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eLibrary > BS EN 60204-1:2018+A1:2025 Safety of machinery. Electrical equipment of machines - General requirements >

BS EN 60204-1:2018+A1:2025 Safety of machinery. Electrical equipment of machines - General requirements, 2025

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BS EN 60204-1:2018+A1:2025 Safety of machinery. Electrical equipment of machines - General requirements, 2025

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CONTENTS
FOREWORD
INTRODUCTION
Figures [Go to Page]
Figure 1 – Block diagram of a typical machine
1 Scope
2 Normative references
3 Terms, definitions and abbreviated terms [Go to Page]
3.1 Terms and definitions
3.2 Abbreviated terms
4 General requirements [Go to Page]
4.1 General
4.2 Selection of equipment [Go to Page]
4.2.1 General
4.2.2 Switchgear
4.3 Electrical supply [Go to Page]
4.3.1 General
4.3.2 AC supplies
4.3.3 DC supplies
4.3.4 Special supply systems
4.4 Physical environment and operating conditions [Go to Page]
4.4.1 General
4.4.2 Electromagnetic compatibility (EMC)
4.4.3 Ambient air temperature
4.4.4 Humidity
4.4.5 Altitude
4.4.6 Contaminants
4.4.7 Ionizing and non-ionizing radiation
4.4.8 Vibration, shock, and bump
4.5 Transportation and storage
4.6 Provisions for handling
5 Incoming supply conductor terminations and devices for disconnecting and switching off [Go to Page]
5.1 Incoming supply conductor terminations
5.2 Terminal for connection of the external protective conductor
5.3 Supply disconnecting (isolating) device [Go to Page]
5.3.1 General
5.3.2 Type
Tables [Go to Page]
Table 1 – Minimum cross-sectional area of copper protective conductors [Go to Page]
5.3.3 Requirements
5.3.4 Operating means of the supply disconnecting device
5.3.5 Excepted circuits
Figure 2 – Disconnector isolator
Figure 3 – Disconnecting circuit breaker
5.4 Devices for removal of power for prevention of unexpected start-up
5.5 Devices for isolating electrical equipment
5.6 Protection against unauthorized, inadvertent and/or mistaken connection
6 Protection against electric shock [Go to Page]
6.1 General
6.2 Basic protection [Go to Page]
6.2.1 General
6.2.2 Protection by enclosures
6.2.3 Protection by insulation of live parts
6.2.4 Protection against residual voltages
6.2.5 Protection by barriers
6.2.6 Protection by placing out of reach or protection by obstacles
6.3 Fault protection [Go to Page]
6.3.1 General
6.3.2 Prevention of the occurrence of a touch voltage
6.3.3 Protection by automatic disconnection of supply
6.4 Protection by the use of PELV [Go to Page]
6.4.1 General requirements
6.4.2 Sources for PELV
7 Protection of equipment [Go to Page]
7.1 General
7.2 Overcurrent protection [Go to Page]
7.2.1 General
7.2.2 Supply conductors
7.2.3 Power circuits
7.2.4 Control circuits
7.2.5 Socket outlets and their associated conductors
7.2.6 Lighting circuits
7.2.7 Transformers
7.2.8 Location of overcurrent protective devices
7.2.9 Overcurrent protective devices
7.2.10 Rating and setting of overcurrent protective devices
7.3 Protection of motors against overheating [Go to Page]
7.3.1 General
7.3.2 Overload protection
7.3.3 Over-temperature protection
7.4 Protection against abnormal temperature
7.5 Protection against the effects of supply interruption or voltage reduction and subsequent restoration
7.6 Motor overspeed protection
7.7 Additional earth fault/residual current protection
7.8 Phase sequence protection
7.9 Protection against overvoltages due to lightning and to switching surges
7.10 Short-circuit current rating
8 Equipotential bonding [Go to Page]
8.1 General
Figure 4 – Example of equipotential bonding for electrical equipment of a machine
8.2 Protective bonding circuit [Go to Page]
8.2.1 General
8.2.2 Protective conductors
8.2.3 Continuity of the protective bonding circuit
8.2.4 Protective conductor connecting points
