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Verification of safety of machines according to IEC/EN 60204 Edition 5

Version 1.0,Code no. 20 751 202

Verification of safety of machines according to IEC/EN 60204 Edition 5 1 Introduction.............................................................................................................3 1.1 The new IEC/EN 60204, Edition 5.....................................................................3 1.2 Scope of the standard .......................................................................................3 Verification of safety of machines ........................................................................5 Visual inspection ....................................................................................................6 Measurements ........................................................................................................7 4.1 Verification of protection against indirect contact by automatic disconnection ..7 4.1.1 Selection of machine status and test extent ...............................................7 4.1.2 Selection of test limits...............................................................................10 4.2 Insulation resistance........................................................................................16 4.2.1 Selection of test limits ....................................................................................16 4.3 4.3 High voltage test........................................................................................17 4.3.1 Selection of test limits ....................................................................................17 4.4 Residual voltage test .......................................................................................17 4.4.1 Selection of test limits...............................................................................17 Connection diagramms........................................................................................19 5.1 Protection against indirect contact...................................................................19 5.1.1 Continuity of protective conductors ..........................................................19 5.1.2 Fault loop impedance ...............................................................................20 5.1.3 Suplemmentary bonding ..........................................................................21 5.2 Insulation resistance........................................................................................22 5.3 High voltage test..............................................................................................23 5.4 Residual voltage test .......................................................................................24 5.5 Functional tests ...............................................................................................25

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Verification of safety of machines according to IEC/EN 60204 Edition 5

1 Introduction
Foreword
This booklet is inteneded to help defining correct procedures for verification of electrical safety of machines. New verification principles in the IEC/EN 60204 Edition 5 (released in 2006) are highlighted.

1.1 The new IEC/EN 60204, Edition 5


The IEC/EN 60204 norm deals with safety of electrical equipment in machines. The 5th edition edition cancels and replaces the fourth edition issued in 1997 and Ammendment 1 (1999). Compared to old versions the new edition: is amended to provide general requirements for machines, including mobile machines and complex (for example large) machine installations. it deals with determination of adequate risk reduction relevant to the machines electrical equipment. is significantly changed in part Verification. The simple test of protective conductors (Voltage Drop test) is substituted by a more thorough testing of protective measures against indirect contact. Now verification tests include appropriateness of protective conductors, of overcurrent disconnection devices and incoming supply impedance. The IEC/EN 60204 Edition 5 is a harmonized EU standard and an important part of the EU Machine Directive. It is also harmonized with the US standard NFPA79.

1.2 Scope of the standard


With help of this standard the risks associated with hazards relevant to electrical equipment can be assessed as apart of the overall requirements for risk assessment of the machine. On base of the assement adequate risk reduction and necessary protective measures can be defined. Typical hazardous situations related to electrical equipment are: failures or faults in the electrical equipment resulting in the possibility of electric shock or electrical fire failures or faults in control circuits resulting in the malfunctioning of the machine; disturbances or disruptions in power sources as well as failures or faults in the power circuits resulting in the malfunctioning of the machine loss of continuity of circuits that depends on sliding or rolling contacts, resulting in failure of a safety function electrical disturbances either from outside the electrical equipment or internally generated, resulting in the malfunctioning of the machine; release of stored energy (either electrical or mechanical) resulting in, for example, electric shock or unexpected movement that can cause injury; audible noise at levels that cause health problems to persons; surface temperatures that can cause injury.

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Verification of safety of machines according to IEC/EN 60204 Edition 5 Part 18 (Verifications) of the standard determines the measurements (methods, limits) that are to be performed to verify the electrical safety of machines. The verification is applicable: after erection of machine after installation of machine after upgrading or changing of machine and during periodic retests of machine

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Verification of safety of machines according to IEC/EN 60204 Edition 5

2 Verification of safety of machines


According to IEC/EN 60204, Ed.5 verification of electrical safety of machines is perfomed by inspection and measurements: 1. Inspection that the electrical equipment complies with its technical documentation 2. Verification of protection against indirect contact by automatic disconnection, 3. Insulation resistance test 4. High voltage test 5. Protection against residual voltages 6. Functional tests The norm describes general requirements regarding electrical equipment of a machine. The extent of verification in usually given in the product standard and/ or technical documentation for a particular machine. Where there is no dedicated product standard for the machine, the verifications shall always include the items 1, 2 and 6 and may include one or more of the items 3,4,5. The decision should be taken by a competent person on site, after evaluation of machines condition. In Table 1 a legend of tables and flowcharts in this document is shown. They include.detailed information about limits, sequences and connection diagrams. Measurement
Protection against indirect contact: Continuity of PE conductors Protection against indirect contact: Fault loop impedance test*

