How to use BS EN 60204-1: 2006 Safety of Machinery

Electrical equipment of machines Part 1: General requirements

Contents

Introduction Objective Scope and type of standard The Standard, its Structure and Annex F Scope Selection of equipment Supply disconnecting (isolating) device Excepted circuits Prevention of unexpected start-up: isolation Protection against electric shock Protection of equipment Equipotential bonding Control circuit supplies Emergency operations Two-hand control Cableless control Control functions in the event of failure Operator interface and machine mounted control devices Controlgear: location, mounting and enclosures Conductors and cables Wiring practices Electric motors and associated equipment Accessories and lighting Marking, warning signs and reference designations Technical documentation Verification Additional user requirements etc - Annex B Annex C Annex D Annex E Annex G Normative references (Clause 2) and the bibliography BS EN 60204 -11: 2001 - Its relationship with BS EN 60204-1 List of standards referred to in this booklet Types of machinery safety standards Applications of types A, B and C standards to machines About the author - Brian James Clark

Section One Section Two Section Three Section Four Section Five Section Six Section Seven Section Eight Section Nine Section Ten Section Eleven Section Twelve Section Thirteen Section Fourteen Section Fifteen Section Sixteen Section Seventeen Section Eighteen Section Nineteen Section Twenty Section Twenty one Section Twenty two Section Twenty three Section Twenty four Section Twenty five Section Twenty six Section Twenty seven Section Twenty eight Section Twenty nine Section Thirty Section Thirty one Section Thirty two Section Thirty three Appendix A Appendix B Appendix C Appendix D

Page 4 Page 5 Page 6 Page 8 Page 9 Page 11 Page 12 Page 14 Page 15 Page 18 Page 21 Page 23 Page 24 Page 25 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51

Copyright © Schneider Electric Limited. This document may be freely copied, stored or transmitted in any form, in part or in whole, provided that its source is acknowleged as being Schneider Electric Limited.

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Section One

Introduction

How to use BS EN 60204-1: 2006 Safety of Machinery Electrical Equipment of Machines Part 1: General requirements By Brian James Clark
OBE DipEE Ceng FIEE

This booklet is intended for designers and those who specify electrical equipment comprising or forming part of an electrical installation of a machine or a number of machines working together in a coordinated manner. BS EN 60204: 2006 Part 1, covers the rules for the selection and application of electrical equipment to machines, including a group of machines operating together in a coordinated manner (particularly those not already covered by a machine product standard). The equipment covered is that operating and supplied at voltages up to 1000V A.C. at frequencies up to 200Hz and 1500V D.C.
Note - BS EN 60204 Part 11 covers equipment operating and supplied at higher voltages up to 36000V (see Section 33).

The Clauses in this standard are identical to the Clauses in IEC 60204-1: 2006 (see also Section 32) and the user will note that many of the normative references in Clause 2 are to IEC and ISO standards. However the additional Annex ZA to BS EN 60204-1 lists these standards together with their corresponding European publications and, where these are EN standards, they will have been published by BSI standards as BS EN standards. Whilst machine product standards take precedence over BS EN 60204-1, many of these standards make reference to (all or specific clauses or subclauses of) BS EN 60204-1. This booklet therefore may still be relevant to those items in BS EN 60204-1 referred to in the product standard. BS EN 60204-1 covers a comprehensive range of machines each of which has its own particular hazards requiring its own unique assessment of risks. The standard in many areas specifies a choice of measures (and equipment) that the designer needs to consider when applying equipment to a particular machine. Whilst Annex F of Part 1 gives some guidance on this, it is recognised that further detailed explanation can be helpful.
Note - This booklet when referring to clauses, subclauses (for example 1.2.3), tables, annexes etc. means those in BS EN 60204-1. References to sections in this booklet are identified by, for example, Section X. References to figures are identified individually.

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Section Two

Objective

The objective of this booklet is to provide guidance to the user of BS EN 60204-1 by: I Giving advice and direction on the use of the advice given in Annex F I Explaining the structure of the standard, its objectives, and how the clauses are interrelated I Providing an explanation of aspects to consider when deciding those requirements that may be appropriate, always bearing in mind the result of a risk assessment I Providing suggestions on solutions that are available and appropriate to deal with hazards and risks of harm, pertinent to the application of electrical equipment, identified by the risk assessment. This booklet is not a detailed design guide and should not be considered as one.
Note - The advice given in this booklet is the author’s opinion of the meaning of the requirements of BS EN 60204-1. Whilst great care has been taken in interpreting them, other opinions may appear equally valid. In cases of dispute, an official interpretation should be obtained from BSI Standards.

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Section Three

Scope and Type of Standard (see Foreword, Introduction and Clause 1 – Scope)

BS EN 60204-1 is a horizontal standard (Type B1 standard in CEN; see Introduction to BS EN ISO 12100-1: 2003) that relates to specific aspects of safety relevant to a large number of types of machines, in this case to the electrical equipment of machines. It is made clear in Note 2 of Clause 1, Scope that the term electrical equipment means electrical, electronic and programmable electronic equipment. It deals with the electrical equipment of the machine from the point at which the machine takes its electrical supply, (e.g. the interface with the building electrical installation) this will be discussed in more detail later in this document. This standard does not cover the requirements for higher level system aspects such as those dealing with remote control, in particular those remote control systems used for process control. For example, consider three machines, the output of two of which is needed to satisfy the overall process needs. When two machines are running and if one machine breaks down the higher level system will signal the remaining machine to start in order to maintain the required level of production needed by the process. The standard covers: a) Provision of means for protection against electric shock from the machine, including enhanced measures for equipment located where handicapped persons and children have access b) Provision of means for: prevention of unexpected start-up, isolation of all or parts of the electrical equipment for work on live conductors and protection against unauthorized, inadvertent and/or mistaken connection c) Measures for the protection of equipment against overcurrent, overload, earth faults, overvoltages and overspeeding d) Restarting of hazardous operation arising out of loss of power supply and subsequent restoration e) Failure to cease operation or inadvertent start of operation caused by the occurrence of earth faults on control circuits f) General requirements for electrical control circuits including: i Design techniques to improve levels of integrity related to safety of machines ii Cableless controls ii Suspension of safety functions and/or protective measures g) Requirements covering machine controls including start, stop, hold-to-run, enabling control, emergency stop and emergency switching off h) Accessibility and layout of electrical control equipment and electrical control devices requiring manual operation i) Selection of conductors and cables including flexible cables, collector wires, collector bars and slip-ring assemblies.

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whilst it deals with the electrical hazards. Where a product (Type C in CEN) standard exists. this standard is a horizontal standard for the application of electrical equipment to machines. Technical committees writing product (vertical) standards for a particular machine or range of machines have been and are encouraged to use. See also Clause 1. Notes are used to give additional information. It is also important to know that power circuits where electrical energy is directly used as a working tool (e. whilst “should” is advisory and should be treated as a recommendation. power tools). “may” is used to give permission.Section Three Scope and Type of Standard (see Foreword. significant requirements are specified that partly deal with machinery control functions.There is no legal obligation for a machine supplier to comply with these standards. Also. Users of BS EN 60204-1 (this applies to all BSI standards) should be aware of the meanings of “shall” and “should” in the standard. 7 . electronic and programmable electronic control systems. in a potentially flammable atmosphere. These are referred to where appropriate in BS EN 60204-1 and their interaction will be covered. See also BS EN62061: 2005 for requirements of safetyrelated electrical. nor is equipment portable by hand whilst working (e. “Shall” is mandatory and has to be complied with. A horizontal standard such as BS EN 60204-1 only applies when its requirements are referred to in the product standard. As stated above. but it is the easier option as the product standard (and those other horizontal standards) is intended to specify the current “state of the art” in following the Essential Health and Safety Requirements contained in the Supply of Machinery (Safety) Regulations (see also Annex C of BS EN 60204-1). designers/manufacturers/suppliers of machines tend to follow the product standard. sometimes the phrase “it is recommended that …” is used instead of “should”. Thus. for example. manufacturer or supplier is shown in Figures 1 and 2 of this booklet. equipment such as an electric arc welder and for machining by electric spark erosion) are not covered in this standard.g. Other relevant horizontal standards include BS EN ISO 12100-1: 2003. and have used. horizontal standards in their work. additional and special requirements apply to the electrical equipment used. in order of priority: 1) Hazardous (to persons) conditions 2) Damage to the machine 3) Damage to the work in progress. Introduction and Clause 1 – Scope) It needs to be noted that the requirements of this standard are concerned with preventing. The word “can” is used to express that something is possible. basic design of control circuits and functional safety (against hazards other than electrical).g. Another important aspect of the wording of standards is the use of “can” and “may”. A list of the standards referred to in this booklet is given in Appendix A of this booklet for easy reference. The relationship between horizontal (Type A & Type B in CEN) machine standards and vertical or product (Type C in CEN) machine standards and the options open to the designer. Scope for the list of circumstances. Note .