8.2.5 Mobile machines
8.2.6 Additional requirements for electrical equipment having earth leakage currents higher than 10 mA
Figure 5 – Symbol IEC 60417-5019: Protective earth
8.3 Measures to restrict the effects of high leakage current
8.4 Functional bonding
9 Control circuits and control functions [Go to Page]
9.1 Control circuits [Go to Page]
9.1.1 Control circuit supply
Figure 6 – Symbol IEC 60417-5020: Frame or chassis [Go to Page]
9.1.2 Control circuit voltages
9.1.3 Protection
9.2 Control functions [Go to Page]
9.2.1 General
9.2.2 Categories of stop functions
9.2.3 Operation
9.2.4 Cableless control system (CCS)
9.3 Protective interlocks [Go to Page]
9.3.1 Reclosing or resetting of an interlocking safeguard
9.3.2 Exceeding operating limits
9.3.3 Operation of auxiliary functions
9.3.4 Interlocks between different operations and for contrary motions
9.3.5 Reverse current braking
9.3.6 Suspension of safety functions and/or protective measures
9.4 Control functions in the event of failure [Go to Page]
9.4.1 General requirements
9.4.2 Measures to minimize risk in the event of failure
9.4.3 Protection against malfunction of control circuits
Figure 7 – Method a) Earthed control circuit fed by a transformer
Figure 8 – Method b1) Non-earthed control circuit fed by transformer
Figure 9 – Method b2) Non-earthed control circuit fed by transformer
Figure 10 – Method b3) Non-earthed control circuit fed by transformer
Figure 11 – Method c) Control circuits fed by transformerwith an earthed centre-tap winding
Figure 12 – Method d1a) Control circuit without transformer connected between a phase and the neutral of an earthed supply system
Figure 13 – Method d1b) Control circuit without transformer connected between two phases of an earthed supply system
Figure 14 – Method d2a) Control circuit without transformer connected between phase and neutral of a non-earthed supply system
Figure 15 – Method d2b) control circuit without transformer connected between two phases of a non-earthed supply system
10 Operator interface and machine-mounted control devices [Go to Page]
10.1 General [Go to Page]
10.1.1 General requirements
10.1.2 Location and mounting
10.1.3 Protection
10.1.4 Position sensors
10.1.5 Portable and pendant control stations
10.2 Actuators [Go to Page]
10.2.1 Colours
10.2.2 Markings
10.3 Indicator lights and displays [Go to Page]
10.3.1 General
10.3.2 Colours
Table 2 – Symbols for actuators (Power)
Table 3 – Symbols for actuators (Machine operation) [Go to Page]
10.3.3 Flashing lights and displays
10.4 Illuminated push-buttons
10.5 Rotary control devices
10.6 Start devices
Table 4 – Colours for indicator lights and their meanings with respect to the condition of the machine
10.7 Emergency stop devices [Go to Page]
10.7.1 Location of emergency stop devices
10.7.2 Types of emergency stop device
10.7.3 Operation of the supply disconnecting device to effect emergency stop
10.8 Emergency switching off devices [Go to Page]
10.8.1 Location of emergency switching off devices
10.8.2 Types of emergency switching off device
10.8.3 Local operation of the supply disconnecting device to effect emergency switching off
10.9 Enabling control device
11 Controlgear: location, mounting, and enclosures [Go to Page]
11.1 General requirements
11.2 Location and mounting [Go to Page]
11.2.1 Accessibility and maintenance
11.2.2 Physical separation or grouping
11.2.3 Heating effects
11.3 Degrees of protection
11.4 Enclosures, doors and openings
11.5 Access to electrical equipment
12 Conductors and cables [Go to Page]
12.1 General requirements
12.2 Conductors
12.3 Insulation
12.4 Current-carrying capacity in normal service
Table 5 – Minimum cross-sectional areas of copper conductors
12.5 Conductor and cable voltage drop
