Safety of machinery Safety requirements for the design and construction of printing and paper converting machines

Transcription

1 BRITISH STANDARD BS EN :2004 Safety of machinery Safety requirements for the design and construction of printing and paper converting machines Part 1: Common requirements The European Standard EN :2004 has the status of a British Standard ICS ;

2 BS EN :2004 National foreword This British Standard is the official English language version of EN :2004. The UK participation in its preparation was entrusted to Technical Committee MCE/3/9, Paper and printing machines Safety, which has the responsibility to: aid enquirers to understand the text; present to the responsible international/european committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; monitor related international and European developments and promulgate them in the UK. A list of organizations represented on this committee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled International Standards Correspondence Index, or by using the Search facility of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. This British Standard was published under the authority of the Standards Policy and Strategy Committee on 21 December 2004 Summary of pages This document comprises a front cover, an inside front cover, the EN title page, pages 2 to 52, an inside back cover and a back cover. The BSI copyright notice displayed in this document indicates when the document was last issued. Amendments issued since publication Amd. No. Date Comments BSI 21 December 2004 ISBN

3 EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM EN December 2004 ICS ; English version Safety of machinery - Safety requirements for the design and construction of printing and paper converting machines - Part 1: Common requirements Sécurité des machines - Prescriptions de sécurité pour la conception et la construction de machines d'impression et de transformation du papier - Partie 1: Prescriptions communes Sicherheit von Maschinen - Sicherheitsanforderungen an Konstruktion und Bau von Druck- und Papierverarbeitungsmaschinen - Teil 1: Gemeinsame Anforderungen This European Standard was approved by CEN on 7 June CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG Management Centre: rue de Stassart, 36 B-1050 Brussels 2004 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN :2004: E

4 Contents Page Foreword...4 Introduction Scope Normative references Terms and definitions List of significant hazards Safety requirements and/or protective measures General Requirements common to printing and paper converting machines Safeguarding of danger points Guards and interlocks Devices for setting-up, cleaning, trouble-shooting during the work process and maintenance Explosion prevention and protection Electrical equipment Control systems Indicators, marking, actuators, prestart warning devices Two-hand controls Electrosensitive protective devices (ESPDs) Pressure sensitive mats, trip devices Safety position switches Work platforms, access stairs, passageways and raised workplaces Stability High contact temperatures Noise Radiation hazards Immunity to electromagnetic disturbances Common devices Stationary knives Rotary tools Dangerous tools Feeding units, delivery units (pile lifting and lowering devices) Reel unwinding and rewinding devices for webs Verification of the safety requirements and/or protective measures Information for use Minimum requirements for machine markings Instruction handbook...38 Annex A (informative) Classification of zones for printing presses and finishing machines (relating to 5.2.4)...39 Annex B (normative) Audible prestart warning devices...42 Annex C (informative) Risk analysis relating to the pitch angle of access stairs...44 Annex D (informative) Example of layout of an instruction handbook...46 Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC

5 Annex ZB (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 94/9/EC...49 Bibliography

6 Foreword This document (EN :2004) has been prepared by Technical Committee CEN/TC 198 Printing and paper machinery - Safety, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by June 2005, and conflicting national standards shall be withdrawn at the latest by June 2005 This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For relationship with EU Directive(s), see informative Annex ZA and ZB, which is an integral part of this document. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. 4

7 Introduction This European Standard is a type C standard as stated in EN 1070:1998. The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document. For machines that have been designed and built according to the provisions of this C standard, the following stipulation applies: When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards. This document consists of the following parts: Part 1 Part 2 Part 3 Part 4 Part 5 Common requirements Printing and varnishing machines including pre-press machinery Cutting machines Bookbinding, paper converting and finishing machines Machines for the production of corrugated board and machines for the conversion of flat and corrugated board. 1 Scope 1.1 This document applies to printing machines for printing on paper and similar materials, including screen printing presses; equipment used in the preparation of the printing process and additional equipment on printing machines are also considered to be printing machines. This standard also covers machinery used for the handling of paper, products, printing formes and inks (before and after the printing process) as well as machinery for cleaning printing formes and checking the print quality (auxiliary printing machinery). paper converting machines, i. e. machines to process, convert or finish paper, board and similar materials which are processed, converted or finished in a similar manner. NOTE Similar substrates are, for example, board, corrugated board, plastic film, aluminium foil, sheet metal and photographic paper. 1.2 This document deals with all common significant hazards relevant to printing and paper converting machinery when they are used as intended and under the conditions foreseen by the manufacturer (see clause 4). This part of the standard defines the common safety requirements for all kinds of printing and paper converting machines and related common devices and shall be used in connection with another part of the EN 1010 series. The specific requirements specified in Part 2 and following parts of EN 1010 take precedence over the respective requirements in EN NOTE In addition, where a machine is not covered by a specific part of this standard, Part 1 of EN 1010 may be used to establish the approach for dealing with the relevant risks. 1.3 This document is not applicable to printing and paper converting machines which are manufactured before the date of publication of this document by CEN. 5