See 3. requirements from Clauses 6. Annex F is the guide for use of this part of BS EN 60204 and.1 applies equally (see Figure 2) to: I Standards technical committees preparing machine product standards (type C in CEN) I Suppliers (and designers of electrical equipment) of machines for which no product standard exists I Machines where a product standards exists and reference is made to BS EN 60204-1. design review. change of use. b) and c) how to go about using the standard but warns that the method and solution used must not reduce (adversely affect) the level of protection identified from the risk assessment as being required for that particular machine.1 of BS EN ISO 12100-1: 2003.1 which are given below.1 will be used when relevant as section headings in this booklet. It also advises that the supplier ensures that the necessary expertise to competently carry out the tasks listed in the penultimate paragraph be available. It describes in a). It shows the interrelationship of the various elements of a typical machine and its associated electrical equipment. 8 .Another representation of a typical machine can also be seen in Figure A. 7 and 8 are relevant to prevention of electric shock by indirect contact).In the context of IEC 60204-1. the subjects listed in Table F. Examples of situations such as this will be made in this booklet. It goes on to advise that when making these decisions and choices.Section Four The Standard. F. in addition to some explanation/expansions of the text in F. A study of this and the contents list should make the reader realise that many Clauses and Subclauses are interrelated (for example. for example as a result of an accident or user feedback. It follows that these tasks need to be conscientiously carried out. The numbers in parentheses on the figure refer to clauses and subclauses in the standard. Note . its Structure and Annex F Figure 1 in BS EN 60204-1 (see Introduction to BS EN 60204-1) is a good starting point for the user of this standard. the term “supplier” refers to any entity in the supply chain. Note . the rationale (including sources/reference as necessary) be documented so that there is a clear audit trail to follow when it becomes necessary to review these decisions.54 of the standard for the exact definition.

Depending upon the machine and its intended use there can also be relevant different requirements. For example. but there are additional requirements to be met to warn the user of the presence of these live conductors and to provide means for their disconnection.1) so that a single device can disconnect the machine from the electrical supply.4.2). namely in the Scope (penultimate paragraph) and in Clause 4.4) arising from the supply and at the intended place of use of the machine.5. In general a single incoming power supply is recommended where possible with other power supplies derived from it (see 5.7) to be part of a machine installation and the supply disconnecting device to them needs to meet the requirements of 5. or an on-board electrical generator. 9 . the building power supply system installation. for example. the power supply installation standard applicable in the UK is BS 7671 – Requirements for Electrical Installations (IEE Wiring Regulations 16th Edition). In this case. Section 5.2 Point(s) of supply(ies) Whilst many machines only require one incoming power supply.Section Five Scope This expands on that given in Section 3 above in two ways. This situation is catered for in 5. Section 5. One is the need to identify additional requirements (see column ii) of Table F.7.1. this device can be considered to be the machine disconnecting device. it is recommended that the incoming supply is terminated at the incoming terminals of the supply disconnecting device see also 5. see 15. The other is to identify the point(s) at which the machine takes its supply(ies). Another example is where there may be several machines supplied by a common set of conductor bars or conductor bars. in the case of a mobile machine supplied by a flexible cable terminated at a disconnecting device at the supply end.2 e).1 and 5. In the case of the former.3. other (often complex or very large) machines need more than one (see 5.3. The point of incoming supply to a machine is where its electrical equipment interfaces with.3) and physical environment and operating conditions (see 4.1). the conductor bars and conductor wires can be considered (see 12.1 Additional requirements and Clause 4 These additional requirements are identified in two places. Except where a plug is provided with the machine for connection to a power supply socket.1 and 15.3 and 12. There are situations where it is important that a second derived (or alternate power supply) source needs to be available when the supply disconnecting device is OFF (for example. The former is self-evident but the general requirements in Clause 4 can impose additional requirements such as those arising from a special power supply (see 4.

then this switchboard can be considered to be part of the machine’s electrical equipment. such as for general lighting of the building. Where outgoing circuits feed machines working together in a coordinated manner.3) is the point of supply for the machine. Such a situation should not give rise to any serious problems where the supplier and user agree contractually what is being provided and by whom. the switchboard incoming supply circuit switchgear (when meeting the requirements of 5.Section Five Scope More often than not. In any event. In this case. derived from that switchboard).3. 10 . the requirements of BS 7671 and BS EN 60204-1 do not. conflict in this area. it is believed. in particular for machines working together in a co-ordinated manner. For example. In the case of larger machines and. the point of supply for single machines is clear. requiring more than one power supply. in the case of a large machine needing several incoming power supplies that are derived from a dedicated switchboard (no other outgoing circuits used for building services. the point of supply to the machine could be considered to be at the switchboard. a switchboard may consist of several outgoing circuits equipped with switchgear meeting the requirements of 5. the point(s) of supply (and hence from what point BS EN 60204-1 is applicable) can become unclear. Alternatively.

Whilst compliance with a recognised international standard is not in itself a guarantee of perfect reliability.g. Schneider Electric participate in the development and revision of many International and European standards including IEC 60204-1. 11 .2. meets recognised IEC standards where possible and is used as intended.2 specifies that the electrical equipment selected needs to satisfy safety requirements as identified by the risk assessment.Section Six Selection of equipment The objective of 4. there is a reasonable degree of assurance that the equipment supplier has had the equipment type tested to the standard and the equipment supplied performs to an identifiable specification with clear instructions for use.1 is to ensure that electrical equipment is suitable. All Schneider Electric’s products are designed and manufactured in accordance with relevant IEC standards. To achieve this. he/she has to ensure that it will also operate without overheating or catastrophic failure during abnormal conditions such as overload or short circuit. The selection and use of equipment complying with IEC 60439-1 is one way of meeting requirements for safe operation particularly where significant load and/or short circuit current levels can be expected.2. in a controlgear panel) operates correctly under normal conditions. 4. the designer of the electrical equipment has not only to ensure that equipment assembled on or near a machine (e.

3.4 (see also Annex E of BS EN 60204-1). 12 . The required switching device interlocked with the plug/socket combination rated at currents greater than 30 A (see 13. The functions that have to be available are that of disconnection (for work on the electrical equipment of the machine) and the capability to switch off the maximum load/overload current of the machine under the conditions described in 5.2 b)) that may be used together with the specific requirements they have to meet. In addition.5 c)) can satisfy the requirements for the supply disconnecting device.1 and Section 27 regarding the neutral conductor.8. a separate device for switching the machine on and off is necessary. Where the device is a plug/socket combination. since there have been electrical burn accidents caused by the removal of plugs rated at 32A when carrying load currents.4. Note . This is a change to the previous edition. There is no reason (apart from cost) why such a request from the machine user should not be satisfied. The majority of Schneider Electric disconnecting devices are available in 3. Auxiliary contacts for control circuit interlock and indications can also be added if required.5 a) to f) are relevant. the requirements of 13.The Vario range can also include early make late break for neutral switching. It should be noted that when a neutral conductor is provided in TN systems. The range of devices allowed has been extended in 5.g: the Vario range rated up to 75A and LK3 range with ratings up to 1250A.3 describes the device or devices used in combination (for example see 5.4. It is not unknown for a 4-pole machine supply disconnecting device to be requested even though the supply requirements of the machine do not include a neutral.3.3. emergency stop.4 and 10. emergency switching off) as specified in 10.The 4th pole on a 4 pole device may comprise either a solid or switched conductor.3.Section Seven Supply disconnecting (isolating) device Subclause 5. some countries require this conductor to be switched by the supply disconnecting device. Schneider Electric can provide disconnecting devices with either black/black or red/yellow operating handle/background. This requirement is not mandatory and often the handles are provided coloured red (with a yellow background) in case they are likely to be used to effect emergency operations (for example. Schneider Electric can supply a wide range of suitable devices. which required an interlocked switching device for plug/socket combinations rated 63A or above. It is recommended that the handles (when provided) of supply disconnecting (isolating) devices not intending to be used for emergency operations be coloured black or grey.or 4-pole.2 d) in this issue of the standard. e.See also 5.7.

