TÜV SÜD Corporate Presentation 27/06/2013 1 · TÜV SÜD Corporate Presentation 27/06/2013 2 TÜV...
Transcript of TÜV SÜD Corporate Presentation 27/06/2013 1 · TÜV SÜD Corporate Presentation 27/06/2013 2 TÜV...
27/06/2013 TÜV SÜD Corporate Presentation 1
TÜV SÜD Product Service
An introduction to
EN 60204-1 Stewart Robinson TÜV SÜD Product Service
TÜV SÜD Product Service
Safety of Machinery - Electrical Equipment of Machines Part 1: General Requirements.
Defined Scope
This part of IEC 60204 applies to the application of electrical and electronic equipment and systems to machines not portable by hand
while working, including a group of machines working together in a co-ordinated manner, but excluding higher level systems aspects (e.g.
communications between systems).
The standard defines the basic terminology and specifies general design methods to help designers and manufacturers in achieving safety in the
design of machinery.
BS EN 60204-1:2006+A1:2009
BS EN 60204-1:2006+A1:2009 Slide 2 27/06/2013
TÜV SÜD Product Service
• EN 60204-1 gives safety guidance and recommendations
on electrical equipment for “non-portable” machinery.
• EN 60204-1 refers to machinery that operates with nominal
supply voltages below 1,000V for alternating current or
1,500V for direct current
• EN 60204-1 covers control circuits and control functions,
wiring practices and protection against electrical shock
EN 60204-1 Scope
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 3
27/06/2013 TÜV SÜD Corporate Presentation 2
TÜV SÜD Product Service
• BS EN 60204-1 does not include guidance on:-
• machinery designed for outdoor use in mines and in
flammable atmospheres
• machinery that produces explosive material
• machinery that operates as a sewing machine.
EN 60204-1 Out of scope
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 4
TÜV SÜD Product Service
EN Standards and European Directives
BS EN 60204-1:2006+A1:2009 Slide 5
“A” type apply to all machines.
“B” type are designed to
promote safety and split in to
B1 and B2.
“C” type apply to a specific
type of machine.
EN 60204-1 is harmonised against the Machinery Directive
and the Low Voltage Directive
27/06/2013
TÜV SÜD Product Service
• BS 7671 - Requirements for electrical installations.
IET Wiring Regulations. Seventeenth edition.
– The guidelines cover all aspects of designing and installing electrical
wiring and temporary or permanent power systems in buildings
• As a general rule BS 7671 applies up to the connection of
the electrical supply to the machine isolator. EN 60204-1
applies from that point onwards
EN 60204-1 and BS 7671 (IET Wiring Regulations)
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 6
27/06/2013 TÜV SÜD Corporate Presentation 3
TÜV SÜD Product Service
• There are 18 clauses in the normative part of the standard
1. Scope
2. Normative references
3. Definitions
4. General requirements
5. Incoming supply conductor terminations and devices for
disconnecting and switching off
6. Protection against electric shock
7. Protection of equipment
8. Equipotential bonding
9. Control circuits and control functions
EN 60204-1 Contents
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 7
TÜV SÜD Product Service
10.Operator interface and machine-mounted control devices
11.Controlgear: location, mounting, and enclosures
12.Conductors and cables
13.Wiring practices
14.Electric motors and associated equipment
15.Accessories and lighting
16.Marking, warning signs and reference designations
17.Technical documentation
18.Verification
EN 60204-1 Contents
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 8
TÜV SÜD Product Service
Barrier
• A part providing protection against direct contact from any
usual direction of access.
Control Circuit (of a machine)
• A circuit used for the control, including monitoring, of a
machine and the electrical equipment.
Control Device
• A device connected into the control circuit and used for
controlling the operation of the machine (for example position
sensor, manual control switch, relay, contactor, magnetically
operated valve).
BS EN 60204-1:2006+A1:2009 Slide 9
Definitions - Examples
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 4
TÜV SÜD Product Service
Control gear
• Switching devices and their combination with associated control,
measuring, protective, and regulating equipment, also
assemblies of such devices and equipment with associated
interconnections, accessories, enclosures, and supporting
structures, intended in principle for the control of electrical
energy consuming equipment.