8 1.4 This document does not apply to: winder-slitters and sheeters in paper finishing (sheeters with unwinders) (see EN :2000, EN :2000, pren :2001); office-type collating machines equipped with friction feeders; mail processing machines; machines used for filling packages (such as machines for shaping, filling, and closing the package), textile printing presses 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 294:1992, Safety of machinery Safety distances to prevent danger zones being reached by the upper limbs. EN 349:1993, Safety of machinery Minimum gaps to avoid crushing of parts of the human body. EN 418:1992, Safety of machinery Emergency stop equipment, functional aspects Principles for design. EN 563:1994, Safety of machinery Temperatures of touchable surfaces Ergonomics data to establish temperature limit values for hot surfaces. EN 574:1996, Safety of machinery Two-hand control devices Functional aspects Principles for design. EN 953:1997, Safety of machinery Guards General requirements for the design and construction of fixed and movable guards. EN 954-1:1996, Safety of machinery Safety-related parts of control systems Part 1: General principles for design. EN 999:1998, Safety of machinery The positioning of protective equipment in respect of approach speeds of parts for the human body. EN 1037:1995, Safety of machinery Prevention of unexpected start-up. EN 1050:1996, Safety of machinery Principles for risk assessment. EN 1070:1998, Safety of machinery Terminology. EN 1088:1995, Safety of machinery Interlocking devices associated with guards Principles for design and selection. EN :1997, Explosive atmospheres Explosion prevention and protection Part 1: Basic concepts and methodology. EN :1997:1997, Safety of machinery Pressure sensitive devices Part 1: General principles for the design and testing of pressure sensitive mats and pressure sensitive floors. 6

9 EN :2001, Safety of machinery Pressure sensitive devices Part 2: General principles for the design and testing of pressure sensitive edges and pressure sensitive bars. EN :2000, Safety of machinery Assessment and reduction of risks arising from radiation emitted by machinery Part 1: General principles. EN 12626:1997, Safety of machinery Laser processing machines Safety requirements. EN 13023:2003, Noise measurement methods for printing, paper converting, paper making machines and auxiliary equipment - Accuracy categories 2 and 3. EN :2001, Non-electrical equipment for potentially explosive atmospheres Part 1: Basic method and requirements. EN :2003, Non-electrical equipment intended for use in potentially explosive atmospheres - Part 5: Protection by constructional safety "c". EN ISO 4871:19986 Acoustics Declaration and verification of noise emission values of machinery and equipment (ISO 4871:1996). EN ISO :2003, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology (ISO :2003). EN ISO :2003, Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles (ISO :2003). EN ISO :2001, Safety of machinery Permanent means of access to machines and industrial plants Part 1: Choice of a fixed means of access between two levels (ISO :2001). EN ISO :2001, Safety of machinery Means of permanent access to machines and industrial plants Part 2: Working platforms and gangways (ISO :2001). EN ISO :2001, Safety of machinery Means of permanent access to machines and industrial plants Part 3: Stairways, stepladders and guard-rails (ISO :2001). EN ISO :1996, Safety of machinery Means of permanent access to machines and industrial plants Part 4: Fixed ladders (ISO :2004). EN 50014:1999, Electrical apparatus for potentially explosive atmospheres General requirement. EN 50015:1998, Electrical apparatus for potentially explosive atmospheres Oil immersion "o". EN 50016:1995, Electrical apparatus for potentially explosive atmospheres Pressurized apparatus "p". EN 50017:1998, Electrical apparatus for potentially explosive atmospheres Powder filling "q". EN 50018:2000, Electrical apparatus for potentially explosive atmospheres Flameproof enclosures "d". EN 50019:2000, Electrical apparatus for potentially explosive atmospheres Increased safety "e". EN 50020:1994, Electrical apparatus for potentially explosive atmospheres Intrinsic safety "i". EN 50039:1980, Electrical apparatus for potentially explosive atmospheres Intrinsic safety "i". EN :1999, Electrical apparatus for use in the presence of combustible dust Part 1-2: Electrical apparatus protected by enclosures; selection, installation and maintenance. 7