4. In the case where more than one power supply is needed. it is important that there are interlocks provided as necessary to ensure that no hazard can arise or damage to the machine or the work in progress can occur when one of the supply disconnecting (isolating) devices is operated. conductor bars and slip ring assemblies for use as a means of disconnection are given in 12. This also applies to the overcurrent protective devices at the point of supply but more will be said about this later.7. Also the supply disconnecting (isolating) device selected (and its associated connections to the electrical equipment) needs to be adequately rated for the power supply to which it is to be connected. The design requirements for removable current collectors on conductor wires.Section Seven Supply disconnecting (isolating) device The type of supply disconnecting (isolating) device(s) and where it is mounted (on the machine or on a separate electrical panel) will be determined by the machine itself and its electricity supply demands. 13 .

such as orange in the case of control circuits for interlocking. in the case of accessories and local lighting Clause 15 will apply.5) have some means of disconnection and are adequately protected against overcurrent.2 above.3.4. Finally protection against direct contact (see Section 10. see 13.2.5 is to give relief where necessary from the strict requirements of 5.1 to 5. Other low power circuits can meet the requirement by use of fully protected (against direct contact) and fully rated withdrawable fuse gear. The use of colour.3. It is important that such circuits (see 5. The reason that such provision is only a recommendation in 5.3. method b) for use of enclosures) might need to be supplied.4. For example. separation and labelling also needs to be considered.3. 14 .2.Section Eight Excepted circuits This subject has already been touched upon in Section 5.

This sentiment is expressed as the first paragraph to the Introduction in ISO 14118: 2000 (BS EN 1037: 1995). testing I Work on power circuits I Major maintenance (works requiring significant dismantling).1 General Prevention of unexpected start-up: isolation Keeping a machine in a stopped or non-operating condition whilst persons are present in danger zones is one of the most important conditions of safe use of machinery and hence one of the major aims of the machinery designer and machine user.) involve electrical equipment that has to be adequate (see Section 6) to fulfil these tasks. to I The provision of isolation and means of energy dissipation (e. Safety of machinery – Prevention of unexpected start-up. etc. ISO 14118 covers all aspects of these requirements from: I Simply relying on prevention of operation of a start control by anyone apart from the operator when he/she. A list of examples of activities (tasks) calling for such measures are given in informative Annex A of ISO 14118 (BS EN 1037). 15 . energy stored or present due to gravity) with means of securing (locking) and warning labels to enable significant dismantling and repair to be carried out safely. Many of the means used for the above (for examples see Section 7. etc.g.) I Setting. Section 9.Section Nine Section 9. The list is repeated below: I Inspection I Corrective actions (clearing blockages. for example is inspecting a work-piece during a machining operation.3. adjustment I Manual loading/unloading I Tool change I Lubrication I Cleaning I Decommissioning I Minor maintenance/repair I Diagnostic.

capable of providing electrical isolation. In many cases this function is achieved by the supply disconnecting device. for example to replace a workpiece. 16 . Access to such an area is intended to be restricted to electrically skilled or instructed persons who should know when it is safe to operate these electrical devices.5 deals specifically with the provision of means for disconnecting (isolating) electrical equipment so that work can be carried out on it when it has been disconnected and isolated from its source(s) of supply.3 Isolation of electrical equipment 5. Other devices. but not isolated. and not necessarily in a locked switch room some distance from the machine.Section Nine Prevention of unexpected start-up: isolation Section 9. is often inside a locked fuse box or a locked electrical equipment panel on or near to the machine.6). withdrawable fuse links. such as disconnectors. Section 9. for example. It needs to be noted that devices that achieve isolation are required to be provided in accordance with 5. their use should only be considered for those intervention activities that always require the attendance of an electrically skilled or instructed person. Whilst the machine supply disconnecting device(s) will satisfy this requirement.4. See 5.2. withdrawable fuse links and withdrawable links are allowed to be supplied providing they are located in an enclosed electrical operating area. Also it should be noted that the location of. appropriate for their intended use and lockable or other means used to minimise the possibility of mistaken operation (See 5. In both cases. last paragraph.3. Work on electrical equipment under the conditions when the equipment is switched off.5 to avoid a risk of electric shock or burn when work is to be carried out on electrical equipment.2 Prevention of unexpected start-up 5. Schneider Electric can provide a full range of disconnectors and withdrawable fuse holders. These devices need to be conveniently placed. is only allowed when there is no risk of electric shock or burn. The machine operator is not normally an electrically skilled or instructed person and will need other means to prevent unexpected start-up for those intervention activities not requiring the assistance/attendance of an electrically skilled or instructed person (see also BS EN 1037). apart from those described in 5. its use can be inappropriate for Schneider Electric’s disconnecting devices incorporate the means to connect up to 3 padlocks.4 specifies electrical devices for switching off be provided to achieve prevention of unexpected start-up during intervention.

Additional means.electrical equipment such as capacitors. Note 1 . by using the means that should have been provided. no further safeguarding of that means needs to be provided. padlocks.5. these other means of isolation (that need to be clearly labelled as to the part of the electrical equipment they supply) are intended to be accessible only to electrically skilled or instructed persons. This aspect is even more important when the work is being carried out by persons who are not electrically skilled or instructed as they might have no means of proving the equipment is dead. those persons using the machine supply disconnecting device(s) to enable work to be carried out on the electrical equipment of the machine. Even so. particularly for items that cannot be locked and therefore have to be located in enclosed electrical operating areas. However. On such occasions it is likely that these means can be appropriate as it is essential that the electrical equipment is safely isolated and deenergised. Advice is contained in Section 12 of PD 5304: 2006.4) and the means for isolation (5.2) that can remain or become electrically charged need to be short circuited and earthed. 17 . and discharged as necessary.Section Nine Prevention of unexpected start-up: isolation the reasons given in 5. The means to be provided are specified as: I Means to secure isolators in the off position (and discharge means in the closed position. see Note 1 below) by for example. as noted above. the machine user may need some advice as described above.4 Protection against unauthorised. However. HV equipment (see Section 33. inadvertent and/or mistaken connection. Where a plug/socket combination is provided and the point of isolation is positioned so it is likely to be under the immediate supervision of the person doing the work. Section 9. Note 2 . trapped key interlocks I Warning labels.6 deals with provision of means for safeguarding the measures for prevention of unexpected start-up (5. Therefore suitable advice needs to be included in the information for use. that other sources of supply not disconnected by the supply disconnecting device (see Sections 7 and 8). as described.Users should be encouraged always to provide and use warning labels irrespective of the means of isolation provided for use. The equipment provided should enable the machine user to easily put into effect safe systems of work for any work carried out on the electrical equipment. are often provide to ensure that part only of the electrical equipment can be isolated and worked on in safety without affecting the availability of other parts of the electrical equipment. inadvertent and/or mistaken connection 5. will need to ensure as necessary. do not generate an electrical risk to those doing the work.5) and energy dissipation against unauthorised.

