Electrical equipment of machines: an overview of the updated European standardBuild it in.

Dirk Meyer1. edition

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EN 60204-1 updateWhite paper

Electrical equipment of machines: an overview of the updated European standard

1. Update to EN 60204-1For more than ten years, EN 60204-1 has ensured the safety of the electrical equipment of machines and systems. While the underlying IEC 60204-1 standard was already updated in 2016, the European version of the world’s most widely used machine safety standard have now also been published. Our white paper provides an overview of the most important changes for machine builders and system integrators, with a special emphasis on switchgear.

2. Technical specifications for safe machineryAny company that wants to place machinery and equipment on the market in the European Union must affix the CE mark to its products. The marking certifies that the machine meets the requirements of all relevant EU directives. CE marking serves as a kind of passport in support of the free movement of goods within the European Economic Area.

EU directives such as the Low Voltage Directive (2014/35/EU) and the Machinery Directive (2006/42/EC) contain requirements for general and occupational safety that must be met by all the products they cover. Separate technical specifications, the so-called harmonized standards, set out how these essential requirements are to be met. If a company manufactures a product or machine in accordance with the relevant harmonized standard, it is assumed that the essential health and safety requirements of the respective directive have also been met (presumption of conformity).

According to both the Machinery Directive and the Low Voltage Directive, EN 60204-1 is the designated harmonized standard for the electrical equipment of machines. It applies to all electrical, electronic and programmable electronic equipment and systems for machines, including machine clusters that operate in a coordinated manner.

It applies to devices and components with rated operating voltages up to 1,000 V AC or 1,500 V DC and a rated frequency of up to 200 Hz. The EN 60204-1 standard applies to the entire electrical installation of a machine, starting from the point where the incoming power cable connects to the terminals or the main switch.

EN 60204-1 is the European version of the international IEC 60204-1 standard, one of the most widely used machine safety standards worldwide. In Europe, the standard was published without changes as EN 60204-1. While the IEC 60204-1 standard was updated already in 2016, the changes have now also been incorporated in the latest version of EN 60204-1(the previous version was still based on the 2005 IEC edition).

Detailed information about machine safety can be found in Eaton’s “Safety Manual”, which is aimed at machine builders and system integrators, as well as at teachers and students and anyone else who is interested in the topic. The manual is available for download at

www.eaton.eu/shb

2 EATON EN 60204-1 update

3. EN 60204-1 (6th edition): the most important changesThe latest (6th) version of the EN 60204-1 standard further elaborates on the basic safety requirements for electrical equipment, but does not include any special or additional requirements as regards the scope of application. Some chapters, including the one on documentation, have been completely revised, while informative annexes have also been added, providing helpful guidelines for project planning (e.g. Annex B) and documentation (e.g. Annex I) purposes.

3.1 General requirements, chapter 4

Although the content of the chapter has not been significantly amended, some of the changes are nevertheless worth mentioning.

References to IEC 61439 and to Annex F have been added to chapter 4.2.2, which deals specifically with switchgear. As a result, it is now possible to apply IEC 61439 in whole or in part when planning a switchgear assembly.

Electromagnetic compatibility (EMC) requirements for electrical installations were already included in the previous version of the standard (chapter 4.4.2). Now, however, Annex H lists the relevant measures and best practices for meeting the EMC requirements in a much more comprehensive, informative and practical manner. At the same time, the new version also makes reference to the IEC 61000 series of standards. An important change

in the new standard is that EMC immunity and emission tests are now mandatory, unless:

- the electrical components already meets the relevant EMC requirements (CE marking),

- the electrical components, the installation and the wiring have been implemented in accordance with the relevant operating instructions as provided by the manufacturers of these components (or, in areas where no relevant EMC regulations exist, if the measures cited in the new EMC annex have already been applied).

In addition, specifications regarding vibration, shock and bump as well as the operating altitude have also been added to the section on environmental conditions. This includes vibrations generated by the machine itself as well as external impacts, for example if the machine is part of a mobile device.

3.2 Devices for disconnecting and switching off, chapter 5

Devices that interrupt the power supply in order to prevent unexpected start-up have now been added to chapter 5, which covers supply conductor terminations and devices for disconnecting and switching off.

