---

Figure D.1 - Methods of conductor and cable installation independent of number of conductors/cables 107

Figure D.2 - Parameters of conductors and protective devices 109

1. - Minimum cross-sectional area of the external protective copper conductor 27

2. - Colour-coding for push-button actuators and their meanings 60

3. - Symbols for push-buttons 60

4. - Colours for indicator lights and their meanings with respect to the condition of the machine 61

5. - Minimum cross-sectional areas of copper conductors 68

6. - Examples of current-carrying capacity (/_z) of PVC insulated copper conductors or cables under steady-state conditions in an ambient air temperature of +40 °С for different methods of installation 70

7. - Derating factors for cables wound on drums 72

8. - Minimum permitted bending radii for the forced guiding of flexible cables 79

9. - Application of the test methods for TN-systems 93

10. - Examples of maximum cable length from each protective device to its load 94

Table A.1 - Maximum disconnecting times for TN systems 96

Table D.1 - Correction factors 106

Table D.2 - Derating factors from I_z for grouping 108

Table D.3 - Derating factors from l_z for multicore cables up to 10 mm² 108

Table D.4 - Classification of conductors 109

Table D.5 - Maximum allowable conductor temperatures under normal and short-circuit

conditions 110

6. 1 - Application options 114

1 - Comparison of conductor sizes 115INTERNATIONAL ELECTROTECHNICAL COMMISSION

SAFETY OF MACHINERY -
ELECTRICAL EQUIPMENT OF MACHINES -

Part 1: General requirements

FOREWORD

1. The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with may participate in this preparatory work. International, governmental and non­governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

2. The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international consensus of opinion on the relevant subjects since each technical committee has representation from all interested IEC National Committees.

3. IEC Publications have the form of recommendations for international use and are accepted by IEC National Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any misinterpretation by any end user.

4. In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications transparently to the maximum extent possible in their national and regional publications. Any divergence between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter.

5. IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any equipment declared to be in conformity with an IEC Publication.

6. All users should ensure that they have the latest edition of this publication.

7. No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and members of its technical committees and IEC National Committees for any personal injury, property damage or other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC Publications.

8. Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is indispensable for the correct application of this publication.

9. Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent rights. IEC shall not be held responsible for identifying any or all such patent rights.

International Standard IEC 60204-1 has been prepared by technical committee 44: Safety of machinery - Electrotechnical aspects.

This edition constitutes a technical revision. It incorporates material from the fourth edition, amended to provide general requirements for machines, including mobile machines and complex (for example large) machine installations.

This consolidated version of IEC 60204-1 consists of the fifth edition (2005) [documents 44/494/FDIS and 44/502/RVD] and its amendment 1 (2008) [documents 44/575/CDV and 44/580/RVC],

The technical content is therefore identical to the base edition and its amendment and has been prepared for user convenience.

It bears the edition number 5.1.

А vertical line in the margin shows where the base publication has been modified by amendment 1.

This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

The following differences exist in some countries:

6.3.3 b), 13.4.5 b), 18.2.1: TT power systems are not allowed (USA).

IEC 60204 consists of the following parts, under the general title Safety of machinery - Electrical equipment of machines:

The committee has decided that the contents of the base publication and its amendments will remain unchanged until the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in the data related to the specific publication. At this date, the publication will be

• reconfirmed,

• withdrawn,

• replaced by a revised edition, or

amended.INTRODUCTION

This part of IEC 60204 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.

More guidance on the use of this part of IEC 60204 is given in Annex F.

Figure 1 has been provided as an aid to the understanding of the inter-relationship of the various elements of a machine and its associated equipment. Figure 1 is a block diagram of a typical machine and associated equipment showing the various elements of the electrical equipment addressed in this part of IEC 60204. Numbers in parentheses () refer to Clauses and Subclauses in this part of IEC 60204. It is understood in Figure 1 that all of the elements taken together including the safeguards, tooling/fixturing, software, and the documentation, constitute the machine, and that one or more machines working together with usually at least one level of supervisory control constitute a manufacturing cell or system.