10 EN :1998, Electrical apparatus for explosive gas atmospheres - Part 14: Electrical installations in hazardous areas (other than mines). EN :1997, Safety of machinery Electrical equipment of machines Part 1: General requirements EN :1994, Safety of laser products Part 1: Equipment classification, requirements and user's guide. EN :2001 Electromagnetic compatibility (EMC) Part 6-2: Generic standards; Immunity for industrial environment. EN :2001, Safety requirements for electrical equipment for measurement, control and laboratory use Part 1: General requirements (IEC :2001). EN :1995, Safety of machinery Indication, marking and actuation Part 1: Requirements for visual, auditory and tactile signals. EN :1995, Safety of machinery Indication, marking and actuation Part 2: Requirements for marking. EN :1997, Safety of machinery Electrosensitive protective equipment Part 1: General requirements and tests. IEC :1997, Safety of machinery Electrosensitive protective equipment Part 2: Particular requirements for equipment using active opto-electronic protective devices. CLC R :1999, Safety of machinery: Guidance and recommendations for the avoidance of hazards due to static electricity. 3 Terms and definitions For the purposes of this European Standard, the terms and definitions given in EN 1070:1998 and the following apply. 3.1 danger points danger points are defined locations in the danger zone of machines where persons can be injured by movements of parts of machines; tools of machines or parts of tools; workpieces or parts of workpieces or materials being processed. NOTE Danger points can exist, for example, on gear, chain and worm drives, V-belt, flat belt, cord and rope drives, pulling and supporting elements on continuous conveyors, spoke wheels and fly wheels, shafts and shaft ends, rollers, slides, push rods and similar parts, tools and clamping devices. Particular points of danger are: crushing and shearing points; trapping points; 8

11 inrunning nips; cutting, punching and impact points. 3.2 inrunning nips nips caused by rotating rollers, cylinders, rolls or drums creating the hazard for parts of the body or the whole body to be drawn in. The risks exist between: a) two counter-rotating rollers, powered or non-powered; b) one rotating roller and an adjacent fixed part of the machine; c) rollers rotating and conveyer belts in the same direction, but with different peripheral speeds or surface properties (friction); d) guide roller and driving belt, conveyor belt and possibly the web (see Figure 1). Inrunning nips also exist on non-powered riding rollers (guide rollers) which are driven by the movement of the web. This hazard may depend on a number of factors, e.g. type and strength of material, wrapping angle, web speed, inertia. - Figure 1 Examples of inrunning nips 3.3 integrated pile lifting and lowering devices devices integrated into sheet and blank feeders or deliveries for lifting and lowering the sheet pile 3.4 format size maximum size of blanks (maximum length times maximum width) that can be printed or converted by the machine 3.5 routine and regular access access to a danger point required for production reasons after each tool closing movement 3.6 web-type materials webs of paper, board, foil or similar material which is to be handled or processed 9

12 3.7 reel unwinding devices those parts of a machine used for unwinding web-type material for processing 3.8 reel rewinding devices those parts of a machine used for rewinding the processed web-type material 3.9 separating elements elements on feeders of sheets or blanks or similar materials which separate the individual sheets, blanks etc raised workplaces workplaces that are at least 0,5 m above the reference plane 3.11 infrequently used access access to workplaces which are used for adjustments, make-ready and maintenance operations, but which are not used for production purposes 3.12 smooth cylinders/rollers rotationally symmetric smooth bodies (cylinders or rollers) without indentations and with no sharp or cutting edges 3.13 residual pile monitoring sensing devices monitoring the residual pile in the feeder. The machine is stopped before the last blank is fed so that the blank safeguards the separating elements of the feeder 3.14 ESPD electro-sensitive protective device 3.15 hold-to-run control device control device where the actuator automatically returns to the start position when released and where machine operation is started and maintained only as long as the actuator is held depressed 3.16 accessible danger zones areas provided with guards or ESPDs, for example, for safeguarding which allow whole-body access 4 List of significant hazards 4.1 This clause contains all the significant hazards, as far as they are dealt with in this standard, identified by the risk assessment significant to this type of machinery and which require action to eliminate or reduce the risk. When carrying out the risk assessment, the machine designer will have to check whether the list of hazards in Table 1 is complete and applicable with respect to the particular machine. 4.2 It is of great importance that the users of this standard, i. e. the designer, manufacturer or supplier, take into account the following principal aspects in accordance with EN 1050:1996: the intended use of the machine including setting-up (make-ready), cleaning and maintenance, including foreseeable misuse; 10

