Safety of machinery - Electrical equipment of machines - Part 1: General requirements

IEC 60204-1:2016 is available as IEC 60204-1:2016 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.
IEC 60204-1:2016 applies to electrical, electronic and programmable electronic equipment and systems to machines not portable by hand while working, including a group of machines working together in a co-ordinated manner. The equipment covered by this part of IEC 60204 commences at the point of connection of the supply to the electrical equipment of the machine. This sixth edition cancels and replaces the fifth edition published in 2005. It constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
- added requirements to address applications involving power drive systems (PDS);
- revised electromagnetic compatibility (EMC) requirements;
- clarified overcurrent protection requirements;
- requirements for determination of the short circuit current rating of the electrical equipment;
- revised protective bonding requirements and terminology;
- reorganization and revision to Clause 9, including requirements pertaining to safe torque off of PDS, emergency stop, and control circuit protection;
- revised symbols for actuators of control devices;
- revised technical documentation requirements;
- general updating to current special national conditions, normative standards, and bibliographical references.

Sécurité des machines - Équipement électrique des machines - Partie 1: Exigences générales

L'IEC 60204-1:2016 s'applique aux équipements et systèmes électriques, électroniques et électroniques programmables des machines non portables à la main en fonctionnement y compris un groupe de machines fonctionnant ensemble d'une manière coordonnée. L'équipement couvert par la présente partie de l'IEC 60204 commence au point de connexion de l'alimentation à l'équipement électrique de la machine. Cette sixième édition annule et remplace la cinquième édition parue en 2005. Cette édition constitue une révision technique. Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
- exigences supplémentaires pour traiter des applications impliquant des systèmes d'entraînements électriques de puissance (PDS);
- exigences révisées concernant la compatibilité électromagnétique (CEM);
- clarification des exigences de protection contre les surintensités;
- exigences pour la détermination des caractéristiques du courant de court-circuit de l'équipement électrique;
- révision des exigences de liaisons de protection et la terminologie;
- réorganisation et révision à l'Article 9, notamment les exigences relatives à la suppression sûre du couple du PDS, à l'arrêt d'urgence, et à la protection du circuit de commande;
- révision des symboles pour les organes de commande des appareils de commande;
- révision des exigences sur la documentation technique;
- mise à jour générale des conditions nationales particulières, des normes et des références bibliographiques.

General Information

Status
Published
Publication Date
12-Oct-2016
Current Stage
PPUB - Publication issued
Completion Date
13-Oct-2016
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IEC 60204-1
Edition 6.0 2016-10
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Safety of machinery – Electrical equipment of machines –
Part 1: General requirements
Sécurité des machines – Équipement électrique des machines –
Partie 1: Exigences générales
IEC 60204-1:2016-10(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 60204-1
Edition 6.0 2016-10
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Safety of machinery – Electrical equipment of machines –
Part 1: General requirements
Sécurité des machines – Équipement électrique des machines –
Partie 1: Exigences générales
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 13.110; 29.020 ISBN 978-2-8322-3621-5

Warning! Make sure that you obtained this publication from an authorized distributor.

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® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 60204-1:2016 © IEC 2016
CONTENTS

FOREWORD ....................................................................................................................... 10

INTRODUCTION ................................................................................................................. 13

1 Scope .......................................................................................................................... 15

2 Normative references................................................................................................... 16

3 Terms,definitions and abbreviated terms ...................................................................... 17

3.1 Terms and definitions .......................................................................................... 17

3.2 Abbreviated terms ............................................................................................... 26

4 General requirements .................................................................................................. 26

4.1 General ............................................................................................................... 26

4.2 Selection of equipment ........................................................................................ 27

4.2.1 General ....................................................................................................... 27

4.2.2 Switchgear ................................................................................................... 27

4.3 Electrical supply .................................................................................................. 28

4.3.1 General ....................................................................................................... 28

4.3.2 AC supplies ................................................................................................. 28

4.3.3 DC supplies ................................................................................................. 28

4.3.4 Special supply systems ................................................................................ 28

4.4 Physical environment and operating conditions .................................................... 28

4.4.1 General ....................................................................................................... 28

4.4.2 Electromagnetic compatibility (EMC) ............................................................ 29

4.4.3 Ambient air temperature ............................................................................... 29

4.4.4 Humidity ...................................................................................................... 29

4.4.5 Altitude ........................................................................................................ 29

4.4.6 Contaminants ............................................................................................... 29

4.4.7 Ionizing and non-ionizing radiation ............................................................... 30

4.4.8 Vibration, shock, and bump .......................................................................... 30

4.5 Transportation and storage .................................................................................. 30

4.6 Provisions for handling ........................................................................................ 30

5 Incoming supply conductor terminations and devices for disconnecting and

switching off ................................................................................................................ 30

5.1 Incoming supply conductor terminations .............................................................. 30

5.2 Terminal for connection of the external protective conductor ................................ 31

5.3 Supply disconnecting (isolating) device................................................................ 31

5.3.1 General ....................................................................................................... 31

5.3.2 Type ............................................................................................................ 31

