructions must not be stored in the control cabinet!

A separate compartment has to be provided. It is important that this compartment can be opened without a key to ensure that every worker has access.



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1.8 Mobile Equipment

Stacker bags shall be placed at the centre of gravity of the device and they shall be attached at the bottom, if possible.

The basic frame of smaller mobile devices shall be designed so that the device can be moved with a common hand elevating truck.

Height-adjustable machine feet shall be provided which are vibration-damped, if required.

1.9 Energy Management System

With the energy management system, we introduced at our company, we have committed improving the energy performance constantly. Therefore we inform our supplier that the evaluation of our purchasing is also based in the supplier’s energy performance.

For the following product groups we have concrete minimum - energy efficiency criteria laid down in the procurement:

1. Engines: Whenever possible motors of energy efficiency class IE3 are to be procured. In any case Regulation (EC) no. 640/2009 of 22 July 2009 implementing Directive 2005/32 / EC of the European Parliament and of the Council with regard to the determination of requirements for the ecodesign of electric motors note.

2. Pump: Efficiency: A, frequency controlled

3. Compressors: It must be selected only frequency-controlled compressors

4. Lighting: There are only energy-saving lamps, LED technology whenever possible to purchase

5. Refrigeration systems: It must be selected only frequency controlled compressor

6. Appliances: Efficiency class: B



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09/2016


1.10 List Of Approved Suppliers

Designation: Manufacturer: Remarks

Flat guides INA (preferably) STAR or THK

Round guides STAR

Flange bearing INA

Pedestal bearing INA

Shock absorber ACE

Swing clamping element DESTACO

Toggle joint spanner DESTACO

Cooling-water heat exchanger

Regloplas

Temperature control units Regloplas

Vacuum units Rietschle

Industrial robots ABB



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09/2016


2 Labour Safety, Environment Protection and Fire Safety

Amendments:

Revision


Date

1 11-23 Original 2010-11-19

2 15,16,19-22

Updating standards, regulations 2015-09-07

Table of contents:

2 .................. Labour Safety, Environment Protection and Fire Safety ..................................... 11

2.1 .............. Scope of Validity ................................................................................................ 13

2.2 .............. General Requirements ....................................................................................... 13

2.2.1 ........... CE Marking ........................................................................................................ 13

2.2.1.1 ........ Ready-to-use Machines ..................................................................................... 13

2.2.1.2 ........ Partly Completed Machinery .............................................................................. 13 2.2.2 ........... Risk Assessment ................................................................................................ 13

2.2.3 ........... Surveillance, Inspection, Notification And Authorisation Requirements .............. 14

2.2.4 ........... Set-up, Maintenance And Repair ....................................................................... 14

2.2.5 ........... Environmental Effects ........................................................................................ 14

2.3 .............. Normative References ........................................................................................ 14

2.4 .............. Dangerous Substances And Preparations .......................................................... 16

2.5 .............. Physical Effects .................................................................................................. 16

2.5.1 ........... Noise .................................................................................................................. 16

2.5.1.1 ........ Emission sound pressure levels at the erection site ........................................... 16

2.5.1.2 ........ Workplace-related Emission Sound Pressure Level (Assessment Level) ........... 17

2.5.1.3 ........ Tonality of noise: ................................................................................................ 17

2.5.1.4 ........ Noise peaks: ...................................................................................................... 17

2.5.1.5 ........ Noise sources outside of buildings ..................................................................... 17 2.5.2 ........... Building Vibrations ............................................................................................. 17

2.5.3 ........... Use Of Energy And Heat .................................................................................... 17

2.5.4 ........... Electromagnetic Fields ....................................................................................... 18

2.5.5 ........... Laser .................................................................................................................. 18

2.6 .............. Fire And Explosion Hazards ............................................................................... 18

2.7 .............. Ergonomics ........................................................................................................ 18

2.8 .............. Immission Protection .......................................................................................... 18

2.9 .............. Handling Of Substances Hazardous To Water ................................................... 19

2.9.1 ........... General Requirements ....................................................................................... 19

2.9.2 ........... Retention Devices .............................................................................................. 19



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2.10 ............ Cooling And Heating Systems ............................................................................ 19

2.11 ............ Waste ................................................................................................................. 20

2.12 ............ Disposal Of Machinery ....................................................................................... 20

2.13 ............ Energy................................................................................................................ 20

2.14 ............ Appendix: Co-applicable Documents .................................................................. 20

2.14.1 ......... Global Standards ............................................................................................... 21

2.14.2 ......... Legal Requirements - Europe ............................................................................. 21

2.14.3 ......... Legal Requirements - Germany ......................................................................... 22



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These instructions shall apply specifically to the requirements for labour safety, environment protection and fire safety for the machinery. They complement the provisions outlined in Chapter “General” and all other technical equipment requirements defined in the Technical Delivery Instructions of IA and are valid in conjunction with them for all IA factories.

2.2 General Requirements

2.2.1 CE Marking

2.2.1.1 Ready-to-use Machines

The ready-to-use machinery must comply with the basic safety and health protection requirements of the respective valid EC directives and marked with a CE marking as specified in Appendix IIA of the Machinery Directive (2006/42/EC). This also applies to the marking obligation under other EU directives.

The EC declaration of conformity must specify all applied standards.

If the scope of the order comprises concatenated machines and equipment (also old systems), the contractor entrusted with the concatenation must provide a common CE marking. The entire scope must be shown in the EC declaration of conformity.

2.2.1.2 Partly Completed Machinery

On principle, the contractor has to deliver machines which are completed, can operate independently and which are safe and which bear the CE mark and for which the declaration of conformity is furnished. If only partly completed machines can be delivered (with "Declaration of Incorporation of Partly Completed Machinery" in compliance with 2006/42/EC), this has to be agreed with the client before the order is placed.

Machinery which, in the sense of the Machinery Directive (2006/42/EC) cannot operate independently, must comply with the essential health and safety requirements of the Machinery Directive (2006/42/EC) up to the interfaces specified in the technical documentation (e.g. circuit diagrams and PC plans, operating instructions, ...) of the contractor.

This has to be confirmed in the "Declaration of Incorporation of Partly Completed Machinery".

2.2.2 Risk Assessment

The risk assessment must be furnished to the client by the contractor upon the completion of the construction at the latest. It is component part of the technical documentation of the machinery.

The safety of control systems must comply with EN 954, EN ISO 13849.

The scope and functional principle of every single safety function have to be documented.

All safety-related parts must be clearly identified as such in the identification of machinery and equipment with the letters "SF". In addition a coloured identification (yellow) must be unique and applied permanently (on top and) beside the equipment.

From a Performance Level (PL) "d" the installation has to be designed compliant to the control system category 3 (redundant design).

The MTTFd has to be designed for the following times of use of the machine:



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cycle time given in the requirement specification

safety functions required due to frequent set-ups, failures, etc.

20 hours running time/day

5 days/week

50 weeks/year

2.2.3 Surveillance, Inspection, Notification And Authorisation Requirements

The machinery must be handed over ready for operation. This includes, in particular, all necessary inspections prior to commissioning in compliance with the legal requirements at the operating site.

The contractor is obliged to inform the client in writing about the respective installations/installation parts which are subject to the surveillance, inspection, notification and authorisation requirement. If inspections of the machinery and/or its respective parts, sub-assemblies, devices, etc. have to be carried out periodically (e.g. for centrifuges, pressure vessels, etc.), this has to be given specifically in the technical documentation both in the operating instructions and in the maintenance instructions.

Inspection books and the list of equipment which is subject to mandatory inspection/surveillance (Appendix 2) must be delivered with the respective inspection intervals and enclosed with the technical documentation of the machinery.

2.2.4 Set-up, Maintenance And Repair

All activities typically connected with the operation of the machinery, such as set-up, maintenance and repair, must allow being carried out by the operator or maintenance worker safely and, if possible, from floor level. If this is not possible due to the machinery or installation, the client must be consulted. Safe means of access and a safe working platform may be required on the machinery (acc. to DIN EN ISO 14122 Sheets 1-4).

2.2.5 Environmental Effects

Unavoidable environmental effects from the machinery must be restricted to a minimum. Their type (e.g. waste, material emissions, noise) and amount have to be specified. The activities for avoidance must be documented.

All process materials used in the machinery must allow being recirculated in the closed system cycle, if possible, or being disposed of in an environmentally friendly way. Deviations have to be communicated to the client separately.

When fluids are used (lubricating coolants, hydraulic oil, etc.), leakproofness of all systems is particularly important, i.e. the machinery must be non-drip and permanently leakproof.

2.3 Normative References

On principle, the requirements with regard to the normative references given in Chapter I "General Information" shall apply.

If there are deviations from harmonised European standards, German standards and technical specifications, it has to be verified and documented that the same safety is achieved in a different way. Resulting effects on price and other effects shall be communicated to the client in detail.



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Note, in particular, the EC directives in the valid version, e.g.:

EC Machinery Directive (2006/42/EC incl. appendices)

Electrical Equipment Directive (EC Low Voltage Directive 2006/95/EC)

Electromagnetic Compatibility Directive 93/68/EEC (89/336/EEC)

Pressure Equipment Directive (97/23/EC)

The contractor is responsible for the proper function of the machinery and for compliance with the regulations which are applicable at the time of contract, e.g.:

Act on making products available on the market (Product Safety Act - ProdSG)

Act on the Regulation of the water balance (Water Resources Act - WHG)

State Water Act (LWG) and the local Technical Facility Regulations (VAwS) at the erection site

Regulation on requirements for the discharge of wastewater into water (Waste Water Ordinance - AbwV) with attachments

Local waste water by-law (AbwS) at the erection site

Regulations on requirements for collecting troughs made of steel (StawaR)

Act to promote circular economy and ensuring the environmentally friendly management of waste (Recycling Act - KrWG)

Act on protection against harmful effects of air pollution, noise, vibrations and similar processes (Federal Pollution Control Act - BImSchG)

other local acts at the erection site

State of the art as specified below:

- EN standards

- VDE regulations (German Association for Electrical, Electronic and Information Technologies)

- DIN standards

- VDI regulations (German Association of Engineers)

- VDA regulations (German Association of the Automotive Industry)

- trade associations' regulations/rules

- AD 2000 Code.

Currently valid national standards are applicable until they are superseded by the respective harmonised European standards.

Special consideration shall be given to:

the inquiry and the preparation of an offer - VDI 2856

the technical design - DIN EN ISO 12100 - Parts 1 and 2

- EN 983

- DIN 24346/DIN EN ISO 1219-2

- DIN EN 13478

- DIN EN 60204

- VDA-LVE (VDA Delivery Instructions for Electrical Equipment of Machinery)

including the cited standards, standard provisions and recommendations.



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For an overview of national laws, regulations and standards refer to the appendix (Chapter 15) of this document.

2.4 Dangerous Substances And Preparations

Material Safety Data Sheets are to be treated in accordance with Regulation (EC) no. 1907/2006 (REACH). To use coming danger and working materials to the customer shall be submitted already at tender for approval.

Preferably such process materials shall be used which the client has already approved at the erection site. The amount of VOC must be specified in the technical documentation. Compliance with the principle of substitution according to the Ordinance of Hazardous Substances is assumed.

Only such parts, sub-assemblies and devices may be incorporated into the machinery which are free of CFC, CHC, PVC and asbestos.

Only phosphate-free cables and lines must be used in the machinery. Exceptions have to be agreed with the client.

Containers and baths with dangerous substances must be permanently identified stating the used medium and marked with a danger symbol.

Pipelines must be identified permanently stating the used medium and marking the direction of flow.

2.5 Physical Effects

2.5.1 Noise

To achieve and maintain low-noise workstations the following noise requirements acc. to DIN EN ISO 4871 (Acoustics - Declaration and verification of noise emission values of machinery and equipment) shall be complied with in consideration of the following points when new machinery is purchased:

2.5.1.1 Emission sound pressure levels at the erection site

Regardless of the operating condition, an emission sound pressure level of LpAFm of max. [78 dB(A)] shall be ensured at every point at a distance of 1 m from the machine or installation surface.

(determined in compliance with DIN 45635 or DIN EN ISO 3740)

Individual noise regulations can be agreed for large-scale installations. The aim is to not increase the workplace-related assessment levels for the existing machinery, installations, office workstations, etc. at the respective IA erection site.

Noise-intensive ventilation and exhaust openings of the machinery shall be provided with sufficiently dimensioned sound dampers so that the admissible immission values will not be exceeded day or night.



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2.5.1.2 Workplace-related Emission Sound Pressure Level (Assessment Level)

A workplace-related emission sound pressure level LpAFm of max. [76 dB(A)] must be maintained on the operator's side of the machinery (assessment level acc. to the respective valid Noise and Vibration Prevention Ordinance [LärmVibArbSchV] to be observed).

Complete work cycles of the machined or processed products in normal operation, incl. all idle, set-up and processing times with specification of tools and workpieces (determined in compliance with national standard or DIN EN ISO 11200 et.seq.) are decisive for the determination.

2.5.1.3 Tonality of noise:

The emission of clearly prominent individual tones shall be prevented regardless of the operating condition.

Emission sound pressure levels of the measurement points which contain tonal components shall be assessed according to national standards (tone adjustment) and documented separately in the inspection or acceptance protocol (third-octave or narrow band spectrum).

2.5.1.4 Noise peaks:

Transient noise peaks must not exceed 85 dB(A) at any measuring point (i.e. percentage level Li<= 85 dB(A)).