Direct opening action (of a contact element)
• achievement of contact separation as the direct result of a
specified movement of the switch actuator through non-resilient
members (for example not dependent upon springs)
[IEC 60947-5-1, K.2.2]
BS EN 60204-1:2006+A1:2009 Slide 10
Definitions - Examples
27/06/2013
TÜV SÜD Product Service
Emergency stop device
• Manually actuated control device used to initiate an emergency
stop function
Emergency switching off device
• Manually actuated control device used to switch off the supply of
electrical energy to all or a part of an installation where a risk of
electric shock or another risk of electrical origin is involved
Definitions - Examples
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 11
TÜV SÜD Product Service
Failure
• Termination of the ability of an item to perform a required
function.
Fault
• State of an item characterized by inability to perform a required
function, excluding the inability during preventive maintenance or
other planned actions, or due to lack of external resources.
“Failure” is an event, as distinguished from “fault”, which is a state
In practice the terms fault and failure are often used synonymously
BS EN 60204-1:2006+A1:2009 Slide 12
Definitions - Examples
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 5
TÜV SÜD Product Service
Live Part
• Conductor or conductive part intended to be energized in normal
use, including a neutral conductor.
Protective Bonding
• Equipotential bonding for protection against electric shock.
Definitions - Examples
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 13
TÜV SÜD Product Service BS EN 60204-1:2006+A1:2009 Slide 14
EN 60204-1: Chapter (6) and (7)
Electrical Hazards
27/06/2013
TÜV SÜD Product Service
General Requirements:
• Risk due to electrical equipment is part of the risk assessment of
machine :
Equipment failure leading to electrical shock.
Control circuit failure leading to malfunction of the machine.
Disturbance / interruption of the power source leading to
malfunction of the machine.
EMC problems leading to malfunction of the machine.
Release of stored energy leading to unexpected movements /
electrical shock.
High surface temperatures leading to burns.
BS EN 60204-1:2006+A1:2009 Slide 15
Risk and Consequence
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 6
TÜV SÜD Product Service
• Correct selection of electrical components and devices based upon
the:
Intended use.
Conformity to applicable standards.
Applied according to manufacturers instructions.
Suitability for purpose.
Ability to withstand the expected influence. Appropriate for the intended use. Suitably placed / positioned. Readily identifiable with physical durable marking of the
component or device.
• Low voltage switchgear / control gear assemblies must comply with
IEC 60439.
BS EN 60204-1:2006+A1:2009 Slide 16
Equipment selection
27/06/2013
TÜV SÜD Product Service
• Emission Protection.
Power supply filtering
Cable shielding.
Enclosures designed to minimize RF radiation.
RF suppression techniques – filters.
• Immunity Protection
The design of functional earth bonding system.
Connect sensitive electrical circuits to chassis.
Connect the chassis to earth (PE) (low RF impedance, short
distance).
Functional earthing conductor (FE) minimize common
disturbance.
The separation of sensitive circuits from disturbance sources.
Enclosures should be designed to minimize RF transmission.
BS EN 60204-1:2006+A1:2009 Slide 17
EMC Requirements
27/06/2013
TÜV SÜD Product Service
A single incoming supply is recommended for machines.
However where a second supply for electronic equipment
with different voltage is required (for example from a 24vdc
PSU), this should be derived from main machine supply.
• Isolators must be readily accessible located between 0.6 m and 1.9 m above servicing level (with an upper limit 1.7 m recommended).
• Isolators should be lockable (LOTO type) and attached
to the machine i.e. on-board.
BS EN 60204-1:2006+A1:2009 Slide 18
Electrical Supply and Isolation
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 7
TÜV SÜD Product Service
• They should disconnect all supplies!!!
• If not intended for emergency operation it is recommended that the isolators should be coloured black or grey.
• Emergency off isolators must be coloured red and yellow.
• It must have one off (isolated) and one on position marked with "O" and "I“.