Limits, parameters, extent of test


Extent of test: flowchart 1 Test sequence: flowcharts 1,2 Conductor resistance: table 3 Extent of test: flowchart 1 Test sequence: flowcharts 1,2 Disconnection times: table 4 Fuse table with limits: table 5 Test sequence and limits: flowchart 2

Connection diagram
Fig. 1

Fig. 2

Protection against indirect Fig. 3 contact: Equipotential bonding Insulation resistance test Test sequence and limits: flowchart 3 Fig. 4 High voltage Tests Test sequence and limits: flowchart 4 Fig. 5 Protection against residual Test sequence and limits: flowchart 5 Fig. 6 voltages Functional test Fig. 7 * TN systems. For TT systems RCD tests, for IT systems IMD check should be performed.

Table 1: Legend of tables, flowcharts

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Verification of safety of machines according to IEC/EN 60204 Edition 5

3 Visual inspection
Maybe it sounds strange but visual check is the most important and effective part of a machine test. The visual inspection discloses most of faults! Electrical testing often does not disclose failures that become apparent on visual inspection. A thorough visual check must be carried out before each electrical safety test. Scope of test: Check of: Wiring connection points. Especially PE connections are important ! Protection covers, housings Inscriptions and markings related to safety must be clearly readable. Cable layout, radiuses, isolation Switches, regulators,lamps, keys Parts subjected to wear out Electrical and mechanical protection devices (barriers, switches, fuses, alarms) Openings, filters Technical documentation, instructions for use available Installation of the appliance must be performed according to the user manuals. During visual inspection the measuring points for the electrical testing have to be determined too. Check that there are no signs of: damage pollution, moisture, dirt that can jeopardize safety corrosion overheating

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Verification of safety of machines according to IEC/EN 60204 Edition 5

4 Measurements
4.1 Verification of protection against indirect contact by automatic disconnection
This verification step is quite complex and must always be carryed out in some form. The standard allows simplified testing procedures regarding to the status of machine.

4.1.1 Selection of machine status and test extent


The status of the machine can be selected on base of condition of supplied machine (dismantled, fully assembled) technical documentation (availability of existing verification report of electrical wiring of machine) length of conductors after installation incoming supply characteristics loop impedance Flowchart 1 describes how to select the apropriate machine status and test extent. It shows when continuity and fault loop ompedance tests can be omitted. Note: Visual inspection of protection measures must always be carryed out. If in doubt it is recommended to carry out the complete verification procedure (marked bold in flowchart 1): - visual inspection - complete continuity test - complete fault loop impedance test Table 2 shows the maximal lenghts of conductors for given disconnection times / conductor /fuse or breaker type). If the lengths are shorter the loop impedance test may be omitted (if source impedance is low enough). The table should be used only if the machines documentation include a verification report of continuity of protective bonding. Note: The distance from the disconection device to all loads must be considered. Especially the most remote connection point must be considered.

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Protection against indirect contact by automatic disconnection TEST SEQUENCE

MACHINE STATUS A B
Verification available / long cables Machine supplied: with confirmation of the verification of continuity of the protective bonding circuits ( by continuity or loop impedance measurement) AND having protective bonding circuits exceeding the cable length for which examples are given in T able 2.

C
Verification availabe / short cables Machines: supplied with confirmation of the verification of continuity of the protective bonding circuits (by continuity or loop impedance measurement) AND having protective bonding circuits not exceeding the cable length for which examples are given in T able 2.

No verification available

Machines: erected and connected on site continuity of the protective bonding circuits has not been confirmed following erection and connection onsite.

(B2)
Machine supplied: supplied dismantled for shipment, where the continuity of protective conductors is ensured after dismantling, transportation and reassembly (for example by the use of plug/socket connections). Machine supplied: is fully assembled and not dismantled for shipment

(B1)

(C2)
Machine supplied: supplied dismantled for shipment, where the continuity of protective conductors is ensured after dismantling, transportation and reassembly (for example by the use of plug/socket connections).