13 identification of the significant hazards. 11

14 Table 1 Significant hazards, danger zones, safety measures Significant hazards Mechanical hazards crushing shearing cutting or severing entanglement drawing-in trapping impacts Mechanical hazards generated by: Mass and stability, Mass and velocity Slipping, tripping, falling Electrical hazards Direct or indirect contact Thermal radiation (burns) Thermal hazards Burns due to possible contact Hazards generated by noise Hearing damage Interference with speech communication Accidents due to interference with the perception of acoustic signals Stress Hazards generated by radiation UV-radiation, laser Danger zone Production area: between rollers, cylinders, drums short linear movements wheels for floor travel revolving handwheels crushing hazards with parts of building guards accessible danger zone make-ready, cleaning, maintenance operations and trouble shooting (holdto-run) safe threading of web-type material impact hazards in passageways, access ways stationary knives rotary tools transport of hazardous tools on feeding and delivery units (pile lifting and lowering devices) unwinding and rewinding units for webtype material stability movable machines feeding units, delivery units Safety measures: reference to clauses in this standard , , , to , , , EN ISO : 2003 EN 1050: 1996 Annex A Work platforms, access stairs, passageways, steps, floor coverings electrical equipment (equipment made , live under electrical fault conditions) supply disconnection device, stop , category rectifier drives degree of protection measuring devices Hot machine parts , All machines , Machines with laser and UV-light ,

15 Significant hazards Hazards from explosion Hazards generated by neglect of ergonomic principles in machine design Unhealthy body postures Danger zone Table 1 (concluded) machinery using flammable liquids or dusts design of actuators and displays safety access, workplaces, catwalks, passageways Safety measures: reference to clauses in EN ISO EN 1050: this standard : Annex A 5.2.4, Annex B , , , Unsuitable construction, place or identification of actuators Failure, malfunction of control system footsteps, handles balance of weight avoidance of irritating reflection machinery with safety circuits to Faults or failures in safety circuits malfunction of software External effects on electrical devices conductor identification separation of chucking cones Iimmunity to electromagnetic disturbances Safety requirements and/or protective measures 5.1 General Machinery shall comply with the safety requirements and/or protective measures of this clause. In addition, the machine shall be designed according to the principles of EN ISO for hazards relevant but not significant, which are not dealt with by this document (e. g. sharp edges of the machine frame). 5.2 Requirements common to printing and paper converting machines Safeguarding of danger points Inrunning nips on cylinders, rollers, drums, rolls and similar parts shall be safeguarded by guards or by applying the safety distances specified in EN 349:1993. On guide rollers, the safety distance specified for the arm is considered to be sufficient where risk assessment has determined that whole-body or head access cannot be expected. Guards shall be designed as follows: a) as guards without openings or with openings for feeding the material (for example sheets, blanks, webs, work pieces). The safety distances shall be established in relation to the width of the opening in accordance with EN 294:1992 (see Figure 2). These guards shall be interlocked with the dangerous movements in accordance with or they shall be fixed to the machine. When the interlocking guard is open, one of the measures set out in shall become effective. 13

16 Figure 2 Safeguarding of inrunning nips b) on smooth-surface rollers or cylinders as fixed nip bars extending across the entire working width, designed in suitable sections. The clearance between the bar and the respective machine part, for example, cylinders, rollers with a smooth surface etc., shall not exceed 6 mm (see Figure 3). Figure 3 Safeguarding an inrunning nip by means of a fixed nip bar The use of trip devices for safeguarding inrunning nips shall be permitted only if the condition defined in is satisfied Linear movements are considered to be sufficiently safe if the maximum distance between moving part and fixed part does not exceed 4 mm. 14

17 NOTE For example, when inserting printing plates, starting and stopping movements of tools; oscillating rod and lever systems between upper and lower tool of riveting, eyeletting and stitching machines (see Figure 4). Figure 4 Example of a linear movement on a plate clamping device On machines which travel under power, the crushing points between wheels and floor shall be safeguarded. Safeguarding of crushing points is achieved, for example, by providing foot guards fixed such that there is a distance of no more than 15 mm between the runway and the lower edge of the guard Handwheels and cranks shall be so designed that they do not automatically rotate when the machine operates at production speed. This is achieved, for example, where handwheels and cranks are decoupled by pressure springs during the production run Where machines with movable parts are used in the workroom, the instruction handbook shall require users to erect machines in such a way that the hazard of crushing of persons between movable machine parts and the building is prevented Guards and interlocks Guards shall satisfy the requirements of EN 953:1997. Interlocking shall satisfy the requirements of clauses 5 and 6 of EN 1088:1995. Stopping times vary with the type of machine used, but should be as short as possible. For interlocking, see (safety position switches with approach reaction) and (control systems) For fence-type enclosures, the safety distances according to EN 294:1992 apply. A further requirement is that the distance between the floor and lower edge of the fence does not exceed 200 mm and between the floor and upper edge is at least 1,4 m Guards and access doors in enclosures which are opened or removed frequently in the production process or for setting-up operations shall be interlocked with the hazardous movements. Guards which do not have to be opened frequently shall be fixed in such a way that their removal necessitates the use of tools. These guards may also be interlocked with the hazardous movements. 15