Table 6 – Examples of current-carrying capacity (Iz) of PVC insulated copper conductors or cables under steady-state conditions in an ambient air temperature of +40 °C for different methods of installation
12.6 Flexible cables [Go to Page]
12.6.1 General
12.6.2 Mechanical rating
12.6.3 Current-carrying capacity of cables wound on drums
12.7 Conductor wires, conductor bars and slip-ring assemblies [Go to Page]
12.7.1 Basic protection
12.7.2 Protective conductors
12.7.3 Protective conductor current collectors
Table 7 – Derating factors for cables wound on drums [Go to Page]
12.7.4 Removable current collectors with a disconnector function
12.7.5 Clearances in air
12.7.6 Creepage distances
12.7.7 Conductor system sectioning
12.7.8 Construction and installation of conductor wire, conductor bar systems and slip-ring assemblies
13 Wiring practices [Go to Page]
13.1 Connections and routing [Go to Page]
13.1.1 General requirements
13.1.2 Conductor and cable runs
13.1.3 Conductors of different circuits
13.1.4 AC circuits – Electromagnetic effects (prevention of eddy currents)
13.1.5 Connection between pick-up and pick-up converter of an inductive power supply system
13.2 Identification of conductors [Go to Page]
13.2.1 General requirements
13.2.2 Identification of the protective conductor / protective bonding conductor
13.2.3 Identification of the neutral conductor
Figure 16 – Symbol IEC 60417-5019
Figure 17 – Symbol IEC 60417-5021 [Go to Page]
13.2.4 Identification by colour
13.3 Wiring inside enclosures
13.4 Wiring outside enclosures [Go to Page]
13.4.1 General requirements
13.4.2 External ducts
13.4.3 Connection to moving elements of the machine
13.4.4 Interconnection of devices on the machine
13.4.5 Plug/socket combinations
Table 8 – Minimum permitted bending radii for the forced guidingof flexible cables [Go to Page]
13.4.6 Dismantling for shipment
13.4.7 Additional conductors
13.5 Ducts, connection boxes and other boxes [Go to Page]
13.5.1 General requirements
13.5.2 Rigid metal conduit and fittings
13.5.3 Flexible metal conduit and fittings
13.5.4 Flexible non-metallic conduit and fittings
13.5.5 Cable trunking systems
13.5.6 Machine compartments and cable trunking systems
13.5.7 Connection boxes and other boxes
13.5.8 Motor connection boxes
14 Electric motors and associated equipment [Go to Page]
14.1 General requirements
14.2 Motor enclosures
14.3 Motor dimensions
14.4 Motor mounting and compartments
14.5 Criteria for motor selection
14.6 Protective devices for mechanical brakes
15 Socket-outlets and lighting [Go to Page]
15.1 Socket-outlets for accessories
15.2 Local lighting of the machine and of the equipment [Go to Page]
15.2.1 General
15.2.2 Supply
15.2.3 Protection
15.2.4 Fittings
16 Marking, warning signs and reference designations [Go to Page]
16.1 General
16.2 Warning signs [Go to Page]
16.2.1 Electric shock hazard
16.2.2 Hot surfaces hazard
16.3 Functional identification
16.4 Marking of enclosures of electrical equipment
Figure 18 – Symbol ISO 7010-W012
Figure 19 – Symbol ISO 7010-W017
16.5 Reference designations
17 Technical documentation [Go to Page]
17.1 General
17.2 Information related to the electrical equipment
18 Verification [Go to Page]
18.1 General
18.2 Verification of conditions for protection by automatic disconnection of supply [Go to Page]
18.2.1 General
18.2.2 Test 1 – Verification of the continuity of the protective bonding circuit
18.2.3 Test 2 – Fault loop impedance verification and suitability of the associated overcurrent protective device
18.2.4 Application of the test methods for TN-systems
Table 9 – Application of the test methods for TN-systems
18.3 Insulation resistance tests
Table 10 – Examples of maximum cable lengths from protective devices to their loads for TN-systems
18.4 Voltage tests
18.5 Protection against residual voltages
18.6 Functional tests
18.7 Retesting
Annexes [Go to Page]
Annex A (normative) Fault protection by automatic disconnection of supply [Go to Page]