2.5.1.5 Noise sources outside of buildings

All building openings with induced ventilation leading outside must be designed according to state-of-the-art noise protection technology.

Noise-intensive ventilation and exhaust openings must be equipped with sufficiently dimensioned sound dampers.

The assessed noise insulation measurement of the sound dampers must be designed so that the reference immission values which are admissible for the respective area character (residential area, mixed area, etc.) will not be exceeded day or night at the neighbouring buildings, not even with the remaining operating noise taken into consideration.

The emission level of machinery Lwa must not exceed ... (this value has to be determined for the specific site by the orderer) dB(A) under full load.

2.5.2 Building Vibrations

Machinery which may induce considerable building vibrations must be vibrationally decoupled in a suitable way. The measures to be implemented on the building must be communicated to and agreed with the client in due time. To avoid impacts on the neighbourhood the reference values specified in DIN 4150 must be observed.

2.5.3 Use Of Energy And Heat

Residual heat which is dissipated through emission shall be quantified and used in the process as far as possible. The contractor elaborates a heat utilisation concept and undertakes to participate in it.

Energy saving measures shall be taken in compliance with the state of the art.



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2.5.4 Electromagnetic Fields

The contractor shall provide details about electromagnetic fields (EMF) of his machinery. If they have no relevance for safety, this has to be confirmed, e.g. in the risk assessment. Otherwise, measured values and exposure areas have to be specified.

2.5.5 Laser

Openly radiating lasers must only be used up to laser class 2.

The contractor shall provide clear information about existing laser equipment.

2.6 Fire And Explosion Hazards

The contractor shall execute a risk assessment relating to the fire and explosion hazards of the machinery. It is part of the risk assessment. Risks and preventive measures or damage-reducing measures shall be provided by the contractor for these risks upon consultation with the client. An explosion protection zone map shall be furnished for machinery with explosion protection zones.

Areas at the erection site which have a risk of explosion already according to the Ordinance of Industrial Safety and Health have to be specified including an assessment of the potential risk of explosion occurring from the operation of the machinery.

If explosive dust/air mixes or vapour/air mixes are exhausted or if such mixes can form during exhaust ventilation, the explosion protection guideline has to be observed in addition.

In the case of explosion risk (one or several) pressure relief flaps (explosion protection flaps) have to be provided on the machine housing. The pressure relief flaps must be arranged so that pressure shocks escaping via them will not pose any danger for persons. The conditions at the actual erection site of the machinery have to be taken into account when the position of the pressure relief flaps is selected. In addition, it has to be ensured that flames from flash fire/explosion will not enter the filter installation via the exhaust device.

2.7 Ergonomics

Workstation designs have to incorporate generally applicable ergonomic design principles.

2.8 Immission Protection

Pollutant emission to outside air is only permitted if recirculation is demonstrably impossible technically/economically.

Required exhaust and cleaning facilities must already be included in the offer. The decision about the type and design of an exhaust system will be taken upon consultation with the client.

An agreement has to be made with the client as to how the official immission limit values specified for the erection site can be observed. The basis for this are TA Lärm (Technical Instructions on Noise Protection), 26. BImSchV (Federal Immission Protection Ordinance), the official zoning plan of the erection site, the distance to the closest neighbouring residential building and, if available, the valid version of the building site plan.

The working room of the machinery shall be designed so that air-polluting and environmentally hazardous substances may not escape.



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2.9 Handling Of Substances Hazardous To Water

2.9.1 General Requirements

If substances hazardous to water are used in the machinery and all respective accessory apparatuses, suitable devices for environment protection (e.g. collecting troughs) have to be provided. They must be designed so that any substances hazardous to water which might escape can be collected safely.

Work performed on pipes, parts or sub-assemblies which contain substances hazardous to water according Water Resources Act (WHG), may only be carried out by authorised specialist companies. Proof of authorisation must be submitted by the contractor without being requested.

Special requirements for machinery used in water protection areas shall be taken into account after consulting the client.

2.9.2 Retention Devices

Collecting troughs and dripping plates which are located below conveyor belts must have a gradient of at least 3%.

The escaping substances must be recirculated to the machinery. Deviations have to be agreed with the client.

The volume of the collecting troughs or rooms must comply with the local Technical Facility Regulations (VAwS) valid at the erection site.

Floor drains are not admissible on principle.

Retention devices must be permanently tight and resistant to media. Respective proof (e.g. inspection certificates, static calculations, construction descriptions, certifications, ...) have to be furnished to the client without being requested.

For coating the collecting troughs the contractor has to proceed in compliance with the technical approval granted by the construction supervision authority (e.g. identification of the coating, type approval).

2.10 Cooling And Heating Systems

If cooling systems are required for operation of the machinery, they have to be designed to ensure low loss and low amounts of waste water. Only such substances may be used as auxiliary chemicals and accessory agents which are admissible according to the Waste Water Ordinance.

A special approval by the client has to be procured for the used chemicals.

The following information is required by the client: used accessory agents (algal formation, corrosion protection, ...), amounts of waste water from regeneration and regeneration cycle.

Special requirements have to be agreed with the client for the cooling and heating of machinery, especially for equipment for the handling of substances hazardous to water (e.g. incorporation of a safety heat exchanger).



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2.11 Waste

Generally, the Avoidance, Minimization and Use Regulation of the Recycling Act (KrWG) shall be observed (e.g. by extending service life of lubricating coolants in machinery or by using maintenance-free filters).

The technically correct disposal of waste of any kind from building measures for the erection, mounting or dismantling of the machinery must be coordinated with the client or his person in charge of waste disposal (local environment protection officer) before work starts. Transport packages are to be taken back by the contractor after delivery.

2.12 Disposal Of Machinery

The contractor must describe in the technical documentation how the machinery is to be disposed of/disassembled after the end of its service life and which special requirements have to be taken into consideration (Design of Recyclable Technical Products, VDI Regulation 2243 [German Association of Engineers]).

Parts, sub-assemblies and devices must be recyclable or allow being disposed of environmentally friendly. Deviations have to be communicated to the client separately.

2.13 Energy

The design of the machinery must allow low-energy operation. Other units with which energy can be saved shall be specified separately in the offer by the contractor.

With the energy management system, we introduced at our company, we have committed improving the energy performance constantly. Therefore we inform our supplier that the evaluation of our purchasing is also based in the supplier’s energy performance.

For the following product groups we have concrete minimum - energy efficiency criteria laid down in the procurement:

1. Engines: Whenever possible motors of energy efficiency class IE3 are to be procured. In any case Regulation (EC) no. 640/2009 of 22 July 2009 implementing Directive 2005/32 / EC of the European Parliament and of the Council with regard to the determination of requirements for the ecodesign of electric motors note.

2. Pump: Efficiency: A, frequency controlled

3. Compressors: It must be selected only frequency-controlled compressors

4. Lighting: There are only energy-saving lamps, LED technology whenever possible to purchase

5. Refrigeration systems: It must be selected only frequency controlled compressor

6. Appliances: Efficiency class: B

2.14 Appendix: Co-applicable Documents

Some important legal, international and national provisions are given for information purposes in the appendix, completeness of the list is not claimed.



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2.14.1 Global Standards

DIN EN ISO 14121-1 Safety of Machinery, Risk Assessment,

Part 1: Principles

DIN EN ISO 12100-1 Safety of Machinery. Basic concepts, general

principles for design.

Part 1: Basic terminology, methodology

DIN EN ISO 12100-2 Safety of Machinery. Basic concepts, general

principles for design. Part 2: Technical principles

DIN EN ISO 14122-1 Safety of machinery - Permanent means of access to

machinery, Part 1: Choice of fixed means of

access between two levels


machinery, Part 2: Working platforms and

walkways


machinery, Part 3: Stairs, stepladders and guard-rails


machinery, Part 4: Fixed ladders

2.14.2 Legal Requirements - Europe

As to 2.1 CE marking: Directives and standards

Directives

Directive 2001/95/EC of the European Parliament and the Council on general product safety

Directive 98/37/EC of the European Parliament and the Council on machinery

Electrical Equipment Directive (EC Low Voltage Directive 2006/95/EC)

Directive 2004/108/EC of the European Parliament and the Council on electromagnetic compatibility

Directive 97/23/EC of the European Parliament and the Council on pressure equipment

Directive 87/404/EEC on simple pressure vessels

Directive 94/9/EC of the European Parliament and the Council on equipment and protective systems intended for use in potentially explosive atmospheres (ATEX)

Regulation (EC) no. 1907/2006 ... concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals ... (REACH)

Standards

EN 60204-1 Electrical equipment of machines

Design of strength of protective screens, e.g. according to

EN 12415 Safety of machine tools. Small numerically controlled turning machines and turning centres

EN 12417 Machine tools - Safety - Machining centres



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EN 60825-1 Safety of laser products - Part 1:

Equipment classification and requirements

In the case of deviation from harmonised safety standards you have to give proof and document that the same level of safety is achieved in a different way.

2.14.3 Legal Requirements - Germany

The EC directives are implemented in Germany by issuing corresponding ordinances for GPSG (German Equipment and Product Safety Act), EMV-G (German Electromagnetic Compatibility Act), etc.

The contractor is responsible for the proper function of the machinery and for compliance with the regulations which are applicable at the time of contract, e.g.:

Act on making products available on the market (Product Safety Act - ProdSG)

Act on the Regulation of the water balance (Water Resources Act - WHG)

State Water Act (LWG) and the local Technical Facility Regulations (VAwS) at the erection site

Regulation on requirements for the discharge of wastewater into water (Waste Water Ordinance - AbwV) with attachments

Local waste water by-law (AbwS) at the erection site

Regulations on requirements for collecting troughs made of steel (StawaR)

Act to promote circular economy and ensuring the environmentally friendly management of waste (Recycling Act - KrWG)

Act on protection against harmful effects of air pollution, noise, vibrations and similar processes (Federal Pollution Control Act - BImSchG)

For concatenated installations: Interpretation paper of BMAS (Federal Ministry of Labour and Social Affairs) and of the federal states, made in coordination with HVBG, the employers' liability insurance associations and VDMA (German Engineering Federation) on the topic "Machinery in its entirety"

other local acts at the erection site

State of the art as specified below:

o EN standards

o VDE regulations (German Association for Electrical, Electronic and Information Technologies)

o DIN standards

o VDI regulations (German Association of Engineers)

o VDI Regulation 2243, Design of recyclable technical products, fundamental principles and design principles

o VDA regulations (German Association of the Automotive Industry)

o trade associations' regulations/rules

o TA Lärm (Technical Instructions on Noise Protection), 26. BImSchV (Federal Immission Protection Ordinance)

o AD 2000 Code.

For the technical design



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o EN 983, Safety of machinery - Safety requirements for fluid power systems and their components - Pneumatics

o DIN 24346, Hydraulic fluid power; hydraulic systems; general rules for application

o DIN EN ISO 1219-2, Fluid power systems and components - Graphic symbols and circuit diagrams - Part 2: Circuit diagrams

o DIN 33411-5, Physical strength of man - Part 5: Maximal isometric action forces, values

o DIN EN 13478, Safety of machinery - fire prevention and protection

o VDA-LVE (VDA Delivery Instructions for Electrical Equipment of Machinery)

o DIN 45681, Acoustics - Determination of tonal components of noise and determination of a tone adjustment for the assessment of noise immissions

o DIN 4150, Vibration in buildings including the cited standards, standard provisions and recommendations.

Currently valid national standards are applicable until they are superseded by the respective harmonised European standards.

Special consideration shall be given to:

the inquiry and the preparation of an offer

o VDI 2856, Standardized specification for inquiries and offers on machine tools

trade associations' regulations

o BGV A3, Electrical equipment

o BGI 5048, Ergonomic design of machines

Pipelines

Work performed on pipes, parts or sub-assemblies which contain substances hazardous to water according to Water Resources Act (WHG)), may only be carried out by authorised specialist companies. Proof of authorisation must be submitted by the contractor without being requested.

Collecting troughs

On principle, requirements for collecting troughs up to 1000 l are provided by the directive on collecting troughs made of steel (StawaR); troughs from series production made of non-metallic materials require the approval granted by the construction supervision authority; steel troughs require the letter of compliance by the manufacturer in accordance with the Building Rules List A, Part 1.

Collecting troughs with a volume exceeding 1000 l must be manufactured according to the Directive on Collecting Troughs Made of Steel and they must be inspected locally by an expert. These troughs require an official suitability test; the expertise is part of this suitability test.

Collecting troughs/collecting rooms must be provided with leakage detection devices which have been granted approval by the construction supervision authority.



