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An introduction to
EN 60204-1
Stewart Robinson
TÜV SÜD Product Service
TÜV SÜD Product Service
BS EN 60204-1:2006+A1:2009
Safety of Machinery - Electrical Equipment of Machines
Part 1: General Requirements.
Defined Scope
This part of IEC 60204 applies to the application of electrical and
electronic equipment and systems to machines not portable by hand
while working, including a group of machines working together in a coordinated manner, but excluding higher level systems aspects (e.g.
communications between systems).
The standard defines the basic terminology and specifies general design
methods to help designers and manufacturers in achieving safety in the
design of machinery.
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EN 60204-1 Scope
• EN 60204-1 gives safety guidance and recommendations
on electrical equipment for “non-portable” machinery.
• EN 60204-1 refers to machinery that operates with nominal
supply voltages below 1,000V for alternating current or
1,500V for direct current
• EN 60204-1 covers control circuits and control functions,
wiring practices and protection against electrical shock
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EN 60204-1 Out of scope
• BS EN 60204-1 does not include guidance on:• machinery designed for outdoor use in mines and in
flammable atmospheres
• machinery that produces explosive material
• machinery that operates as a sewing machine.
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EN Standards and European Directives
EN 60204-1 is harmonised against the Machinery Directive
and the Low Voltage Directive
“A” type apply to all machines.
“B” type are designed to
promote safety and split in to
B1 and B2.
“C” type apply to a specific
type of machine.
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EN 60204-1 and BS 7671 (IET Wiring Regulations)
• BS 7671 - Requirements for electrical installations.
IET Wiring Regulations. Seventeenth edition.
– The guidelines cover all aspects of designing and installing electrical
wiring and temporary or permanent power systems in buildings
• As a general rule BS 7671 applies up to the connection of
the electrical supply to the machine isolator. EN 60204-1
applies from that point onwards
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EN 60204-1 Contents
• There are 18 clauses in the normative part of the standard
1.
2.
3.
4.
5.
6.
7.
8.
9.
Scope
Normative references
Definitions
General requirements
Incoming supply conductor terminations and devices for
disconnecting and switching off
Protection against electric shock
Protection of equipment
Equipotential bonding
Control circuits and control functions
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EN 60204-1 Contents
10.Operator interface and machine-mounted control devices
11.Controlgear: location, mounting, and enclosures
12.Conductors and cables
13.Wiring practices
14.Electric motors and associated equipment
15.Accessories and lighting
16.Marking, warning signs and reference designations
17.Technical documentation
18.Verification
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Definitions - Examples
Barrier
• A part providing protection against direct contact from any
usual direction of access.
Control Circuit (of a machine)
• A circuit used for the control, including monitoring, of a
machine and the electrical equipment.
Control Device
• A device connected into the control circuit and used for
controlling the operation of the machine (for example position
sensor, manual control switch, relay, contactor, magnetically
operated valve).
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Definitions - Examples
Control gear
• Switching devices and their combination with associated control,
measuring, protective, and regulating equipment, also
assemblies of such devices and equipment with associated
interconnections, accessories, enclosures, and supporting
structures, intended in principle for the control of electrical
energy consuming equipment.
Direct opening action (of a contact element)
• achievement of contact separation as the direct result of a
specified movement of the switch actuator through non-resilient
members (for example not dependent upon springs)
[IEC 60947-5-1, K.2.2]
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Definitions - Examples
Emergency stop device
• Manually actuated control device used to initiate an emergency
stop function
Emergency switching off device
• Manually actuated control device used to switch off the supply of
electrical energy to all or a part of an installation where a risk of
electric shock or another risk of electrical origin is involved
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Definitions - Examples
Failure
• Termination of the ability of an item to perform a required
function.
Fault
• State of an item characterized by inability to perform a required
function, excluding the inability during preventive maintenance or
other planned actions, or due to lack of external resources.
“Failure” is an event, as distinguished from “fault”, which is a state
In practice the terms fault and failure are often used synonymously
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Definitions - Examples
Live Part
• Conductor or conductive part intended to be energized in normal
use, including a neutral conductor.
Protective Bonding
• Equipotential bonding for protection against electric shock.
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Electrical Hazards
EN 60204-1: Chapter (6) and (7)
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Risk and Consequence
General Requirements:
• Risk due to electrical equipment is part of the risk assessment of
machine :
 Equipment failure leading to electrical shock.
 Control circuit failure leading to malfunction of the machine.
 Disturbance / interruption of the power source leading to
malfunction of the machine.
 EMC problems leading to malfunction of the machine.
 Release of stored energy leading to unexpected movements /
electrical shock.
 High surface temperatures leading to burns.
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Equipment selection
• Correct selection of electrical components and devices based upon
the:








Intended use.
Conformity to applicable standards.
Applied according to manufacturers instructions.
Suitability for purpose.
Ability to withstand the expected influence.
Appropriate for the intended use.
Suitably placed / positioned.
Readily identifiable with physical durable marking of the
component or device.
• Low voltage switchgear / control gear assemblies must comply with
IEC 60439.
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EMC Requirements
• Emission Protection.