A.1 Fault protection for machines supplied from TN-systems [Go to Page]
A.1.1 General
A.1.2 Conditions for protection by automatic disconnection of the supply by overcurrent protective devices
Table A.1 – Maximum disconnecting times for TN systems [Go to Page]
[Go to Page]
A.1.3 Condition for protection by reducing the touch voltage below 50 V
A.1.4 Verification of conditions for protection by automatic disconnection of the supply
Figure A.1 – Typical arrangement for fault loop impedance (Zs) measurement in TN systems
Figure A.2 – Typical arrangement for fault loop impedance (Zs) measurement for power drive system circuits in TN systems [Go to Page]
A.2 Fault protection for machines supplied from TT-systems [Go to Page]
A.2.1 Connection to earth
A.2.2 Fault protection for TT systems
A.2.3 Verification of protection by automatic disconnection of supply using a residual current protective device
Table A.2 – Maximum disconnecting time for TT-systems [Go to Page]
[Go to Page]
A.2.4 Measurement of the fault loop impedance (Zs)
Figure A.3 – Typical arrangement for fault loop impedance (Zs) measurement in TT systems
Figure A.4 – Typical arrangement for fault loop impedance (Zs) measurement for power drive system circuits in TT systems
Annex B (informative) Enquiry form for the electrical equipment of machines
Annex C (informative) Examples of machines covered by this part of IEC 60204
Annex D (informative) Current-carrying capacity and overcurrent protection of conductors and cables in the electrical equipment of machines [Go to Page]
D.1 General
D.2 General operating conditions [Go to Page]
D.2.1 Ambient air temperature
D.2.2 Methods of installation
Table D.1 – Correction factors
Figure D.1 – Methods of conductor and cable installation independent of number of conductors/cables [Go to Page]
[Go to Page]
D.2.3 Grouping
Table D.2 – Derating factors for Iz for grouping
Table D.3 – Derating factors for Iz for multicore cables up to 10 mm2 [Go to Page]
[Go to Page]
D.2.4 Classification of conductors
D.3 Co-ordination between conductors and protective devices providing overload protection
Figure D.2 – Parameters of conductors and protective devices
Table D.4 – Classification of conductors [Go to Page]
D.4 Overcurrent protection of conductors
Table D.5 – Maximum allowable conductor temperatures under normal and short-circuit conditions [Go to Page]
D.5 Effect of harmonic currents on balanced three-phase systems
Annex E (informative) Explanation of emergency operation functions
Annex F (informative) Guide for the use of this part of IEC 60204
Table F.1 – Application options
Annex G (informative) Comparison of typical conductor cross-sectional areas
Table G.1 – Comparison of conductor sizes
Annex H (informative) Measures to reduce the effects of electromagnetic influences [Go to Page]
H.1 Definitions [Go to Page]
H.1.1 apparatus
H.1.2 fixed installation
H.2 General
H.3 Mitigation of electromagnetic interference (EMI) [Go to Page]
H.3.1 General
H.3.2 Measures to reduce EMI
Figure H.1 – By-pass conductor for screen reinforcement [Go to Page]
H.4 Separation and segregation of cables
Table H.1 – Minimum separation distances using metallic containment as illustrated in Figure H.2
Figure H.2 – Examples of vertical separation and segregation
Figure H.3 – Examples of horizontal separation and segregation
Figure H.4 – Cable arrangements in metal cable trays
Figure H.5 – Connections between metal cable trays or cable trunking systems [Go to Page]
H.5 Power supply of a machine by parallel sources
H.6 Supply impedance where a Power Drive System (PDS) is used
Figure H.6 – Interruption of metal cable trays at fire barriers
Annex I (informative) Documentation / Information
Table I.1 – Documentation / Information that can be applicable
Bibliography [Go to Page]

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