EN60204 Testing
EN60204 Testing
At Safety Systems Technology, we provide comprehensive verification of permanently installed electrical systems to ensure strict compliance with the BS EN 60204-1 standard. Guided by Clause 18, our process involves detailed inspection, testing and rigorous documentation to validate equipment safety.
Our expert team utilises advanced diagnostics to ensure your machinery is safe, insurable and fully compliant with PUWER and the Electricity at Work Regulations.
What is EN60204 Testing?
Electrical systems are at the heart of machinery in all modern industrial and commercial environments. From high-speed intralogistics conveyors to multi-axis robotic assembly cells, from palletisers to sorting and grading systems, the sophistication of automated systems introduces a complex matrix of electrical hazards that requires rigorous management.
While the introduction outlines the regulatory framework, it is important to understand the practical application. Compliance with BS EN 60204-1 (Safety of machinery. Electrical equipment of machines) is the primary means of discharging the statutory obligations mentioned above – specifically under the Provision and Use of Work Equipment Regulations 1998 (PUWER) and the Electricity at Work Regulations 1989 (EAWR). At SST, we provide the comprehensive compliance and verification services necessary to ensure your machinery is safe, legal and insurable.
What is BS EN 60204-1?
BS EN 60204-1 is the “Designated Standard” in the UK and the benchmark for electrical safety. It applies to electrical, electronic and programmable electronic equipment and systems for machines not portable by hand.
Significantly, it covers the electrical equipment starting from the point of connection of the supply to the machine and so is distinct from the building wiring covered by BS 7671.
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Key Standard Clauses and Verification Areas
| Clause | Focus Area | What This Means for Your Machinery |
|---|---|---|
| Clause 4.4 | Environmental Suitability | Equipment must be suitable for its intended operating environment, accounting for factors such as ambient temperature, humidity (e.g. in cold storage) and altitude. |
| Clause 8.2 | Protective Bonding | The “Earth Path” must be verified. In the event of an insulation failure – such as a live wire touching the metal frame – current must flow back to the earth terminal to trip the breaker instantly. |
| Clause 9 | Control Circuits | Control functions, such as interlocks and stop functions, are tested to confirm they perform correctly and “fail-safe” in the event of a fault. |
| Clause 13 | Wiring Practices | Cables are required to be correctly routed and identified, with adequate protection against mechanical damage to prevent interference. |
| Clause 18 | Verification | A structured sequence of inspections and tests required to validate the design assumptions and prove the integrity of the installation. |
The Value of Regular Testing Beyond Compliance
Investing in regular EN 60204-1 verification is a strategic imperative that extends beyond statutory law into asset protection and financial risk transfer.
Mitigating Insurance
Risk Commercial insurance policies often contain conditions requiring compliance with all statutory regulation. A fire originating from a machine’s internal control panel without evidence of maintenance (such as an EN 60204-1 test report) can lead insurers to void policies, leaving businesses liable for the entire cost of damages and business interruption.
Asset Protection and Uptime
Many of our customers use regular testing as a preventative maintenance measure. Tests such as earth loop impedance and insulation resistance can identify incipient faults – such as water ingress or loosening terminals due to vibration – sometimes months before they would become obvious and cause a catastrophic failure.
In high-throughput manufacturing and warehousing environments, scheduling downtime for testing—potentially preventing a single unplanned outage—is clearly more cost-effective than neglecting it.
UKCA and Market Access
Since Brexit and the transition to the UK Conformity Assessed (UKCA) mark, any new machine, complex assembly or significantly modified equipment commercially available on the GB market must have a Technical File demonstrating compliance with BS EN 60204-1.
Our Proven Verification Methodology
We do not just “tick boxes”; we validate the physical integrity of your installation using the granular methodology detailed in Clause 18.
1. Comprehensive Visual Inspection
Before connecting instruments, we perform a deep inspection to detect mechanical defects electrical meters cannot see. We check for compromised IP seals, “bird-caging” of wires in terminals and correct colour coding, and ensure the installed equipment matches your electrical schematics.
2. Protective Bonding (Earth Continuity) Testing
We verify the earth path using a high test current (e.g. 10A or 25A) to stress the joints. This reveals latent defects such as loose bolts or painted-over washers that a simple multimeter check would miss.
3. Insulation Resistance (IR) Testing
We test the integrity of insulation material separating live parts from earth using 500V DC. This significant test identifies degradation that leads to short circuits and fire. Our engineers carefully isolate sensitive electronics (such as VSDs and PLCs) during this process to prevent damage.
4. Residual Voltage and Functional Safety
We verify protection against residual voltage, ensuring dangerous charges (e.g. in capacitors) discharge to safe levels (<60V) within 5 seconds of isolation. We also functionally test machine guarding interlocks and Emergency Stops to confirm they execute the correct stop category.
5. Documentation and Reporting
The output of our service is a rigorous Test Report and assistance with the Technical Construction File (TCF). Our reports include measured values (not simply “Pass/Fail”), instrument traceability and the signature of a competent person – something vital to keep as essential evidence for a Declaration of Conformity (DoC).
Advanced Technology and Expertise
Accurate testing requires precision equipment. SST utilises industry-leading hardware, such as the Gossen Metrawatt ProfiTest Prime, to ensure verifiable accuracy.
Our engineers possess the specific competence required for machinery. Unlike standard building electricians, our team understands control logic, Safety Integrity Levels (SIL) and the specific nuances of industrial automation. This means we are experienced in testing effectively without disrupting sensitive programming or electronics.
Experience Across Sectors
We adapt our testing approach to the specific risks of your industry:
- Warehousing and logistics: Meticulous verification of long conveyor runs where vibration often loosens earth bonding.
- Cold storage: Verification of equipment resilience against condensation and moisture ingress common in sub-zero environments.
- Food and beverage: Inspection of IP ratings and seals to ensure they withstand high-pressure washdowns.
- Heavy industry: Specialised testing for equipment exposed to harsh elements, ensuring resilience against extreme heat, outdoor weather and conductive dust, as well as vibration.
Advanced Technology and Expertise
Accurate testing requires precision equipment. SST utilises industry-leading hardware, such as the Gossen Metrawatt ProfiTest Prime, to ensure verifiable accuracy.
Our engineers possess the specific competence required for machinery. Unlike standard building electricians, our team understands control logic, Safety Integrity Levels (SIL) and the specific nuances of industrial automation. This means we are experienced in testing effectively without disrupting sensitive programming or electronics.
We adapt our testing approach to the specific risks of your industry:
- Warehousing and logistics: Meticulous verification of long conveyor runs where vibration often loosens earth bonding.
- Cold storage: Verification of equipment resilience against condensation and moisture ingress common in sub-zero environments.
- Food and beverage: Inspection of IP ratings and seals to ensure they withstand high-pressure washdowns.
- Heavy industry: Specialised testing for equipment exposed to harsh elements, ensuring resilience against extreme heat, outdoor weather and conductive dust, as well as vibration.
Partner with SST for Robust EN 60204-1 Compliance
Don’t leave your electrical safety to chance or untrained personnel. Contact our expert engineering team today to discuss your compliance needs and schedule a survey.
Request a callback
Partner with SST for Robust EN 60204-1 Compliance
Don’t leave your electrical safety to chance or untrained personnel. Contact our expert engineering team today to discuss your compliance needs and schedule a survey.
Get in touch with us today to ask for a no obligation survey