18 NOTE Guards and doors are removed "frequently", including for maintenance purposes, if they are removed, for example, at least once per working shift. Guards and doors are removed for "setting-up" purposes, for example: to supply the material to be processed; to change the size; to change tools; for make-ready; for washing-up Automatic travel of movable guards shall not create danger points. EN 953:1997 shall be complied with Guards that can be opened shall be safeguarded against gravity falls if this creates a risk of injury. Measures to prevent such gravity falls include, for example, devices for balancing the weight; pneumatic springs; latches which automatically hold the parts open; power-driven worm gear drives actuated by hold-to-run; by ensuring that the centre of gravity of the guard in the open position is sufficiently far behind the axis of rotation. Springs used for balancing the weight shall be designed such that, in the event of a spring failure, no dangerous closing movement may occur. Compression-type springs are to be preferred Where production processes need to be observed, guards shall ensure permanent sufficient vision of the functional point without being impaired by reflections. This requirement is satisfied, for example, by mesh-type guards painted in matt black Devices for setting-up, cleaning, trouble-shooting during the work process and maintenance Where accessible danger zones cannot be observed from positions from which hazardous movements can be started, one of the following requirements shall be satisfied: where accessible danger zones are safeguarded by a fence-type enclosure, it shall not be possible for the person(s) within the enclosure to close the interlocking access gate or an additional control device shall be provided outside the enclosure in such a position that it cannot be actuated from the inside. Any hazardous movement shall be permitted only after the access door has been closed and the control device been actuated; where accessible danger zones are safeguarded by means of ESPDs, an additional control element shall be provided outside the danger zone that cannot be reached from any position in the danger zone. Provisions shall be made that the hazardous movement can only be started after the person has actuated the additional control element When the interlocking guard is opened or removed or if a person has entered the danger zone and there are danger points unprotected, it shall only be possible to start a machine by means of a) Hold-to-run control devices 16

19 1) with a displacement limited to a maximum of 25 mm or with a maximum operating speed of 1 m/min, 2) with displacement limited to a maximum of 75 mm or with a maximum operating speed of 5 m/min where there would be no substantially increased hazard and where the measures defined in 1) above would reduce the ability of the machine to perform its function. For hold-to-run devices designed as two-hand controls, the same limitations of displacement and speed shall apply. Any two-hand control device shall satisfy the requirements defined in The stopping path shall be as short as technically feasible. Starting the machine in the hold-to-run mode after opening an interlocking guard may be done without operating a selector switch, if production operation during hold-to-run control is positively prevented by the interlocking device. A selector switch is required for machines which allow two modes of hold-to-run control (hold-to-run control with one actuator and two-hand control). b) Manual operation Devices which allow manual operation of the machine or parts of the machine shall be designed so that persons are not exposed to danger From the place of operation of the hold-to-run control, it shall be possible to observe the danger points and danger zones Where hold-to-run controls are being used for safeguarding a danger point, starting the machine in the hold-to-run mode after opening the interlocking guard shall only be possible when other interlocking guards outside the area that can be observed by the operator are closed Safe threading of the web-type material shall be ensured. On power-driven web threading devices, access to danger points shall be prevented by guards. Access to danger points is considered prevented if, for example, on rope-type threading devices, the inrunning nips between threading rope and idler pulley are safeguarded. Safeguarding may include the provision, on the outside of the pulleys, of a fixed disc, the radius of which is at least 120 mm larger than that of the pulley, on power-driven bar-type threading devices with transport chains, the inrunning nips between chains and chain wheels are provided with guards filling the inrunning nips as far as possible, threading is carried out under hold-to-run control with speed limitation Explosion prevention and protection All electrical and non-electrical equipment and components intended for use in potentially explosive atmospheres shall be designed and constructed according to good engineering practice and conform to the required categories for group II equipment to ensure avoidance of any ignition source as specified in 5.3 of EN :1997. To classify the category of the equipment, it shall be subjected to an ignition hazard assessment in accordance with 5.2 of EN : Explosion prevention and protection is not required for machinery where there are no flammable liquids with a flash point below 55 C being used and no flammable liquids are sprayed or heated to a temperature above flash point under operating conditions. All other machinery shall be designed to satisfy the requirements specified in EN :1997 for the zones described in Annex A. 17

