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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
2 3 4
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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.
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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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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.
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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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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.
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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
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
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)
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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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
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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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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.
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Withstanding voltage
Un < 500Vrms
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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
Standard machine
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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).
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