Section 10. For example the measure of protection against direct contact by placing out of reach (see 6.2.6) should only be used where protection by enclosure (see 6. 18 . This. (the measures used are described in this standard as protection against indirect contact (see 6.1 and 12.2. An important requirement.2.1. Furthermore.Section Ten Section 10. See also 6.2 and whilst the requirements are self explanatory.2 Protection against direct contact The measures are described in 6. by definition.2. needs to be justified as being appropriate.4)) I Exposed conductive parts which have become live as a result of an insulation fault between live parts and exposed conductive parts.3)). includes children and disabled persons. The application options here are confined to selection from the measures given in Clause 6. It should be noted that the requirements in Clause 11 (and Clause 14 in the case of motors) are also relevant.2 and 6.2.7. the reader is directed to IEC 60364-4-41 (see also BS 7671 – Requirements for Electrical Installations (IEE Wiring Regulations). It can be noted that the requirements for those measures commonly used and appropriate for machines are given in full whilst for the others. IEC 60529 needs to be carefully studied. often the requirements for protection against ingress of solids and water (see 11. Even so the selection of the measure is restricted to (qualified by) that which provides the highest possible level of protection. is the enhanced level of protection for electrical equipment located in places to which access is available to the general public. certain of these merit explanation of the reasoning behind them.1 General Protection against electric shock Electric shock can arise from contact by persons with: I Live parts of the electrical equipment (the measures used are described in this standard as protection against direct contact (see 6.3) can be such as to be more than adequate in meeting 6. Protection by enclosure (see 6.2) is the most common measure employed on machinery. To this end and to understand fully the meaning of the requirements.2) is not practicable and even then. not currently directly specified in many other standards.

2. those live parts that are likely to be inadvertently touched (including those on the back of doors) have to have some protection against direct contact. management control to ensure access is only allowed to authorised persons.3 to 6. the use of a key or tool is necessary.4) is particularly important as the user will assume that once 19 .1. a). TeSys model D contactors incorporate removable safety covers to prevent manual actuation of the contactor. Virtually all Schneider Electric devices have fully finger-protected (IP2X) terminals.2. This measure also now applies to those enclosures covered by condition b). for conductor wires. b) and c) are specified that need to be met before access can be gained (for example by opening a door) to such an enclosure. Protection against direct contact with residual voltages (e.2.There are other reasons (for example. or have separate shrouds available to enable IP2X protection. Where the interlock can be defeated. Note . In the case of c) access is possible at all times because the equipment inside is adequately protected against direct contact.Section Ten Protection against electric shock Three conditions. the intent being to restrict access to electrically skilled or instructed persons.2. conductor bars and slip-ring assemblies in 12.2.g. the intent is that access to the enclosure can only be gained after the supply disconnecting device is opened and all the equipment inside is isolated and any other parts still live being adequately protected against direct contact. In the case of a). Even so. to minimise risk of production loss arising from malicious or inadvertent interference) why a user may wish to restrict access to electrical equipment and the designer needs to be aware of such user requirements. 2) When the doors are re-closed the interlock needs to be fully restored irrespective of whether the disconnecting device is in the off or on position. Other measures for protection against direct contact are specified in 6. the reason being that the electrical equipment can remain live when a special tool is used to defeat the interlock (again intended to be used only by electrically skilled or instructed persons). In condition b).5 and 6. when capacitors are present) (see 6.6 are by reference to those relevant requirements specified in IEC 60364-4-41 (see also 10 above). it should not be possible to defeat this interlock without using a special tool provided by the supplier. It should be noted that the requirements specified in 6. Important requirements that need to be carefully considered when designing this type of enclosure are: 1) All access doors to the enclosure need to be fully interlocked with the disconnecting device and it should not be possible to switch on with any door left open.6 and.7.

20 .4) provides protection against the effects of both indirect contact and limited area direct contact.3. Section 10.Section Ten Protection against electric shock the supply disconnector has been opened or the supply plug is withdrawn from its socket. the electrical equipment is no longer live at a dangerous voltage.4). or b) by electrical separation. and c) Characteristics of the protective devices that detect insulation faults (see Clause 7). These measures are not commonly found in machine installations apart from individual items of equipment and cables for which. Otherwise.3 specifies measures most commonly used on machinery. additional measures are required (see also 12. As stated. 6. The designer needs to take care to ensure that any hazardous voltage source dissipates to a safe level within 5 seconds if within an enclosure or 1 second in the case of exposed pins of a plug. it needs to be realised that the voltage limits of this measure are relevant only for equipment located in dry locations. Protection against electric shock is achieved by the removal of a touch voltage. this requires co-ordination between the: a) Type of power supply and the earthing system b) Impedance values of the different elements of the protective bonding system (see Clause 8). there are certain specialist areas (e. textile machinery) where this measure may be appropriate.3.7. in many cases.g.2). product standards exist. Section 10.3 Protection against indirect contact The measures are described in 6. appearing on the occurrence of an insulation fault. High voltages can exist within variable speed drives for several minutes. The addition of normative Annex A – ‘Protection against indirect contact in TN-systems’ has both helped the designer and provided information to enable verification to be carried out (see 18. before it can cause harm. and the discharge time is marked on the drive enclosure. Even so.4 Protection by the use of PELV This measure (see 6.3. Whilst not commonly found on machinery.2 specifies measures to prevent the occurrence of a touch voltage by either a) provision of Class II equipment or by equivalent insulation. 6.

Section 11. 21 . connection to a supply with the incorrect phase sequence and overvoltage due to lightning and switching surges. overcurrent and undercurrent can be monitored by the Schneider Electric RM4 and RM84 range of measurement relays.1 General Protection of equipment Clause 7 is concerned with: 1) Protecting electrical equipment against excessive damage arising from a fault within the equipment itself and the other equipment subjected to the effects of the fault. short circuit) currents (motors and other machine electrical equipment can also contribute to fault currents) 2) Protection against the effects of temperature rise above normal arising from loss of cooling and overloading of circuits such as those supplying motors.2) is not responsible for providing the overcurrent protective device on the supply conductors to the machine. It must also not be forgotten that correct coordination of protection (settings) is also needed to ensure that sufficient protection against Schneider Electric’s Telemecanique contactors and overload relays pioneered the use of independently-certified combinations with Type 2 coordination.2. of course. That described in 2) above has been thoroughly reviewed and. This damage can result from the electromagnetic forces and/or excessive temperatures caused by the value and/or duration of the fault (e.2 Supply conductors The electrical equipment supplier (see 7.g. This information is needed so the supplier can select suitable electrical equipment and protective devices (suitably set) to ensure adequate coordination and discrimination of the protective devices in the electrical equipment of the machine. more accurately specified. In this edition of the standard. It should be noted that generally the electrical equipment does not have an insulation fault. be an agreement between the equipment supplier and user. it is believed. earth fault/residual current. the supplier of the equipment still needs to know (or clearly specify) the setting of the overcurrent device and (importantly) the maximum short circuit current and time duration. overspeed of machine elements. The requirements in Clause 7 are clear and it can be seen from Table F. Variations in voltage. those circumstances identified as giving rise to excessive temperature rise and those protective measures to detect this and protect the equipment against damage are more clearly specified 3) Protection against the effects of supply voltage variation. There can. phase loss. phase rotation.1 there are no application options. In the absence of such an agreement.Section Eleven Section 11.

Also. the above mentioned point. for example.3). The three conditions are given with the objective of minimising the probability of a short circuit occurring due to an insulation failure arising from. 22 . The objective of this requirement is to ensure that the conductors are adequately protected against the effects of a short circuit arising from an insulation fault close to.3 Location of overcurrent protective devices The location of overcurrent protective devices (see 7.Section Eleven Protection of equipment the effect of indirect contact is achieved (see Section 10. Section 11. mechanical damage. It is realised that it is not always possible to meet this requirement and a conditional relaxation is permitted.2.8) requires that they be put at any point where the reduction in the cross-sectional area of the conductor or other causes reduces the current carrying capacity of the circuit conductor. between the point of load rating reduction and the protective device. but downstream of. if a fault occurs. the protection upstream should still be able to detect the overcurrent and disconnect the supply before excessive damage or fire occurs and a risk to persons develops.

