MACHINE SAFETY I


By Darren Hugheston-Roberts, senior manager within Industrial and Digital Solutions at TÜV SÜD


ngress protection (IP) testing reduces the risk of product failure in the field by assessing the degree of protection provided against mechanical intrusion, dust, accidental contact, and water entering casings and enclosures. However, sourcing equipment that reacts well has its challenges as, for example, even the smallest sealing flaws will result in water ingress into machinery. As machinery can deteriorate, malfunction or become unsafe when water or dust enters, it is vital to ensure that it has the correct protection for its intended use. IEC 60529 - Degrees of Protection provided by IP Code - is the standard that must be followed. It is applicable for commercial electrical equipment rated for voltages not exceeding 72.5kV. The standard contains the criteria for assessing equipment to its appropriate IP code, there also are standards for specific industry sectors, such as food processing and pharmaceuticals. This ensures a product’s protection and resistance against the ingress of solid materials and liquids, so that machinery can handle the environment within which it has been installed. For example, for machinery end-users the protection rating gives an assurance that the equipment can be left outside without the risk of damaging electrical components or increasing the electrical hazard risks to personnel.


CLASSIFICATIONS


The International Electrotechnical Commission’s (IEC) ingress protection (IP) ratings grade an enclosure’s level of resistance to items entering it, defining three different types of ingress protection that an enclosure could provide against:


1. The protection of human access to hazardous components within an enclosure.


2. The protection of equipment from solid objects including dust.


3. The protection provided by an enclosure against the ingress of water.


The IP code classifies the effectiveness of enclosures against the intrusion of solid bodies and/or liquid. The code consists of the letters IP followed by two


ENSURING THE INTEGRITY OF MACHINE ENCLOSURES


digits and an optional letter. The first digit indicates the level of protection that the enclosure provides against access to hazardous parts and the ingress of solid foreign objects. It is rated on a scale from 0 to 6:


0 - no protection against the penetration of solid particles, objects or dust.


1 - the equipment is protected against any solid object larger than 50 mm.


2 - the equipment is protected against any solid object larger than 12.5 mm.


3 - the equipment is protected against any solid element larger than 2.5 mm. For example, if a machinery operator attempted to insert fine tools etc.


4 - the equipment is protected against any solid object larger than 1 mm. For example, larger types of tools or screws etc.


5 – the equipment is partially protected against dust. This rating means that while dust can enter crevices within the equipment, it cannot damage it, and that contact is not possible.


6 – the equipment is completely dustproof, so that dust is unable to enter crevices so that the equipment cannot be soiled or damaged.


The second digit indicates protection of the equipment inside the enclosure against harmful ingress of liquids, using a scale from 0 to 9. This covers both the amount of water and the depth of immersion, including the power of a jet. The additional letter can be appended to classify only the level of protection against access to hazardous parts by persons:


0 - no protection against moisture or any liquid coming into contact with the equipment.


1 – the equipment is protected against liquid falling vertically only.


2 – the equipment is protected against drops falling at an angle of 15 degrees.


12 AUTUMN 2025 | INDUSTRIAL COMPLIANCE


3 – the equipment is protected against liquid sprays in all directions, provided that they do not exceed an angle of 60 degrees.


4 – the equipment is protected against splashing.


5 – the equipment is protected against water projections.


6 – the equipment protected against powerful water jets. For example, if equipment is being cleaned with a high-pressure device.


7 – the equipment is waterproof up to a depth of 1 metre.


8 – the equipment is waterproof beyond a depth of 1 metre, so water may be able to seep into the equipment, but it cannot damage it.


9 – the equipment can resist high-pressure hot water from different angles.


For example, IP69 rated machinery is effective against powerful high-temperature water jets used in environments that require a more stringent washdown, while IP66 is effective against powerful water jets. Another example is that the necessary protection rating for motor units with integrated electronics will vary according to their end use. As with all equipment this includes considering location (indoor or outdoor), dust exposure and water infiltration etc.). Water seepage can create a risk of machine fire, or dust can damage the equipment over time. So, a protection rating of IP65 should be considered as it indicates complete airtightness and a good level of water resistance.


Equipment installed in outdoor locations must be protected against weather extremes, as well as the potential of physical impact. A rating for industrial enclosures located outside can extend as high as IP68. This confirms prevention of ingress from the equivalent of high-pressure water jets, as well as protection when equipment is immersed for a stated period. It also gives an assurance of protection from dust particle contamination.


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