(C1)
Machine supplied: fully assembled and not dismantled for shipment

No verification report available

Previous Zloop calulation avaliable Incoming Zloop known

Verification of safety of machines according to IEC/EN 60204 Edition 5

Flowchart 1: Protection against indirect contact selection of test sequence (according to EN/IEC 60204, Table 9)

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Zloop(source) < Zcalc., Ztest It can be confirmed that the supply source impedance on site is less than or equal to: that used for the calculation OR the supply source impedance of the test supply measured with ZLOOP test. VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PEterminal of the machine. ZLOOP TEST (complete) Zloop(source) < Zcalc., Ztest It can be confirmed that the supply source impedance on site is less than or equal to: that used for the calculation OR the supply source impedance of the test supply measured with ZLOOP test. VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PE-terminal of the machine all connections of the protective conductor(s) that were disconnected for shipment. VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PE-terminal of the machine;

VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PE-terminal of the machine. CONTINUITY TEST (complete) ZLOOP TEST (complete)

IF previous calculations of the ZLOOP by the manufacturer are available AND ? arrangement of the the installations permits the verification of the length and cross-sectional area of the conductors used for the calculation AND ? can be confirmed that the it supply source impedance on site is less than or equal to that of the supply used for the value assumed for the calculation by the manufacturer.

VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PE-terminal of the machine. ZLOOP TEST (complete)

VISUAL INSPECTION All connections of the protective conductor(s) that were disconnected for shipment. For a machine: fully assembled and not dismanted for shipment.

VISUAL INSPECTION For a machine not connected to the power supply by a plug/socket combination, the correct connection of the incoming external protective conductor to the PEterminal of the machine

VISUAL INSPECTION connections of the power supply incoming external protective conductor to the PE-terminal CONTINUITY TEST of the protective circuits connected on site

Verification of safety of machines according to IEC/EN 60204 Edition 5


Supply source impedance to each protective device Crosssectional area Nominal rating or setting of the protectiv e device (IN) Fuse discon nect time 5 s Adjustab le circuitbreaker Ia = 8 x IN disconn ect time 0,1 s Maximum cable length in m from each protective device to its load 97 53 76 30 28 115 135 145 125 175 133 136 141 138 152 157 57 66 59 41 73 94 114 133 132 179 34 35 40 33 55 36 38 42 37 61 38 73 66 46 98 79 Fuse disconn ect time 0,4 s Miniature circuitbreaker char.B Ia = 5 x IN disconnect time 0,1 s Miniature circuitbreaker char.C Ia = 10 x IN disconnect time 0,1 s

m 500 500 500 400 300 200 200 100 100 100 50 50

mm2 1,5 2,5 4,0 6,0 10 16 25 (line) / 16 (PE) 35 (line) / 16 (PE) 50 (line) / 25 (PE) 70 (line) / 35 (PE) 95 (line) / 50 (PE) 120 (line) / 70 (PE)

A 16 20 25 32 50 63 80 100 125 160 200 250

The values of the maximum cable length in the table are based on the following assumptions: PVC cable with copper conductors, conductor temperature under short circuit conditions 160C cables with line conductors up to 16 mm2 provide a protective conductor of equal cross sectional area to that of the line conductors; cables above 16 mm2 provide a reduced size protective conductor as shown; 3-phase system, nominal voltage of the power supply 400 V; maximum supply source impedance to each protective device in accordance with column 1; . A deviation from these assumptions can require a complete calculation or measurement of the fault loop impedance. Further information is available from IEC 60228 and IEC 61200-53.

Table 2: Maximal cable lengths that allow omitting loop impedance tests (EN/IEC 60204, table 10)

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Verification of safety of machines according to IEC/EN 60204 Edition 5

4.1.2 Selection of test limits


Once the machine status and test extent are defined the limits for the Continuity and/ or ZLOOP test should be defined. Flowchart 2 shows how to define test limits for the continuity and fault loop test.

4.1.2.1 Continuity test limits Table 3 shows expected limit resistance values for the continuity test (for typical conductor lengths and sizes). On base of given specific resistance of copper and influence of temperature limit resistance values for other conductor shapes and temperatures can be calculated.