8) are necessary to minimise the possibility of an electric shock hazard occurring. It should be noted that BS 7671 Section 607 contains requirements for the installation of equipment having high protective conductor current.1 that there are no application options.Section Twelve Equipotential bonding The requirements in Clause 8 are clear and it can be seen from Table F.3 with a further reference to 12. Figure 2 has been changed to make it clearer. conductor bars and slip-ring assemblies.2.3). It needs to be noted that the protective bonding circuit is part of the measure for protection against electric shock from indirect contact (see Section 10.2. both dealing with equipotential bonding measures for electrical equipment having relatively high values of earth leakage currents. An important requirement is to arrange the protective bonding circuit so that removal of any item of equipment does not affect the bonding circuit for the remaining equipment.8 and 8.2 for conductor wires.7. New items included in this issue of BS EN 60204-1 are 8.2. The immediate consequences arising from failure of the protective conductor to such items of electrical equipment are so severe that special measures (see 8.4. Continuity of the protective bonding circuit has to be maintained and requirements are specified in 8. 23 .

It is there to reduce the effects and consequences of an overcurrent arising from an insulation failure on the control circuit.1.1. thereby minimising burn and fire hazards.Section Thirteen Control circuit supplies Control circuit supply transformers are required except as specified in the last paragraph of 9. This is to take into account the difference in relay coil rated voltage arising from the use of a supply frequency of 60Hz instead of 50Hz. persons carrying out fault finding (see 9.2). This requirement is not there (as is thought by many) primarily for the reason of minimising the possibility of electric shock to. for example. 24 . The impedance of the transformer significantly reduces the value of the overcurrent. Schneider Electric offer the ABL-6 range for transformers and ABL-7 range for DC switch-mode power supplies.1. It needs also to be noted that the maximum transformer-derived nominal control voltage limit is specified as 277 V.

25 .2.5.2 Emergency stop (see 9. Section 14. when initiated. and 2) Use of different requirements. means to release trapped persons. There will be situations where items on the machine (for example.ISO 13850 is under review and when published could replace BS EN 418 as BS EN ISO 13850. coolant pumps or fans) may have to be left in operation or automatically started (emergency start) to ensure a hazardous situation does not develop. this is not always the case. two are specified in 9.1 General Emergency operations Annex E (informative) describes what is meant by emergency operations. Both options and other considerations are discussed in turn in Sections 14.The term “stop category” has been introduced to avoid confusion with the categories for control system behaviour in the presence of faults that are described in BS EN 954-1. Whilst often the same part of the control circuit is employed for both functions. This standard specifies in general terms the types (characteristics) of machines that are required to be equipped with emergency stop and the type of stop (stop category 1 or stop category 2. Of the four control functions described.2. This incorrect use of the term is deprecated because it continues to confuse machine users and equipment designers. The machine supplier will need to carefully consider this as part of the risk assessment of the machine.1 shows actions to be considered as: 1) Selection from the measures given.Section Fourteen Section 14. The term emergency stop is often erroneously used when referring to the automatic stop action generated as a result of operation of a primary safeguard such as a guard interlock or trip device. Note . It specifies that the emergency stop function is not to be considered as a primary safeguard and it is initiated by a single human action.2 and 14. see 9. does not give rise to additional hazards both during the stopping process and whilst the machine remains in the non-operational condition until the emergency stop has been reset. Note .4.2 Stop functions) considered to be necessary.5. The important criteria that also need to be considered are the means to ensure that an emergency stop function.2) Requirements for emergency stop are specified in ISO 13850 and BS EN 418.3.4 and Table F.2.

Where the consequences of accidental or malicious operation can be severe.3 and 10. employ a stop category 1 emergency stop function. A product standard (IEC 60947-5-5) exists for these devices.7. albeit imperfectly. They need to be readily accessible and should not place the person in danger when operating them. If. 26 . use alternative stopping systems. but. There is a need to provide information for use or other means to minimise confusion between active and inactive devices where emergency stop devices are at control stations that can be disabled. in order to prevent additional hazards being generated during the emergency stopping process. together with a range of Preventa safety relays to monitor emergency stops where required. additional means can be employed always providing ease of operation and other requirements in this standard. ISO 13850 and the device product standard are met.7.1). because the consequences of failure of such a stopping system are very severe. Harmony style 4 & 5 meet these requirements.2) then the power supply has to be switched off to complete. Multiple contact blocks are available where they are needed by the safety requirement. the emergency stop process. This is usually achieved by omitting the yellow background around the device. Types of human actuated emergency stop control devices together with their location and other requirements are specified in 10. These back-up systems can be activated during an emergency stop sequence if the control system detects that the machine deceleration is not meeting the required deceleration rate.2. however. Schneider Electric recommends the use of trigger-action emergency stop devices in order to meet the relevant essential requirement of the Machinery Directive.2. Furthermore they need to be clearly visible even though there might be a possibility of accidental or malicious operation. this system fails to achieve the stop (see 9. Some complex machines rely on deceleration control systems. that can be unsuitable for normal production. Such control stations are those for cableless control and pluggable control pendant controllers used for setting/teach purposes when preparing a machine(s) for production (see 9.Section Fourteen Emergency operations The appropriate electrical or other control equipment will need to be included to achieve this. It needs to be born in mind that these control devices are to be located wherever it is considered to be necessary from the risk assessment of the machine.7. There are other machines which. One means is to equip the emergency stop push button with a lockable reset facility with management control of the key. as back-up systems.

Furthermore. In these and similar cases the supply disconnecting device may meet the requirements of 10. The important thing to bear in mind is that unlike emergency stop which applies a stop only to those machine functions needing to be stopped.7. in those situations where both emergency stop and emergency switching off devices are present.Section Fourteen Emergency operations Local operation of the supply disconnecting device to effect emergency stop (see 10. 27 .2. when operated. Situations such as this have been seen on paper making and associated machinery where the emergency switching off device has been provided (for example. emergency switching off is carried out at the point of supply to the machine or part of the machine concerned. then means to prevent confusion will need to be provided (see 10. in a break glass enclosure) which. opens the power supply switchgear located in remotely placed switch rooms. Often the reason for providing this facility is to enable fire fighting to start without delay.6) in 12.2.3.1 (See also Section 20).7.3 Emergency switching off (see 9.1).4) may be appropriate for those machines where a separate emergency stop is not considered to be necessary.4.7.5.2. Hence the possibility of other hazards appearing as a result of removal of the power supply(ies) needs to be considered and changes made or measures applied to minimise the possibility of hazardous situations arising as necessary.3) The prime reasons for provision of emergency switching off are described (see also 6.5. 6. Section 14.8.

6. The ergonomic aspects of two-hand control can be met by the use of Telemecanique XY2SB two hand control stations. An appropriate Preventa safety relay can be used to monitor the two-hand control station.Section Fifteen Two-hand control Two-hand control is a form of hold-to-run control. Even so. Although full requirements for two-hand control are specified in ISO 13851 (BS EN 574).2. The circumstances that determine which type (of the three types described) of two-hand control can be used either alone or in conjunction with other protective measures are outside the scope of this standard.2 that a Type 1 is not considered to be suitable for the initiation of hazardous operation. it is stated in 9. this subclause is retained in BS EN 60204-1 for completeness. 28 .

It leaves the user of cableless controls to specify parameters.Section Sixteen Cableless control 9. The response time of such machines can vary significantly and has to be specified by the machine supplier according to the risk assessment. such as time to respond in case of loss of communication signal.1.1). to suit the particular machine operating conditions to which it is applied (see also Table F. It sets out the basic essential functional requirements which have been accepted by many.2. Of the differing types of machine needing cableless control. 29 .7 Cableless control was added at the previous issue of BS EN 60204-1 and has changed little in this issue. overhead travelling cranes (see BS EN 60204-32) and other mobile rail mounted machines are good examples.5 also apply to cableless control stations. It is sometimes forgotten that the requirements of 10.

