Guidline Machines ANG

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Verification of safety of machines according to IEC/EN 60204 Edition 5Version 1.0,Code no. 20 751 202

Verification of safety of machines according to IEC/EN 60204 Edition 5 1 Introduction.............................................................................................................3 1.1 The new IEC/EN 60204, Edition 5.....................................................................3 1.2 Scope of the standard .......................................................................................3 Verification of safety of machines ........................................................................5 Visual inspection ....................................................................................................6 Measurements ........................................................................................................7 4.1 Verification of protection against indirect contact by automatic disconnection ..7 4.1.1 Selection of machine status and test extent ...............................................7 4.1.2 Selection of test limits...............................................................................10 4.2 Insulation resistance........................................................................................16 4.2.1 Selection of test limits ....................................................................................16 4.3 4.3 High voltage test........................................................................................17 4.3.1 Selection of test limits ....................................................................................17 4.4 Residual voltage test .......................................................................................17 4.4.1 Selection of test limits...............................................................................17 Connection diagramms........................................................................................19 5.1 Protection against indirect contact...................................................................19 5.1.1 Continuity of protective conductors ..........................................................19 5.1.2 Fault loop impedance ...............................................................................20 5.1.3 Suplemmentary bonding ..........................................................................21 5.2 Insulation resistance........................................................................................22 5.3 High voltage test..............................................................................................23 5.4 Residual voltage test .......................................................................................24 5.5 Functional tests ...............................................................................................25

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Verification of safety of machines according to IEC/EN 60204 Edition 5

1 IntroductionForewordThis booklet is inteneded to help defining correct procedures for verification of electrical safety of machines. New verification principles in the IEC/EN 60204 Edition 5 (released in 2006) are highlighted.

1.1 The new IEC/EN 60204, Edition 5The IEC/EN 60204 norm deals with safety of electrical equipment in machines. The 5th edition edition cancels and replaces the fourth edition issued in 1997 and Ammendment 1 (1999). Compared to old versions the new edition: is amended to provide general requirements for machines, including mobile machines and complex (for example large) machine installations. it deals with determination of adequate risk reduction relevant to the machines electrical equipment. is significantly changed in part Verification. The simple test of protective conductors (Voltage Drop test) is substituted by a more thorough testing of protective measures against indirect contact. Now verification tests include appropriateness of protective conductors, of overcurrent disconnection devices and incoming supply impedance. The IEC/EN 60204 Edition 5 is a harmonized EU standard and an important part of the EU Machine Directive. It is also harmonized with the US standard NFPA79.

1.2 Scope of the standardWith help of this standard the risks associated with hazards relevant to electrical equipment can be assessed as apart of the overall requirements for risk assessment of the machine. On base of the assement adequate risk reduction and necessary protective measures can be defined. Typical hazardous situations related to electrical equipment are: failures or faults in the electrical equipment resulting in the possibility of electric shock or electrical fire failures or faults in control circuits resulting in the malfunctioning of the machine; disturbances or disruptions in power sources as well as failures or faults in the power circuits resulting in the malfunctioning of the machine loss of continuity of circuits that depends on sliding or rolling contacts, resulting in failure of a safety function electrical disturbances either from outside the electrical equipment or internally generated, resulting in the malfunctioning of the machine; release of stored energy (either electrical or mechanical) resulting in, for example, electric shock or unexpected movement that can cause injury; audible noise at levels that cause health problems to persons; surface temperatures that can cause injury.

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Verification of safety of machines according to IEC/EN 60204 Edition 5 Part 18 (Verifications) of the standard determines the measurements (methods, limits) that are to be performed to verify the electrical safety of machines. The verification is applicable: after erection of machine after installation of machine after upgrading or changing of machine and during periodic retests of machine

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Verification of safety of machines according to IEC/EN 60204 Edition 5

2 Verification of safety of machinesAccording to IEC/EN 60204, Ed.5 verification of electrical safety of machines is perfomed by inspection and measurements: 1. Inspection that the electrical equipment complies with its technical documentation 2. Verification of protection against indirect contact by automatic disconnection, 3. Insulation resistance test 4. High voltage test 5. Protection against residual voltages 6. Functional tests The norm describes general requirements regarding electrical equipment of a machine. The extent of verification in usually given in the product standard and/ or technical documentation for a particular machine. Where there is no dedicated product standard for the machine, the verifications shall always include the items 1, 2 and 6 and may include one or more of the items 3,4,5. The decision should be taken by a competent person on site, after evaluation of machines condition. In Table 1 a legend of tables and flowcharts in this document is shown. They include.detailed information about limits, sequences and connection diagrams. MeasurementProtection against indirect contact: Continuity of PE conductors Protection against indirect contact: Fault loop impedance test*

Limits, parameters, extent of testExtent of test: flowchart 1 Test sequence: flowcharts 1,2 Conductor resistance: table 3 Extent of test: flowchart 1 Test sequence: flowcharts 1,2 Disconnection times: table 4 Fuse table with limits: table 5 Test sequence and limits: flowchart 2

Connection diagramFig. 1

Fig. 2

Protection against indirect Fig. 3 contact: Equipotential bonding Insulation resistance test Test sequence and limits: flowchart 3 Fig. 4 High voltage Tests Test sequence and limits: flowchart 4 Fig. 5 Protection against residual Test sequence and limits: flowchart 5 Fig. 6 voltages Functional test Fig. 7 * TN systems. For TT systems RCD tests, for IT systems IMD check should be performed.

Table 1: Legend of tables, flowcharts

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Verification of safety of machines according to IEC/EN 60204 Edition 5

3 Visual inspectionMaybe it sounds strange but visual check is the most important and effective part of a machine test. The visual inspection discloses most of faults! Electrical testing often does not disclose failures that become apparent on visual inspection. A thorough visual check must be carried out before each electrical safety test. Scope of test: Check of: Wiring connection points. Especially PE connections are important ! Protection covers, housings Inscriptions and markings related to safety must be clearly readable. Cable layout, radiuses, isolation Switches, regulators,lamps, keys Parts subjected to wear out Electrical and mechanical protection devices (barriers, switches, fuses, alarms) Openings, filters Technical documentation, instructions for use available Installation of the appliance must be performed according to the user manuals. During visual inspection the measuring points for the electrical testing have to be determined too. Check that there are no signs of: damage pollution, moisture, dirt that can jeopardize safety corrosion overheating

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Verification of safety of machines according to IEC/EN 60204 Edition 5

4 Measurements4.1 Verification of protection against indirect contact by automatic disconnectionThis verification step is quite complex and must always be carryed out in some form. The standard allows simplified testing procedures regarding to the status of machine.

4.1.1 Selection of machine status and test extentThe status of the machine can be selected on base of condition of supplied machine (dismantled, fully assembled) technical documentation (availability of existing verification report of electrical wiring of machine) length of conductors after installation incoming supply characteristics loop impedance Flowchart 1 describes how to select t