4.1.2.2 ZLOOP test limits disconnection time In general 5s disconnection time should be considered for the ZLOOP test. Disconnection times for circuits that: supply, through socket-outlets or directly without socket-outlets, Class I handheld equipment or portable equipment (typical examples are socket-outlets on a machine for accessory equipment) are lower than 5s. Disconnection times for TN systems and standard nominal voltages are shown table 4.

4.1.2.3 ZLOOP test limits fault impedance/ prospective fault current IPFC (prospective fault current) and ZLOOP (fault impedance) limit values are defined on base of: fuse type and size relevant disconnection time nominal voltage The increase of resistance of the conductors with the increase of temperature due to the fault current must be taken into account as specified below: ZLOOPcalculated = ZLOOPmeasured 1.5 IPFCcalculted = IPSCmeasured 0.66 ZLOOP.................fault loop impedance IPSC.....................prospective fault current 1.5, 0.66.....temperature correction factors Table 5 shows limit values for nominal voltage of 230V, with the temperature correction factor considered. Eq. 1 Eq. 2

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Verification of safety of machines according to IEC/EN 60204 Edition 5 4.1.2.4 Protection against indirect contact selection of limit values

Flowchart 2: Protection against indirect contact selection of limits

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Verification of safety of machines according to IEC/EN 60204 Edition 5 4.1.2.5 Expected resistance limit values for the continuity test Wire Size mm2 0,2 24 0,3 22 0,5 20 0,75 18 1,0 16 1,5 14 2,5 12 4 10 6 8 10 6 16 4 25 2 35 1 50 Gauge No (AWG) Cross-sectional area mm2 0,196 0,205 0,283 0,324 0,500 0,519 0,750 0,823 1,000 1,31 1,500 2,08 2,500 3,31 4,000 5,26 6,000 8,37 10,000 13,3 16,000 21,1 25,000 33,6 35,000 42,4 47,000 inches2 0,000 304 0,000 317 0,000 438 0,000 504 0,000 775 0,000 802 0,001 162 0,001 272 0,001 550 0,002 026 0,002 325 0,003 228 0,003 875 0,005 129 0,006 200 0,008 152 0,009 300 0,012 967 0,015 50 0,020 610 0,024 800 0,032 780 0,038 800 0,052 100 0,054 200 0,065 700 0,072 800 d.c. resistance of copper at 20c Ohms per km 91,62 87,60 63,46 55,44 36,70 34,45 24,80 20,95 18,20 13,19 12,20 8,442 7,56 5,315 4,700 3,335 3,110 2,093 1,840 1,320 1,160 0,829 5 0,734 0 0,521 1 0,529 0 0,413 9 0,391 0 Circular mils

387 404 558 640 987 1 020 1 480 1 620 1 973 2 580 2 960 4 110 4 934 6 530 7 894 10 380 11 841 16 510 19 735 26 240 31 576 41 338 49 740 66 360 69 073 83 690 92 756

Table 3: Expected copper conductor resistance (at 20C) on base length and crosssection (EN/IEC 60204, Table G.1) The resistance for temperatures other than 20C can be found using the formula: R = R1 [1+0,003 93 (t-20)] R1........ resistance at 20C; R......... the resistance at a temperature tC. Eq.3

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Verification of safety of machines according to IEC/EN 60204 Edition 5 4.1.2.6 Disconnection times for TN systems (supplying parts of machines)
Uo (V) a) 120 230 277 400 Disconnecting time s 0,8 0,4 0,4 0,2

>400 0,1 a) Uo is the nominal a.c. r.m.s. voltage to earth. For voltages which are within the tolerance band stated in IEC 60038, the disconnecting time appropriate to the nominal voltage applies. For intermediate values of voltage, the next higher value in the above table is to be used.