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09/2016


3 Electrical Engineering Amendments:

Revision


Date

1 24-46 Original 2010-11-19

2 40, 43 EU-Regulation (EC) No 640/2004 2015-06-10

3 35 added 3.11.6.2 Remote maintenance 2016-08-30

Table of contents:

3 .................. Electrical Engineering ......................................................................................... 24



3.3 .............. Definitions .......................................................................................................... 28


3.4.1 ........... Selecting the Equipment .................................................................................... 28

3.4.1.1 ........ Operating Equipment ......................................................................................... 28

3.4.1.2 ........ Delivery Requirements ....................................................................................... 28 3.4.2 ........... Electrotechnical Design and Installation ............................................................. 28

3.4.3 ........... Shutting off Peripheral Equipment to Save Energy ............................................. 29

3.5 .............. Electrical Supply and Network Connections ....................................................... 29

3.5.1 ........... Line Entry ........................................................................................................... 29

3.5.2 ........... Mains Connection .............................................................................................. 29

3.5.3 ........... Control Circuit Grounding ................................................................................... 29

3.5.4 ........... Main Switch ........................................................................................................ 29

3.5.5 ........... Supply Voltage ................................................................................................... 29

3.5.6 ........... Disturbances ...................................................................................................... 30

3.5.7 ........... Start-Up Routines ............................................................................................... 30

3.5.8 ........... Plug-In Power Supply Units ................................................................................ 30

3.6 .............. Protection Against Electric Shock ....................................................................... 30

3.7 .............. Protection of Equipment ..................................................................................... 30

3.7.1 ........... Overcurrent Protection ....................................................................................... 30

3.7.1.1 ........ Overload and Short-Circuit Protection ................................................................ 30

3.7.1.2 ........ Switch Response ............................................................................................... 30

3.7.1.3 ........ Special Motors ................................................................................................... 31

3.7.1.4 ........ Feedback / Compensation.................................................................................. 31 3.8 .............. Equipotential Bonding / Shielding ....................................................................... 31

3.9 .............. Control Circuits and Control Functions ............................................................... 31

3.9.1 ........... Control Voltage .................................................................................................. 31

3.9.2 ........... Operating Modes and Functions......................................................................... 31



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3.9.3 ........... EMERGENCY STOP / Error ............................................................................... 31

3.9.3.1 ........ Coordination of Safety Equipment ...................................................................... 31

3.9.3.2 ........ Interlinking in Case of Hazards ........................................................................... 31

3.9.3.3 ........ Signaling and Display ......................................................................................... 31 3.9.4 ........... Protective Locks / Protective Doors .................................................................... 32

3.9.5 ........... Safe Condition .................................................................................................... 32

3.10 ............ Operator Interface and Control Equipment Attached to the Machine .................. 32

3.10.1 ......... Status and Error Displays ................................................................................... 32

3.10.2 ......... Machine and Process Monitoring ....................................................................... 32

3.10.3 ......... Distinction .......................................................................................................... 32

3.10.4 ......... Signaling the Switching Statuses........................................................................ 32

3.10.5 ......... Lamp Test .......................................................................................................... 32

3.10.6 ......... Additional Displays ............................................................................................. 32

3.10.7 ......... Controls .............................................................................................................. 32

3.11 ............ Electronic Equipment/ Control Interfaces ............................................................ 33

3.11.1 ......... Control Design ................................................................................................... 33

3.11.1.1 ..... Control System ................................................................................................... 33

3.11.1.2 ..... Software Structure ............................................................................................. 33

3.11.1.3 ..... Visualization ....................................................................................................... 33

3.11.1.4 ..... Implementation of Functions .............................................................................. 33

3.11.1.5 ..... Selecting the Operating Systems ....................................................................... 33

3.11.1.6 ..... PC Use............................................................................................................... 33 3.11.2 ......... Control Units ...................................................................................................... 33

3.11.3 ......... Software ............................................................................................................. 34

3.11.4 ......... Operating Units / Operating Panels .................................................................... 34

3.11.4.1 ..... Program / Programming ..................................................................................... 34

3.11.4.2 ..... Range Pointers for OP Interface Parameterization ............................................. 34

3.11.4.3 ..... Help Texts .......................................................................................................... 34

3.11.4.4 ..... Pictograms ......................................................................................................... 34 3.11.5 ......... Programming Units ............................................................................................ 34

3.11.6 ......... Interfaces ........................................................................................................... 34

3.11.6.1 ..... Connection ......................................................................................................... 35

3.11.6.2 ..... Remote maintenance ......................................................................................... 35 3.11.7 ......... Coupling of Multiple Control Units and Systems ................................................. 35

3.11.7.1 ..... Bus Topology ..................................................................................................... 36

3.11.7.2 ..... Test Documents ................................................................................................. 36 3.12 ............ Switchgear: Arrangement, Setup and Housing ................................................... 36

3.12.1 ......... General Requirements ....................................................................................... 36

3.12.1.1 ..... Protection of Components .................................................................................. 36

3.12.1.2 ..... Standard Locking ............................................................................................... 36

3.12.1.3 ..... Installation Space ............................................................................................... 36



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3.12.2 ......... Arrangement and Setup ..................................................................................... 36

3.12.2.1 ..... Installing a Switchgear Cabinet .......................................................................... 36

3.12.2.2 ..... Multilayer Installation .......................................................................................... 36

3.12.2.3 ..... Swing Frames .................................................................................................... 37

3.12.2.4 ..... Front Panel ........................................................................................................ 37

3.12.2.5 ..... Circuit Diagram Bag ........................................................................................... 37 3.12.3 ......... Switchgear Cabinet Cooling ............................................................................... 37

3.12.3.1 ..... Temperature ...................................................................................................... 37

3.12.3.2 ..... Prefilter............................................................................................................... 37

3.12.3.3 ..... Draining Condensate .......................................................................................... 37

3.12.3.4 ..... Temperature Monitoring ..................................................................................... 37

3.12.3.5 ..... Heat Requirement Calculation ............................................................................ 37 3.12.4 ......... Switches / Polling ............................................................................................... 38

3.12.5 ......... Safety Photoelectric Light Barriers ..................................................................... 38

3.12.6 ......... Signals (I < 10 mA) ............................................................................................. 38

3.13 ............ Conductors, Cables and Wires ........................................................................... 38

3.13.1 ......... Color Coding ...................................................................................................... 38

3.13.2 ......... Arrangement of Wiring ....................................................................................... 38

3.14 ............ Circuitry .............................................................................................................. 39

3.14.1 ......... Wiring Inside of Housings ................................................................................... 39

3.14.2 ......... Wiring Outside of Housings ................................................................................ 39

3.14.2.1 ..... Installation .......................................................................................................... 39

3.14.2.2 ..... Cable Entry ........................................................................................................ 39

3.14.2.3 ..... Line Ducts .......................................................................................................... 39

3.14.2.4 ..... Plug-in Connections ........................................................................................... 39

3.14.2.5 ..... Wiring at Heat-Treatment Systems ..................................................................... 40 3.15 ............ Electric Motors and Related Equipment.............................................................. 40

3.15.1 ......... Actual-Path Measuring Systems......................................................................... 40

3.15.2 ......... Drive Elements and Actuators ............................................................................ 40

3.15.3 ......... Design of Electric Motors ................................................................................... 40

3.15.4 ......... Three-Phase Motors........................................................................................... 41

3.15.5 ......... Brake Motors ...................................................................................................... 41

3.16 ............ Accessories and Lighting ................................................................................... 41

3.16.1 ......... Socket Outlets .................................................................................................... 41

3.16.2 ......... Lighting .............................................................................................................. 41

3.16.3 ......... Lighting and Outlet Circuits ................................................................................ 41

3.16.4 ......... Workpiece or Operating Hour Counters.............................................................. 41

3.16.4.1 ..... Measuring Devices ............................................................................................. 41 3.17 ............ Warning Signs and Labeling of Operating Equipment ........................................ 42

3.17.1 ......... Inside the Switchgear Cabinet ............................................................................ 42

3.17.2 ......... Outside the Switchgear Cabinet ......................................................................... 42



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3.17.3 ......... Cable Identification ............................................................................................. 42

3.17.4 ......... Individual Core Identification .............................................................................. 42

3.18 ............ Technical Documentation ................................................................................... 42

3.19 ............ Testing and Inspection ....................................................................................... 43

3.20 ............ Startup, Final Acceptance, Training .................................................................... 43

3.21 ............ Other Applicable Documents .............................................................................. 43

3.22 ............ List of Approved Suppliers.................................................................................. 45



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The technical requirements specified herein apply particularly to the electrical engineering of the machine / machine system. They complement the provisions outlined in Chapter I “General” of the Technical Delivery Instructions of IDEAL Automotive and are valid in conjunction with them for all factories.


In principle, the provisions with regard to normative references listed in Chapter I “General” shall apply.

They are valid for the electrical equipment of machines / machine systems and must be considered as a supplement to DIN EN 60204-1 and VDA-LVE in their current versions.

DIN EN 60 204-1 (VDE 0113 Part 1) and DIN EN 50 178 (VDE 0160) must be observed, including the directory provisions and recommendations contained therein.

3.3 Definitions

The definitions given in Chapter I “General” and in the VDA-LVE must be complied with.


3.4.1 Selecting the Equipment

3.4.1.1 Operating Equipment

The contractor shall select or design all operating equipment in such a way that it can be connected to the locally existing distribution networks in a fully operational state - despite any voltage fluctuations or interfering pulses.

3.4.1.2 Delivery Requirements

Only components and subassemblies included in the Lists of Approved Suppliers may be used. They may only be installed in their original condition and without any modifications. Any deviations are permitted only after consultation with the ordering party and confirmation in writing.

3.4.2 Electrotechnical Design and Installation

Wiring and cabling must comply with the EMC directive.

Inductive and capacitive interferences (e. g. caused by power converters, contactor coils, controlled drives, transformers and their wiring, etc.) must not affect the functioning of the PLC.

It must be taken into account that switchgear cabinets can be placed in the vicinity of cable routes that the customer uses for other machinery.

For analog signals, interfaces and bus cables, shielded cables must be used as specified by the manufacturer.

The directives for installation defined by the manufacturer of the control systems must be observed.



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The devices must allow easy access. Changing of modules and components, as well as removing of covers must be possible without the need to dismount other components.

In the case of special-purpose machines, 30% of free space must be available in the switchgear cabinet at the time of ordering.

3.4.3 Shutting off Peripheral Equipment to Save Energy

During non-productive operation (idling) and in due consideration of the required quality and industrial safety, the auxiliary units must shut off or switch to an energy-saving mode after a variably adjustable period of time.

Reactivation must be automatic.

3.5 Electrical Supply and Network Connections

3.5.1 Line Entry

The energy supply provided by the customer for all installations must always come in from the top. Pipes, hoses and cables must be bundled in vertical cross-rails and led downwards.

For this reason, all connection of the machine / machine system must be joined in one place to the extent possible.

If several connections of the same type of energy are required, the supplier shall bring them together, too. The internal cabling / piping shall be part of the contractor’s scope of delivery.

The supply to the switchgear cabinet shall be provided by the customer. Cable glands or screwed cable connectors, including strain relief devices as well as covers, are part of the scope of delivery of the machine / machine system.

3.5.2 Mains Connection

For connections to the mains supply of up to 240 mm², terminal blocks must be used. Pay attention to the clockwise rotating field! An equipotential bonding bar must be provided and linked with the protective conductor (PE) on the line side.

Principally, a 5-wire connection must be installed (TN-S system). A connection between N and PE inside the machine / machine system is not permitted.

3.5.3 Control Circuit Grounding

The grounding of the control circuit may only be implemented my means of an isolating terminal.

3.5.4 Main Switch

Every machine / machine system must be equipped with a mechanically actuated, lockable main switch.

Door couplings are not permitted or the switch knob must be permanently connected with the switching element.

If several manufacturers collaborate on the project management of a plant, the control side

and the power supply side must be linked “Common Main Switch”.

3.5.5 Supply Voltage

In the event of a power outage, the control unit must perform an automatic restart when power is restored, reestablishing all configuration parameters automatically without operator



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action and without prompting a start of the machine / machine system (processing operation/motion).

To backup the program and parameter data, the control unit must be provided with an integrated non-rechargeable or rechargeable battery. The charge state of the rechargeable or non-rechargeable battery must be displayed on the operator panel.

3.5.6 Disturbances

After power dips or failures, as well as system malfunction, the program must resume its operation properly. The control unit must allow the operator to advance the production equipment to the next cycle or move it to home position.

3.5.7 Start-Up Routines

The technical documentation of the machine / machine system must describe any special start-up routines to be performed after an overall reset of a system.

3.5.8 Plug-In Power Supply Units

Plug-in power supply units are not permitted.

3.6 Protection Against Electric Shock

The terms and conditions defined in DIN EN 60204-1 shall apply.

3.7 Protection of Equipment

3.7.1 Overcurrent Protection

3.7.1.1 Overload and Short-Circuit Protection

With rated currents not exceeding 63 A, Diazed-type fuse links of sizes D II and D III and Neozed-type fuse links of sizes D 01 and D 02 must preferably be used.

Automatic circuit-breakers are also permitted with currents not exceeding 32 A, provided that the short-circuit breaking capacity is sufficient.

With rated currents exceeding 63 A, low-voltage high-breaking-capacity fuse switch disconnectors with LVHBC fuses of sizes 00, 1, 2 and 3 (LVHBC fuses with insulated grip lugs) must be used.

For motor circuits of up to 100 A, motor protecting switches must be used. The motor protecting switches must be set to the nominal current of the particular motor. The rated motor current should be indicated on the protecting switch.

3.7.1.2 Switch Response

The operator panel must display the response of every motor protecting switch and circuit-breaker separately.

If several protective devices are connected in line, selective disconnecting behavior must be ensured.



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3.7.1.3 Special Motors

Multiple-speed motors or motors with special mode of operation or P=7.5 kW and higher must be protected by PTC thermistors.

Electrical servo-drives must always be provided with PTC thermistor protection. In the case of speed control from nmin to nmax, motors with forced ventilation must be used.

3.7.1.4 Feedback / Compensation

The contractor must ensure that no harmonic waves are fed back into the supply system.

If the power factor falls below 0.95, while the total power of the machine exceeds 50 kVA, correction will be necessary. At least a power factor of 0.95 must be achieved. The power factor corrector must be installed in the switchgear cabinet (see List of Approved Suppliers).