20 NOTE 1 For washing units on printing presses, see of pren :2001. NOTE 2 Heating of a flammable liquid occurs under operational conditions, for example, in film and printing plate development units with bath heating. For information about conductive flooring, see requirements for instruction handbooks in Electrical equipment Any electrical equipment intended for use in a potentially explosive atmosphere caused by gas, vapour, mists or dust shall comply with the requirements of EN Where relevant, these requirements may be supplemented or modified by EN 50015:1998, EN 50016:1995, EN 50017:1998, EN 50018:2000, EN 50019:2000, EN 50020:1994 and EN 50039:1980 as appropriate Group II category 1G, 2G or 3G equipment for installation in a particular zone shall be selected according to clause 5 of EN : Group II category ID, 2D or 3D equipment for installation in a particular zone shall be selected according to EN : Non-electrical equipment All non-electrical equipment, intended for use in a potentially explosive atmosphere caused by gas, vapour, mist or dust, shall comply with the requirements of EN :2001 and EN :2003 and, where relevant, the European Standards to be applied for the specific type of ignition protection Group II category 1G or ID equipment, for installation in zone 0 or 20 respectively, shall not contain any effective ignition source during expected malfunctions or rare malfunctions Group II category 2G or 2D equipment, for installation in zone 1 or 21 respectively, shall not contain any effective ignition source during normal operation or expected malfunction Group II category 3G or 3D equipment, for installation in zone 2 or 21 respectively, shall not contain any effective ignition source during normal operation The surface temperature of all parts of category 1 and 2 non-electrical equipment likely to come into contact with potentially explosive atmospheres and the temperature of the potentially explosive atmosphere shall not exceed 80 % of the ignition temperature in C of the gases or vapours. The temperature of all surfaces which can come into contact with dust clouds shall not exceed 2/3 of the minimum ignition temperature in C of the dust cloud On surfaces where the deposition of potentially glowing dust cannot be positively prevented, the surface temperature of all parts of non-electrical equipment shall not exceed the minimum ignition temperature of the dust layer reduced by 75 K. See pren : Brakes and clutches shall be designed such that they cannot be a source of ignition in accordance with EN : Undesirable electrostatic discharges shall be avoided by earthing and interconnecting all the metallic components. Note Further information on this topic is given in the CENELEC report R "Safety of machinery - Guidance and recommendations for the avoidance of hazards due to static electricity" Hoses and pipes used for exhausting flammable dusts and other flammable materials (paper, plastic etc.) shall be conductive and electrostatically grounded (resistance less than 10 6 Ω). Respective reference shall be made in the instruction handbook. 18

21 Hoses and pipes for inks, coating substances and impregnating materials and glues as well as for exhausting solvent vapours shall be conductive and electrostatically grounded (resistance less than 10 6 Ω). Note See for information in instruction handbook The distance between the electric drive motor and the agitator for viscosity control and the outer flange of the agitating device shall be at least 50 mm (lantern-type fixing). It is also recommended that a disc should be mounted on the shaft to increase the preventive effect. Note This prevents solvents evaporating from the agitator shaft from reaching the motor (see Figure 5). Key 1 Drive motor 2 Agitator 3 Top view Figure 5 Distance between drive motor and agitator (lantern) The electric drive motor on recirculating pumps on supply tank for inks, coating substances, impregnating material or glues shall be protected in accordance with EN 50018:2000 with regard to ignition protection. Where protective motor switches are mounted on the pump, EN 50019:2000 is sufficient Electrical equipment All electrical equipment shall be designed such that electrical hazards (for example electric shock, burns) according to EN :1997 are prevented. The requirements of EN :1997 shall be fulfilled, taking into account the following additional requirements Machines shall be provided with a supply disconnecting device in accordance with a) or c) of EN :1997. The device shall be provided with a means to be locked in the OFF position. Where the operation of the emergency stop control devices causes galvanic disconnection from the power supply by undervoltage tripping, a circuit-breaker in accordance with c) of EN :1997 is required. Where circuits as specified in of EN :1997 are not disconnected by the supply disconnecting device, such circuits shall be provided with their own disconnecting device. See also Emergency stop devices shall be designed in accordance with of EN :1997 either as a category 0 stop or as a category 1 stop. On machines where inrunning nips are safeguarded by trip bars according to , the emergency stop shall function as a category 1 stop. See also On rectifier drives, the actuation of an emergency stop control device may, as a deviation from of EN :1997, cause stopping of the drive as a category 2 stop according to of EN :1997 if 19

