Materials Handling and Intralogistics. Industrial Trucks. In accordance with the Directive Equipment for potentially explosive atmospheres (ATEX)

Transcription

1 Materials Handling and Intralogistics Industrial Trucks In accordance with the Directive Equipment for potentially explosive atmospheres (ATEX)

2

3 LEGAL NOTICE 1 Legal notice The guideline Industrial Trucks for use in potentially explosive atmospheres (In accordance with the Directive Equipment for potentially explosive atmospheres (ATEX)) is for information only and provides an overview in order to determine whether Industrial Trucks for use in potentially explosive atmospheres (EX-IT 1 ) are conforming or non-conforming to the directive. It claims neither to be complete nor to accurately interpret the existing laws and regulations. Therefore it cannot substitute for studying the relevant directives, laws and ordinances in order to appraise products in detail. Also, it is necessary to take into account product specific features as well as their potential applications. Consequently, alternative constellations, apart from the assessments and procedures described in this guide-line, may be applicable. Introduction EX-IT placed on the European market (EU, EFTA and candidate countries) for the first time shall comply with all safety and environmental requirements of the applicable EU directives. EX-IT not meeting these requirements are not CE-conform and it is prohibited to place them on the EU market. This guideline intends to help distinguish between conforming and non-conforming EX-IT. The document describes basic criteria, verifiable without detailed or technical information. Thus, this brochure is not comprehensive, but it may serve as an early warning tool. Failure to comply with one or several of its criteria may constitute sufficient grounds for doubting the conformity of the EX-IT in question. It is a health and safety risk to place on the market and/or put into service a non-conforming EX-IT in the EU. This would increase the probability of accidents involving non-conforming machinery which often fail to meet European standards. These machines are also a source of unfair competition, thereby jeopardising the R&D and product compliance efforts of respectable manufacturers. In the end, it will compromise the competitiveness of the European Industrial Truck industry and the jobs this industry creates. The text of this guideline mainly references the requirements of European Norm EN 1755:2015 and its generic European Directives: Machinery Directive 2006/42/EC (MD) Equipment for potentially explosive atmospheres 2014/34/EU (ATEX) 1) EX-IT: Industrial Trucks for use in potentially explosive atmospheres

4 2 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Content Content Legal notice 1 Content 2 1 Marking of industrial trucks 3 2 Documents Declaration of Conformity Instruction handbook 8 3 ATEX characteristics Feasible indicators for compliant designs Examples of dubious explosion-proof designs 19 4 Annex Directives Standards 20

5 MARKING OF INDUSTRIAL TRUCKS 3 1 Marking of industrial trucks The applicable Directives demand that the following information be affixed in an obvious, clearly legible and durable manner: name and address of the manufacturer Designation of the truck CE mark 2) Designation of series or type Serial number, as applicable Year of manufacture, i.e. the year in which the manufacturing process was completed unladen mass of the truck in working order and without removable attachments, and without battery in the case of batterypowered trucks, but with fork arms or integral attachments, the actual mass being permitted to vary from the stated mass by up to ± 5 % or kg, Rated capacity Actual capacity at maximum lift height with the load centre distance Actual capacity at other lift heights and load centres distances Actual capacity with each removable attachment fitted at the manufacturer s authorized lift height(s) and load centre(s) on battery-powered trucks, the authorized maximum and minimum battery mass and the system voltage Nominal power, in kw Guaranteed noise emission, in db (as applicable) 2) Note: The Declaration of Conformity lists the directives the product complies with and has been awarded the CE mark for.

6 4 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Where intended for use in potentially explosive atmospheres, Industrial Trucks shall additionally marked in conformity with the ATEX Directive. Refer to the harmonised engineering standard on EX-IT (EN 1755:2015) for additional marking requirements. EX symbol (hexagon) symbol for the equipment group: II Marking of equipment category 2 or 3 followed by the letter G (gas protection) and/or D (dust protection) Symbol for the explosive group (gas group): II, followed by the symbol for the subdivision: (e.g. IIA or IIB or IIB+H2 or IIB+H2+C2H2) Symbol for the explosive group (dust group): III, followed by the symbol for the subdivision: (e.g. IIIA or IIIB or IIIC) Explanatory note The equipment categories (2G 3G 2D 3D) stand for the level of safety of the piece of equipment (EX-IT). They refer to the use in potentially explosive atmos-pheres, which are classified in zones (Zone 1 Zone 2 Zone 21 Zone 22 specified in the ATEX Work-place Directive 1999/92/EC) according to the type of hazard (gas or dust) and the probability of occurrence (frequency). Typical examples of EX-IT marking II 2G IIB T4 II 2D IIIB T 135 C marking concerning maximum surface temperatures Classified by one of the temperature classes T1 to T6 (gas protection) or defined by the maximum surface temperature in C (dust or gas protection)