4. These categories however should not be considered to be hierarchical as far as performance (integrity) or their contribution to risk reduction is concerned. The equipment used to implement these control functions (particularly the operator interface devices) is specified in Clause 10 and this principle has now been consistently applied (see Note 2 in 9. 30 .1 now refers (in addition to ISO 13849-1: 1999) to IEC 62061: 2005.2).4.1 dealing with protection against maloperation due to earth faults.2). ISO 13849-1 covers safety-related parts of control systems. The remainder of this subclause is generally unchanged apart from the expansion of 9. IEC 62061 applies to the complete safety-related electrical control system implementing the safety control functions identified from the risk assessment of the machine under consideration.3. 9. It specifies 5 differing categories of a safety-related part of a control system the performance of which. electronic and programmable electronic safety-related control systems. It applies equally to electrical.Section Seventeen Control functions in the event of failure This is dealt with in 9. This has been expanded to more clearly describe 3 methods of meeting the requirement (see also Figure 3 and Figure 4 of BS EN 60204-1). The control functions described in 9.4 of BS EN 60204-1. which is a new standard implementing IEC 61508 for the machine sector.2 specify what shall happen with the assumption that the function is operating normally (see Note 1 in 9. is related to the effect of a single fault occurring in it (mainly based on the system architecture).

It covers the requirement to select. All colours are available for both pushbuttons and indicator lamps from the Telemecanique Harmony style 4 & 5 range of metal or all insulated pilot devices.1. keypads and keyboards) (see 10.2 and are self explanatory. 31 . It now includes general requirements designed to cater for modern devices (for example. code and mount these devices so as to minimise the possibility of incorrect operation of control and misinterpretation of signals generated by indication devices. Section 18. Providing the ergonomic requirements can be satisfied the three-position type is likely to be more effective as the operator does not have to react in just one way (as in the two–position type) to stop hazardous machine operation. no product standard exists for these devices and great care should be taken when selecting a suitable device.1. indicators and position sensors. yet it allows use of the colours green and red at those places where existing machines using these colours are installed. This allows for the adoption of white and black for machines supplied at locations where machines have not been installed previously. However a new recommendation for indicating towers has been added. Green for start and red for stop are also included with a ban on their use for stop and start respectively.2 Colours for push buttons Users of this standard will have noted the preference for use of push button actuator colours of white for start.3 Colours for indicator lights These are specified in 10.4 Enabling control device Requirements to enable the appropriate selection of a suitable enabling control device are specified in 10. The Telemecanique XY2-AU range is a three-position type. Section 18.Section Eighteen Section 18.1 General Operator interface and machine mounted control devices Clause 10 deals with the requirements for control devices. and black for stop.9.).3. The XVB indicating towers range can comply fully with the recommendations. particularly where hazardous machine operation is involved. Currently. touch screen. In any event the choice of colour can require consultation with the user (see Annex B of BS EN 60204-1) to minimise the possibility of confusion at the place of use of the machine. Section 18.

Accordingly. In addition. This can enable work on non-electrical parts of a machine to be carried out often without the need to access areas containing electrical equipment which can present a hazard.2 Degrees of protection Degrees of protection of controlgear against the effects of solids and water are specified in IEC 60529 and the level needed will depend upon the environment at the location in which the equipment is intended to be used.1 General Controlgear: location.3 Access to controlgear Safe means of access. Section 19. in 11.Section Nineteen Section 19.1. For example. devices and terminals as far as is possible. Other measures can be necessary to protect against the ingress of other liquids such as oil etc b) The tests in IEC 60529 evaluate the resistance of enclosures to the ingress of solid objects applied without significant force. 6th paragraph. the degrees of protection shown in 11. and to the ingress of water during a 30 minute test.3 are typical only and the degree needed needs to be determined. These are framed to enable the user of the machine to minimise risk from electrical hazards to those requiring access to the electrical equipment or to the machine. mounting and enclosures The objectives of Clause 11 are given in 11. Section 19.2. Furthermore it should be realised that the: a) Degrees of protection in IEC 60529 apply to solids and water only.4. Other measures can be necessary to protect against the forcible introduction of solid objects or against the long-term ingress of water.1. the requirements of 10.5.2 there is a requirement to segregate nonelectrical equipment from electrical equipment and to separate/group power and control circuits. c) Requirements for protection against electric shock (see Clause 6) also need to be satisfied.3 are appropriate particularly when considering panel mounted operator interface devices. A similar requirement is contained in 11. 32 . adequate clearance for work and provision for means of escape are specified in 11.

first and second paragraphs.1.7. If this is not possible. Conductor wires. The requirements for conductors and cables specified in Clause 12 are compatible with those specified in IEC 60364. used as part of the electrical equipment of the machine.7.7. 33 .Section Twenty Conductors and cables Clause 12 does not apply to the internal/integral wiring of items of selected electrical equipment (usually meeting its own IEC product standard) such as variable speed drives. always be protected against direct contact to 12. All types of conductors and cables used on machines are covered including flexible cables wound onto drums.7. It cannot be stressed too emphatically that even though conductor bars and conductor wires are located such that they are normally out of reach they should. then emergency switching off needs to be provided in accordance with 12. It includes requirements for protection against direct contact (see 12. when practicable.2) and use of removable connectors with a disconnecting function (see 12.1).1.7.4). ensuring the continuity of the protective bonding circuit (see 12.7. third paragraph. The apparent difference seen by the user is there only because the ambient temperature limits specified in both standards differ (BS EN 60204-1 uses 400 C). conductor bars (please note the change in description) and slip-ring assemblies are comprehensively dealt with in 12.

the requirement might be met by a simple wiring diagram.1 will often be determined by the machine itself. interlocks. a copy of which may be mounted on the inside of the control cabinet door. However. 34 .5 has been extensively modified to include all relevant requirements for plug/socket combinations.4) have been included (see also Sections 19. the particular relevant requirements are called up in other clauses by reference as.2) and the use of an inductive power supply system (see 13.1. Then. Whilst other methods of compliance with 13. once the complexity of the wiring becomes significant. important changes/additions to facilitate maintenance (see Section 21. Even so. to take account of mobile and other machines having long flexible cables (see 13. for example in 5.4. For example.2 Identification of conductors and/or terminations The method used to meet the requirement specified in 13. The addition of the 6th paragraph of 13.2). particularly on circuits such as control circuits used for safety-related machine functions for example.1 can be cheaper to implement and reduce the initial cost of the machine to the user.3.Section Twenty one Section 21.3). In the case of a more complex machine.2.1.2. 13.1 is an important change insofar as assisting maintenance and fault finding.2. In addition. Section 21. this arrangement does not easily lend itself to ease of maintenance and fault finding activities (see below). and c) Reduce machine operating costs.1. there are circumstances where the more expensive option can: a) Enable speedy fault finding to take place b) Minimise the risk of error when carrying out re-connection. in the case of a machine having a single control cabinet with a simply wired motor starter and perhaps one or two items of electrical equipment (interlock position switch) on the machine.1 and its cross reference to 13. a wiring schedule can be used complete with details of each connection and its connection points. Cable markers such as those in the AR1 range are recommended by Schneider Electric.3.1 General Wiring practices The requirements of Clause 13 have remained basically unchanged. thereby outweighing the extra capital cost.2 and 19.

Section Twenty one Wiring practices In addition. colour blindness. care should be taken that the colours used can be easily distinguished from each other. the operating voltage(s). Section 21. the use of colours can help in the identification of the general function of the wiring and. on occasions.Colour can sometimes be difficult to identify due to discolouration with age. either dragged along by the machine (as in a quarry) or mounted in a cable guide way. Note . poor lighting. that needs to be longer than that supplied (on a drum) by the cable supplier.3 General An exception has been added to 13. An example of this is on a mobile machine supplied by a flexible cable. 35 . When identification is by colour alone.2 to allow for the use of cable splices or joints in particular well-defined circumstances.1.

Therefore it follows that in order to ensure that a particular machine motor can operate at the quoted rated output over the voltage range. a voltage drop of up to 5% of the nominal supply voltage between the point of supply to the machine and the motor terminals (see 12. a larger motor may need to be selected.Section Twenty two Electric motors and associated equipment Whilst the requirements for motors and associated electrical equipment remain essentially the same as before. In addition.3.1 (+ or – 10%). Motor performance specified in IEC 60034-1 is guaranteed over a narrower range of supply voltage than specified in 4. 36 . there exists an apparent misunderstanding among some users of the standard as follows.5) needs to be taken into account.