22 pulse blocking in the rectifier and disconnecting the voltage supply to encoder and associated control circuitry are separate functions in accordance with category 3 of EN 954-1: Electrical devices and conductors shall be installed in such a way that damage from mechanical stresses and environmental influences are prevented. Electrical devices should be to IP 54 according to EN 60529: For insulated single-core conductors laid between two terminals inside an enclosure (for example, a switch cabinet), one of the following methods shall be used for conductor identification: identification by number or alphanumerically; identification by colour in accordance with of EN :1997; securing conductors in position, for example by using comb-type wire fixing in such a way that any confusion of conductors when changing electric components is safely prevented; or another adequate method All electrical equipment shall be designed such that it will withstand the testing specified in 19.2 to 19.6 of EN :1997. Voltage tests as specified in 19.4 of EN :1997 are not required for electronic control circuits provided by computer systems or electronic control components Measuring devices which are part of machines shall comply with EN : Control systems Control requirements for machines which do not require routine and regular access to danger points In the hydraulic/pneumatic control system, the safety-related parts shall satisfy at least category 1 (6.2.2) of EN 954-1:1996. In the electric/electronic control system, the safety-related parts shall satisfy at least category 3 (6.2.4) of EN 954-1:1996. Only single main contactors may be provided. The minimum requirement is that faults in the auxiliary relays and auxiliary contactors in the control circuit shall be detected and hazardous movements stopped. When using computers or PLC (Programmable Logic Control) for monitoring, safety-related malfunctions shall be detected and lead to disconnection. When using computers or PLC, this requirement may be satisfied, for example, by monitoring the function of safety-related signals using parallel computer control systems or redundant contact-type circuit breaking principles. Any malfunctions shall result in the hazardous movement being stopped. Safety-related parts of control systems include, for example, emergency stop circuits, electric interlocking circuits, limitation of displacement or operating speed on hold-to-run controls. For safety aspects, see also definitions in EN 954-1:1996. External influences and faults in these parts of the control systems may cause hazardous movements and hazards. Depending on the type of machine, hazardous movements include, for example: unintended start-up or unintended speed increase up to production speed; 20

23 unintended movement following an intended movement (unintended cycle); unintended continuation of a movement where stopping of the movement is intended. A hazard may, for example, also be the build up of potentially explosive atmospheres by faults in the control systems. NOTE See Bibliography and IEC On rectifier and inverter drives, the control system shall be designed such that, in the event of any guard or safety device causing the machine to stop, the main contactor will also be switched off, for example by using an electric/electronic timer for switching it off after a preset time or any other adequate measure such as the application of a mechanical brake with a braking torque greater than the drive torque of the motor. Safety devices are, for example, emergency stop devices, ESPDs, interlocked guards, trip devices. On rectifier and inverter drives which feed energy back into the electric circuit during stopping, appropriate control-related measures shall be taken, in addition to pulse blocking, to ensure that the main contactor is switched off no later than after elapse of the normal stopping time, or any other adequate measure to that effect. During hold-to-run control operations, there is no need to disconnect the main contactor during the release time of the prestart warning device (see Annex B). NOTE 1 On rectifier and inverter drives, the speed of rotation of the motor is changed, for example, by shifting the supply voltage frequency When an emergency stop device is fitted with a main contactor which detects a low voltage condition, it shall disconnect the main power supply at least of category 1 of EN 954-1:1996. NOTE The opening contact of the emergency stop device directly disconnects, for example, the power supply to the low-voltage tripping coil Mutual interlocking of safety devices safeguarding individual areas each of which can be observed by the operator shall satisfy the requirements of at least category 1 of EN 954-1:1996. Interlocking may be computer controlled. For areas to be observed, see Residual pile monitoring systems shall comply with category B of EN 954-1: Increased control requirements for machines which require routine and regular access to danger points, for example guillotines, hand-fed platen machines, hand-fed screen printing presses and hand-fed label punching machines In the hydraulic/pneumatic control system, the safety-related parts shall satisfy at least category 3 (6.2.4) of EN 954-1:1996. In the electric/electronic control system, the safety-related parts shall satisfy category 4 (6.2.5) of EN 954-1:1996. Main contactors shall be provided in duplicate. Faults in the main contactors shall be detected and lead to lockout. For requirements of position switches, see Electronic braking systems on their own shall not be admissible on machines with routine and regular access. Such braking systems require the provision of additional mechanical brakes for back-up. The mechanical brake torque shall be greater than the maximum electric drive torque of the rectifier and inverter drive. NOTE Electronic brakes exist, for example, on rectifier and inverter drives where the braking effect is caused by energy being fed back into the circuit. 21