Table 4: Maximum disconnection times for TN supplying circuits part of machines (EN/IEC 60204, Table A.1)

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Verification of safety of machines according to IEC/EN 60204 Edition 5 4.1.2.7 Disconnection times for TN systems Fuse tables for disconnection time of 5 seconds.
Fuse type NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV NV gG gG gG gG gG gG gG gG gG gG gG gG gG gG gG B B B B Fuse tripout time 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s Fuse current rating 2A 4A 6A 10 A 16 A 20 A 25 A 35 A 50 A 63 A 80 A 100 A 125 A 160 A 200 A 250 A 315 A 400 A 500 A 630 A 710 A 800 A 1000 A 1250 A 2A 4A 6A 10 A 13 A 16 A 20 A 25 A 32 A 35 A 40 A 50 A 63 A 80 A 100 A 6A 10 A 13 A 16 A Min. prospective short- Zloop for Un= 230V/400V circuit current (A) with with correction factor correction factor included included 25.3 9.1 12.3 18.7 8.6 26.7 5.0 46.4 3.5 66.3 2.7 86.7 2.1 109.3 1.4 169.5 0.9 266.9 0.7 319.1 0.5 447.9 0.4 585.4 0.3 765.1 0.2 947.9 0.2 1354.5 0.1 1590.6 0.1 2272.9 0.1 2766.1 0.1 3952.7 0.0 4985.1 0.0 6423.2 0.0 7252.1 0.0 9146.2 0.0 13070.1 25.3 9.1 12.3 18.7 8.6 26.7 5.0 46.4 4.1 56.2 3.5 66.3 2.7 86.7 2.1 109.3 1.4 159.1 1.4 169.5 1.2 190.1 0.9 266.9 0.7 319.1 0.5 447.9 0.4 585.4 7.7 30 4.6 50 3.5 65 2.9 80

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Verification of safety of machines according to IEC/EN 60204 Edition 5


B B B B B B C C C C C C C C C C C C C C C D D D D D D D D D D D D 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 5s 20 A 25 A 32 A 40 A 50 A 63 A 0.5 A 1A 1.6 A 2A 4A 6A 10 A 13 A 16 A 20 A 25 A 32 A 40 A 50 A 63 A 0.5 A 1A 1.6 A 2A 4A 6A 10 A 13 A 16 A 20 A 25 A 32 A 2.3 1.8 1.4 1.2 0.9 0.7 85.2 42.6 26.7 21.3 10.6 7.1 4.3 3.3 2.7 2.1 1.7 1.3 1.1 0.9 0.7 85.2 42.6 26.7 21.3 10.6 7.1 4.3 3.3 2.7 2.1 1.7 1.3 100 125 160 200 250 315 2.7 5.4 8.6 10.8 21.6 32.4 54 70.2 86.4 108 135 172.8 216 270 340.2 2.7 5.4 8.6 10.8 21.6 32.4 54 70.2 86.4 108 135 172.8

Table 5: Disconnection times for TN supplying circuits part of machines

4.1.2.8 Limits for suplemmentary bonding Where the requirements for prospective falt current cannot be assured supplementary bonding may be used in order to reduce the touch voltage below 50V. Supplementary bonding means additional connection of simultaneously accessible exposed metal parts. The following condition below must be fullfilled: RPE < 50V / Ia (5s) Ia(5s).........5 s operating current of the protective device; Eq.3

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Verification of safety of machines according to IEC/EN 60204 Edition 5 RPE........... resistance of the protective bonding circuit between the PE terminal and the equipment anywhere on the machine, or between simultaneously accessible exposed conductive parts and/or extraneous conductive parts.

4.2 Insulation resistance 4.2.1 Selection of test limits


Flowchart 3 shows how to define test limits for the insulation test. Normally the test may be made on individual sections of the complete electrical installation. Limitations are: Care must be taken if machine includes sensitive electrical equipment that could be damaged if a to high test voltage would be applied to them. In this case the sensitive part should be disconnected from the tested circuitry. Depending on the product standard, they should be tested with an apropriately lower test voltage. If surge protection devices are installed the test can be carryed out only in a limited manner. Procedures in this case of is described in flowchart 3.

Flowchart 3: Insulation resistance selection of limit

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Verification of safety of machines according to IEC/EN 60204 Edition 5

4.3 4.3 High voltage test 4.3.1 Selection of test limits


Flowchart 4 shows the methodology to define test limits for the high voltage. Normally the test may be made on individual sections of the complete electrical installation. Limitations are: Care must be taken if machine includes sensitive electrical equipment that could be damaged if a to high test voltage would be applied to them. The test may be made on individual sections of the complete electrical installation.