Physical
environment
(4.4)

Warning signs, item designation
(Clause 16)

Technical documentation
(Clause 17)

System/cell
controller

Power supply
(4.3)

(External protective
conductor connection)

Conductors and
cables
(Clause 12)

Supply disconnecting device
(5.3)

Protection against electrical shock
(Clause 6)

Protection of equipment
(Clause 7)

Earth (PE) terminal

(5.2)

Protective bonding circuit
(8.2)

Control circuits and control functions
(Clause 9)

Emergency stop function

(9.2.5.4)

Controlgear
(Clause 11)

Accessories and lighting
(Clause 15)

Data link

Wiring
practices
(Clause 13)

Testing
(Clause 18)

Motor
control equipment

Programmable
controller

Input/output
interface

Emergency
stop device
(10.7)

Operator control
station
(Clause 10)

Safeguards and warning devices

Motors
(Clause 14) and
transducers

Actuators and
sensors

Processing equipment

IEC 1388/05

Figure 1 - Block diagram of a typical machine

SAFETY OF MACHINERY -
ELECTRICAL EQUIPMENT OF MACHINES -

Part 1: General requirements

1. Scope

This part of IEC 60204 applies to the application of 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.

NOTE 1 This part of IEC 60204 is an application standard and is not intended to limit or inhibit technological advancement.

NOTE 2 In this part of IEC 60204, the term electrical includes electrical, electronic and programmable electronic matters (i.e. electrical equipment means electrical, electronic and programmable electronic equipment).

NOTE 3 In the context of this part of IEC 60204, the term person refers to any individual and includes those persons who are assigned and instructed by the user or his agent(s) in the use and care of the machine in question.

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 (see 5.1).

NOTE 4 The requirements for the electrical supply installation in buildings are given in the IEC 60364 series.

This part of IEC 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 (a.c.) and not exceeding 1 500 V for direct current (d.c.), and with nominal supply frequencies not exceeding 200 Hz.

NOTE 5 For higher voltages, see IEC 60204-11.

This part of IEC 60204 does not cover all the requirements (for example guarding, interlocking, or control) that are needed or required by other standards or regulations in order to protect persons from hazards other than electrical hazards. Each type of machine has unique requirements to be accommodated to provide adequate safety.

This part specifically includes, but is not limited to, the electrical equipment of machines as defined in 3.35.

NOTE 6 Annex C lists examples of machines whose electrical equipment can be covered by this part of IEC 60204.

This part of IEC 60204 does not specify additional and special requirements that can apply to the electrical equipment of machines that, for example:

• are intended for use in open air (i.e. outside buildings or other protective structures);

• use, process, or produce potentially explosive material (for example paint or sawdust);

• are intended for use in potentially explosive and/or flammable atmospheres;

• have special risks when producing or using certain materials;

• are intended for use in mines;are sewing machines, units, and systems (which are covered by IEC 60204-31);

• are hoisting machines (which are covered by IEC 60204-32).

Power circuits where electrical energy is directly used as a working tool are excluded from this part of IEC 60204.

2. Normative references

The following referenced documents are indispensable for the application of this part of IEC 60204. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

IEC 60034-1, Rotating electrical machines - Part 1: Rating and performance

IEC 60034-5, Rotating electrical machines - Part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code) - Classification

IEC 60034-11, Rotating electrical machines - Part 11: Thermal protection

IEC 60072-1, Dimensions and output series for rotating electrical machines - Part 1: Frame numbers 56 to 400 and flange numbers 55 to 1 080

IEC 60072-2, Dimensions and output series for rotating electrical machines - Part 2: Frame numbers 355 to 1 000 and flange numbers 1 180 to 2 360

IEC 60073:2002, Basic and safety principles for man-machine interface, marking and identification - Coding principles for indicators and actuators

IEC 60309-1:1999, Plugs, socket-outlets, and couplers for industrial purposes - Part 1: General requirements

IEC 60364-4-41:2005, Low-voltage electrical installations - Part 4-41: Protection for safety - Protection against electric shock

IEC 60364-4-43:2001, Electrical installations of buildings - Part 4-43: Protection for safety - Protection against overcurrent

IEC 60364-5-52:2001, Electrical installations of buildings - Part 5-52: Selection and erection of electrical equipment - Wiring systems

IEC 60364-5-53:2002, Electrical installations of buildings - Part 5-53: Selection and erection of electrical equipment - Isolation, switching and control