24 5.2.7 Indicators, marking, actuators, prestart warning devices The requirements relating to indicating, marking and actuators as defined in EN :1995 and EN :1995 shall be satisfied On machines where overall vision is restricted and communication between operating personnel is difficult, prestart warning devices shall be provided which positively give a clearly distinguishable audible signal before the machine starts. The requirements defined in Annex B shall be satisfied. In addition to an audible warning device, one or more visual warning devices may be required. Overall vision may be restricted and communication between operating persons be difficult if the machine length exceeds 7 m, or if, on printing machines, there is more than one printing unit side frame and the machine height, measured from floor level, exceeds 1,6 m, or if, on automatic platen machines, the control panels are in positions from which the waste discharge area cannot be observed. Where prestart warnings are frequent, the stipulations defined in 5.3 of EN ISO :2003 shall be taken into consideration Machines shall be provided with at least one operating element for starting and stopping. This function can also be achieved by a power supply disconnector mounted on the machine. Control switches for starting and stopping and their related operating elements shall satisfy the requirements of EN :1997 and of EN ISO : Operating elements of control switches for starting hazardous movements shall be safeguarded against unintended actuation Machines shall be provided with separate main control switches for each type of energy used. The requirements of EN 1037:1995 shall be satisfied For emergency stopping devices, the requirements of EN 418:1992 and EN :1997 shall be satisfied Two-hand controls Two-hand controls as safety devices are acceptable only if any hazardous movement stops when only one of the two actuators is released. The hazardous movement shall come to a stop in a time that, taking into consideration the hand approach speed, ensures there is no danger for the operator. The hand approach speeds specified in EN 999:1998 shall be taken as a basis. The requirements of type III of EN shall be satisfied For hydraulic/pneumatic two-hand controls, the requirements specified for type III A and for electric/electronic two-hand controls, the requirements specified for type III B of EN 574:1996 shall be satisfied As a deviation from , hydraulic/pneumatic two-hand controls safeguarding danger points requiring routine and regular access shall satisfy the requirements specified for type III B and electric/electronic two-hand controls the requirements specified for type III C of EN 574: Two-hand controls on trailing cables used for make-ready and trouble-shooting are permissible in accordance with In these circumstances, EN 999:1998 is not applied. Trailing cables shall have 22

25 sufficient strength to withstand any mechanical stresses to be anticipated and be provided with measures to prevent the lead being pulled out of its connection point Electrosensitive protective devices (ESPDs) ESPDs shall satisfy the requirements of type 2 of EN :1997 and IEC : As a deviation from , ESPDs which safeguard routine and regular access to the danger zone shall satisfy the requirements of type 4 of EN :1997 and IEC : The hand approach speed specified in EN 999:1998 shall be used as a basis for determining the correct positioning of the ESPD. For ESPDs fitted as start-up inhibiting devices, EN 999:1998 does not apply. Additional safety devices shall be installed Where ESPDs are used for preventing whole-body access to safeguarded danger zones, at least two ESPD beams shall be provided at a height of 400 mm and 900 mm respectively Pressure sensitive mats, trip devices Pressure sensitive mats shall satisfy the requirements of EN :1997, trip bars shall satisfy the requirements of EN :2001. The requirements of category 3 of EN 954-1:1996 shall be satisfied (see 4.15 of EN :1997 or 4.18 of EN :2001). Trip devices and pressure-sensitive mats which safeguard routine and regular access to a danger point shall comply with category 4 of EN 954-1: After tripping the stop function, the length of the movement of the trip device shall be longer than the stopping path of the hazardous movements Safety position switches The requirements of clauses 5 and 6 of EN 1088:1995 shall be satisfied For safety position switches built in accordance with EN :1997 and installed in accordance with EN :1997, it may be assumed that malfunctions are not likely to occur. For machines where routine and regular access is not required, it is therefore sufficient to provide only one position switch for each interlocking guard Short circuits between two electric wires outside the switch cabinet due to physical impacts can be prevented by mechanical protection of the cable (for example locating within ducts, in the machine frame) Work platforms, access stairs, passageways and raised workplaces General requirements For operation, make-ready and regular maintenance, safe workplaces including their means of access and passageways shall be provided according to EN ISO :2001, EN ISO :2001, EN ISO :2001 and EN ISO : Floor coverings shall be slip resistant. This may be achieved, for example, by using profiled steel plate or material satisfying the requirements of classification group R 10 of EN ISO : The minimum clear height for passage shall comply with the stipulations of EN ISO :2001. Where this clearance cannot be complied with for constructional reasons, the protruding parts shall be padded and provided with danger marking Raised permanent workplaces should have a clear working area of at least 1,5 m² per person and the smallest width should be 1,0 m unless this inhibits ergonomic requirements (for example, handling of objects). 23