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Records of assessment to standards

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Introduction BS EN 60204-1 Electrical Equipment This standard provides requirements and recommendations relating to the electrical equipment of machines so as to promote: safety of persons and property consistency of control response ease of maintenance.

Part 1 of BS EN 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 (i.e. communications between systems). The equipment covered by this standard commences at the point of connection of the supply to the electrical equipment of the machine. Part 1 of BS EN 60204 is applicable to the electrical equipment or parts of the electrical equipment that operate with nominal supply voltages not exceeding 1,000 V for alternating current and not exceeding 1,500 V for direct current, and with nominal frequencies not exceeding 200 Hz. Complying with this standard is deemed to meet the essential requirements of the low voltage directive. The following list is a check list that shows that this machine/control system meets the requirements of this standard:

Power supply Requirement single source; additional supply derived from devices (transformer); supply conductor connected to supply disconnector neutral conductor should not be used; no connection between neutral conductor and earth; all terminals clearly marked. Compliance

External protective conductor terminal Requirement terminal in vicinity of associated phase terminals; appropriate size; terminal marked with PE or grounding symbol Compliance

Supply Disconnector Requirement hand operated for each incoming supply when two or more provided, interlock required either; switch disconnect or, circuit breaker capable of being locked in off position one ON and one OFF position, clearly marked visible gap or position indicator external operating handle, not red unless E Stop black lightning sign easily accessible 0.6 to 1.9 m above servicing level. Compliance

Protection against direct contact Requirement Enclosures must use a key live parts protected to at least IP1X or IP XXA; parts intended to be touched while connected require IP2X or IPXXB; opening enclosure disconnects supply Parts that are still live when enclosure is opened must be protected to IP 2X or IP XXB and so marked; or if the disconnector is not door interlocked, all live parts require IP2X or IPXXB. Compliance

Protection by insulation of live parts Requirement live parts completely covered with insulation, Compliance

Protection against indirect contact Requirement Protection by automatic disconnection of supply connection of exposed conductive parts to PBC, and use of protective device; coordination between supply and protective device use of switchgear having total insulation application of supplementary insultation Compliance

Protection by electrical separation Requirement Protection by the use of PELV max nominal voltage 25V ac, or 6OV dc max current in case of failure 1 A ac or 0.2A dc only indoors in dry conditions source of supply and live ports separated or isolated from circuits with higher voltages connected to protective bonding conductor associated with higher voltage Compliance

Protection of equipment Requirement all conductors except earthed neutral contain devices to detect and interrupt neutral conductors with cross sectional area equal to phase conductor current carrying capacity is of conductors is at least equal to that required for the load conductors directly connected to supply and circuits feeding control circuit transformers, Transformers shall be protected in accordance with IEC 76-5 and EN60742 as appropriate avoid nuisance tripping due to transformer magnetizing; avoid excessive winding temperature Socket Outlets required for circuits feeding maintenance equipment each connecting conductor to the protection device is no longer than 3m; Fuses or setting current as low as possible but adequate for anticipated over current. Conductors protected in duct. Compliance

Overload protection of motors Requirement Motors 0.5kW normally in continuous operation protection by overload protection devices; temperature sensing devices current limitation (inverter driven motors) Auto restarting shall be prevented unless no risk Compliance

Equipotential Bonding Circuit Requirement PE terminal; conductive structural parts of electrical equipment and machine; all exposed conductive parts bonded to PBC protective conductors in equipment of machine identified, shape, location, marking, colour Copper wires preferred. resistance of any part not allow hazardous current adequate connection/bonding appropriate termination, type and size; metal conduits and metallic sheaths, not used as PCS but must be connected to PBC; appropriate lids and enclosure doors shall be protected by PBC provided for purpose where doors, lids etc are part removed PBC must not be interrupted connections must be secure from accidental loosening Compliance

Conductors & Cables Requirement generally Copper Insulation appropriate for use (e.g. fire, toxic fume from PVC): adequate dielectric strength @ 50V ac or 12OV dc test V : 2000V ac for 5 min PELV, 500~ ac for 5 min; Cables have adequate mechanical strength Adequate insulation thickness Current carrying capacity in normal service Voltage Drop not exceed 5% of nominal voltage Wiring Practices secure against accidental loosening Terminals suitable connection for csa of cables used more than one conductor per terminal ok if designed for that purpose terminals on terminal blocks identified, as per circuit diagram; shielded conductors properly terminated ID tags clear and appropriate for environment terminal blocks mounted and wired to prevent crossing potentials wires (ie. Terminal barriers end stops etc) conductors identifiable at each termination protective conductor shall be readily identified colour (Green/Yellow) identification of neutral conductor: YeS l if ID by colour = Light Blue . identification of other conductors l Black: at and dc Power circuits identification of other conductors Red: ac control circuits identification of other conductors Blue: dc control circuits identification of other conductors Orange: interlock control circuits supplied from Y?S external power source.

insulation not available in required colours where multi conductor cable is used.

Visual & Functional Testing Requirement Testing Continuity of PBC Insulation Resistance Voltage test (Flash Test) protection against residual voltage Electromagnetic Tests Functional Tests - Starting Functional Tests - Stopping Emergency stop located at workstations Emergency stop colour and background Emergency stop hardwired and to BS EN 418:1992 category 3 Emergency stop removes power to actuators, PLC outputs and dumps stored energy (pneumatic) Compliance

Control & Signalling Devices Requirement Indicators and buttons red - emergency yellow - cautionary green - normal operation blue - mandatory intervention black - stop white - start Compliance