Power supply filtering
Cable shielding.
Enclosures designed to minimize RF radiation.
RF suppression techniques – filters.
• Immunity Protection
 The design of functional earth bonding system.
 Connect sensitive electrical circuits to chassis.
 Connect the chassis to earth (PE) (low RF impedance, short
distance).
 Functional earthing conductor (FE) minimize common
disturbance.
 The separation of sensitive circuits from disturbance sources.
 Enclosures should be designed to minimize RF transmission.
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Electrical Supply and Isolation
A single incoming supply is recommended for machines.
However where a second supply for electronic equipment
with different voltage is required (for example from a 24vdc
PSU), this should be derived from main machine supply.
• Isolators must be readily accessible located between 0.6
m and 1.9 m above servicing level (with an upper limit
1.7 m recommended).
• Isolators should be lockable (LOTO type) and attached
to the machine i.e. on-board.
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Electrical Supply and Isolation
• They should disconnect all supplies!!!
• If not intended for emergency operation it is
recommended that the isolators should be coloured
black or grey.
• Emergency off isolators must be coloured red and
yellow.
• It must have one off (isolated) and one on position
marked with "O" and "I“.
• The isolator must be clearly identified as to its function
i.e. what it isolates.
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Electrical Supply and Isolation
• The isolator should ideally be interlocked to the panel
door. If this is not possible then IP2X protection must
be installed to all devices that remain live when to
door is opened.
• The isolator must not be mounted on the door itself.
• For large complex machinery there may be a need for
more than one incoming supply, therefore
consideration must be given to ensuring all supplies
can be appropriately isolated by the use of protective
interlocks for correct operation to prevent hazardous
situations arising, including damage to the machine.
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Electrical Supply and Isolation
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Supply Termination
Incoming Supply Terminations and the Neutral Conductor:
• All terminals for incoming supply connection must be
clearly identified e.g., L1, L2, L3, N, PE, and 400V (or the
appropriate voltage).
• Should be clearly indicated in technical documentation
installation diagram and circuit diagram.
• The Neutral should have a separate insulated terminal,
labelled ‘N’.
• There should be no connection between neutral and
protective bonding circuit inside electrical equipment .
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Protection against electric shock
Persons must be protected from electric shock from:
 Direct contact.
 Indirect contact.
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Protection against indirect contact
The risk in this case is an insulation fault between live
parts and exposed conductive parts.
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Protection by enclosures
Protection against electric shock by locating live parts inside enclosures
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Protection by enclosures
• The opening of the enclosure (i.e. opening doors,
lids, covers, and the like) must be by one of the
following:
– The use of a key or tool
– Disconnection of live parts inside before opening which
can be achieved by Interlocking the door with a
disconnecting device.
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Enclosures
 Enclosure doors should not be wider than 0.9m
 Ideally vertical hinges, with an angle of opening of
at least 95°
 There must be no opening between enclosures
containing electrical equipment and compartments
containing coolant, lubricating or hydraulic fluids,
or those into which oil, other liquids, or dust can
penetrate.
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Defeat Interlocked Isolator
• However it is allowed to defeat the interlock with a special
device or tool provided that:
• It is always possible to operate and lock the
disconnecting device in the off position.
 When closing the door, the interlock is automatically
restored.
• All live parts, used for resetting or adjusting while
connected must have at least IP2X protection.
• All other live parts inside the enclosure must have at
least IP1X protection.
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Protection by Insulation
• Live parts protected by insulation shall be completely
covered with insulation that can only be removed by
destruction.
• Such insulation shall be capable of withstanding the
mechanical, chemical, electrical, and thermal stresses
to which it can be subjected under normal operating
conditions.
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Potential sources of electrical shock from
wiring
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Protection Against Residual Voltages
• Live parts with a residual voltage of greater than
60v must discharge to 60v or less within 5 s (as
long as the discharge does not interfere with the
proper functioning of the equipment)
• If this is not possible then a durable warning notice
with required delay before opening time on it
should be fitted.
• In the case of plugs or similar devices the minimum
discharge time shall be less than 1 second,
otherwise protection to IP2X must be installed or
fitted.
• If neither can be achieved such as on removable
collectors on conductor wires, conductor bars, or
slip-ring assemblies then additional switching
devices or appropriate warning devices (warning
notice), must be installed or fitted.
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Appliance Classes
Appliance Class
Marking
Protection
Class 0
No Marking
Single level of insulation
no protective-earth
Chassis Connected to
Electrical Earth (PE)
Class I
Class II
"Class II"
„Double Insulated„
Double Insulated
Supplied from a SELV
Class III
(Separated Extra-Low Voltage)
Power Source.
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Protection against indirect contact - touch voltage
Use class II equipment or equipment with the
equivalent level of insulation.
This is provided by one or more of:
– Class II electrical devices or apparatus with double
insulation, reinforced insulation or by equivalent insulation
in accordance with IEC 61140.
– Switchgear and control gear assemblies with total insulation
in accordance with IEC 60439-1.
– Supplementary or reinforced insulation in accordance with
article 412 of IEC 60364-4-41.
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Protection by the use of Extra Low Voltage
• Protective Extra Low Voltage PELV:
 Limited voltage.
