TÜV SÜD Corporate Presentation 27/06/2013 1 - TUV SUD · PDF fileTÜV SÜD...

27/06/2013 TÜV SÜD Corporate Presentation 1

TÜV SÜD Product Service

An introduction to

EN 60204-1 Stewart Robinson TÜV SÜD Product Service


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 co-ordinated 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.

BS EN 60204-1:2006+A1:2009

BS EN 60204-1:2006+A1:2009 Slide 2 27/06/2013


• 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

EN 60204-1 Scope

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• 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.

EN 60204-1 Out of scope

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 4


EN Standards and European Directives

BS EN 60204-1:2006+A1:2009 Slide 5

“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.

EN 60204-1 is harmonised against the Machinery Directive

and the Low Voltage Directive

27/06/2013


• 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

EN 60204-1 and BS 7671 (IET Wiring Regulations)

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 6



• There are 18 clauses in the normative part of the standard

1. Scope

2. Normative references

3. Definitions

4. General requirements

5. Incoming supply conductor terminations and devices for

disconnecting and switching off

6. Protection against electric shock

7. Protection of equipment

8. Equipotential bonding

9. Control circuits and control functions

EN 60204-1 Contents

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 7


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

EN 60204-1 Contents

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 8


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).

BS EN 60204-1:2006+A1:2009 Slide 9

Definitions - Examples

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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]

BS EN 60204-1:2006+A1:2009 Slide 10


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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


27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 11


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

BS EN 60204-1:2006+A1:2009 Slide 12


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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.


27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 13

TÜV SÜD Product Service BS EN 60204-1:2006+A1:2009 Slide 14

EN 60204-1: Chapter (6) and (7)

Electrical Hazards

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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.

BS EN 60204-1:2006+A1:2009 Slide 15

Risk and Consequence

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• 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.

BS EN 60204-1:2006+A1:2009 Slide 16

Equipment selection

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• 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.

BS EN 60204-1:2006+A1:2009 Slide 17

EMC Requirements

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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.

BS EN 60204-1:2006+A1:2009 Slide 18

Electrical Supply and Isolation

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• 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.


27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 19


• 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.

BS EN 60204-1:2006+A1:2009 Slide 20


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BS EN 60204-1:2006+A1:2009 Slide 21 27/06/2013



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 .

BS EN 60204-1:2006+A1:2009 Slide 22

Supply Termination

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Persons must be protected from electric shock from:

Direct contact.

Indirect contact.

BS EN 60204-1:2006+A1:2009 Slide 23

Protection against electric shock

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The risk in this case is an insulation fault between live parts and exposed conductive parts.

BS EN 60204-1:2006+A1:2009 Slide 24

Protection against indirect contact

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Protection by enclosures

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 25

Protection against electric shock by locating live parts inside 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.

BS EN 60204-1:2006+A1:2009 Slide 26

Protection by enclosures

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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.

BS EN 60204-1:2006+A1:2009 Slide 27

Enclosures

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• 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.

Defeat Interlocked Isolator

27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 28


• 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.

BS EN 60204-1:2006+A1:2009 Slide 29

Protection by Insulation

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Potential sources of electrical shock from

wiring

BS EN 60204-1:2006+A1:2009 Slide 30 27/06/2013



• 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.

BS EN 60204-1:2006+A1:2009 Slide 31

Protection Against Residual Voltages

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Appliance Classes

Appliance Class Marking Protection

Class 0 No Marking Single level of insulation

no protective-earth

Class I Chassis Connected to

Electrical Earth (PE)

Class II "Class II"

„Double Insulated„ Double Insulated

Class III Supplied from a SELV

(Separated Extra-Low Voltage)

Power Source.

BS EN 60204-1:2006+A1:2009 Slide 32 27/06/2013


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.

BS EN 60204-1:2006+A1:2009 Slide 33

Protection against indirect contact - touch voltage

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http://en.wikipedia.org/wiki/File:Schutzklasse_1.svg

http://en.wikipedia.org/wiki/File:Double_insulation_symbol.svg

http://en.wikipedia.org/wiki/File:Schutzklasse_3.svg

http://en.wikipedia.org/wiki/File:Wire_yellow_green_stripe.svg



• 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.

BS EN 60204-1:2006+A1:2009 Slide 34

Protection by the use of Extra Low Voltage

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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.

BS EN 60204-1:2006+A1:2009 Slide 35

Protection of equipment

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• 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.

BS EN 60204-1:2006+A1:2009 Slide 36

Control Functions - Examples

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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.

BS EN 60204-1:2006+A1:2009 Slide 37

Start Functions

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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.

BS EN 60204-1:2006+A1:2009 Slide 38

Stop Functions

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• 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.

BS EN 60204-1:2006+A1:2009 Slide 39

Stop Functions

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Operator Interface and Machine-Mounted Control Devices –

Colour-coding for Push Buttons:

Colour Meaning Explanation Examples of application Additional description

RED Emergency

Actuate in hazardous situation or

emergency

Emergency Stop / Off. Initiation of emergency function.

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.

YELLOW Abnormal

Actuate under abnormal

condition

Intervention to suppress abnormal condition .

Intervention to restart an interrupted

automatic cycle.

BLUE Mandatory

Actuate when requiring mandatory

action Reset function.

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.

GREEN Normal Actuate to initiate normal conditions

WHITE

No specific meaning

assigned

For general initiation of functions except

emergency stop

Start / On (preferred) Stop / Off 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.

GREY Start / On Stop / Off

BLACK Stop / On Stop / Off (preferred)

BS EN 60204-1:2006+A1:2009 Slide 40

Recommended colours – Push buttons

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Examples of poor wiring

BS EN 60204-1:2006+A1:2009 Slide 41 27/06/2013


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:

Hot Surface Electrical Shock

BS EN 60204-1:2006+A1:2009 Slide 42

Marking, Warning Signs and Reference

Designations:

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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.

BS EN 60204-1:2006+A1:2009 Slide 43

Verification and Testing

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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.

BS EN 60204-1:2006+A1:2009 Slide 44

Verification and Testing – Functional Tests

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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.

BS EN 60204-1:2006+A1:2009 Slide 45

Verification and Testing – Documentation of

Results

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BS EN 60204-1:2006+A1:2009

BS EN 60204-1:2006+A1:2009 Slide 46 27/06/2013


BS EN 60204-1:2006+A1:2009

Thank you for Your Time and for Listening

Any Questions

BS EN 60204-1:2006+A1:2009 Slide 47 27/06/2013


Thank you for listening

For more information contact: +44 (0)1642 345637 [email protected] www.tuv-sud.co.uk/machinery

TÜV SÜD BS EN 60204-1:2006+A1:2009 Slide 48 27/06/2013

TÜV SÜD Corporate Presentation 27/06/2013 1 - TUV SUD · PDF fileTÜV SÜD...

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