7 MARKING OF INDUSTRIAL TRUCKS 5 Examples of compliant marking of EX-IT Example of non- compliant marking of EX-IT Manufacturer A: ATEX retrofitter Manufacturer B: Supplier of non-atex machine Concerns Two manufacturers and two CE marks are not allowed to show the EU conformity of one EX-IT Manufacturer not clearly identified Wrong CE mark of manufacturer B CE marking according EU Directives, e.g. MD

8 6 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES 2 Documents 2.1 Declaration of Conformity (DoC) The manufacturer is solely responsible for issuing this Declaration of Conformity (DoC). A DoC must at least contain the following: Product model/product (number of product, type, batch or series) Manufacturer s or its representative s name and address Applicable directives that the device conforms to Noise emission directive for combustion engine powered IT only Name of the person authorised to draw up the technical file Signed for and on behalf of Place and date of issue name, function signature 2G and / or 2D marks: registration number or number of an EU type examination certificate 3G and / or 3D marks: manufacturer s documentation number EX label Applicable harmonised standards (such as EN 1755:2015) or other technical specifications may be added.

9 DOCUMENTS 7 Example of compliant EC/EU Declaration of Conformity (DoC) of EX-IT EC-/ EU-Declaration of Conformity Manufacturer Ltd. Truckstreet Truckcity EC-/ EU-Declaration of Conformity Manufacturer Ltd. Truckstreet Truckcity We declare herewith that the machine Industrial Truck Model Type Serial-No. Gas-Explosion-Protection Forklift Truck E20 EX ABC We declare herewith that the machine II 2G IIB T4 Industrial Truck Model Forklift Truck Type E20 EX Serial-No. ABC Dust-Explosion-Protection II 2D IIIB T 135 C EU-Type Examination NB 15 ATEX 1234 (2GD - optional) or Document-Deposit-No. NB (2GD - minimum) or Document-No. Manufacturer 1234 (3GD - Ident-No. Manufacturer Documents) Gas-Explosion-Protection II 2G IIB T4 Dust-Explosion-Protection II 2D IIIB T 135 C EU-Type Examination NB 15 ATEX 1234 (2GD - optional) or Document-Deposit-No. NB (2GD - minimum) or conforms to following Directives in the latest valid version and for industrial trucks harmonized standards: Document-No. Manufacturer 1234 (3GD - Ident-No. Manufacturer Documents) EC Machinery Directive 2006/42/EC EN ISO :2015 EMC Directive 2014/30/EU EN 12895:2015 EU-ATEX Directive 2014/34/EU EN 1755:2015 EC- Directive for Noise Emissions 2000/14/EC o o conforms to following Directives in the latest valid version and for industrial trucks harmonized standards: Measured sound power level LWA : 77 db Guaranteed sound power level LWA : 79 db Person authorised to compile the technical file: Name Address EC Machinery Directive 2006/42/EC EN ISO :2015 EMC Directive 2014/30/EU EN 12895:2015 EU-ATEX Directive 2014/34/EU EN 1755:2015 EC- Directive for Noise Emissions 2000/14/EC o Measured sound power level LWA : 77 db o Guaranteed sound power level LWA : 79 db James Brown Head of Development Manufacturer Ltd. - Truckstreet Truckcity Sign Person authorised to compile the technical file: Name James Brown Head of Development Sign James Brown Head of Development Address Manufacturer Ltd. - Truckstreet Truckcity Will Smith Head of Quality Sign Sign James Brown Will Smith Head of Development Head of Quality

10 8 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES 2.2 Instruction handbook The instruction handbook must provide information about the intended use, type and way of operation, maintenance, foreseeable misuse, and the use in potentially explosive atmospheres. The instruction handbook must be written in the national language of the EU member state that the EX-IT will be made available in. Making available means the transfer of the product, that is, either the transfer of ownership, or the physical hand-over of the product by the manufacturer, his authorised representative in the EU or the importer to the person responsible for distributing these onto the EU market or the passing of the product to the final consumer, intermediate supplier or user in a commercial transaction, for payment or free of charge, regardless of the legal instrument upon which the transfer is based (sale, loan, hire, leasing, gift, or any other type of commercial legal instrument). The EX-IT product shall comply with the directive at the time of transfer. The instruction handbook shall either be the Original instructions or a Translation of the original instructions. The original instruction handbook shall be labelled as Original instructions and handed over together with the translation. The instruction handbook shall include, as applicable, at least the following information: intended and prohibited use of the truck and its attachments all in accordance with the manufacturer s design parameters; instructions to only conduct service and maintenance operations in a non-explosive hazardous area e.g. filling of fuel tanks; procedure for mounting of attachments operation of the gas detection system; type and frequency of periodic inspections and maintenance operations; relevant maintenance aspects for the electrical system and gas detection system; verification of wheels, castors, earthing straps, fan belts etc. for good condition and the possible loss of conductivity due to contamination; required actions to bring the truck to a controlled stop following a safety shutdown taken into account a 30 s time delay; verification of seat and non-metallic covers for bonding and surface resistance; The instruction handbook shall contain the business name and full address of the manufacturer and/or of his authorised representative. The instruction handbook shall repeat the designation of the Industrial Truck as marked on the truck itself, except for the serial number.