3.8 Equipotential Bonding / Shielding

Equipotential bonding must converge in a central location and comply with the EMC directive.

The shielding of signal lines must be effected in relation to the device itself and may not be used for equipotential bonding.

3.9 Control Circuits and Control Functions

3.9.1 Control Voltage

The control voltage of PLC, initiators, light barriers, valves, solenoids, etc. must be 24 VDC.

Measuring devices must have separate power supply units.

3.9.2 Operating Modes and Functions

The customer shall be consulted about operating modes and functions (e.g. Manual Mode, Stop at Cycle End and Idling “All Units in Home Position”).

3.9.3 EMERGENCY STOP / Error

3.9.3.1 Coordination of Safety Equipment

The customer shall be consulted about all system safety equipment, as well as the boundaries of the “EMERGENCY STOP” circuits between individual system sections.

In the case of interlinked facilities / machines, the supplier shall draw up an emergency stop concept to be coordinated with the customer.

3.9.3.2 Interlinking in Case of Hazards

Interlinking of various “EMERGENCY STOP” areas will be required, if there is any hazard to persons and/or machines/machine systems at the transfer points of interlinked machines / machine systems.

3.9.3.3 Signaling and Display

The “EMERGENCY STOP” command must be signaled to the PLC and displayed.



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3.9.4 Protective Locks / Protective Doors

Protective doors for access to moving equipment (e.g. robots, gantries, …) should preferably have protective switches with tumblers. In case of emergency, it must be possible to unlock them manually. Deviations must be approved in writing by the customer.

3.9.5 Safe Condition

After a disruption, the machine/machine system must shut down in a defined condition (if possible from a safety perspective).

3.10 Operator Interface and Control Equipment Attached to the Machine

3.10.1 Status and Error Displays

All operating statuses must be displayed on the operator interface.

The system status must be indicated at the main control panel by means of a signaling column.

Access areas for machine operators must be provided with signaling columns (traffic lights).

Color codes for operating and signaling devices correspond to IEC/EN 60073 (VDE 0199), IEC/EN 60204-1 (VDE 0113 Part 1).

3.10.2 Machine and Process Monitoring

Error messages (at least the last 30) must remain after their acknowledgement (e.g. circular buffer, log book). Only errors/alarms may be registered in the log book, no operating messages.

3.10.3 Distinction

A clear distinction must be possible between error messages and operating messages.

3.10.4 Signaling the Switching Statuses

The output statuses of safety control devices used (“EMERGENCY STOP”, protective doors, two-hand start, …) must be signaled individually to the PLC via their signaling contacts.

If multiple actions are assigned to a safety control device, they must additionally be signaled back to the PLC individually by means of auxiliary contacts and displayed on the operator panel.

3.10.5 Lamp Test

If 5 or more illuminated indicators and/or illuminated pushbuttons have been installed, one lamp test button will be required for each control panel.

3.10.6 Additional Displays

Additional displays shall be coordinated with the customer.

3.10.7 Controls

The number of operating elements (buttons for manual functions) must be kept small, but common operating elements which are used most frequently must be designed as hardware buttons.



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All devices, including controllers, timer relays and the like, must allow operation without the need to open the switchgear cabinet.

Inscriptions on control and signaling units must be written in German and in the local language of the country of destination.

3.11 Electronic Equipment/ Control Interfaces

3.11.1 Control Design

3.11.1.1 Control System

Principally, the control concept SIMATIC S7-1200/1500 (Siemens) must be used.

The customer must agree to and approve any deviations from this control concept.

3.11.1.2 Software Structure

The software structure (PLC, NC, robot programs, etc.) and the programming style must be coordinated with the customer.

3.11.1.3 Visualization

Visual display must be provided for every control unit. This must be coordinated with the customer.

3.11.1.4 Implementation of Functions

Functions that are not always executed manually must be implemented within the visual display.

Functions that are always executed manually shall be implemented using separate pushbuttons.

3.11.1.5 Selecting the Operating Systems

When selecting the operating systems, the Lists of Approved Suppliers are binding.

The operating system shall use the local language of the operator.

In each case, the license number must be attached to the unit so that it is visible and cannot be lost.

3.11.1.6 PC Use

Industrial PCs must be used. They must be provided with uninterruptible power supply.

3.11.2 Control Units

The supply circuits for the inputs and outputs must be divided into groups and selectively protected so that a short-circuit will not lead to failure or CPU stop.

Inputs: 24V DC max. 2A

Outputs: 24V DC max. 8A (with 2A output boards)

230 V AC modules and relay cards are not permitted.

Only one consumer may be assigned to each output and only one actuator to each input.



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If the I/O level consists of distributed I/O devices, addressing must be provided in linked blocks with corresponding reserve areas (min. 20 %) (e.g.: E 0.0-0.7, and then E1.0-1-7). The CPU must have a reserve of 20 %.

When the control unit is “OFF”, its power supply must remain active.

3.11.3 Software

The software and software versions for all programmable systems must be coordinated with the customer and subsequently delivered. The release and current version must be indicated in the circuit diagram (cover sheet).

Any necessary licenses must be included.

Locking the PLC modules by means of know-how protection is not permitted.

The software to modify, expand, reload and archive the programmable system or systems is part of the scope of delivery of the machine/machine system.

3.11.4 Operating Units / Operating Panels

3.11.4.1 Program / Programming

The program of operating panels (e.g. Simatic OPs) must be available as source code.

Standard program modules (from Siemens as a rule) must be used for programming.

3.11.4.2 Range Pointers for OP Interface Parameterization

Range pointers must preferably be stored as data blocks.

3.11.4.3 Help Texts

If additional information is needed to operate the machine, help texts related to the operating function must be configured.

3.11.4.4 Pictograms

When using pictograms, the Siemens standard must be used throughout. Furthermore, pictograms are permitted in text displays.

3.11.5 Programming Units

Any additional programming devices, interface modules, manual programming modules, as well as interface cables that are required for operation and maintenance of the machine / machine system must be included in the scope of delivery. Otherwise, they must be offered separately.

It must be possible to connect a programming unit at any time without the need to disconnect wires from the PLC or operator’s console. This must not affect the functioning of the control system.

3.11.6 Interfaces

The interfaces and interface signals to integrated and peripheral equipment (e.g. industrial robots, conveyor systems, …) shall be coordinated among the individual subcontractors or device and system manufacturers and presented for approval to the customer without further request. Interface signals must be implemented in 24 VDC and potential free.



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3.11.6.1 Connection

A connection for the programming unit must be provided in the switchgear cabinet. In the case of spatially extended machines/machine systems, multiple connections must be provided. Interface connections at the CPU must be designed with double contacts (MPI and Profibus).

3.11.6.2 Remote maintenance

As remote maintenance access a so-called VPN tunnel is possible. Other connections are not allowed.

A corresponding VPN claim form must be completed in advance with the Department ICT / IDEAL Automotive.

The VPN connection will set up by Deutsche Telekom. The connection (cable connection) system controller to the network is part of IDEAL Automotive. The supplier has to equip his control with the necessary hardware (Ethernet interface) accordingly.

Side of IDEAL Automotive: IP 82.210.228.142 (vpn.ideal-automotive.com), static

Opposite side: either static (preferred) or dynamically

During tunnel definition i.a. will defined to which device(s) is allowed to accessed at IDEAL Automotive.

The possibility of connection to other devices is not excluded in principle. IDEAL Automotive prohibits only access between machine network and other networks. Each system in machine network must be protected by suitable measures by Supplier himself against unauthorized access.

3.11.7 Coupling of Multiple Control Units and Systems

Bus systems shall be taken from the List f Approved Suppliers.



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3.11.7.1 Bus Topology

The circuit diagram must contain the bus topology with the following information in clear format:

Slave address

Wire lengths laid between the individual bus nodes

Clear wire designations

Installation location of the bus nodes within the system (block diagram)

The bus segment must be recognizable.

3.11.7.2 Test Documents

Test documents must be issued for the following parameters:

The real wire lengths (max. 100 m) and the impedance values of a Profibus segment.

The transmission level of all bus nodes as bar chart (min. 2.5 V and no signal distortions are permitted).

The bus cycle time (average, max/min) and the number of error messages per hour (< 30).

3.12 Switchgear: Arrangement, Setup and Housing


3.12.1.1 Protection of Components

All electrical components of a machine/machine system must be installed or protected in such a way that they cannot be damaged or triggered if anybody steps on them.

3.12.1.2 Standard Locking

The standard locking method must be a two-way key bit.

3.12.1.3 Installation Space

Installation space for electrical components (terminal boxes, consoles, etc.) generally requires an IP54 type of protection, hinges and two-way bit standard locking system. Observation windows must be provided for I/O modules.

3.12.2 Arrangement and Setup

3.12.2.1 Installing a Switchgear Cabinet

A switchgear cabinet may stand alone or be attached to the machine. Testing of the machine functions should be possible from the open switchgear cabinet. The distance from the bottom of the switchgear cabinet to the lower edge of the devices installed in the switchgear cabinet must be not less than 0.4 m, to the terminal strips not less than 0.25 m. The height of the switchgear cabinet may not exceed 2.20 m (mounting height of switchgear max. 2 m).

The position of the switchgear cabinet must be coordinated with the customer.

3.12.2.2 Multilayer Installation

Devices and panels may not be installed in multilayer arrangement in the switchgear cabinet.



Last updated:

09/2016


3.12.2.3 Swing Frames

Swing frames are only permitted if the opening angle is greater than 110° and if the unsecured switchgear cabinet does not tip over when the frame swings out.

The components behind the swing frame must be accessible.

3.12.2.4 Front Panel

The front panel (of terminal boxes and panels) must swivel if there are more than 6 control and signaling devices. The devices must be mounted to the front panel (front-mounted with rear connection).

Devices in doors and front panels must be connected by means of a terminal strip.

3.12.2.5 Circuit Diagram Bag

An adequately dimensioned bag must be provided to hold the circuit diagrams.

3.12.3 Switchgear Cabinet Cooling

3.12.3.1 Temperature

The temperature inside the switchgear cabinet must not exceed 40 °C above control/drive components and operating panels. This aspect is based on the assumption that the regular ambient temperature in the factory building is 45 °C; any possible temperature peaks and specific local conditions (altitude, solar radiation, etc.) must be taken into consideration.

Only cooling units with temperature control are permitted.

When the doors of the switchgear cabinet are being opened, the switchgear cabinet cooling system must be interrupted by means of a door switch.

If a filter fan is used, it must generate overpressure in the switchgear cabinet (i.e. blow air through a filter into the switchgear cabinet).

3.12.3.2 Prefilter

Air conditioners must be provided with prefilters.

3.12.3.3 Draining Condensate

The condensate must be drained on the outside of the switchgear cabinet and collected or disposed of by means of a sufficiently sized device. An appropriate collecting vessel must be provided, too.

3.12.3.4 Temperature Monitoring

The temperature in the switchgear cabinet must be monitored and displayed as an alarm message if the permissible temperature (40 °C) is exceeded, however, the maximum value may never exceed 45 °C.

3.12.3.5 Heat Requirement Calculation

The heat requirement must be calculated to determine the adequate size of the cooling units for the electrical installation spaces (e.g. switchgear cabinet, …) and then included with the technical documentation of the machine / machine system.



Last updated:

09/2016


3.12.4 Switches / Polling

Position polling must be executed with the help of position switches and not with pushbutton switches.

Serial or parallel polling is not permitted. Individual evaluation is mandatory.

Every supply pressure must be polled for presence, also partial supply, e.g. behind pressure regulating valve, etc.

3.12.5 Safety Photoelectric Light Barriers

With regard to contactless acting safety devices, the EN standards shall be binding.

The output contacts of the safety devices must be provided with spark suppressing elements.

The connection guidelines of the light barrier manufacturer are mandatory.

The switching statuses must be indicated on the operator interface.

The light barriers must be installed so as not to get damaged when handling production materials.

The light-barrier holders must be of sturdy design, free from vibrations and adjustable.

Their labeling must be clearly visible, including information about overtravel time and distance, as well as safety distance.

3.12.6 Signals (I < 10 mA)

Signals with amperage of less than 10 mA must be transmitted contactless.

3.13 Conductors, Cables and Wires

3.13.1 Color Coding

Circuits that are not switched off by the main switch (external voltage) must be marked in orange in the entire circuit (wire or flexible tubing).

Wires and cables that are tapped before the main switch (permanent voltage) must be marked in yellow along the entire route (wire or flexible tubing).

Short-circuit proof wires must be used between the main switch and the first fuse if the conductor’s cross-sectional size does not match the rated amperage of the fuse.

The following color coding must be used for switchgear manufacturing:

Main circuit AC or DC: BLACK

Control circuit with 230 VAC: RED

Neutral or middle conductor (N): LIGHT BLUE

Control circuit with 24 VDC: DARK BLUE

Grounded potential DC: BLUE/WHITE

Interlocking circuit (external voltage): ORANGE

Protective / equipotential bonding conductor: GREEN/YELLOW

Measuring leads: BROWN, VIOLET

3.13.2 Arrangement of Wiring

Data, bus and measuring lines must run separately from the other power lines or be adequately shielded.



Last updated:

09/2016


3.14 Circuitry

3.14.1 Wiring Inside of Housings

Wires leading to devices mounted on swing frames or doors must have protective flexible tubing.

The switchgear cabinet wiring must be in cable ducts.

