Contents
Operator interface and machine mounted control devices Section Eighteen Page 31
Marking, warning signs and reference designations Section Twenty four Page 38
Normative references (Clause 2) and the bibliography Section Thirty two Page 46
BS EN 60204 -11: 2001 - Its relationship with BS EN 60204-1 Section Thirty three Page 47
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Section Introduction
One
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 - 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 Objective
Two
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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Note - Another representation of a typical machine can also be seen in Figure A.1 of BS
EN ISO 12100-1: 2003.
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 follows that these tasks need to be conscientiously
carried out.
Note - In the context of IEC 60204-1, the term “supplier” refers to any entity in the supply
chain. See 3.54 of the standard for the exact definition.
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Section Scope
Five
This expands on that given in Section 3 above in two ways. One is the
need to identify additional requirements (see column ii) of Table F.1.
The other is to identify the point(s) at which the machine takes its
supply(ies).
Whilst many machines only require one incoming power supply, other
(often complex or very large) machines need more than one (see 5.1).
In general a single incoming power supply is recommended where
possible with other power supplies derived from it (see 5.1) so that a
single device can disconnect the machine from the electrical supply.
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, see 15.1 and 15.2). This
situation is catered for in 5.3.5, 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.
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Section Scope
Five
More often than not, the point of supply for single machines is clear. In
the case of larger machines and, in particular for machines working
together in a co-ordinated manner, requiring more than one power
supply, the point(s) of supply (and hence from what point
BS EN 60204-1 is applicable) can become unclear. For example, a
switchboard may consist of several outgoing circuits equipped with
switchgear meeting the requirements of 5.3. Where outgoing circuits
feed machines working together in a coordinated manner, the point of
supply to the machine could be considered to be at the switchboard.
Alternatively, 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, such as for general
lighting of the building, derived from that switchboard), then this
switchboard can be considered to be part of the machine’s electrical
equipment. In this case, the switchboard incoming supply circuit
switchgear (when meeting the requirements of 5.3) 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. In any event, the requirements of
BS 7671 and BS EN 60204-1 do not, it is believed, conflict in this area.
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The objective of 4.2.1 is to ensure that electrical All Schneider Electric’s products are
equipment is suitable, meets recognised IEC standards designed and manufactured in
where possible and is used as intended. Whilst accordance with relevant IEC
compliance with a recognised international standard is standards. Schneider Electric
not in itself a guarantee of perfect reliability, there is a participate in the development and
reasonable degree of assurance that the equipment revision of many International and
supplier has had the equipment type tested to the European standards including
standard and the equipment supplied performs to an IEC 60204-1.
identifiable specification with clear instructions for use.
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Subclause 5.3 describes the device or devices used in Schneider Electric can supply a
combination (for example see 5.3.2 b)) that may be used wide range of suitable devices, e.g:
together with the specific requirements they have to the Vario range rated up to 75A and
meet. The range of devices allowed has been extended LK3 range with ratings up to
in 5.3.2 d) in this issue of the standard. The functions that 1250A.
have to be available are that of disconnection (for work Auxiliary contacts for control circuit
on the electrical equipment of the machine) and the interlock and indications can also be
capability to switch off the maximum load/overload added if required.
current of the machine under the conditions described in
5.3.3.
It should be noted that when a neutral conductor is The majority of Schneider Electric
provided in TN systems, some countries require this disconnecting devices are available
conductor to be switched by the supply disconnecting in 3- or 4-pole.The 4th pole on a 4
device. It is not unknown for a 4-pole machine supply pole device may comprise either a
disconnecting device to be requested even though the solid or switched conductor.The
supply requirements of the machine do not include a Vario range can also include early
neutral. There is no reason (apart from cost) why such a make late break for neutral
request from the machine user should not be satisfied. switching.
Note - See also 5.1 and Section 27 regarding the neutral conductor.
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This subject has already been touched upon in Section 5.2 above. It is
important that such circuits (see 5.3.5) have some means of
disconnection and are adequately protected against overcurrent. The
reason that such provision is only a recommendation in 5.3.5 is to give
relief where necessary from the strict requirements of 5.3.1 to 5.3.4.
For example, in the case of accessories and local lighting Clause 15
will apply. 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, see 13.2.4, such as orange in the case of
control circuits for interlocking, separation and labelling also needs to
be considered. Finally protection against direct contact (see Section
10.2, method b) for use of enclosures) might need to be supplied.
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Many of the means used for the above (for examples see Section 7,
Section 9.3, etc.) involve electrical equipment that has to be adequate
(see Section 6) to fulfil these tasks.
