ES 3: Advanced Training on EN 60204-1

Industrial Control Panels according to the Machinery Directive

Last edit: 26/10/2023

Training objective

The training objective is to be able to design and engineer an industrial control panel according to the European Standard EN 60204-1. We will also touch on other important standards like IEC 60364-4-41, IEC 60364-4-43, IEC 60364-5-52, IEC 60364-5-53. Since October 2021, the 2006 edition of EN 60204-1 is not anymore harmonised and the new edition has become compulsory. We will also touch on the new editions of IEC 61439-1 and IEC 61439-2 (2020). Despite adhering to the language of the standard, the training is practical, with several examples.


DURATION: 28 hours

MODULE 1 (4 hours)

  • Fixed installations vs Electrical Equipment of Machinery
  • Main Reference Standards
  • CE Marking of Electrical Installation
  • General prescriptions
  • Cable shielding
  • EMC and Annex H
  • Harmonic currents
  • Main Disconnect
  • Grounding Cable
  • Unexpected start up
  • Use of an unfused disconnect as a General Disconnector
  • How to distribute power inside the control panel
  • Protection against electric shock
  • Interface Parameters

MODULE 2 (8 hours) Overcurrents

  • The Circuit Breaker protections
  • Miniature CB
  • MCCB and ACB
  • Residual Current Devices and the G Curve
  • The Fuse link
  • Overload Protection
  • The Short Circuit
  • The Interrupting Rating
  • Selectivity
  • The SCCR
  • Energy Limiting properties
  • Selectivity under short circuit conditions
  • The I2t concept and why it is important
  • Tap Conductors
  • How to properly size a contactor

MODULE 3 (8 hours) Protection against electric shock

  • Basic Protection
  • Fault protection in TN Systems
  • The concept of Exposed Conductive Part
  • The concept of Extraneous Conductive Part
  • The Fault Loop
  • TN System (solidly grounded Y)
  • Amendment IEC 60204-1 – September 2021 
  • Residual Current Device
  • RCD and Variable Speed Drives
  • The G curve of MCCB and ACB
  • The high sensitivity RCD
  • TT systems
  • TN Systems
  • Electrical insulation
  • Direct Current and its safety
  • Equipotentiality between Exposed and Extraneous Conductive Parts
  • How to solve the issue of the Extraneous Conductive parts
  • TN system in Machinery
  • Class II Cables
  • Double insulation according to IEC 60364-4-41
  • IEC 60204-1: what shall be bonded
  • SELV, PEVL and FELV circuits

MODULO 4 (8 ore) Ampacity and verifications

  • Free air cable ampacity according to IEC 60364-5-52
  • Cable Ampacity according to IEC 60204-1 and IEC 61439-1
  • Cable Ampacity: GT Engineering recommendation
  • Protection against control circuit malfunctioning
  • Switching power supplies
  • The use of PELV circuits in Machinery
  • Operator interface
  • Cabling techniques
  • The nameplate
  • Nominal vs maximum current
  • Continuity test
  • Earth Leakages
  • Protection against indirect Contacts in TN Systems
  • Fault protection in case of VSDs
  • Fault Protection in TT Systems
  • Dielectric Test
  • Insulation Test
  • Residual voltage test


GT Engineering is a member of the following Technical Committees

  • Member of the Technical Committee IEC/TC44 MT 60204-1 for IEC 60204-1: Safety of machinery – Electrical equipment of machines.
  • Member of the Technical Committee IEC/TC64 MT9 for  IEC 60364-4-41: Low-voltage electrical installations – Protection against electric shock
  • Member of the UL Standard Technical Panel (STP) for UL 508A
  • Principal (Special Expert) on the NFPA 79 Technical Committee.
  • Member of WG 4-006 of the CE Code (Canadian Electrical Code C22.1)