Only one wire may be connected to each connecting point of every terminal block. All connections must be of clamp or plug-in type. Soldered connections are not permitted, except for data and measuring lines. All clamped lines must be provided with individual connector sleeves with plastic collar or cable lugs (crimped connection). The screw-type terminals of all devices must be provided with pressure plate, terminal clamp or clamping lug to protect the conductor, i.e. direct contact between screw and conductor is not permitted. No terminals or terminal connections may be mounted inside of the wiring ducts.

3.14.2 Wiring Outside of Housings

3.14.2.1 Installation

Multi-strand leads must be used for machine installation outside of the switchgear cabinet and control panel. Cores (single wires) are not permitted. This does not apply to additional protective or equipotential bonding conductors.

For bundles of cables, leads or individual wires, a cable duct must be installed.

Depending on the strain imposed on leads being subject to operational motion, they must be highly flexible and suitable for the particular application. If motion occurs more than once within an hour, it is considered operational motion. Such leads must be laid in adequate energy chains.

Leads, cables and ducts may not be laid on the floor.

3.14.2.2 Cable Entry

Cable entries must guarantee that they will not allow any moisture to penetrate or cause any damage to the leads.

Multiple M-type screwed glands are not permitted; cable penetration systems are allowed. Pre-assembled lines must be exchangeable without disassembling the connector.

3.14.2.3 Line Ducts

The line ducts must be made of metal.

Walkable cable ducts shall generally be avoided and may only be installed after consultation with the customer. If used, the cable ducts must be safe to tread on.

The metal cable ducts must be sufficiently grounded.

3.14.2.4 Plug-in Connections

Initiators and other peripheral devices must be of plug-in type. The switching status must be indicated by LED. It must be easy to change the connected lines (e.g. in the cable trailing device).

The cable length of sensors / actuators with fixed connection lines may only exceed 1.5 m if they are easily accessible.



Last updated:

09/2016


If the connection cables are under heavy load, radiation cross-linked cables with e.g. higher temperature range must be used.

If multiple plug-and-socket devices are used next to one another, adequate measures must be taken (e.g. plug coding, specified fixed line lengths, …) to avoid confusion.

Up to a rated current of 36 A, all connection lines for system parts that need to be electrically disconnected for transporting the machine / machine system must have one-sided plug-and-socket devices.

The setup of the sections of the energy chain must be documented. The energy chain must be exchangeable as a subassembly through plug-in connections within a period of time defined in agreement with the customer.

Plug-and-socket devices for auxiliary equipment (e.g. pumps, filters, measurement control units, …) must be connected behind the main switch.

3.14.2.5 Wiring at Heat-Treatment Systems

The connection lines of thermoelements in heat-treatment systems must be installed without terminals up to the measuring point. If this is impossible, compensation terminals must be used.

Thermal e.m.f. lines may principally be installed as shielded and grounded lines only. This applies also to the switchgear area.

3.15 Electric Motors and Related Equipment

3.15.1 Actual-Path Measuring Systems

Actual-path measuring systems (e.g. glass scales) must be installed on the machine so as to allow their operation with minimum maintenance , i.e. they must be protected against dirt of all kind (e.g. using sealing air).

They must be mechanically fastened in such a way that no adjustment is necessary after replacement of components.

3.15.2 Drive Elements and Actuators

All drive elements and actuators must be designed for continuous operation (100%).

3.15.3 Design of Electric Motors

Engines must be desinged according to the EU-Regulation (EC) No 640/2009 and must fulfil the currently applicable efficiency class, whenever possible energy efficiency class IE3.

Motors must comply at least with IP 54 degree of protection according to IEC 34 Part 5.

Duty type S1 (continuous operation) is required.

For motors of P=7.5 KW and higher, the winding must be designed for 400 V delta.

Power should be sized so that the motor will run within the last quarter of its performance range.

In the case of pumps, conveyor belts and fan drives, an additional lockable maintenance switch must be installed.



Last updated:

09/2016


3.15.4 Three-Phase Motors

Three-phase motors with a power of 7.5 kW and higher must have a star-delta starter or be provided with an electronic soft start function. The starting conditions must be coordinated with the competent technical department of the customer.

3.15.5 Brake Motors

Brake motors are only permissible with rectifiers installed on the motor.

3.16 Accessories and Lighting

3.16.1 Socket Outlets

Every switchgear cabinet must be provided with a grounding-type outlet complying with the national standard of the installation site, which must easily be accessible from outside and connected before the main switch.

Inside the switchgear cabinet, there must be a grounding-type outlet as well as lighting, being connected before the main switch. Specific local regulations for exemption must be agreed with the customer.

Next to every programming interface, a grounding-type outlet must be provided, being connected behind the main switch and protected separately.

3.16.2 Lighting

The switchgear cabinet lighting must be wired for each switchgear panel via its own door contact switch.

An energy-saving machine space / workstation illumination must be installed, allowing to be switched on/off. If possible, LED technology should be used.

As a rule, workstations should have a luminance level of not less than 500 lux.

Lighting must be installed in such a way that it will not cause any disturbing shadow areas, dazzling effects and dangerous stroboscopic effects through moving parts.

3.16.3 Lighting and Outlet Circuits

Lighting and outlet circuits may not be connected on the secondary side of control-power transformers.

3.16.4 Workpiece or Operating Hour Counters

The machine/machine system must be provided with a resettable workpiece counter to count the number of workpieces processed (shift counter) to be implemented preferable by software.

A cycle-dependent, non-resettable operating hour counter as well as a non-resettable system workpiece counter (total counter) must be provided, preferably software-based.

If cycle/time-dependent maintenance intervals are necessary, the machine/machine system must have corresponding counter functions and a signaling system.

3.16.4.1 Measuring Devices

Position measuring systems and controller boards must be supplied from a separate stabilized power supply unit.



Last updated:

09/2016


3.17 Warning Signs and Labeling of Operating Equipment

3.17.1 Inside the Switchgear Cabinet

The operating equipment inside the switchgear cabinet must be labeled permanently on the mounting plate and the component.

The designations and symbols must comply with the standards (“+” for location name, “-“ for component name, “=” for functional group).

The designation on sensor/actuator level and PLC / control unit must be intuitively consistent/uniform.

Contacts and terminals remaining under tension when the main switch is in OFF position must be covered and labeled with the warning:

"Caution! Voltage still present when main switch is off"

(For Czech Republic: "Pozor stale pod napětím i při vypnutem hlavnim vypínači“)

3.17.2 Outside the Switchgear Cabinet

The operating equipment outside the switchgear cabinet must be permanently, completely, and clearly visibly labeled next to the component and on the cable, using engraved/embossed or etched signs. This also applies to any plugs, switch boxes, command boxes and operating elements.

All electrical installation spaces must be marked with a warning sign (lightning bolt).

The main switch must be labeled “Main Switch” (for Czech Republic: „hlavní vypínač“)

Terminal boxes must be identified outside with labels stating the terminal strip numbers and showing a lightning bolt.

3.17.3 Cable Identification

All cables must permanently be labeled on both ends.

The cable identification and the electrical diagram (e.g. terminal diagram) must indicate the target and the source of the cable.

3.17.4 Individual Core Identification

Devices where multiple cores must be disconnected to replace the device must have a permanent identification of the individual cores. Exceptions may be agreed with the customer.

3.18 Technical Documentation

For requirements, see “Technical Equipment Requirements”, Chapter : “Technical Documentation”.



Last updated:

09/2016


3.19 Testing and Inspection

The electrical test report based on DIN EN 60204 (BGV A3) must be included with the technical documentation of the machine/machine system.

A test record on the insulation resistance and the loop impedance of the grounding conductor must be included with the technical documentation of the machine/machine system.

Final acceptance and first start-up of safety light grids, including overtravel distance measurement, form part of the scope of delivery and must be documented.

3.20 Startup, Final Acceptance, Training

For Startup, Final Acceptance and Training, see Chapter I “General”.

3.21 Other Applicable Documents

Standard Designation

Directive 2006/42/EC Machinery Directive

Directive 2006/95/EC Electrical equipment (Low-Voltage Directive)

Directive 2004/108/EC Electromagnetic compatibility (EMC)

EU Regulation No 640/2009 Engine Regulation

Directive 94/9/EEC Equipment / protective systems intended for use in potentially explosive atmospheres (“ATEX Product Directive”)

VSG Regulations on Safety and Health Protection (Germany)

GPSG Equipment and Product Safety Act (Germany)

DIN EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements (see Chapters 2,6)

DIN EN ISO 9000 Quality Management Systems - Fundamentals and Vocabulary (ISO 9000: December 01. 2005)

(see Chapter 16.5.4)

VDA-LVE Delivery Instructions for the Electrical Equipment of Machines, Machine Systems and Facilities.

(see Chapters 2,3)



Last updated:

09/2016


DIN EN 60204 (BGV A3) Selection for electrical installations and equipment (according to BGV A3)

(see Chapter 19)



Last updated:

09/2016


3.22 List of Approved Suppliers

Country of Destination Germany Czech Republic Remarks

Designation: Manufacturer: Manufacturer:

Switchgear cabinets, terminal boxes

Rittal Rittal / Etezet

Switchgear cabinet lighting Rittal Rittal

Programmable Controllers Siemens

S7-1200/ 1500

(S7-300/400)

Siemens

S7-1200/ 1500

(S7-300/400)

Bus systems Profibus / ASi Profibus / ASi

ASi-bus components Siemens / ifm Siemens

Main Switches Siemens / Eaton (Moeller)

Siemens / Eaton (Moeller)

Control transformers Siemens Siemens

Power supply units Siemens Siemens

Circuit -breakers ABB Siemens / ABB

Motor protecting switches Siemens / Moeller Siemens

Main contactors Siemens Siemens

Auxiliary contactors Siemens Siemens

Relays Finder / Kuhnke / Wieland

Only semiconductor relays are permitted

PTC thermistor relays Siemens Siemens

Star-delta relays Siemens Siemens

Timer / multi-range relays Finder / Siemens Siemens

Emergency-OFF relays Pilz / Siemens Pilz / Siemens

Two-hand relays Pilz Pilz

Terminal blocks Wieland / Phoenix / Weidmüller

Wieland / Phönix

Isolating terminals Wieland / Phoenix / Weidmüller

Weidmüller

Plug-and-socket devices Wieland / Harting Wieland / Harting



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09/2016


Hydraulic-valve amplifiers (prop, servo)

Bosch-Rexroth / Völkel Bosch-Rexroth

Control, operating and signaling devices, mounting diameter 22.5 mm

Siemens/

Eaton (Moeller)

Siemens Indicator lights in LED design

Door safety switches Euchner / Schmersal /

Allen Bradley-Guardmaster

Allen Bradley-Guardmaster

Safety photoelectric light barriers, scanners

Sick / Lumiflex Sick / Cedes / Lumiflex

Switching strips and mats Mayser Mayser

Limit switches Siemens Siemens / Telemecanique

Light barriers and sensors Sick / ifm Balluf steckbar

Proximity switches (capacitive and inductive)

ultrasonic sensors

Siemens / ifm / Festo / Contrinex

(or of equivalent design)

Balluf plug-in type;

only pnp connection with status indication or

NAMUR design

Magnetic field sensors (cylinder)

Festo Festo/ Balluf

Linear position measuring systems

Baluff Baluff Micropulse BTL…

Rotary encoders (abs., incr.) elobau Fraba Posital OCD-SL-00G-1212-…

Counters Hengstler

Energy chains igus

Motors SEW / Siemens / VEM / Lenze

Frequency converters Siemens / SEW / Lenze

Nord / SEW

Servo-controllers Siemens / SEW

Pyrometers Raytec Raytec Raymid 10LTCB3

Resistance thermometers JUMO

Infrared radiators Vulcan / Elstein

Capacitors (compensation) Siemens / KBR

Siemens / KBR / ABB IAOE: detuned;

other manufacturers: non-detuned;



Last updated:

09/2016


4 Hydraulics Amendments:

Revision


Date

1 47-58 Original 2010-11-19

Table of contents:

4 .................. Technical Delivery Instructions Hydraulics ......................................................... 47



4.2.1 ........... Delivery Instructions ........................................................................................... 49

4.2.2 ........... Accessibility ....................................................................................................... 49

4.2.3 ........... Collecting Troughs ............................................................................................. 49

4.2.4 ........... Design ................................................................................................................ 49

4.2.5 ........... Protective Actions .............................................................................................. 49

4.2.6 ........... Readjustment Devices ....................................................................................... 49



4.3.2 ........... Requirements For Pressure Vessels, Pipes, Equipment And Hydraulic Accumulators ..................................................................................................... 50

4.4 .............. Fluid Container ................................................................................................... 50

4.4.1 ........... Suction Pipes ..................................................................................................... 50

4.4.2 ........... Design ................................................................................................................ 50

4.4.3 ........... Indication Of Filling Level ................................................................................... 50

4.4.4 ........... Level Control ...................................................................................................... 50

4.4.5 ........... Operating Temperature ...................................................................................... 51

4.4.6 ........... Temperature Monitoring ..................................................................................... 51

4.4.7 ........... Ventilation Filter ................................................................................................. 51

4.4.8 ........... Filling ................................................................................................................. 51

4.4.9 ........... Drain .................................................................................................................. 51

4.5 .............. Pumps ................................................................................................................ 51

4.6 .............. Cylinders ............................................................................................................ 51

4.6.1 ........... Running Faces ................................................................................................... 51

4.6.2 ........... Damping ............................................................................................................. 51

4.7 .............. Valves ................................................................................................................ 51