5.3.3 Requirements .............................................................................................. 32

5.3.4 Operating means of the supply disconnecting device .................................... 32

5.3.5 Excepted circuits .......................................................................................... 33

5.4 Devices for removal of power for prevention of unexpected start-up ..................... 34

5.5 Devices for isolating electrical equipment ............................................................ 34

5.6 Protection against unauthorized, inadvertent and/or mistaken connection ............. 35

6 Protection against electric shock .................................................................................. 35

6.1 General ............................................................................................................... 35

6.2 Basic protection .................................................................................................. 35

6.2.1 General ....................................................................................................... 35

6.2.2 Protection by enclosures .............................................................................. 36

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IEC 60204-1:2016 © IEC 2016 – 3 –

6.2.3 Protection by insulation of live parts ............................................................. 37

6.2.4 Protection against residual voltages ............................................................. 37

6.2.5 Protection by barriers ................................................................................... 37

6.2.6 Protection by placing out of reach or protection by obstacles ........................ 37

6.3 Fault protection ................................................................................................... 37

6.3.1 General ....................................................................................................... 37

6.3.2 Prevention of the occurrence of a touch voltage ............................................ 38

6.3.3 Protection by automatic disconnection of supply ........................................... 38

6.4 Protection by the use of PELV ............................................................................. 39

6.4.1 General requirements ................................................................................... 39

6.4.2 Sources for PELV ........................................................................................ 40

7 Protection of equipment ............................................................................................... 40

7.1 General ............................................................................................................... 40

7.2 Overcurrent protection ......................................................................................... 40

7.2.1 General ....................................................................................................... 40

7.2.2 Supply conductors ....................................................................................... 40

7.2.3 Power circuits .............................................................................................. 41

7.2.4 Control circuits ............................................................................................. 41

7.2.5 Socket outlets and their associated conductors ............................................. 41

7.2.6 Lighting circuits ............................................................................................ 41

7.2.7 Transformers ............................................................................................... 42

7.2.8 Location of overcurrent protective devices .................................................... 42

7.2.9 Overcurrent protective devices ..................................................................... 42

7.2.10 Rating and setting of overcurrent protective devices ..................................... 42

7.3 Protection of motors against overheating ............................................................. 42

7.3.1 General ....................................................................................................... 42

7.3.2 Overload protection ...................................................................................... 43

7.3.3 Over-temperature protection ......................................................................... 43

7.4 Protection against abnormal temperature ............................................................. 43

7.5 Protection against the effects of supply interruption or voltage reduction and

subsequent restoration ........................................................................................ 44

7.6 Motor overspeed protection ................................................................................. 44

7.7 Additional earth fault/residual current protection .................................................. 44

7.8 Phase sequence protection ................................................................................. 44

7.9 Protection against overvoltages due to lightning and to switching surges .............. 44

7.10 Short-circuit current rating ................................................................................... 45

8 Equipotential bonding .................................................................................................. 45

8.1 General ............................................................................................................... 45

8.2 Protective bonding circuit .................................................................................... 47

8.2.1 General ....................................................................................................... 47

8.2.2 Protective conductors ................................................................................... 47

8.2.3 Continuity of the protective bonding circuit .................................................... 48

8.2.4 Protective conductor connecting points ......................................................... 49

8.2.5 Mobile machines .......................................................................................... 49

8.2.6 Additional requirements for electrical equipment having earth leakage

currents higher than 10 mA .......................................................................... 49

8.3 Measures to restrict the effects of high leakage current ........................................ 50

8.4 Functional bonding .............................................................................................. 50

9 Control circuits and control functions ............................................................................ 50

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– 4 – IEC 60204-1:2016 © IEC 2016

9.1 Control circuits .................................................................................................... 50

9.1.1 Control circuit supply .................................................................................... 50

9.1.2 Control circuit voltages ................................................................................. 51

9.1.3 Protection .................................................................................................... 51

9.2 Control functions ................................................................................................. 51

9.2.1 General ....................................................................................................... 51

9.2.2 Categories of stop functions ......................................................................... 51

9.2.3 Operation ..................................................................................................... 51

9.2.4 Cableless control system (CCS) ................................................................... 55

9.3 Protective interlocks ............................................................................................ 57

9.3.1 Reclosing or resetting of an interlocking safeguard ....................................... 57

9.3.2 Exceeding operating limits............................................................................ 57

9.3.3 Operation of auxiliary functions .................................................................... 57

9.3.4 Interlocks between different operations and for contrary motions ................... 57

9.3.5 Reverse current braking ............................................................................... 57

9.3.6 Suspension of safety functions and/or protective measures ........................... 58

9.4 Control functions in the event of failure ................................................................ 58

9.4.1 General requirements ................................................................................... 58

9.4.2 Measures to minimize risk in the event of failure ........................................... 59

9.4.3 Protection against malfunction of control circuits ........................................... 60

10 Operator interface and machine-mounted control devices ............................................. 66

10.1 General ............................................................................................................... 66