11 INSTRUCTION HANDBOOK 9 verification of correct functioning of safety monitoring and shutdown systems including the sensors; periodic replacement of safety critical or consumable parts; admissible maximum of excessive wear and axial play of brake linings and in the case of constructional safety brakes the correct positioning of the thermal sensor after repair; verification of the minimum thickness of 1 mm cladding of load handling devices relevant maintenance aspects for the internal combustion engine given in EN and EN ; verification of the integrity of enclosures protected by specific types of protection. Safety information The instruction handbook shall state the following warnings: This equipment could present hazards if it is not operated according to the information given in this instruction handbook, and shall include, as applicable, at least the following information: description of the operational limitations of equipment marked with the symbol X ; all warnings necessary for proper operation of the equipment; measures in case of failures or repair; footwear to be worn by the operator to comply with EN ISO 20344; protective clothing to be worn by the operator, including gloves to comply with to EN ; a warning that trucks shall only be operated in hazardous areas with dissipative floors; a warning about the possible dangerous electrostatic charging of non-conductive parts on the truck due to, e.g. contact with flexible doors or strip curtains; time interval for the testing of conductive tyres, dissipative tyres and earthing straps including the test procedure; function of the safety devices.

12 10 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Information for charging of the battery and battery handling The instruction handbook shall contain the following additional information, taking into account the requirements for battery charging rooms and charging areas with regards to: charging of batteries, if appropriate, in hazardous areas shall comply with the requirements of EN and EN gas production during charging and discharging of the battery and requirements for battery charging stations suitable equipment and provisions to ensure safe battery handling battery charging equipment general battery information service information for batteries

13 ATEX CHARACTERISTICS 11 3 ATEX characteristics 3.1 Feasible indicators for compliant designs Conductivity of surfaces (e.g. by marking Equipotential Bonding )

14 12 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES ATEX marking of electrical equipment e.g.: Non-sparking alarm horn standard explosion-proof device Intrinsically safe equipment (special type of protection) featuring blue cables or labels

15 ATEX CHARACTERISTICS 13 Explosion-proof light fixtures (e.g. flameproof enclosure) Manually operated wiper non-sparking

16 14 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Flameproof enclosures housings of sparking relays and hot electronic assemblies Battery connector and green/yellow equipotential bonding wire

17 ATEX CHARACTERISTICS 15 Measures to prevent electrostatic discharge Plastic tiller with conductive coating Hand guard of conductive polycarbonate, where applicable Conductive wheel, R<1 MOhm Plastic covers with conductive coating Electrically conductive hydraulic hoses, tank and pipework Seat with electrically conductive seat cover (Ex-proof) Fork arms completely cladded with stainless steel or brass Covering parts made of electrically conductive plastic All wheels electrically conductive all around

18 16 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Attachments load handling equipment examples

19 Spark protection by brass or stainless steel coating ATEX CHARACTERISTICS 17

20 18 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES Warning labels other signs typically found on EX-IT Examples: Do not open in EX area (carries voltage) Do not charge in EX area Hexagon Do not unplug battery connector in EX area Cleaning with a damp cloth only

21 EXAMPLES OF DUBIOUS EXPLOSION-PROOF DESIGNS Examples of dubious explosion-proof designs Uncovered and sparking electrical equipment Damaged electrical equipment (e.g. lamp lens broken) Bare live cables and wires Uncovered battery terminals (e.g. no cover on traction batteries) Standard fork arms and/or standard attachment not ex-proof Negative battery pole attached to chassis Non-marking ( yellow ) tyres, no earthing strap Electrical equipment without ATEX labelling e.g. radio, tablet, wireless, production data acquisition, printer, heater standard electrical equipment Uncovered openings in flameproof enclosures

22 20 INDUSTRIAL TRUCKS CONFORMING TO THE ATEX DIRECTIVES 4 Annex 4.1 Directives Machinery Directive 2006/42/EC (MD) EMC Directive 2014/30/EU ATEX Equipment Directive 2014/34/EU (EXD explosion control directive) Noise Emission Directive 2000/14/EC ATEX Workplace Directive 1999/92/EC 4.2 Standards EN ISO :2015 Industrial trucks Safety requirement and verification Part 1: Self-propelled industrial trucks, other than driverless trucks, variable- reach trucks and burden-carrier trucks EN 12895:2015 Industrial trucks Electromagnetic compatibility EN 1755:2015 Industrial Trucks Safety requirements and verification Supplementary requirements for operation in potentially explosive atmospheres

23 Imprint Imprint VDMA Materials Handling and Intralogistics Lyoner Str Frankfurt am Main Editor Andreas Scherb Contact Materials Handling and Intralogistics Andreas Scherb Phone Fax Internet foerd.vdma.org Date January 2016

24 VDMA Materials Handling and Intralogistics Lyoner Str Frankfurt am Main Contact Materials Handling and Intralogistics Andreas Scherb Phone Fax Internet foerd.vdma.org foerd.vdma.org DesignStudio Cover: Linde Material Handling GmbH