4.7.2 ........... Modular Design .................................................................................................. 52



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4.7.3 ........... Electrical Actuation ............................................................................................. 52

4.7.4 ........... Manual Operation ............................................................................................... 52

4.7.5 ........... Safety Valves ..................................................................................................... 52

4.7.6 ........... Shut-Off Valve And Non-Return Valve ............................................................... 52

4.8 .............. Pressure Accumulator ........................................................................................ 52


4.8.2 ........... Filling Gas .......................................................................................................... 52

4.9 .............. Line System ....................................................................................................... 52

4.9.1 ........... Pipelines ............................................................................................................ 52

4.9.2 ........... Hose Assemblies ............................................................................................... 53

4.9.3 ........... Line Connections ............................................................................................... 53

4.9.3.1 ........ Number .............................................................................................................. 53

4.9.3.2 ........ Flange Connections ........................................................................................... 53 4.9.4 ........... Pressure Measurement Points ........................................................................... 53

4.9.4.1 ........ Arrangement ...................................................................................................... 53

4.9.4.2 ........ Pressure Gauge Selector Valve ......................................................................... 53 4.10 ............ Filter ................................................................................................................... 54


4.10.2 ......... Purity .................................................................................................................. 54

4.10.3 ......... Accessibility ....................................................................................................... 54

4.10.4 ......... Monitoring Of Filter Contamination ..................................................................... 54

4.10.5 ......... Other Instructions ............................................................................................... 54

4.11 ............ Heat Exchangers ................................................................................................ 54

4.12 ............ Hydraulic Fluid ................................................................................................... 55

4.12.1 ......... Use .................................................................................................................... 55

4.12.2 ......... Flow Rate ........................................................................................................... 55

4.12.3 ......... Fire Hazard ........................................................................................................ 55

4.13 ............ Identification ....................................................................................................... 55


4.13.2 ......... Additional Instructions ........................................................................................ 55

4.14 ............ Appendix: Co-applicable Documents .................................................................. 56

4.14.1 ......... Requirements - Europe ...................................................................................... 56

4.14.2 ......... Legal Requirements - Germany ......................................................................... 56

4.15 ............ List Of Approved Suppliers ................................................................................. 58



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These technical instructions shall apply specifically to the design of the hydraulic system of the machinery. They complement the provisions outlined in "General" of the Technical Delivery Instructions of IA and are valid in conjunction with them for all IA plants.


4.2.1 Delivery Instructions

You may only use components, sub-assemblies, devices and process materials which are specified in the Lists of Approved Suppliers.

Any deviations are permitted only after consultation with the ordering party and confirmation in writing.

4.2.2 Accessibility

All components and sub-assemblies must be easily accessible for maintenance and repair and they must not be hidden by pipes and hose assemblies or other components/sub-assemblies.

The hydraulic system must not have any screw connections at points that are difficult to access.

4.2.3 Collecting Troughs

All parts, sub-assemblies and tanks which transport or contain substances or media hazardous to water must be equipped with collecting troughs.

The Water Management Act (WHG) valid at the erection site of the machinery shall be observed for the design of the collecting trough. This applies likewise to the design and erection of a so-called floor pan.

4.2.4 Design

The hydraulic system must be designed that a sufficient reserve of pressure and quantity is available in one working cycle.

4.2.5 Protective Actions

Suitable protective actions must be selected according to the specific local conditions which exist at the erection site and to which the machinery will be exposed.

4.2.6 Readjustment Devices

Readjustment devices on parts (e.g. pumps, flow control and pressure valves, ...) must be protected against accidental operation.



On principle, the requirements with regard to the normative references given in Chapter I "General Information" shall apply.



Last updated:

09/2016


The basis of this Technical Equipment Requirement for the hydraulic system of the machinery is DIN 24346 which has to be complied with, including its recommendations and additional requirements.


4.3.2 Requirements For Pressure Vessels, Pipes, Equipment And Hydraulic

Accumulators

The pressure equipment must comply with the Pressure Equipment Directive (PED 97/23/EC) or the Simple Pressure Vessels Directive (SPVD 87/404/EEC) and the AD 2000 Z1 Code.

The following documents must be furnished as documentation on hydraulic accumulators:

drawings of the vessel with specification of materials

CE declaration of the vessel and safety valves

maximum admissible load cycles of the vessel

risk assessment

operating instructions

4.4 Fluid Container

4.4.1 Suction Pipes

Suction pipes must end at least 50 mm above the container bottom and they must be decoupled mechanically.

4.4.2 Design

Fluid tanks must be protected against contamination.

The fluid tank size must be designed so that it will hold at least the three to five-fold pumping capacity.

Tanks must be designed to DIN 24339 (container form AN, cover form C)

Two easy to access (reserve) holes must be provided in the tank which correspond to the size of the suction pipe/coarse-pitch thread (closed with plug) to allow, for instance, oil filtering in bypass operation.

4.4.3 Indication Of Filling Level

The filling level of the hydraulic fluid must be indicated at an easy-to-access and exchangeable inspection glass and it must be visible well from outside when the tank is filled, during operation and at a standstill of the machinery. Using dip sticks is not allowed.

The specified maximum filling level for standstill of the machinery and maximum and minimum filling levels for machine operation must be permanently marked at the filling level indicator and visible well from outside.

4.4.4 Level Control

The fluid tank must have a level control with two switching points for the minimum filling level:

1. Switching point oil level min. prewarning (top up oil)



Last updated:

09/2016


2. Switching point oil level < min. shutdown (after end of cycle).

4.4.5 Operating Temperature

The maximum pump inlet temperature of hydraulic systems specified by the pump manufacturer must not be exceeded at maximum ambient temperature at the erection site of the machinery.

4.4.6 Temperature Monitoring

It has to be demonstrated that the temperature in the fluid tank cannot exceed 65 °C.

The temperature monitoring must be carried out with a switching point:

Switching point oil too hot shutdown (after end of cycle).

4.4.7 Ventilation Filter

The fluid tank must be provided with a ventilation filter for ventilation and deaeration. The filter element of the ventilation filter must be exchangeable and its mesh size must be smaller than that of the finest filter in the system.

The ventilation filter must have a visual contamination indication if it is used in an environment with increased dirt or dust loads.

4.4.8 Filling

The fluid tank has to be filled via a filter (e.g. filler neck with integrated filling sieve).

4.4.9 Drain

There must be a drain with a blind plug at the lowest point of the fluid tank.

4.5 Pumps

All pumps used in the machinery must have a reserve delivery rate of at least 20% and rate-controlled or pressure-controlled pumps shall be preferred.

The pumps have to be installed outside the container/tank.

4.6 Cylinders

4.6.1 Running Faces

The running faces of the piston rods must be hardened, have been finish-machined and be corrosion-resistant.

4.6.2 Damping

Exact cylinder movements must be damped in the limit positions (with oil brake, if required).

4.7 Valves


The valves used in the hydraulic system of the machinery must be designed to DIN 24340 and DIN ISO 7368.



Last updated:

09/2016


4.7.2 Modular Design

Interlinked valves (interlinking systems) must be used in modular design.

Interlinked and control plates must be mounted rigid, safe and tension-free on the respective parts.

4.7.3 Electrical Actuation

Valves with electric connections - not applicable to continuous valves - must be provided with appliance couplers (line sockets) with a LED, a flyback diode, connection pattern acc. to DIN EN 17301-803, electric voltage of 24 V DC and protective circuit.

Continuous valves must have an appliance coupler (line socket).

4.7.4 Manual Operation

It must be possible to manually operate electrically operated directional valves, except proportional and continuous valves (manual auxiliary operation in case of emergency); however, it must not be possible to operate the valve accidentally.

4.7.5 Safety Valves

All safety valves must have a CE mark and the relevant EC declaration of conformity must be included in the technical documentation of the machinery.

The safety valve must accommodate the allowable pressure of the pressure accumulator with the ability to release the entire pump capacity. Any resulting pressure increase must not exceed 10%.

4.7.6 Shut-Off Valve And Non-Return Valve

A shut-off valve (coll. stopcock) must be installed in the supply line and a non-return valve must be installed in the tank line for interlinked and control plates.

4.8 Pressure Accumulator


Safety shut-off blocks must be used for all pressure accumulators.

It must be ensured that movement caused by a shut-down (also “emergency stop”) or a power failure will not pose any danger to operators and the machinery.

Only fixed pipelines leading to the pressure accumulators are permitted.

4.8.2 Filling Gas

Nitrogen must be used as filling gas for the pressure accumulator.

4.9 Line System

4.9.1 Pipelines

Seamlessly drawn precision steel pipes must be used for pipelines which must meet the requirements of up to the nominal width of DN 30 and of from the nominal width of DN 40, DIN EN 10220.



Last updated:

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Seamlessly drawn pipes made of stainless steel to DIN EN ISO 1127 must be used in areas of the machinery which are subject to corrosion (chemicals, water spray, condensation, etc.).

4.9.2 Hose Assemblies

Hose assemblies must comply with DIN 20066 and may only be used

for moving units

when units/sub-assemblies are changed due to production needs

to dampen mechanical and hydraulic vibrations and/or noise

for measurement lines

Failure of hydraulic hose assemblies (leakage of pressure medium/uncontrolled swinging of hose) must not lead to danger for persons. This hazard may be prevented by providing the hose assemblies used within the work station's range or at transport routes with protective covers and safety chains/wire ropes or screens.

Hose assemblies must be checked regularly.

Hose assemblies older than 2 years must not be installed.

4.9.3 Line Connections

4.9.3.1 Number

The number of connections in the line system must be kept to a minimum (e.g. using curved pipes instead of threaded elbow joints, distribution blocks instead of screwed T connections, etc.).

4.9.3.2 Flange Connections

Flange connections with DN 40 and bigger must have O-ring seals.

4.9.4 Pressure Measurement Points

4.9.4.1 Arrangement

The machinery must have a pressure measurement point on every pressure switch and on every pressure overflow and safety valve.

Additionally, accessible pressure measurement points must be provided

with M 16x2 screw connections (miniature measurement connection) on all cylinder control lines next to the cylinder connections and before and after every pressure line filter to permit pressure measurement inspections.

4.9.4.2 Pressure Gauge Selector Valve

All pressure measurement points must be led to a pressure gauge selector valve where the selected operating pressure is displayed.



Last updated:

09/2016


4.10 Filter


The hydraulic fluid filters installed in the machinery must ensure that the hydraulic fluid is constantly cleaned.

Only filters compliant to DIN 24550 are permitted for filtering the hydraulic fluid.

The filtering must be designed to ensure that the service life of the filter elements is at least six months under operating conditions specified for the machinery while maintaining the demanded purity of the hydraulic fluid.

The filter manufacturer and/or subcontractor must be consulted with regard to the design of the filters.

4.10.2 Purity

On principle, the selected purity class is determined by the most sensitive component:

General hydraulics: classification to ISO 4406, at least purity class 19/16/13

Proportional-action valves: classification to ISO 4406, at least purity class 17/15/12

Servo-valves: classification to ISO 4406, at least purity class 15/13/10.

4.10.3 Accessibility

Filters must be easily accessible and the filter inserts must be replaceable without disassembling other components/sub-assemblies.

4.10.4 Monitoring Of Filter Contamination

The filters must have an electronic contamination indicator with an indication/signal on the control panel. If the maximum admissible filter contamination level is exceeded, the machinery must be shut down in accordance with the agreed criteria.

The filter contamination level must be monitored at two switching points:

1. Switching point filter contamination 75% prewarning: "Change filter!"

2. Switching point filter contamination 100% shutdown (after end of cycle).

The contamination warning must be suppressed in the first 15 minutes after the hydraulic unit has been switched on in order to avoid incorrect warnings due to cold oil.

4.10.5 Other Instructions

Partial-flow filters shall be preferred.

Reverse filters with bypass valve are permitted only in connection with pressure filters.

Pressure filters must only be used with a bypass valve. Pressure filter as protection filter only without bypass valve and only with high-pressure filter elements.

Filters with screw cartridges and suction filters are not permitted.

Filters behind safety valves are not permitted.

4.11 Heat Exchangers

The use of heat exchangers must be coordinated with the client according to local conditions.

Only safety heat exchangers are permitted in conjunction with drinking water/river water.



Last updated:

09/2016


Immersion heaters (surface power density must not exceed 0.7 W/cm²) and oil preheaters must be protected with a safety thermostat or dry running protection.

4.12 Hydraulic Fluid

4.12.1 Use

The hydraulic fluid used in the hydraulic system must not be used for lubrication.

Only hydraulic oils to DIN 51524-2 must be used which do not attack lead or lead-containing bearing materials.

4.12.2 Flow Rate

The flow rate level of the hydraulic fluid in the pipes must ensure that the functions and desired performance of the machinery are achieved as specified at any operating temperature. Standard values for the flow rate level of the hydraulic fluid must be fulfilled.

The hydraulic fluid used in the hydraulic system must not be used for lubrication.

4.12.3 Fire Hazard

If there is a fire hazard for the machinery, the hydraulic fluid must be hardly inflammable.

4.13 Identification


Identification signs must be

engraved or etched from aluminium

easily legible

attached permanently at a visible point

next to the components, sub-assemblies and devices

next to the installation room in the case of equipment that is installed hidden

The identification signs must not be attached to components, sub-assemblies and devices which may be replaced.