 25vac or 60vdc for dry conditions
 6vac or 15vdc in all other cases
 One side connected to protective earth
 Safe separation (by double or reinforced
insulation) of the PELV system to all non PELV
systems.
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Protection of equipment
Equipment should be protect against the effects of:
• Over current arising from a short circuit.
• Overload and / or loss of cooling of motors.
• Abnormal temperature.
• Loss of or reduction in the supply voltage.
• Over speed of machines / machine elements.
• Earth fault / residual current.
• Incorrect phase sequence.
• Over voltage due to lightning and switching surges.
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Control Functions - Examples
• Start Functions.
• Stop Functions.
• Operating Modes.
• Suspension of Safety Functions and / or
Protective Measures.
• Normal Operation.
• Other Control Functions such as Hold to Run
Devices, Two Hand Controls, and Enabling
devices.
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Start Functions
Shall only be possible only when all safety functions and / or
protective measures are in place and fully operational.
Where safety functions and / or protective measures cannot be
applied for certain operations, manual control of such
operations by hold-to-run controls, together with enabling
devices must be activated and fully controlled.
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Stop Functions
Stop functions fall into three categories
Stop category 0 - Stopping by immediate removal of the
power.
Stop category 1 - A controlled stop with power available to the
actuators to achieve the stop, then final removal of power.
Stop category 2 - A controlled stop with power left available to
the actuators.
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Stop Functions
• Emergency Stop where the emergency stop device
complies with EN ISO 13850
 An emergency stop can only be a category 0 or 1 stop.
 The initiation of the emergency stop must supersede all
modes of operation and other functions.
 There must be no automatic restart of the machine on reset.
• The switching of an ‘Emergency Off’ device (EMO) but only if the
hazard is from electricity.
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Recommended colours – Push buttons
Operator Interface and Machine-Mounted Control Devices –
Colour-coding for Push Buttons:
Colour Meaning
Explanation
Emergency
YELLOW
Abnormal
Actuate under
abnormal
condition
BLUE
Mandatory
Actuate when
requiring mandatory
action
GREEN
Normal
Actuate to initiate
normal conditions
WHITE
GREY
No specific
meaning
assigned
Examples of application Additional description
Actuate in hazardous
Emergency Stop / Off.
situation or
Initiation of emergency function.
emergency
RED
Intervention to suppress abnormal
condition .
Intervention to restart an interrupted
automatic cycle.
Reset function.
Start / On (preferred)
Stop / Off
For general initiation
of functions except Start / On
emergency stop
Stop / Off
Stop / On
Stop / Off (preferred)
BLACK
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RED is permitted also for only Stop / Off function, but it
is recommended that RED is not used near an
emergency operation device. RED shall not be used for
Start / On.
Reset push-buttons shall be BLUE, WHITE, GREY or
BLACK. Where they also act as a Stop / Off button, the
colours WHITE, GREY or BLACK are preferred with the
main preference being for BLACK.
WHITE, GREY or BLACK are the preferred colours for
push-button actuators that alternately act as Start / On
and Stop / Off push-buttons. Where WHITE for Start / On
and for Stop / Off is used a additional description shall be
used for the identification of this push-button actuator.
BS EN 60204-1:2006+A1:2009
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Examples of poor wiring
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Marking, Warning Signs and Reference
Designations:
Where appropriate the system / machine must be marked with
all mandatory signage and appropriate warning labels and
signs, and identifiers for cables etc., as previously discussed.
Some examples being:
Electrical Shock
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Hot Surface
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Verification and Testing
If there is no dedicated product standard (a ‘C’ standard) for the
machine the verifications shall always include the items a), b)
and f) and may include one or more of c) to e), in the following
order:
• a) Verification that electrical equipment complies with its
technical documentation.
• b) in case of protection against indirect contact by automatic
disconnection, conditions for protection by automatic
disconnection shall be verified
• c) Insulation resistance test.
• d) Voltage test.
• e) Protection against residual voltage.
• f) Functional tests.
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Verification and Testing – Functional Tests
f) Functional tests:
The functions of electrical equipment shall be tested,
particularly those relating to safety and safeguarding,
verification shall be completed for all steps
neccessary for safe intendend use.
Verification is more than just verification of electrical
parameters, it must also include the verification of all
mechanical safety devices such as interlocks,
ventilation, and cooling etc.........
It must also include verification of the operating
manual and manufacturers instructions as necessary.
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Verification and Testing – Documentation of
Results
Results of the inspections and verifications should reflect the
following:
The date of the test or inspection.
The actual results.
Whether or not the system or machines passed or failed the
test or inspection.
Any comments.
Any corrective action required or carried out.
The name and signature of tester.
It should also be remembered that where a portion of the
machine and its associated equipment is changed or modified,
that portion shall be verified and retested, as is appropriate.
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BS EN 60204-1:2006+A1:2009
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BS EN 60204-1:2006+A1:2009
Thank you for Your Time and for Listening
Any Questions
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Slide 47
Thank you for listening
For more information contact:
+44 (0)1642 345637
[email protected]
www.tuv-sud.co.uk/machinery
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