• The isolator must be clearly identified as to its function
i.e. what it isolates.
Electrical Supply and Isolation
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 19
TÜV SÜD Product Service
• The isolator should ideally be interlocked to the panel door. If this is not possible then IP2X protection must be installed to all devices that remain live when to door is opened.
• The isolator must not be mounted on the door itself.
• For large complex machinery there may be a need for
more than one incoming supply, therefore consideration must be given to ensuring all supplies can be appropriately isolated by the use of protective interlocks for correct operation to prevent hazardous situations arising, including damage to the machine.
BS EN 60204-1:2006+A1:2009 Slide 20
Electrical Supply and Isolation
27/06/2013
TÜV SÜD Product Service
Electrical Supply and Isolation
BS EN 60204-1:2006+A1:2009 Slide 21 27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 8
TÜV SÜD Product Service
Incoming Supply Terminations and the Neutral Conductor:
• All terminals for incoming supply connection must be
clearly identified e.g., L1, L2, L3, N, PE, and 400V (or the
appropriate voltage).
• Should be clearly indicated in technical documentation
installation diagram and circuit diagram.
• The Neutral should have a separate insulated terminal,
labelled ‘N’.
• There should be no connection between neutral and
protective bonding circuit inside electrical equipment .
BS EN 60204-1:2006+A1:2009 Slide 22
Supply Termination
27/06/2013
TÜV SÜD Product Service
Persons must be protected from electric shock from:
Direct contact.
Indirect contact.
BS EN 60204-1:2006+A1:2009 Slide 23
Protection against electric shock
27/06/2013
TÜV SÜD Product Service
The risk in this case is an insulation fault between live parts and exposed conductive parts.
BS EN 60204-1:2006+A1:2009 Slide 24
Protection against indirect contact
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 9
TÜV SÜD Product Service
Protection by enclosures
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 25
Protection against electric shock by locating live parts inside enclosures
TÜV SÜD Product Service
• The opening of the enclosure (i.e. opening doors, lids, covers, and the like) must be by one of the following:
– The use of a key or tool
– Disconnection of live parts inside before opening which
can be achieved by Interlocking the door with a disconnecting device.
BS EN 60204-1:2006+A1:2009 Slide 26
Protection by enclosures
27/06/2013
TÜV SÜD Product Service
Enclosure doors should not be wider than 0.9m
Ideally vertical hinges, with an angle of opening of at least 95°
There must be no opening between enclosures containing electrical equipment and compartments containing coolant, lubricating or hydraulic fluids, or those into which oil, other liquids, or dust can penetrate.
BS EN 60204-1:2006+A1:2009 Slide 27
Enclosures
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 10
TÜV SÜD Product Service
• However it is allowed to defeat the interlock with a special device or tool provided that:
• It is always possible to operate and lock the disconnecting device in the off position.
When closing the door, the interlock is automatically
restored.
• All live parts, used for resetting or adjusting while connected must have at least IP2X protection.
• All other live parts inside the enclosure must have at least IP1X protection.
Defeat Interlocked Isolator
27/06/2013 BS EN 60204-1:2006+A1:2009 Slide 28
TÜV SÜD Product Service
• Live parts protected by insulation shall be completely
covered with insulation that can only be removed by
destruction.
• Such insulation shall be capable of withstanding the
mechanical, chemical, electrical, and thermal stresses
to which it can be subjected under normal operating
conditions.
BS EN 60204-1:2006+A1:2009 Slide 29
Protection by Insulation
27/06/2013
TÜV SÜD Product Service
Potential sources of electrical shock from
wiring
BS EN 60204-1:2006+A1:2009 Slide 30 27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 11
TÜV SÜD Product Service
• Live parts with a residual voltage of greater than 60v must discharge to 60v or less within 5 s (as long as the discharge does not interfere with the proper functioning of the equipment)
• If this is not possible then a durable warning notice
with required delay before opening time on it should be fitted.
• In the case of plugs or similar devices the minimum discharge time shall be less than 1 second, otherwise protection to IP2X must be installed or fitted.
