#statusMessage#
Do you want to start the comparison now?
Serie
Machine testing in accordance with DIN EN 60204-1 is far more than a formal obligation prior to commissioning. Particularly in modern machines incorporating variable frequency drives and automation components, professional assessment is essential for producing a robust safety verification. A systematic approach to protective bonding connections, leakage currents, and documentation reduces non-conformities and increases confidence throughout the testing process. This article explains which test points require particular attention and how common pitfalls can be avoided.
The electrical equipment of machines has become significantly more complex in recent years. Variable frequency drives, decentralized drive systems (Power Drive Systems, PDS), safety-related control systems, and networked automation components expand the functional capabilities of modern machines – while also increasing the requirements for planning, testing, and documentation.
In acceptance tests and periodic inspections, non-conformities are rarely caused by major design defects. More often, they result from seemingly minor details: missing protective conductor connections, inadequate equipotential bonding, incorrectly assessed leakage currents, or incomplete test documentation. DIN EN 60204-1 (VDE 0113-1) defines the requirements for the electrical equipment of machines and specifies the tests to be performed before commissioning. In practice, five typical weak points frequently lead to incorrect assessments during machine testing:
Scope of the electrical equipment of the machine
A common challenge arises at the outset: determining which standard applies to which part of an installation. DIN EN 60204-1 applies to the electrical equipment of machines from the mains supply terminal or the plug-and-socket connection of the machine onward. The electrical installation upstream of this point, by contrast, falls within the scope of installation and operation standards, in particular DIN VDE 0100-600 and DIN VDE 0105-100.
These responsibilities can become blurred, especially in the case of modifications, relocation, or modernization of installations. Before testing begins, the interface between the electrical installation and the electrical equipment of the machine should therefore be clearly defined. This boundary should be documented in the test report or the accompanying project documentation.
For operators, this means:
Testing the protective bonding connections is one of the fundamental verification measures required by DIN EN 60204-1. Its purpose is to demonstrate that accessible conductive parts are reliably connected to the protective bonding circuit.
In practice, protective conductor connections are often treated as a routine test item. For this reason, visual inspection and measurement should always be considered together: connection points, mounting plates, movable conductive parts, bonding straps, and retrofitted components must not only be measured but also assessed from a design and construction perspective. A measurement value that complies with the standard does not, by itself, demonstrate that the connection is mechanically reliable over the long term and remains effective during operation.
This is particularly critical in the case of:
Equipotential bonding and EMC are closely interrelated in modern machines. At the same time, modern drive technology, variable frequency drives, and EMC considerations are becoming increasingly important in planning, testing, and operation.
In many projects, equipotential bonding is initially considered primarily from the perspective of protection against electric shock. In modern machines, however, an effective equipotential bonding system performs several functions:
Assessing leakage currents is one of the more demanding test tasks for machines incorporating modern drive technology. With the increasing use of Power Drive Systems (PDS), variable frequency drives, EMC filters, and power electronic components, this aspect of machine testing continues to gain importance. An elevated leakage current does not automatically indicate an insulation fault. In modern drive systems, operational leakage currents may instead be caused by:
From the perspective of many project participants, successful functional testing is initially the primary objective at the end of a project. For regulatory evidence, however, it is essential that the technical documentation is not compiled only shortly before acceptance, but developed throughout the project. Machinery Directive 2006/42/EC and Regulation (EU) 2023/1230 on machinery, which will apply from 20 January 2027, require complete technical documentation. This includes, among other things:
DIN EN 60204-1 requires tests to be performed and assessed by suitably qualified persons. In addition, the German Technical Rules for Operational Safety (TRBS) 1201 and 1203 define requirements for competent persons and those responsible for testing.
Against this background, the role of test personnel is changing. While modern measuring instruments now automate a large proportion of measurement acquisition, the importance of professional interpretation continues to increase. The key question is increasingly no longer “How is the measurement performed?” but rather “How should the result be assessed in a standards-compliant and traceable manner?” Anomalies should not merely appear as measurement values in the test report; they should be documented together with an assessment, justification, and any necessary corrective actions. This transforms a measurement into robust safety verification.
Many non-conformities are not caused by installation errors, but by uncertainty in the application of standards, assessment, and documentation. For manufacturers, operators, and maintenance personnel, this means that technical knowledge must be updated regularly – particularly in light of new editions of standards, modern drive technology, and the forthcoming Machinery Regulation (EU) 2023/1230.
The dataTec Academy supports technical professionals with practice-oriented training on machine testing, electrical and functional safety, and modern measurement technology. The objective is to combine standards requirements, measurement practice, and technical assessment in a clear and practical manner and transfer this knowledge into day-to-day work.
DIN EN 60204-1 defines far more than a series of measurements to be performed before commissioning. It describes a systematic safety verification process for the electrical equipment of machines.
This safety verification does not begin with the final measurement. It results from the interaction of planning, implementation, testing, assessment, and documentation. Particularly in the case of modifications or extensions, it should therefore be determined at an early stage which standards apply and which interfaces exist with other areas of the electrical installation. Considering the scope of application, protective bonding circuit, equipotential bonding, leakage-current assessment, functional safety, and documentation as an integrated system creates the conditions for safe, standards-compliant machines with long-term availability.
In an era of increasing automation, project success is therefore determined not only by the quality of the technology, but also by the quality of the testing. In addition to suitable measurement technology, this requires sound knowledge of the normative requirements and their professional assessment. Companies therefore benefit from the combination of modern test equipment, standards-compliant test procedures, and up-to-date technical expertise.
Expand your knowledge and learn how to safely and practically perform electrical tests in accordance with current VDE standards.