Withstanding voltage

Un < 500Vrms Un....nominal phase to neutral voltage

Un < 500Vrms

Utest = 1000Vac ttest = 1s limit = no breakdown

Utest = 2 Un ttest = 1s limit = no breakdown

Flowchart 4: High voltage test selection of limit

4.4 Residual voltage test 4.4.1 Selection of test limits


Flowchart 5 shows the methodology to define test limits for the residual voltage test. Live parts having a residual voltage greater than 60 V after the supply has been disconnected, shall be discharged to 60 V or less within a time period of 5 s after disconnection of the supply. Exempted from this requirement are components having a stored charge of Q = 60 C or less.

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Verification of safety of machines according to IEC/EN 60204 Edition 5 Q = CU Q................stored charge in Coloumbs C................capacitance in Farads U................voltage in Volts For plugs or similar devices with exposed conductors (for example pins) if plugged out the discharge time shall be discharged to 60 V or less within a time period of 1 s after disconnection of the supply. In case of longer discharging times the conductors / connectors shall be protected against direct contact to at least IP2X or IPXXB. If neither a discharge time of 1 s nor a protection of at least IP2X or IPXXB can be achieved (for example in the case of removable collectors on conductor wires, conductor bars, or slip-ring assemblies) additional switching devices or an appropriate warning device (for example a warning notice) shall be applied. Eq. 4

Residual voltage (discharging time)

Standard machine

Plugs or similar devices with exposed pins if plugged out

Ulimit = 60V tlimit = 5s

Ulimit = 60V tlimit = 5s

Flowchart 5: Residual voltage test selection of limit

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5 Connection diagramms
5.1 Protection against indirect contact 5.1.1 Continuity of protective conductors
5.1.1.1 Continuity test The resistance of each protective bonding circuit between the main PE terminal and individual relevant points that are part of each protective bonding circuit shall be measured. Size of test current should be between at least 0,2 A and approximately 10 A Higher currents are prefered ,especially for low resistance values, i.e. larger cross sectional areas and/or lower conductor length. The measured resistance shall be in the expected range according to the length, the cross sectional area and the material of the related protective bonding conductor(s).

Fig. 1: Continuity of protective conductors

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.1.2 Fault loop impedance


5.1.2.1 ZLOOP, IPFC test The fault loop impedance is measured between L and PE conductors at connection points of machines loads. Result is compared with Ia of belonging disconnection devices (fuses, breakers) For three phase machines all three (L1-PE, L2-PE, L3-PE impedances must be considered).

Fig. 2: Fault loop impedance

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.1.3 Suplemmentary bonding


5.1.3.1 Continuity test Suplemmentary bonding is measured between the main PE terminal and PE connections anywhere on the machine, or between simultaneously accessible exposed conductive parts and/or extraneous conductive parts. Size of test current should be between at least 0,2 A and approximately 10 A Higher currents are prefered ,especially for low resistance values, i.e. larger cross sectional areas and/or lower conductor length. The measured resistances shall be low enough to assure a contact voltage lower than 50V between two simultaneously accessible conductive parts.

Fig. 3: Equipotential bonding

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.2 Insulation resistance


5.2.1.1 Insulation resistance test Insulation resistance is measured between connected live pins and PE terminal. The test may be made on individual sections of the complete electrical installation. Components and devices that are not rated to withstand the test voltage shall be disconnected during the testing. Lower test voltages should be used for sensitive electronic equipment and surge protective devices.

Fig. 4: Insulation resistance

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.3 High voltage test


5.3.1.1 Withstanding voltage test The test voltage shall be applied between the power circuit conductors and the protective bonding circuit for a period of approximately 1 s. Components and devices that are not rated to withstand the test voltage shall be disconnected during the testing. Components and devices that have been voltage tested in accordance with their product standards may be disconnected during testing.

Fig. 5: Withstanding test

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.4 Residual voltage test


5.4.1.1 Withstanding voltage test The measurement is performed on disconnected machines supply pins There are different limit times for fixed connected machines and machines with plug / socket connections.

Fig. 6: Residual voltage

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Verification of safety of machines according to IEC/EN 60204 Edition 5

5.5 Functional tests


In its simplest form a functional check is simply a check to ensure that the machine is working properly.

Fig. 7: Functional test

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Verification of safety of machines according to IEC/EN 60204 Edition 5

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