• If neither can be achieved such as on removable collectors on conductor wires, conductor bars, or slip-ring assemblies then additional switching devices or appropriate warning devices (warning notice), must be installed or fitted.
BS EN 60204-1:2006+A1:2009 Slide 31
Protection Against Residual Voltages
27/06/2013
TÜV SÜD Product Service
Appliance Classes
Appliance Class Marking Protection
Class 0 No Marking Single level of insulation
no protective-earth
Class I Chassis Connected to
Electrical Earth (PE)
Class II "Class II"
„Double Insulated„ Double Insulated
Class III Supplied from a SELV
(Separated Extra-Low Voltage)
Power Source.
BS EN 60204-1:2006+A1:2009 Slide 32 27/06/2013
TÜV SÜD Product Service
Use class II equipment or equipment with the
equivalent level of insulation.
This is provided by one or more of:
– Class II electrical devices or apparatus with double
insulation, reinforced insulation or by equivalent insulation
in accordance with IEC 61140.
– Switchgear and control gear assemblies with total insulation
in accordance with IEC 60439-1.
– Supplementary or reinforced insulation in accordance with
article 412 of IEC 60364-4-41.
BS EN 60204-1:2006+A1:2009 Slide 33
Protection against indirect contact - touch voltage
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 12
TÜV SÜD Product Service
• Protective Extra Low Voltage PELV:
Limited voltage.
25vac or 60vdc for dry conditions
6vac or 15vdc in all other cases
One side connected to protective earth
Safe separation (by double or reinforced
insulation) of the PELV system to all non PELV
systems.
BS EN 60204-1:2006+A1:2009 Slide 34
Protection by the use of Extra Low Voltage
27/06/2013
TÜV SÜD Product Service
Equipment should be protect against the effects of:
• Over current arising from a short circuit.
• Overload and / or loss of cooling of motors.
• Abnormal temperature.
• Loss of or reduction in the supply voltage.
• Over speed of machines / machine elements.
• Earth fault / residual current.
• Incorrect phase sequence.
• Over voltage due to lightning and switching surges.
BS EN 60204-1:2006+A1:2009 Slide 35
Protection of equipment
27/06/2013
TÜV SÜD Product Service
• Start Functions.
• Stop Functions.
• Operating Modes.
• Suspension of Safety Functions and / or
Protective Measures.
• Normal Operation.
• Other Control Functions such as Hold to Run
Devices, Two Hand Controls, and Enabling
devices.
BS EN 60204-1:2006+A1:2009 Slide 36
Control Functions - Examples
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 13
TÜV SÜD Product Service
Shall only be possible only when all safety functions and / or
protective measures are in place and fully operational.
Where safety functions and / or protective measures cannot be
applied for certain operations, manual control of such
operations by hold-to-run controls, together with enabling
devices must be activated and fully controlled.
BS EN 60204-1:2006+A1:2009 Slide 37
Start Functions
27/06/2013
TÜV SÜD Product Service
Stop functions fall into three categories
Stop category 0 - Stopping by immediate removal of the power.
Stop category 1 - A controlled stop with power available to the
actuators to achieve the stop, then final removal of power. Stop category 2 - A controlled stop with power left available to
the actuators.
BS EN 60204-1:2006+A1:2009 Slide 38
Stop Functions
27/06/2013
TÜV SÜD Product Service
• Emergency Stop where the emergency stop device
complies with EN ISO 13850 An emergency stop can only be a category 0 or 1 stop.
The initiation of the emergency stop must supersede all
modes of operation and other functions.
There must be no automatic restart of the machine on reset.
• The switching of an ‘Emergency Off’ device (EMO) but only if the
hazard is from electricity.
BS EN 60204-1:2006+A1:2009 Slide 39
Stop Functions
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 14
TÜV SÜD Product Service
Operator Interface and Machine-Mounted Control Devices –
Colour-coding for Push Buttons:
Colour Meaning Explanation Examples of application Additional description
RED Emergency
Actuate in hazardous situation or
emergency
Emergency Stop / Off. Initiation of emergency function.