Section Twenty three Accessories and lighting Clause 15 deals with the requirements for machine mounted socket outlets and local machine lighting together with a choice of lighting power supply arrangement. 37 . Schneider Electric can supply a number of ranges of RCDs. The first note refers the user to Annex B.1) in this issue of the standard. the enquiry form and the second note refers to the provision of residual current protective devices (see also Annex B). Two notes have been added (see 15.

2.5 of the previous issue of BS EN 60204-1 has been removed (see 16.5).Section Twenty four Marking.2. Users of the standard should note that the relaxation for simple equipment previously allowed in subclause 17. warning signs and reference designations Telemecanique variable speed drives carry this warning label when the heatsink can reach hazardous temperatures. 38 . The users’ attention is brought to the addition of a new requirement for the warning sign for hot surfaces hazard in 16.

Within the EU there are specific requirements specified in the Machinery Directive. 39 . In addition it is noted (see 17.1) that documentation provided with items of electrical equipment can form part of the documentation for the electrical equipment of the machine and the requirement to use specific languages is covered by legal requirements in some countries.Section Twenty five Technical documentation Clause 17 has been updated as is necessary to reflect changes to the reference standards. Note .

normative Annex A has been added to detail the conditions that need to be satisfied.2 of the previous issue of BS EN 60204-1.5 and 18.3 Verification of conditions for protection (against indirect contact) by automatic disconnection of supply This verification incorporates in 18. Attention is drawn to the warnings concerning possible hazardous situations and actions needed to minimise the possibility of a hazard being present during testing.6 has been amended to strictly reflect that the scope of BS EN 60204-1 is restricted to the electrical equipment.6 (see below). Section 26.4 Insulation resistance tests This type of test is often performed after installation on site.2 Test 1 the “continuity of the protective bonding circuit” requirement contained in 19.7 of the previous edition.3. It also specifies that the verifications shall always include those in 18. Section 26.5 and 19. Even so care needs to be taken to ensure that equipment that can be damaged by the test voltage is disconnected first.Section Twenty six Section 26.6 Other verifications The verifications in 18.2.7 have not changed from those in 19.1 b) and 18. However 18. 18. 18. The remaining mandatory verifications are contained in 18. It needs to be stressed that Table 10 gives examples only based on the assumptions stated at the bottom of the table. It also allows for tests (or calculations where appropriate) to be carried out to ensure the machine installation complies with 6.1 General Verification As a result of a thorough review.3. significant changes have taken place in Clause 18 and these are described in detail below. All equipment that is not rated to withstand the test voltage needs to be disconnected first and the duration of the test voltage is limited to approximately 1 second to minimise any damage/deterioration to solid insulation arising from application of the test voltage.1 a).5 Voltage tests This type of test is normally performed only when there is good reason to do so. Section 26. 40 . particularly when significant cable installation or similar work that could result in damage to insulation has been carried out. As part of this verification process.1 it is stated (as it was before) that the verifications to be carried out will be specified in the dedicated product standard (type C standard in CEN – see Figures 1 and 2 of this booklet) for a particular machine.2 Mandatory verifications In 18. The tests in Table 9 that are necessary are determined from the status of the machine.1 f). Section 26. Section 26. Table 10 has been provided as an aid to determine the machine status.1 a) requires that the equipment complies with its technical documentation.2 and 18.

other special conditions) under which the machine is to be used I Details of the overcurrent protective device(s) on the power supply(s) connections and whether or not disconnection of the neutral is required I Special colour preferences (for example to align colours of push buttons. etc with existing machinery I Additional or special requirements such as. voltage and temperature range. 41 . specific details of means required to identify conductors and provision of degree of protection against specified materials. indicator lamps. This Annex has been reviewed and is now organised in a way that allows the reader to identify more clearly those relevant clauses and sub-clauses of the standard that apply to each question.Section Twenty seven Additional user requirements etc – Annex B Annex B is the basis for a form that can be used by the intended user of the electrical equipment (machine) to inform the supplier of: I Basic conditions (for example. indoors or outdoors. to facilitate an agreement between them.

At the same time the reader should not forget the status of this standard as explained in Section 3 above. there may be other types of machines to which this standard could be applied. 42 . It needs to be stressed that this list is of examples only and it is not an exclusive list.Section Twenty eight Annex C This Annex has been extended to include agriculture and forestry machines in the list.

43 . the objective being to ensure cables are not damaged as a result of excessive temperature rise.Section Twenty nine Annex D This Annex provides supporting data for Clauses 12 and it also provides information for those determining the overcurrent and overload protective devices and their settings.

44 .Section Thirty Annex E Please see Section 13.1.

Section Thirty one Annex G This Annex has been reinstated at the request of the US national committee. 45 . Whilst this information is readily available elsewhere. the user of this standard may find it convenient to use when designing for the American market.

see 6. Those standards listed in the bibliography are often those.5).Section Thirty two Normative references (Clause 2) and the bibliography Schneider can often give advice on the content of these standards. 46 . Schneider Electric can give advice regarding the differences that exist in some countries and how to comply with local requirements.2). but not always. A final note. Suppliers of electrical equipment for machines intended for use in these countries need to be aware of these differences.2. when IEC 60204-1 was adopted as EN 60204-1 in Europe. However. Users of BS EN 60204-1 should be aware that the technical requirements in this standard are identical to those in IEC 60204-1 and therefore can apply to those countries outside Europe that have decided to adopt IEC 60204-1 as their own national standard. referred to in notes for further reading (for example. see NOTES 1 and 2 of 4. its Foreword was replaced by a European one. Those standards listed in Clause 2 are normative references and need to be complied with to achieve compliance with that particular requirement (for example.4. As a global supplier. There is in the IEC Foreword a final paragraph listing differences that exist in some countries.

Electrical equipment of machines – Part 11: Requirements for HV equipment for voltages above 1000 V a.c. and tested to verify the conductors are dead.7 regarding bonding connections to building steel work in close proximity to the machine is also of note. short-circuited and connected to earth. Equipotential bonding has to be comprehensively applied to successfully create and maintain an equipotential zone suitable to contribute to the measures specified in 6. 1500 V d. Section 33. Even so. On the other hand those parts of controlgear for HV equipment covered by its own product standard will need to comply with the relevant requirements of that standard where they exist.2 Use of means of earthing equipment Persons should not work on HV equipment conductors until they are isolated from all sources of supply. Safety of machinery .1 General BS EN 60204 -11: 2001 . The user will note that many requirements are similar to Part 1 which has been followed as far as is feasible. Part 1 of the standard will apply to those circuits (for examples used for LV drives such as lubrication pumps etc on the machine and the associated controlgear.2. The requirements dealing with this are in 5. 5. important differences.2. essential for HV equipment.3. the value of the hazardous touch voltage is a much smaller proportion of the supply voltage. and not exceeding 36 kV.Section Thirty three Section 33. 47 . is a very similar standard to Part 1 and both parts 1 and 11 normally need to be applied to machines having a HV supply. Section 33. exist and these are dealt with below. A further point is that IEC 60204-1: 1997 is referred to and needs to be used by users of Part 11 although the later issue should be used where possible (see first paragraph of Clause 2).4 and Clause 16.2.3.3 Equipotential Bonding Requirements for Part 11 differ significantly (see Figure 2 of BS EN 60204-11) because with HV equipment. The requirement in 8. See also 6.2 for measures to prevent the occurrence of a hazardous touch voltage.Its relationship with BS EN 60204-1 BS EN 60204-11: 2000.c.3.3 required to achieve protection against indirect contact.