IEC 60364-5-54:2002, Electrical installations of buildings - Part 5-54: Selection and erection of electrical equipment - Earthing arrangements, protective conductors and protective bonding conductors

IEC 60364-6-61:2001, Electrical installations of buildings - Part 6-61: Verification - Initial verification

IEC 60417-DB:2002², Graphical symbols for use on equipment

ІЕС 60439-1:1999, Low-voltage switchgear and controlgear assemblies - Part 1: Type-tested and partially type-tested assemblies

IEC 60445:1999, Basic and safety principles for man-machine interface, marking and identification - Identification of equipment terminals and of terminations of certain designated conductors, including general rules for an alphanumeric system

IEC 60446:1999, Basic and safety principles for man-machine interface, marking and

identification - Identification of conductors by colours or numerals

IEC 60447:2004, Basic and safety principles for man-machine interface, marking and

identification - Man-machine interface (MMI) - Actuating principles

IEC 60529:1999, Degrees of protection provided by enclosures (IP Code)

Amendment 1 (2001)

IEC 60617-DB:2001³, Graphical symbols for diagrams

IEC 60621-3:1979, Electrical installations for outdoor sites under heavy conditions (including open-cast mines and quarries) - Part 3: General requirements for equipment and ancillaries

IEC 60664-1:1992, Insulation co-ordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests

IEC 60947-1:2004, Low-voltage switchgear and controlgear - Part 1: General rules

IEC 60947-2:2003, Low-voltage switchgear and controlgear - Part 2: Circuit-breakers

IEC 60947-3:1999, Low-voltage switchgear and controlgear - Part 3: Switches, disconnectors, switch-disconnectors, and fuse combination units

IEC 60947-5-1:2003, Low-voltage switchgear and controlgear - Part 5-1: Control circuit devices and switching elements - Electromechanical control circuit devices

IEC 60947-7-1:2002, Low-voltage switchgear and controlgear - Part 7-1: Ancillary equipment - Terminal blocks for copper conductors

IEC 61082-1:1991, Preparation of documents used in electrotechnology - Part 1: General requirements

IEC 61082-2:1993, Preparation of documents used in electrotechnology - Part 2: Function- oriented diagrams

IEC 61082-3:1993, Preparation of documents used in electrotechnology - Part 3: Connection diagrams, tables and lists

IEC 61082-4:1996, Preparation of documents used in electrotechnology - Part 4: Location and installation documents

IEC 61140:2001, Protection against electric shock - Common aspects for installation and equipment

IEC 61310 (all parts), Safety of machinery - Indication, marking and actuation

IEC 61346 (all parts), Industrial systems, installations and equipment and industrial products - Structuring principles and reference designationsIEC 61557-3:1997, Electrical safety in low voltage distribution systems up to 1000 V a.c. and 1500 V d.c. - Equipment for testing, measuring or monitoring of protective measures - Part 3: Loop impedance

IEC 61558-1:1997, Safety of power transformers, power supply units and similar - Part 1: General requirements and tests

Amendment 1 (1998)

IEC 61558-2-6, Safety of power transformers, power supply units and similar - Part 2-6: Particular requirements for safety isolating transformers for general use

IEC 61984:2001, Connectors - Safety requirements and tests

IEC 62023:2000, Structuring of technical information and documentation

IEC 62027:2000, Preparation of parts lists

IEC 62061:2005, Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems

IEC 62079:2001, Preparation of instructions - Structuring, content and presentation

ISO 7000:2004, Graphical symbols for use on equipment - Index and synopsis

ISO 12100-1:2003, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology

ISO 12100-2:2003, Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles

ISO 13849-1:2006, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design

ISO 13849-2:2003, Safety of machinery - Safety-related parts of control systems - Part 2: Validation

I ISO 13850:2006, Safety of machinery - Emergency stop - Principles for design

3. Terms and definitions

For the purposes of this document, the following terms and definitions apply.

actuator

part of a device to which an external manual action is to be applied

NOTE 1 The actuator may take the form of a handle, knob, push-button, roller, plunger, etc.

NOTE 2 There are some actuating means that do not require an external actuating force, but only an action.

NOTE 3 See also 3.34.

ambient temperature

temperature of the air or other medium where the equipment is to be used

barrier

part providing protection against direct contact from any usual direction of access

cable tray

cable support consisting of a continuous base and raised edges and no covering