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Other devices, apart from those described in 5.3.2, Schneider Electric can provide
capable of providing electrical isolation, such as a full range of disconnectors
disconnectors, withdrawable fuse links and withdrawable and withdrawable fuse
links are allowed to be supplied providing they are holders.
located in an enclosed electrical operating area. 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. Also it should be
noted that the location of, for example, withdrawable fuse
links, is often inside a locked fuse box or a locked
electrical equipment panel on or near to the machine;
and not necessarily in a locked switch room some
distance from the machine. In both cases, their use
should only be considered for those intervention activities
that always require the attendance of an electrically
skilled or instructed person. 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).
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5.6 deals with provision of means for safeguarding the measures for
prevention of unexpected start-up (5.4) and the means for isolation
(5.5) and energy dissipation against unauthorised, inadvertent and/or
mistaken connection. The means to be provided are specified as:
Means to secure isolators in the off position (and discharge means
in the closed position; see Note 1 below) by for example, padlocks,
trapped key interlocks
Warning labels, particularly for items that cannot be locked and
therefore have to be located in enclosed electrical operating areas.
Note 1 - electrical equipment such as capacitors, HV equipment (see Section 33.2) that
can remain or become electrically charged need to be short circuited and earthed.
Note 2 - 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. Therefore suitable advice needs to be included in
the information for use. Advice is contained in Section 12 of PD 5304:
2006.
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The measures are described in 6.2 and whilst the requirements are
self explanatory, certain of these merit explanation of the reasoning
behind them.
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In the case of a), the use of a key or tool is necessary; Virtually all Schneider
the intent being to restrict access to electrically skilled or Electric devices have fully
instructed persons. Even so, those live parts that are finger-protected (IP2X)
likely to be inadvertently touched (including those on the terminals, or have separate
back of doors) have to have some protection against shrouds available to enable
direct contact. This measure also now applies to those IP2X protection.
enclosures covered by condition b); 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).
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the supply disconnector has been opened or the supply High voltages can exist within
plug is withdrawn from its socket, the electrical variable speed drives for
equipment is no longer live at a dangerous voltage. The several minutes, and the
designer needs to take care to ensure that any discharge time is marked on
hazardous voltage source dissipates to a safe level within the drive enclosure.
5 seconds if within an enclosure or 1 second in the case
of exposed pins of a plug. Otherwise, additional
measures are required (see also 12.7.4).
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The requirements in Clause 8 are clear and it can be seen from Table
F.1 that there are no application options. 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.
New items included in this issue of BS EN 60204-1 are 8.2.8 and 8.4,
both dealing with equipotential bonding measures for electrical
equipment having relatively high values of earth leakage currents.
The immediate consequences arising from failure of the protective
conductor to such items of electrical equipment are so severe that
special measures (see 8.2.8) 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.
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Control circuit supply transformers are required except as Schneider Electric offer the
specified in the last paragraph of 9.1.1. This requirement ABL-6 range for transformers
is not there (as is thought by many) primarily for the and ABL-7 range for DC
reason of minimising the possibility of electric shock to, switch-mode power supplies.
for example, persons carrying out fault finding (see
9.1.2). It is there to reduce the effects and consequences
of an overcurrent arising from an insulation failure on the
control circuit. The impedance of the transformer
significantly reduces the value of the overcurrent, thereby
minimising burn and fire hazards.
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Note - ISO 13850 is under review and when published could replace BS EN 418 as
BS EN ISO 13850.
Note - 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.
The important criteria that also need to be considered are the means
to ensure that an emergency stop function, when initiated, 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. The machine supplier will need to
carefully consider this as part of the risk assessment of the machine.
There will be situations where items on the machine (for example,
means to release trapped persons, coolant pumps or fans) may have
to be left in operation or automatically started (emergency start) to
ensure a hazardous situation does not develop.
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9.4.1 now refers (in addition to ISO 13849-1: 1999) to IEC 62061:
2005, which is a new standard implementing IEC 61508 for the
machine sector. 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. It applies equally to electrical, electronic and
programmable electronic safety-related control systems. ISO 13849-1
covers safety-related parts of control systems. It specifies 5 differing
categories of a safety-related part of a control system the performance
of which, is related to the effect of a single fault occurring in it (mainly
based on the system architecture). These categories however should
not be considered to be hierarchical as far as performance (integrity)
or their contribution to risk reduction is concerned.
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Section 18.2 Colours for push buttons All colours are available for
both pushbuttons and
Users of this standard will have noted the preference for indicator lamps from the
use of push button actuator colours of white for start, and Telemecanique Harmony style
black for stop. Green for start and red for stop are also 4 & 5 range of metal or all
included with a ban on their use for stop and start insulated pilot devices.
respectively. This allows for the adoption of white and
black for machines supplied at locations where machines
have not been installed previously, yet it allows use of the
colours green and red at those places where existing
machines using these colours are installed. 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.
These are specified in 10.3.2 and are self explanatory. The XVB indicating towers
However a new recommendation for indicating towers range can comply fully with
has been added. the recommendations.