Eaton offers a comprehensive portfolio of devices for disconnecting the power supply – commonly known as main switches.

Our T and P cam switches, the switch-disconnectors of the Dumeco series, the (P)N1 to (P)N4 switch-disconnectors as well as the NZM1 to NZM4 circuit breakers with rotary handles meet all the disconnection requirements outlined in the EN 60204-1 standard.

www.eaton.eu/nzmwww.eaton.eu/dumecowww.eaton.eu/camswitches

The use of residual-current devices is an effective means of preventing fires and protecting against electric shocks. The RCCBs from Eaton's xEffect series meet the relevant EN 60204-1 requirements.

What’s more, Eaton’s drive solutions and residual-current devices are also designed to complement each other. The devices safely disconnect the power supply in the event of a fault, while also preventing nuisance tripping due to earth fault currents caused by the system itself. For frequency inverter applications, Eaton recommends the use of type F and type Bfq residual-current devices, which in many cases are already mandatory. These devices enable safe and reliable machine operation with high system availability.

Our white paper on the interaction between drives and residual-current devices can be downloaded via the following link:

www.eaton.eu/en/cp/rcd

Digital residual-current protection enhances safety and operational continuity

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3.3 Protection of equipment, chapter 7

Chapter 7 (“Protection of equipment”) now includes a section on earth fault/residual-current protection. In this context, the text also refers to residual-current devices (RCDs) in accordance with IEC / TR 60755.

However, the most important change to this chapter pertains to the rated short-circuit current, which must now be determined and specified for the entire electrical equipment. That being said, the standard does not specify any concrete procedures for this purpose; instead, it permits the application of design rules as well as calculations or type tests. In this context, the text refers to the methods outlined in IEC 61439-1, IEC 60909-0, IEC/TR 60909-1 and IEC/TR 61912-1.

Pursuant to IEC 61439-1, the short-circuit strength can be verified through comparison with a reference design, for example. Table 13 of the EN 61439-1 standard contains a checklist for this purpose – if the answer to all questions is “yes”, the equipment is deemed to be short-circuit resistant. Proof is only required if the rated short-time withstand current Icw at the busbar / the short-circuit current Icc at the installation point of the switchgear assembly exceeds 10 kAeff, or if the Id value of the current-limiting equipment exceeds 17 kA (peak value).

3.4 Operator interface and machine-mounted control devices, chapter 10

For supply-disconnecting devices, EN 60204-1 now clearly distinguishes between emergency-stop and emergency switching-off.

What’s the difference between the two? An emergency stop is required wherever mechanical hazards are present, i.e. in order to stop the machine from moving or to bring it to a safe position in a controlled manner. Emergency

switching-off devices are only required if an electrical risk has been identified. Emergency switching-off devices interrupt the voltage and thus the power supply.

The updated IEC 60204-1 standard now explicitly states that the activation of the stop function of a frequency inverter may be regarded as a category 0 stop. As such, this function may be used to stop the movement of a machine during emergency switching-off.

Software tools such as Eaton’s user-friendly xSpider program make it possible to calculate the rated short-circuit current. This graphical design tool can be used to plan low-voltage networks that incorporate Eaton’s protective equipment. It facilitates the calculation of voltage drops, load distribution and short-circuit currents in radial or meshed networks and makes it possible to check the suitability of the selected cables and protective devices. The program is primarily aimed at designers and technical estimators.

www.eaton.eu/xspider

xSpider software for network calculation

Main switches and emergency power-off switches must always be easily accessible for operators. And this requires a flexible range of mounting options. The example shows a version for side-wall installation.

Eaton's RMQ-Titan range of pilot devices offers products with emergency-stop as well as emergency switching-off function. In addition, it is also possible to use the NZM circuit breakers in emergency switching-off applications.

www.eaton.eu/e-stop

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3.6 Residual-current protection for socket outlets up to 20 A, chapter 15.1

In the previous version of the EN 60204-1 standard, residual-current devices (RCDs) were merely optional in socket outlets up to 20 A. The updated version now generally mandates RCDs with a rated differential current of I∆n ≤ 30 mA (chapter 15.1).