10.1.1 General requirements ................................................................................... 66

10.1.2 Location and mounting ................................................................................. 66

10.1.3 Protection .................................................................................................... 66

10.1.4 Position sensors .......................................................................................... 66

10.1.5 Portable and pendant control stations ........................................................... 67

10.2 Actuators ............................................................................................................ 67

10.2.1 Colours ........................................................................................................ 67

10.2.2 Markings ...................................................................................................... 67

10.3 Indicator lights and displays ................................................................................ 68

10.3.1 General ....................................................................................................... 68

10.3.2 Colours ........................................................................................................ 68

10.3.3 Flashing lights and displays .......................................................................... 69

10.4 Illuminated push-buttons ..................................................................................... 69

10.5 Rotary control devices ......................................................................................... 69

10.6 Start devices ....................................................................................................... 69

10.7 Emergency stop devices ...................................................................................... 70

10.7.1 Location of emergency stop devices ............................................................. 70

10.7.2 Types of emergency stop device .................................................................. 70

10.7.3 Operation of the supply disconnecting device to effect emergency stop ......... 70

10.8 Emergency switching off devices ......................................................................... 70

10.8.1 Location of emergency switching off devices ................................................. 70

10.8.2 Types of emergency switching off device ...................................................... 70

10.8.3 Local operation of the supply disconnecting device to effect emergency

switching off ................................................................................................. 71

10.9 Enabling control device ....................................................................................... 71

11 Controlgear: location, mounting, and enclosures .......................................................... 71

11.1 General requirements .......................................................................................... 71

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IEC 60204-1:2016 © IEC 2016 – 5 –

11.2 Location and mounting ........................................................................................ 71

11.2.1 Accessibility and maintenance ...................................................................... 71

11.2.2 Physical separation or grouping .................................................................... 72

11.2.3 Heating effects ............................................................................................. 72

11.3 Degrees of protection .......................................................................................... 73

11.4 Enclosures, doors and openings .......................................................................... 73

11.5 Access to electrical equipment ............................................................................ 74

12 Conductors and cables ................................................................................................ 74

12.1 General requirements .......................................................................................... 74

12.2 Conductors ......................................................................................................... 74

12.3 Insulation ............................................................................................................ 75

12.4 Current-carrying capacity in normal service ......................................................... 75

12.5 Conductor and cable voltage drop ....................................................................... 76

12.6 Flexible cables .................................................................................................... 77

12.6.1 General ....................................................................................................... 77

12.6.2 Mechanical rating ......................................................................................... 77

12.6.3 Current-carrying capacity of cables wound on drums .................................... 77

12.7 Conductor wires, conductor bars and slip-ring assemblies .................................... 78

12.7.1 Basic protection ........................................................................................... 78

12.7.2 Protective conductors ................................................................................... 78

12.7.3 Protective conductor current collectors ......................................................... 78

12.7.4 Removable current collectors with a disconnector function ............................ 79

12.7.5 Clearances in air .......................................................................................... 79

12.7.6 Creepage distances ..................................................................................... 79

12.7.7 Conductor system sectioning ........................................................................ 79

12.7.8 Construction and installation of conductor wire, conductor bar systems

and slip-ring assemblies ............................................................................... 79

13 Wiring practices ........................................................................................................... 80

13.1 Connections and routing ...................................................................................... 80

13.1.1 General requirements ................................................................................... 80

13.1.2 Conductor and cable runs ............................................................................ 80

13.1.3 Conductors of different circuits ..................................................................... 81

13.1.4 AC circuits – Electromagnetic effects (prevention of eddy currents) ............... 81

13.1.5 Connection between pick-up and pick-up converter of an inductive

power supply system .................................................................................... 81

13.2 Identification of conductors .................................................................................. 81

13.2.1 General requirements ................................................................................... 81

13.2.2 Identification of the protective conductor / protective bonding conductor ........ 82

13.2.3 Identification of the neutral conductor ........................................................... 82

13.2.4 Identification by colour ................................................................................. 83

13.3 Wiring inside enclosures ...................................................................................... 83

13.4 Wiring outside enclosures ................................................................................... 84

13.4.1 General requirements ................................................................................... 84

13.4.2 External ducts .............................................................................................. 84

13.4.3 Connection to moving elements of the machine ............................................ 84

13.4.4 Interconnection of devices on the machine ................................................... 85

13.4.5 Plug/socket combinations ............................................................................. 85

13.4.6 Dismantling for shipment .............................................................................. 86

13.4.7 Additional conductors ................................................................................... 86

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– 6 – IEC 60204-1:2016 © IEC 2016

13.5 Ducts, connection boxes and other boxes ............................................................ 86

13.5.1 General requirements ................................................................................... 86

13.5.2 Rigid metal conduit and fittings ..................................................................... 87

13.5.3 Flexible metal conduit and fittings ................................................................. 87

13.5.4 Flexible non-metallic conduit and fittings ...................................................... 87

13.5.5 Cable trunking systems ................................................................................ 87

13.5.6 Machine co
...

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