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Safe means of access, adequate clearance for work and provision for
means of escape are specified in 11.5.
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The method used to meet the requirement specified in Cable markers such as those
13.2.1 will often be determined by the machine itself. For in the AR1 range are
example, in the case of a machine having a single control recommended by Schneider
cabinet with a simply wired motor starter and perhaps Electric.
one or two items of electrical equipment (interlock
position switch) on the machine, the requirement might
be met by a simple wiring diagram, a copy of which may
be mounted on the inside of the control cabinet door. In
the case of a more complex machine, a wiring schedule
can be used complete with details of each connection
and its connection points. However, once the complexity
of the wiring becomes significant, this arrangement does
not easily lend itself to ease of maintenance and fault
finding activities (see below).
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Clause 15 deals with the requirements for machine Schneider Electric can supply
mounted socket outlets and local machine lighting a number of ranges of RCDs.
together with a choice of lighting power supply
arrangement. Two notes have been added (see 15.1) in
this issue of the standard. The first note refers the user to
Annex B, the enquiry form and the second note refers to
the provision of residual current protective devices (see
also Annex B).
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The users’ attention is brought to the addition of a new Telemecanique variable speed
requirement for the warning sign for hot surfaces hazard drives carry this warning
in 16.2.2. label when the heatsink can
reach hazardous
temperatures.
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Note - Within the EU there are specific requirements specified in the Machinery
Directive.
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Section Verification
Twenty six
In 18.1 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. It
also specifies that the verifications shall always include those in 18.1 a),
18.1 b) and 18.1 f). 18.1 a) requires that the equipment complies with its
technical documentation. The remaining mandatory verifications are
contained in 18.2 and 18.6 (see below).
This type of test is normally performed only when there is good reason to
do so. 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.
The verifications in 18.5 and 18.7 have not changed from those in 19.5
and 19.7 of the previous edition. However 18.6 has been amended to
strictly reflect that the scope of BS EN 60204-1 is restricted to the
electrical equipment.
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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:
Basic conditions (for example, voltage and temperature range,
indoors or outdoors, other special conditions) under which the
machine is to be used
Details of the overcurrent protective device(s) on the power
supply(s) connections and whether or not disconnection of the
neutral is required
Special colour preferences (for example to align colours of push
buttons, indicator lamps, etc with existing machinery
Additional or special requirements such as, specific details of
means required to identify conductors and provision of degree of
protection against specified materials, to facilitate an agreement
between them.
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.
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Section Annex C
Twenty eight
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Section Annex D
Twenty nine
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Section Annex E
Thirty
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Section Annex G
Thirty one
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Those standards listed in Clause 2 are normative Schneider can often give
references and need to be complied with to achieve advice on the content of these
compliance with that particular requirement (for example, standards.
see 6.2.5). Those standards listed in the bibliography are
often those, but not always, referred to in notes for
further reading (for example, see NOTES 1 and 2 of
4.4.2).
A final note.
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The user will note that many requirements are similar to Part 1 which
has been followed as far as is feasible. Even so, important differences,
essential for HV equipment, 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).
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Type A standards
Examples are:
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standards
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After serving:
- a 5 year student (Electrical) apprenticeship with Ministry of Supply
(Ministry of Defence) at Royal Ordnance Factory, Leeds;
- 6 months as a Production Test Engineer at AEI Ltd., Trafford Park,
Manchester – work on design of test equipment for main frame
computer components; and
- 18 months as a Laboratory Engineer at English Electric Co. Ltd.,
Aircraft Equipment Division, Thornbury, Bradford - Testing and
development of aircraft power supply systems;
he joined the electricity supply industry in October 1962 as an
assistant power systems protection engineer with the Central Electricity
Generating Board, Transmission Division (Protection design &
diagrams section), North Eastern Region Headquarters at Leeds. The
work involved inspection, approval and development of systems used
for power system protection, interlocking and sequence switching on
the super-grid system and at new power stations; in particular Drax
Power Station.
Brian Clark was employed by the HSE since 1976 and retired from the
UK Civil Service on 11 September 1998. He now is a Standards
Consultant on Machinery Safety – Electrotechnical Aspects.
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. In recognition of his work in
machinery safety standards, he was awarded the O.B.E. on 31
December 1996 with the citation “for services to the Health and Safety
Executive”.
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. He became chairman of PEL/44 (now GEL/44) Safety of
machinery – Electrotechnical aspects in January 1995. He ceased to
be chairman in 1999 but remains on the committee.
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He also served on the working group that prepared Part 32 for hoisting
machines which was published in 1998. 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. This standard is now
available as BS EN 60204-11: 2000.
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Product showrooms
Industrial systems and solutions showroom
Schneider Electric Ltd, University of Warwick Science Park, Sir William Lyons Road, Coventry CV4 7EZ
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SE 5941 JUL 2006