ES 2: How to Design Control Panels according to EN 60204-1

The training objective is to be able to design and engineer an industrial control panel according to the European Standard EN 60204-1. 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).

Finally, we will go into detail about the Neutral earthing systems: TN, TT and IT, we will address the issue of bonding of Exposed Conductive Parts and the problem of extraneous conductive parts.

Despite adhering to the language of the standard, the training is practical, with several examples.

DURATION: 16 hours

MODULE 1 (8 hours) Introduction and Overcurrents

• Fixed installations vs Electrical Equipment of Machinery
• Main Reference Standards
• CE Marking of Electrical Installation
• General prescriptions
• Cable shielding
• 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
• Residual Current Devices and the G Curve
• Overload Protection
• The Short Circuit
• The Interrupting Rating
• Selectivity
• The SCCR
• Tap Conductors
• The Circuit Breaker protections
• Miniature CB
• MCCB and ACB
• Residual Current Devices and the G Curve

MODULE 2 (8 hours) Indirect Contacts, Ampacity and verifications

• 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
• Basic and Fault protection in TN Systems
• The concept of Exposed and Extraneous Conductive Part
• The Fault Loop and the TN System
• Amendment IEC 60204-1 – September 2021
• Residual Current Device
• The high sensitivity RCD
• TT and TN systems
• Class II Cables
• IEC 60204-1: what shall be bonded
• 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
• Operator interface and Cabling techniques
• The nameplate
• Nominal vs maximum current
• Tests and Verifications: Continuity test, Earth Leakages, Dielectric, Insulation 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)