RED is permitted also for only Stop / Off function, but it is recommended that RED is not used near an
emergency operation device. RED shall not be used for
Start / On.
YELLOW Abnormal
Actuate under abnormal
condition
Intervention to suppress abnormal condition .
Intervention to restart an interrupted
automatic cycle.
BLUE Mandatory
Actuate when requiring mandatory
action Reset function.
Reset push-buttons shall be BLUE, WHITE, GREY or BLACK. Where they also act as a Stop / Off button, the
colours WHITE, GREY or BLACK are preferred with the
main preference being for BLACK.
GREEN Normal Actuate to initiate normal conditions
WHITE
No specific meaning
assigned
For general initiation of functions except
emergency stop
Start / On (preferred) Stop / Off WHITE, GREY or BLACK are the preferred colours for
push-button actuators that alternately act as Start / On
and Stop / Off push-buttons. Where WHITE for Start / On
and for Stop / Off is used a additional description shall be
used for the identification of this push-button actuator.
GREY Start / On Stop / Off
BLACK Stop / On Stop / Off (preferred)
BS EN 60204-1:2006+A1:2009 Slide 40
Recommended colours – Push buttons
27/06/2013
TÜV SÜD Product Service
Examples of poor wiring
BS EN 60204-1:2006+A1:2009 Slide 41 27/06/2013
TÜV SÜD Product Service
Where appropriate the system / machine must be marked with all mandatory signage and appropriate warning labels and signs, and identifiers for cables etc., as previously discussed.
Some examples being:
Hot Surface Electrical Shock
BS EN 60204-1:2006+A1:2009 Slide 42
Marking, Warning Signs and Reference
Designations:
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 15
TÜV SÜD Product Service
If there is no dedicated product standard (a ‘C’ standard) for the
machine the verifications shall always include the items a), b)
and f) and may include one or more of c) to e), in the following
order:
• a) Verification that electrical equipment complies with its
technical documentation.
• b) in case of protection against indirect contact by automatic
disconnection, conditions for protection by automatic
disconnection shall be verified
• c) Insulation resistance test.
• d) Voltage test.
• e) Protection against residual voltage.
• f) Functional tests.
BS EN 60204-1:2006+A1:2009 Slide 43
Verification and Testing
27/06/2013
TÜV SÜD Product Service
f) Functional tests:
The functions of electrical equipment shall be tested,
particularly those relating to safety and safeguarding, verification shall be completed for all steps neccessary for safe intendend use.
Verification is more than just verification of electrical
parameters, it must also include the verification of all mechanical safety devices such as interlocks, ventilation, and cooling etc.........
It must also include verification of the operating
manual and manufacturers instructions as necessary.
BS EN 60204-1:2006+A1:2009 Slide 44
Verification and Testing – Functional Tests
27/06/2013
TÜV SÜD Product Service
Results of the inspections and verifications should reflect the
following:
The date of the test or inspection.
The actual results.
Whether or not the system or machines passed or failed the
test or inspection.
Any comments.
Any corrective action required or carried out.
The name and signature of tester.
It should also be remembered that where a portion of the
machine and its associated equipment is changed or modified,
that portion shall be verified and retested, as is appropriate.
BS EN 60204-1:2006+A1:2009 Slide 45
Verification and Testing – Documentation of
Results
27/06/2013
27/06/2013 TÜV SÜD Corporate Presentation 16
TÜV SÜD Product Service
BS EN 60204-1:2006+A1:2009
BS EN 60204-1:2006+A1:2009 Slide 46 27/06/2013
TÜV SÜD Product Service
BS EN 60204-1:2006+A1:2009
Thank you for Your Time and for Listening
Any Questions
BS EN 60204-1:2006+A1:2009 Slide 47 27/06/2013
TÜV SÜD Product Service
Thank you for listening
For more information contact: +44 (0)1642 345637 [email protected] www.tuv-sud.co.uk/machinery
TÜV SÜD BS EN 60204-1:2006+A1:2009 Slide 48 27/06/2013