The total heating effect can be determined using the power loss values contained in the data sheets of the respective Eaton products. In addition, most device manufacturers, ECAD vendors and control panel enclosure manufacturers also provide software tools for temperature calculation. Eaton’s temperature calculator can be used to verify the switchgear temperature rise in accordance with EN 61439-1.

www.eaton.eu/tools

Further information on IEC 61439-1 compliant switchgear can be found in the Eaton publication “Power switchgear and controlgear assemblies and distribution boards according to EN 61439”.

http://www.eaton.eu/ecm/groups/public/@pub/@europe/@electrical/documents/content/pct_1128235.pdf

3.5 Switchgear Location, mounting and enclosures, chapter 11

With regard to switchgear location, the specifications covering heating effects have been completely revised. It is now necessary to carry out a heat calculation and to draw up a heat balance, with the aim of preventing the machine from overheating during operation.

A possible calculation method is the verification according to IEC 61439. While switchgear assemblies with a rated current greater than 1,600 A must always be tested in accordance with IEC 61439, a calculation according to chapter 10.10 of EN 61439-1, the so-called RDF method, is the standard for rated currents InA up to 630 A, which are common in machine-building applications. For rated currents InA up to 1,600, a calculation in accordance with IEC 60890 is necessary.

Eaton’s xEffect series switchgear has been specifically designed for use in industrial applications.

www.eaton.eu/rcd

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Eaton's PowerXL frequency inverters offer standard-compliant protection and automatically switch off the outgoing power supply in the event of a fault. The operating instructions of frequency inverters that do not offer this feature must contain information on the additional measures that need to be taken to achieve an equivalent level of protection.

www.eaton.eu/powerxl

3.7 Technical documentation requirements, chapter 17

The technical documentation requirements have been comprehensively revised. Conveniently, the updated standard now only requires those documents that are absolutely necessary. This refers to any documents that manufacturers are obliged to provide for their machines under all circumstances. The documentation has to cover the entire life cycle of the machine – from identification, transport, installation, use and maintenance to the decommissioning and disposal of the electrical equipment. Annex I offers useful guidance on this topic and contains a table listing the recommended documents. Of course, it is nevertheless still possible to include additional documents with the machine documentation.

3. 8 Testing of power drive systems (PDS), chapter 18.2

The verification chapter has also been updated. The most important addition are the specifications for the testing of power drive systems. These include the requirement to test the automatic disconnection of the power supply in the event of a fault. Even if a frequency inverter or a servo

drive is installed within the circuit, a fault in the field must always lead to shutdown. The precise method is at the discretion of the project engineer.

The easiest option are modern inverters with internal overload and short-circuit protection, which switch off the motor independently in the event of a fault. However, even a fault in the inverter itself must lead to shutdown. For this purpose, the standard stipulates continuity testing of the protective conductor, i.e. the protective circuit must be continuous from the motor through the inverter all the way to the main protective conductor. In addition, the loop impedance – i.e. the responsiveness of the relevant protective device in the event of a fault – also needs to be tested. If the inverter itself does not include an appropriate protective device, an “external” protective device needs to be installed to take over this task.

4. EN 60204-1 versus IEC 61439As the Machinery Directive specifically refers to the EN 60204-1 safety standard (“Safety of machinery - Electrical equipment of machines”), it is mandatory for all machines. While the electrical equipment of the machine may be supplemented with components that comply with IEC 61439, the application of IEC 61439 alone is not sufficient to ensure machine safety.

5. The bottom line: The selection of electrical equipment mattersThe updated version of IEC 60204-1 is already the sixth edition of one of the world’s most widely used machine safety standards. Many sections of the text have been revised and references to other standards have also been added. However, the number of actual changes that machine builders and system integrators need to implement is manageable. Anyone who has previously designed and built machines and systems in a standard-compliant manner will not find the requirements of the revised version particularly challenging. When it comes to the selection of electrical equipment and switchgear, what matters is simply to choose products that comply with the latest version of the EN 60204-1 standard. This is the only way to ensure that machines and systems provide maximum safety and availability.

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Notes

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