Appendix A List of standards referred to in this booklet BS EN ISO 12100-1: 2003. Low-voltage switchgear and controlgear assemblies – Part 1: Type-tested and partially type-tested assemblies. Electrical installations of buildings – Part 4-41: Protection for safety – Protection against electric shock.c. BS EN 60204-1: 200X. electronic. IEC 60529: 2001. IEC 60034-1: 1996. Safety of machinery – Basic concepts. Safety of machinery – Electrical equipment of machines – Part 32: Particular requirements for hoisting machines. Functional safety of electrical/electronic/programmable electronic safety-related systems. general principles for design – Part 1: Basic terminology. methodology. BS EN 60947-5-5: 1998. IEC 60364-4-41: 2001. 48 . IEC (BS EN) 61508 (all parts). Safety of machinery – Prevention of unexpected start-up. BS EN 60204-11: 2000. Safety of machinery – functional safety of safety-related electrical. IEC (BS EN) 62061: 2005. Rotating electrical machines – Part 1: Rating and performance. and not exceeding 36 kV. Specification for low-voltage switchgear and controlgear — Control circuit devices and switching elements — Electrical emergency stop device with mechanical latching function. Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design. ISO 13850: 1996 (BS EN 418: 1992). BS EN 60204-32: 1998. 1500 V d. Safety of machinery – Electrical equipment of machines – Part 1: General requirements. ISO 13851: 2002 (BS EN 574: 1997). programmable electronic control systems.Electrical equipment of machines – Part 11: requirements for HV equipment for voltages above 1000 V a. Degrees of protection provided by enclosures (IP code). amended 2002 and 2004. Safety of machinery .c. Safety of machinery – Two-hand control devices – Functional aspects and design principles. Safety of machinery – Emergency stop – Principles for design. ISO 13849-1: 1999 (BS EN 954-1: 1997). BS 7671: 2001 – Requirements for electrical Installations (IEE Wiring Regulations 16th Edition). IEC 60439-1: 1999. ISO 14118: 2000 (BS EN 1037: 1995).

Safety-related parts of control systems. BS EN 422 . BS EN 61496 .General principles for design ISO 14121 . Types of machinery safety standards Type A standards BS EN ISO 12100 . ISO 13850 . Standard(s) applies when the protective device(s) is used on the machine Type C (Product) standards Examples are: BS EN 940 .Electrical equipment of machines. ISO 13849 .Pressure sensing mats and floors.Risk assessment Apply to all machines Type B1 standards (Horizontal standards) Examples are: BS EN 60204-1 .Two-hand controls. BS EN 1760-1 .Safety-related electrical control systems.Appendix B Figure 1. IEC 62061 .Rubber & plastics machines 49 . Those standards that are relevant apply Type B2 standards (Protective device product standards) Examples are: ISO 13851 .Basic concepts .Emergency stop.Electro-sensitive protective equipment.Combined woodworking machines.

Basic concepts.Appendix C Figure 2.Safety of machinery .Principles for risk assessment Type B1 (horizontal) and B2 (product) standards BS EN 60204-1 Electrical equipment of machines IEC 62061 Safety-related electrical control systems ISO 13849-1 Safety-related parts of control systems ISO 13850 Emergency stop Protective device standards.Safety of machinery . ISO 13851 Type C (product) standards for machines Guidance for the design of those machines for which no Type C (product) standard exists 50 .g. e. B and C standards to machines Type A (horizontal) standards BS EN ISO 12100 . general principles for design ISO 14121 . Application of types A.

. 51 . Trafford Park. Thornbury.. North Eastern Region at Drax Power Station. It also included redesigning and installing switchgear operational interlocking systems and trouble shooting. Aircraft Equipment Division. He has been involved in work on British Standards Institution Technical Committees since 1979 and in 1982 became a member of the BSI technical committees dealing with electrical equipment of machines and photo-electric guards and has since served continuously on both committees. interlocking and sequence switching on the super-grid system and at new power stations.B. He now is a Standards Consultant on Machinery Safety – Electrotechnical Aspects. . testing and acceptance of all items of plant operating at voltages up to 13. He ceased to be chairman in 1999 but remains on the committee. Leeds. approval and development of systems used for power system protection. When the commissioning work was completed. Brian Clark was employed by the HSE since 1976 and retired from the UK Civil Service on 11 September 1998.8kV. on 31 December 1996 with the citation “for services to the Health and Safety Executive”. The work involved commissioning. in particular Drax Power Station. North Eastern Region Headquarters at Leeds. He became chairman of PEL/44 (now GEL/44) Safety of machinery – Electrotechnical aspects in January 1995. The work involved inspection. He was trained and appointed as a Senior Authorized Person both for mechanical and electrical work including electrical testing.6 months as a Production Test Engineer at AEI Ltd. and . Manchester – work on design of test equipment for main frame computer components. Ltd. Generation Division. he was appointed as the Electrical Maintenance Engineer for the coal and ash handling plant at Drax Power Station.Appendix D About the author Eur Ing Brian James Clark OBE DipEE CEng FIEE Date of birth: 12 September 1938 After serving: .E. Bradford . He joined the UK Health and Safety Executive (HSE) in June 1976 as Senior Electrical Inspector of Factories for the South Yorkshire and Humberside Area.a 5 year student (Electrical) apprenticeship with Ministry of Supply (Ministry of Defence) at Royal Ordnance Factory.Testing and development of aircraft power supply systems. In June 1970 he was appointed as 1st Engineer (Commissioning) at Central Electricity Generating Board. In recognition of his work in machinery safety standards.18 months as a Laboratory Engineer at English Electric Co. and engineering plant improvements. Transmission Division (Protection design & diagrams section). he joined the electricity supply industry in October 1962 as an assistant power systems protection engineer with the Central Electricity Generating Board. he was awarded the O. This involved managing a team of electrical craftsmen maintaining the plant and machinery. During this employment by HSE and from April 1982 he held the post of HM Principal Specialist Inspector and headed the Machine Control and Electrical Safety Section of the Electrical and Control Systems Unit in the Technology Division of the HSE.

This standard is now available as BS EN 60204-11: 2000.Electrical equipment of industrial machines. In addition to steering the work of CENELEC TC 44X. and the CEN TC 114/CLC TC 44X Joint Working Group 9 that prepared the European standards for emergency stop and prevention of unexpected start-up. He was Chairman of CENELEC TC 44X . e.Safety of machinery: Electrotechnical aspects. IEC 61496. BS EN 418/ISO 13850. Advice was also provided on behalf of the BSI Technical Committee as its chairman.g.General requirements. He has served on Working Groups 1 and 2 (EN 61496 Electrosensitive protective equipment) of CLC TC 44X. He also served on the working group that prepared Part 32 for hoisting machines which was published in 1998. In 1987 he became involved in international standardization as Convenor/Secretary of IEC TC 44 Working Group 3 charged with the task of revising IEC 204-1:1981 and held this position until the publication of the revision in 1992 (It was subsequently slightly modified and published as BS EN 60204-1: 1993). He was (until September 2000) also the Project Leader of IEC TC44’s Working Group 7 preparing a new standard on functional safety of machine electrical. He also provided input (either directly or via the relevant BSI committee) to various CEN technical committees preparing machine safety standards. This European Technical Committee is deeply involved in the mandated standardization work in support of EU Directives. Results of this work included BS EN 60204-1:1998 . The IEC 60204-1 standard was further revised and published in 1997 and was published in the UK as BS EN 60204-1: 1998 which was. This European standard was ratified in 1985 and was published in the UK as BS 2771:1986. BS EN 61310: 1995 .Appendix D About the author He became involved in European standardization as a member of the UK team negotiating the harmonization of IEC 204-1:1981 .Electro-sensitive protective equipment . he was actively involved in the "internationalization" of the machinery standards work initiated in Europe and attended meetings of IEC TC 44 as a member of the UK delegation and as Chairman of CENELEC TC 44X. He served as a UK expert on the maintenance team that prepared the update of Part 1 which is now available as BS EN 60204-1: 2006. He was Convenor of CENELEC TC 44X Working Group 1 which prepared the draft of the new Part 11 of IEC/EN 60204 dealing with Electrical equipment of machines operating at high voltages up to 36kV. 52 .Safety of machinery Electrical equipment of machines: Part I . on the use of standards such as EN 60204-1. BS EN 60204.Indication. as EN 60204-1 in the CENELEC BT Task Force set up in 1982.General requirements and tests. marking and actuation and BS EN 61496-1:1998 .Safety of machinery . This is now available as BS EN 62061: 2005.Specification for general requirements. for the first time. technically identical to the international standard. on the use and interpretation of standards. electronic and programmable electronic control systems.Safety of machinery . Part 1 . since its creation in 1988 until October 2001.

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