4.13.2 Additional Instructions

The following instructions have to be observed for the identification of the hydraulics of the machinery:

for valves, the controlled function (e.g. “release clamping device”) must be included beside the identification (e.g. Pos. No.) according to the circuit diagram

for pumps, the type of use (e.g. main pump, feed pump, control pressure pump) must be indicated

for pressure accumulators, the gas preload pressure must be indicated

electric designations must be indicated according to the circuit diagram

for oil tanks, the type and quantity of the hydraulic fluid must be indicated



Last updated:

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for appliance couplers (line sockets), the detachable parts must also be identified with labels

for cylinders, the set pressure and the cylinder designation must be indicated

The pressure measurement points must be marked clearly at the machinery in compliance with the connection diagram with desired pressures indicated in bar (e.g. MM1, MM2, ...).


4.14.1 Requirements - Europe

As to 3.2 Requirements for Pressure Vessels, Pipes, Equipment and Hydraulic Accumulators

Directive 97/23/EC of the European Parliament and the Council on pressure equipment

Directive 87/404/EEC on simple pressure vessels

AD 2000 Z1 Code (AD: Working Team Pressure Vessels).

As to 7.3 Electric Requirements (Valves)

DIN EN 175301-803 Detail Specification: Rectangular connectors -

Flat contacts with 0.8 mm thickness, undetachable locking screw

4.14.2 Legal Requirements - Germany

As to 3.1 General Requirements (Normative References)

DIN 24346 Hydraulic fluid power; hydraulic systems;

general rules for application

As to 3.2 Requirements for Pressure Vessels, Pipes, Equipment and Hydraulic Accumulators

All hydraulic accumulators are subject to the Ordinance on Industrial Safety and Health §15 as well as the corresponding Technical Rules for Pressure Vessels (TRB).

As to 4.2 Design (Fluid Tanks)

DIN 24339 Hydraulic fluid power; hydraulic tanks made of steel; dimensions,

requirements, inspection; nominal sizes 63 to 1250 (container form AN, cover form C)

As to 7.1 General Requirements (Valves)

DIN 24340-2 Hydraulic valves; mounting surfaces and connecting plates for



Last updated:

09/2016


directional control valves

DIN ISO 7368 Hydraulic fluid power; two-port slip-in cartridge valves; cavities

As to 9.1 Pipes

DIN EN 10220 Seamless and welded steel tubes - Dimensions

and masses per unit length

DIN EN ISO 1127 Stainless steel tubes - Dimensions, tolerances and

conventional masses per unit length

As to 9.2 Hose Assemblies

DIN 20066 Hydraulic fluid power - Hose assemblies - Dimensions,

requirements

Hose assemblies must be checked regularly acc. to DIN.

As to 10.1 General Requirements (Filters)

DIN 24550 Fluid power - Hydraulic filters

As to 12.1 Use (Hydraulic Fluid)

DIN 51524-2 Pressure fluids - Hydraulic oils - Part 2:

HLP hydraulic oils; Minimum requirements



Last updated:

09/2016



Designation: Manufacturer: Remark:

Valves Bosch-Rexroth

Cylinders Bosch-Rexroth

Pumps Bosch-Rexroth

Pressure accumulators HYDAC,

Bosch-Rexroth

Proportional amplifiers Völkel,

Bosch-Rexroth



Last updated:

09/2016


5 Pneumatics Amendments:

Revision


Date

1 59-64 Original 2010-11-19

Table of contents:

5 .................. Technical Delivery Instructions Pneumatics ....................................................... 59



5.2.1 ........... Delivery Instructions ........................................................................................... 60

5.2.2 ........... Design ................................................................................................................ 60

5.2.3 ........... Accessibility ....................................................................................................... 60

5.2.4 ........... Outgoing air ....................................................................................................... 60



5.3.2 ........... Requirements For Pressure Vessels, Pipes And Equipment .............................. 60

5.4 .............. Cylinders ............................................................................................................ 60

5.5 .............. Valves ................................................................................................................ 61


5.5.2 ........... Solenoid Valves ................................................................................................. 61

5.5.3 ........... Pressure Control Valves ..................................................................................... 61

5.5.4 ........... Flow Control And Shut-Off Valves ...................................................................... 61

5.6 .............. Line System ....................................................................................................... 61


5.6.2 ........... Maintenance Unit ............................................................................................... 61

5.6.3 ........... Line Connections ............................................................................................... 62

5.6.4 ........... Sound Dampers ................................................................................................. 62

5.6.5 ........... Pressure Gauges ............................................................................................... 62

5.7 .............. Identification ....................................................................................................... 62


5.7.2 ........... Additional Instructions ........................................................................................ 62

5.8 .............. Appendix: Co-applicable Documents .................................................................. 63

5.8.1 ........... International Requirements ................................................................................ 63

5.8.2 ........... Requirements - Europe ...................................................................................... 63

5.9 .............. List Of Approved Suppliers ................................................................................. 64



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These technical instructions shall apply specifically to the design of the pneumatic system of the machinery. They complement the provisions outlined in "General" of the Technical Delivery Instructions of IA and are valid in conjunction with them for all IA plants.


5.2.1 Delivery Instructions

You may only use components, sub-assemblies and devices which are specified in the Lists of Approved Suppliers.

Any deviations are permitted only after consultation with the ordering party and confirmation in writing.

5.2.2 Design

The pneumatic system must be designed and monitored during operation so that its proper function is ensured at 90% of the supply line pressure at the site where the machinery is erected.

5.2.3 Accessibility

All components and sub-assemblies must be easily accessible for maintenance and repair and they must not be hidden by pipes and hose assemblies or other components/sub-assemblies.

5.2.4 Outgoing air

Residues from oil mist are not allowed in the outgoing air.



The basis of this Technical Equipment Requirement for the pneumatic system of the machinery is ISO 4414 which has to be complied with, including its recommendations and additional requirements.


5.3.2 Requirements For Pressure Vessels, Pipes And Equipment

For requirements refer to the Technical Equipment Requirements for Hydraulic Systems. Pipe installations using pressfittings are not permitted!

5.4 Cylinders

Cylinders with standard strokes must be installed in the pneumatic system of the machinery in compliance with DIN ISO 6432/DIN ISO 15552.

Every cylinder has to be designed that the counterforce is max. 70% of the effective cylinder piston force.



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The number of variants (number of different types) of the cylinders used in the machinery must be as low as possible.

5.5 Valves


Valves must be installed grouped on connection plates, if possible.

The bus system has to be agreed with the client.

If the master switch has been switched off, the pneumatic supply must be interrupted by an automatically closing valve. Pressure-accumulating parts must be exhaust ventilated.

5.5.2 Solenoid Valves

Electric line sockets acc. to DIN EN 175301-803, solenoid voltage 24 V DC with LED display and protective circuit to be used.

A solenoid valve must also allow manual operation (in emergencies); accidental operation must not be possible though.

5.5.3 Pressure Control Valves

The pressure control valves must be provided with secondary deaeration and a pressure gauge showing the secondary pressure.

5.5.4 Flow Control And Shut-Off Valves

Flow control and shut-off valves must be provided to permit defined setting of the speeds which are to be achieved with pneumatic drives.

5.6 Line System


The energy supply provided by the customer for all installations must always come in from the top.

Pipes, hoses and cables must be bundled in vertical cross-rails and led downwards.

For this reason, all connections of the machinery must be joined in one place to the extent possible.

If several connections of one type of power are required, the supplier has to position them in one place as well. The internal piping/cabling is included in the contractor's scope of delivery.

The main compressed-air connection of mobile devices or small equipment shall be provided with a 1/2" male quick coupling.

If sub-distribution connections for compressed-air guns, pneumatic wrenches, etc. are used on the machinery, a quick-action coupling is to be used as closure coupling (female).

5.6.2 Maintenance Unit

The pneumatic system must be provided with a maintenance unit which is installed at an easily accessible position of the machinery.

The maintenance unit must contain the following components/sub-assemblies:



Last updated:

09/2016


shut-off valve (coll. stopcock) with vent,

filter,

pressure controller, lockable, with pressure gauge,

start-up valve for preventing uncontrolled movements (to protect operators and the machinery),

oiler (if required),

water separator.

5.6.3 Line Connections

The pneumatic system must not have any line connections at points that are difficult to access.

5.6.4 Sound Dampers

All vents of the pneumatic system must be provided with sound dampers. Only low-noise nozzles and orifices must be used. They must not be installed at head level.

5.6.5 Pressure Gauges

Adjustable pressures must allow being read easily on a pressure gauge or minimeters.

The pressure gauge must indicate the minimum pressures with green marks and the maximum pressures with red marks.

5.7 Identification


Identification signs must be

engraved or etched from aluminium

easily legible

attached permanently at a visible point

next to the components, sub-assemblies and devices

next to the installation room in the case of equipment that is installed hidden

The identification signs must not be attached to components, sub-assemblies and devices which may be replaced.

5.7.2 Additional Instructions

The following instructions have to be observed for the identification of the pneumatics of the machinery:

The function identification must be attached in compliance with the electric diagram as component identification and in clear text directly on the component or sub-assembly.

The pressure measurement points must be marked clearly at the machine/equipment in compliance with the connection diagram with desired pressures indicated in bar (e.g. MM1, MM2, ...).



Last updated:

09/2016



5.8.1 International Requirements

As to 3.1 Normative References, General Requirements

ISO 4414 Pneumatic Fluid Power - General Rules Relating to Systems

As to 4 Cylinders

DIN ISO 6432 Pneumatic fluid power; single rod cylinders;

10 bar (1000 kPa) series; bores from 8 to 25 mm; mounting dimensions

DIN ISO 15552 Pneumatic fluid power - Cylinders with detachable

mountings, 1000 kPa (10 bar) series, bores from 32 mm to 320 mm - Basic, mounting and accessories dimensions

5.8.2 Requirements - Europe

Safety valves with a CE marking have to be used which were inspected by a specified body.

As to 5.2 Solenoid Valves

DIN EN 175301-803 Detail Specification: Rectangular connectors -

Flat contacts with 0.8 mm thickness, locking screw

not detachable



Last updated:

09/2016



Designation: Manufacturer: Remarks

General Festo/ SMC



Last updated:

09/2016


6 Technical Documentation Amendments:

Revision


Date

1 65-74 Original 2010-11-19

2 67 Language 2016-06-01

Table of contents:

6 .................. Technical Delivery Instructions Technical Documentation .................................. 65



6.2.1 ........... Scope and Time of Delivery ............................................................................... 67

6.2.2 ........... Language ........................................................................................................... 67

6.2.3 ........... Structure ............................................................................................................ 67

6.2.4 ........... Format of Documents ......................................................................................... 68

6.2.5 ........... Filing of Documents............................................................................................ 68

6.2.6 ........... Marking .............................................................................................................. 68

6.2.7 ........... Revisions and Modifications ............................................................................... 68

6.2.8 ........... Filling In Labeling Fields ..................................................................................... 69


6.4 .............. Contents of Technical Documentation ................................................................ 69

6.4.1 ........... General .............................................................................................................. 69

6.4.1.1 ........ Operating Instructions ........................................................................................ 69

6.4.1.2 ........ Operator Maintenance Plan ................................................................................ 69

6.4.1.3 ........ Maintenance Instructions ................................................................................... 69

6.4.1.4 ........ Service and Maintenance Plan ........................................................................... 69

6.4.1.5 ........ Setup Instructions .............................................................................................. 70

6.4.1.6 ........ Transport, Installation and Assembly Instructions ............................................... 70

6.4.1.7 ........ Foundation Drawings ......................................................................................... 70

6.4.1.8 ........ Installation Plan / Layout .................................................................................... 70

6.4.1.9 ........ Function Charts .................................................................................................. 70

6.4.1.10 ..... Spare and Wear Parts Lists ................................................................................ 70

6.4.1.11 ..... Workpiece-Specific Accessories, Production Resources and Tools, Machining Plan .................................................................................................................... 71

6.4.1.12 ..... Machine Setting Data ......................................................................................... 71

6.4.1.13 ..... Vendor Documentation / Product Description ..................................................... 71

6.4.1.14 ..... Certificates and Licenses ................................................................................... 71 6.4.2 ........... Electrical Engineering ......................................................................................... 71

6.4.2.1 ........ Circuit Diagrams / Parts List ............................................................................... 71



Last updated:

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6.4.2.2 ........ Manuals and System Descriptions ..................................................................... 72

6.4.2.3 ........ Interface Description .......................................................................................... 72

6.4.2.4 ........ Electrical Test Reports ....................................................................................... 72 6.4.3 ........... Mechanics .......................................................................................................... 72

6.4.3.1 ........ General Assembly Drawing / Parts Lists ............................................................. 72

6.4.3.2 ........ Subassembly Drawing / Parts Lists .................................................................... 72 6.4.4 ........... Hydraulic System ............................................................................................... 73

6.4.4.1 ........ Circuit Diagrams / Parts Lists ............................................................................. 73 6.4.5 ........... Pneumatic System ............................................................................................. 73

6.4.5.1 ........ Circuit Diagrams / Parts Lists ............................................................................. 73 6.4.6 ........... Occupational and Environmental Safety and Fire Protection .............................. 73

6.4.6.1 ........ EC Declaration of Conformity / Risk Assessment ............................................... 73

6.4.6.2 ........ Test Reports / Certificates / Overview List .......................................................... 73 6.5 .............. Instructions for Technical Documentation on Data Storage Media ...................... 73

6.6 .............. Other Applicable Documents .............................................................................. 74



Last updated:

09/2016



The requirements specified herein apply particularly to the development of the technical documentation of the machine / machine system. They complement the provisions outlined in Chapter “General” and all other technical equipment requirements defined in the Technical Delivery Instructions of IA and are valid in conjunction with them for all IA factories.


6.2.1 Scope and Time of Delivery

One copy of the technical documentation must be delivered in the adequate language (see subsection 2.2) on paper and on a data storage medium.

A preliminary documentation including at least operating instructions, declaration of conformity and circuit diagrams must be provided when the machine/machine system is delivered/commissioned.

Scope and date of delivery of the final technical documentation must be coordinated with the customer.

6.2.2 Language

All documents must be drawn up in the national language of the customer’s site of installation and in English (and German) language.

6.2.3 Structure

The technical documentation must be structured. The folder structure defined by IA shall be binding.

Folder structure

Mxxxx

00-Preliminary Documentation

01-General

01-Operating Instructions

02-Operator Maintenance Plan

03-Maintenance Instructions

04-Service and Maintenance Plan

05-Setup Instructions

06-Transport and Assembly Instructions

07-Foundation Drawings

08-Installation Plan-Layout

09-Function Charts

10-Spare and Wear Parts Lists

11-Machine Setting Data

12-Vendor Documentation

13-Certificates Licenses Records



Last updated:

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02-Electrical Engineering

01-Circuit Diagrams

02-System Descriptions

03-Interface Description

03-Mechanics

01-General Assembly Drawings and Parts Lists

02-Subassembly Drawings and Parts Lists

04-Hydraulic System

05-Pneumatic System

06-Occupational and Environmental Safety and Fire Protection

07-IA-Internal Documentation

6.2.4 Format of Documents

As a rule, the format of the documents included in the technical documentation must be coordinated with the customer.

Subject to the customer’s agreement, all documents - except for drawings - must preferably be created in A4 format (according to DIN EN ISO 216).

Drawings contained in the technical documentation must be produced at least in A3 format (according to DIN EN ISO 216) or original size. All drawings must be clearly legible.

6.2.5 Filing of Documents

The documents must be grouped in sturdy file folders or ring binders and include table of contents and register (including vendor documentation).

Documents in formats larger than A3 must have reinforced holes.

To the extent described in Annex 1 to the technical documentation, documents must be delivered in clear plastic pockets.

6.2.6 Marking

The customer must be consulted about how to mark the spine labels of the folders, or the folders must be marked according to the customer’s specification (e.g. indicating the machine number).

The file folders must be numbered in sequence, stating also the total number.

6.2.7 Revisions and Modifications

All changes made to the machine/machine system during manufacture, assembly, installation, startup, and trial operation at the customer's site must immediately be added to the relevant technical documents by the contractor.

The final technical documentation must match the state of the machine/machine system at the time of final acceptance.

If at a later point of time, which may even be after expiry of the warranty period, it is discovered that the documents provided be the contractor do not match the delivered object, the contractor must bear the costs for any revision or compensation delivery of the technical documents.



Last updated:

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Unless otherwise agreed with the customer, any changes, extensions or modifications to existing machines/machine systems must be described in the relevant technical documents, using the original drawing and designation system.

6.2.8 Filling In Labeling Fields

Filling in the labeling fields in the documents is part of the scope of delivery. Requirements regarding labeling shall be coordinated with the customer.


In principle, the provisions with regard to normative references listed in “General” shall apply.

6.4 Contents of Technical Documentation

6.4.1 General

6.4.1.1 Operating Instructions

The requirements outlined in the Machinery Directive must be observed for the operating instructions.

The operating instructions must include all necessary information on how the machine/machine system can be reset to home position or restarted after a malfunction.

Furthermore, all operating station functions (initiated both by means of switching elements as well as visual display) must be described along with any interlocks to be observed, too.

6.4.1.2 Operator Maintenance Plan

The operator maintenance plan outlines the inspection and maintenance work to be done by the operator. If applicable, the relevant contractor’s form sheet shall be used.

All necessary/prescribed operations, including those defined by the subcontractors and suppliers, must be compiled in a central list. Otherwise, they are not binding to the customer.

6.4.1.3 Maintenance Instructions

Special information on technically correct inspection, maintenance and repair of the machine/machine system. Diagnostic aids, fault/error lists and detailed fault/error descriptions in case of malfunctions.

This also includes a list of necessary project planning software (e.g. for visual displays, axis assemblies, frequency converters) and communication software.

Any necessary adjustment and alignment aids for machine components must be listed, too.

6.4.1.4 Service and Maintenance Plan

The service and maintenance plan outlines the inspection and maintenance work to be done by the maintenance technician. If applicable, the relevant customer’s form sheet shall be used.

All necessary/prescribed operations, including those defined by the subcontractors and suppliers, must be compiled in a central list. Otherwise, they are not binding to the customer.



Last updated:

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6.4.1.5 Setup Instructions

Description of an optimally synchronized setup process.

6.4.1.6 Transport, Installation and Assembly Instructions

Information on proper transport, installation, and assembly must be added to the technical documentation.

6.4.1.7 Foundation Drawings

The basic requirements on the foundation (stiffness, recesses, precision, loads in general and at specific points) must be entered to the foundation drawings.

The customer must specify the main axes X, Y for the dimensions, based on the particular company system. All dimensions must refer to these axes and heights.

6.4.1.8 Installation Plan / Layout

Installation plan and layout of the machine / machine system based on the customer's specifications. A complete and an abridged version must be delivered.

If structural calculations are required and ordered by the customer, they must be included with the delivery.

6.4.1.9 Function Charts

The function charts must comply with DIN EN 60848. They must clearly outline the ON/OFF conditions, as well as the control and interlocking conditions.

The function chart must mainly contain: Function sequence, mechanical and drive specifications, auxiliary device specifications, and a brief description of the controls if they are hydraulically, pneumatically or electrically operated.

Parts that are not included in the contractor's scope of delivery must be identified in the function chart.

The function diagram must be comprehensive enough that the electric control system can be implemented based on this description.

A functional description shall be added to the function chart at the customer’s request.

6.4.1.10 Spare and Wear Parts Lists

Parts and components that the contractor believes should be stored at the customer's site are compiled in a central list. This also applies to purchased parts and delivery scopes of subcontractors.

Among other things, the spare and wear parts lists must contain:

Name of the manufacturer of the part or component

Manufacturer’s order number

Designation

Quantity

Identification as spare part (S) or wear part (W)

The format of the lists must be coordinated with the customer.



Last updated:

09/2016


6.4.1.11 Workpiece-Specific Accessories, Production Resources and Tools, Machining Plan

Scope and procedures must be coordinated with the customer.

6.4.1.12 Machine Setting Data

These include setting parameters, such as pressure values, flow volumes, parameter lists for electric systems, and workpiece-specific data.

6.4.1.13 Vendor Documentation / Product Description

The technical documents of assemblies and components provided by subcontractors, such as control components, measurement control units, servo-valves, etc. must be included in the delivery and if necessary filed separately. These documents must contain setting information and functional descriptions.

Providing general catalogs is not sufficient.

6.4.1.14 Certificates and Licenses

These include certificates and licenses, such as certificates of origin and software licenses.

6.4.2 Electrical Engineering

6.4.2.1 Circuit Diagrams / Parts List

The circuit diagram as well as the parts list and its layout must comply with DIN EN 61 082.

Create them with a common E-CAD system. The documentation should be structured as described below and contain at least the following:

Cover sheet

Supplements/comments (with order data, wire colors, fuse protection, performance data, software and software versions used)

Table of contents

Amendments list

Design drawings of switchgear cabinets

Mounting plates, consoles and terminal boxes; disposition plan of the components outside the switchgear cabinet; circuit diagrams; routing diagrams/signal exchange; installation plan, connection diagrams and terminal diagrams

Parts list with manufacturer data.

The following information must be included in the circuit diagrams: Voltages, frequency, rated currents of fuses, ratings and settings (e.g. motors, etc.)

Bus structures and hardware setup of the visual display system must be also represented in the circuit diagram.

The delivered hardware and firmware versions as well as the hardware setting (DIL switches) must be noted in the circuit diagram for all intelligent modules (also PC).

Component and location identification must refer to location and sheet.



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Example: H1+ K1 - 7 K24

K24 = Designation: Serial number

7 = Designation: Sheet number in circuit diagram

K1 = Place

H1 = Location

The PLC inputs/outputs must be depicted as a linked, continuous block.

The designation on sensor/actuator level and PLC / control unit must be intuitively consistent/uniform.

6.4.2.2 Manuals and System Descriptions

A basic software license must be included in the delivery for all operating systems, visualization systems and the software of all programmable systems.

The scope of delivery includes manuals and system descriptions, installation disks, boot disks, drivers used (GSD files), the description of storage structure/files, and interfaces.

As a rule, the PLC programs must be saved as S7 projects and delivered on data storage media.

Hard drives of PC-based systems (e.g. robot control units) must be delivered as hard drive images on data storage media.

The complete documentation must be delivered on data storage media in PDF format. Hydraulic, pneumatic and electric diagrams must be provided additionally in a common CAD format.

6.4.2.3 Interface Description

Interface descriptions must be coordinated among the contractors and submitted for approval. They must be incorporated in the documentation of both contractors. The designation and pin configuration must be uniform.

6.4.2.4 Electrical Test Reports

These include, among other things, the electrical test report according to DIN EN 60204, the test report on insulation resistance, the test report on the loop impedance of the grounding conductor, and the Profibus measuring report

6.4.3 Mechanics

6.4.3.1 General Assembly Drawing / Parts Lists

The general assembly drawings and, if possible, the exploded drawings must clearly show how to dismount and mount the components. There must be a reference to the parts list.

6.4.3.2 Subassembly Drawing / Parts Lists

Subassembly drawings must be made stating the weights of the individual subassemblies, transport plan, suspension points, load and service life data.



Last updated:

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6.4.4 Hydraulic System

6.4.4.1 Circuit Diagrams / Parts Lists

Circuit diagrams and parts lists must comply with DIN ISO 1219.

All electrical devices must be listed that have a functional relation to the hydraulic assemblies. For larger or more complex production facilities, the diagrams must be structured in functional groups.

The circuit diagrams must show the plate-mounted or interlinked valves according to their local position, indicating also item number, electrical designation and the functions they trigger.

In the case of extensive and large-scale systems, the pipes and connections shall be depicted in the installation plan, upon agreement with the customer.

6.4.5 Pneumatic System

6.4.5.1 Circuit Diagrams / Parts Lists

Circuit diagrams and graphical symbols must comply with DIN ISO 1219.

All electrical devices must be listed that have a functional relation to the pneumatic assemblies. For larger or more complex production facilities, the diagrams must be structured in functional groups.

The circuit diagrams must show the plate-mounted or interlinked valves according to their local position, indicating also item number, electrical designation and the functions they trigger.

The diagrams must include information about compressed air consumption, cross-sectional areas of connections, etc.

6.4.6 Occupational and Environmental Safety and Fire Protection

6.4.6.1 EC Declaration of Conformity / Risk Assessment

The EC Declaration of Conformity and Risk Assessment (in consideration of DIN EN ISO 12100-1, EN 954 Part 1 and EN ISO 14121) must be included in the delivery.

6.4.6.2 Test Reports / Certificates / Overview List

When installing pressure vessels, non-contact protective devices, presses and other equipment subject to mandatory testing, the contractor must complete the overview list (see Annex 2 Overview List).

Components subject to test intervals must be listed and agreed upon.

Any necessary test certificates, e.g. documents of approved inspection bodies (such as TÜV), seal integrity tests, noise measurement records, must be included in the delivery.

Documents subject to the Pressure Equipment Directive, AD 2000 standards, or the Ordinance on Industrial Safety and Health must be submitted at the startup at the latest.

6.5 Instructions for Technical Documentation on Data Storage Media

The machine number shall be entered on the upper-most level. The customer will assign such numbers.



Last updated:

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The files must be stored on the lowest level of the folder structure. The file name must start with the designation in plain text.

For drawings, the file name is: designation, drawing number.

For parts lists, the file name is: designation, drawing number, parts list.

Non-embedded images must be delivered in JPG format.

6.6 Other Applicable Documents

Standard Designation

DIN EN ISO 216 Writing paper and certain groups of printed matter - trimmed sizes - A and B series and indication of direction of machine travel

DIN EN 60848 GRAFTEC - Specification language for sequential function charts

DIN EN 61082 Documents of electrical engineering

DIN EN 60204 Safety of machinery - Electrical equipment of machines - Part 1: General requirements

DIN ISO 1219-1 Fluid power systems - graphic symbols and circuit diagrams -

Part 1: Graphic symbols for conventional use and data processing applications

DIN ISO 1219-2 Fluid power systems - Graphic symbols and circuit diagrams -

Part 2: Circuit diagrams

DIN EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design -

Part 1: Basic terminology, methodology

DIN EN 954-1 Safety of machinery - Safety related parts of control systems -

Part 1: General principles of design

DIN EN ISO 14121 Safety of machinery - Risk assessment



Last updated:

09/2016


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IDEAL Automotive is a reliable supplier and manufacturer of solution-oriented product developments. An efficient, resource, cost and time saving production is very important for our products.

IDEAL Automotive GmbH Kapellenfeld 1 D - 96138 Burgebrach

Administrative headquarters: Margaretendamm 34 D - 96052 Bamberg

How to contact us:

Phone: +49 (0)951 78-0 Fax: +49 (0)951 78-204 E-mail: [email protected] www.ideal-automotive.com

IDEAL Automotive –

International system supplier and development partner for the automotive industry