Step 1_Lego_Day Training Vers 1.pdf

03-06-2013

1

LEGO Step 1 – Basic Level – Introduction machinery and equipment safety

1 Day Training

LEGO Basic Safety Training, June 6, 2013 Enrique GranadosCertified Machinery Safety Expert (TÜV Nord/Pilz),Machinery Safety Consultant Pilz de México, Convento de Actopan 36 Col. Jardines de Santa Monica, 54050Tlalnepantla, Edo de Mex

� Training IntroductionCourse Material and Certification

Course Material

Course handbook:

� Presentation reference material� Supplementary information� Exercise documents� Evaluation form

Certification of Completion

�Upon successful completion of your course, PILZ will issue youwith a Certificate

2

03-06-2013

2

� Training IntroductionTraining Instructor

Introduction to the Instructor

Attendee Participation

� Relate the issues covered to your workplace� Please comment if the course pace is unsuitable � Your feedback is very important to us!! Please

fill your Course Evaluation Form

3

� Attendee Participation

Attendees are actively encouraged to participate in training and discussions

Questions and feedback are welcomed

Where…?

How…?

When…?

Why…?

4

03-06-2013

3

� Training Introduction

It sounds like English, but I can't

understand a word you're saying

5

� The Company

“Ideas are nothing without action.”

Renate Pilz, Managing Partner, Pilz GmbH & Co. KG

“Ideas are nothing

without action.”

Renate Pilz, Managing Partner,

Pilz GmbH & Co. KG

6

03-06-2013

4

� The CompanyOstfildern, Germany: Headquarters

Safety Services teams supported Internationallly through:

� Services Research and Development

� Knowledge management

� Industry sector specialists

� Standards and best practise monitoring

7

� The CompanyGlobal Player

8

03-06-2013

5

� The CompanySafety Services

We are the trusted provider of Safety

Services to leading national andinternational industrial companies:

� Viable solutions to the most complex safety issues

� Best manufacturing practises guarantee availability and productivity of plants

� Consistent focus on customer benefits

� Customer proximity through local knowledge, local resources and international support

9

� Safety Services Machinery Life Cycle

We can implement the complete lifecycle or

provide discrete services at critical stages,

including from

� Risk Assessment

� Safety Concept

� Safety Design

� System Implementation

� Safety Validation

10

03-06-2013

6

� Safety Services PortfolioContinued

� Plant Assessment

Provides your organisation with an outline analysis of the safety status of all

machinery and equipment

� CE Marking

Management of activities and processes generating the necessary

compliance strategies, safety designs and documents

� International Compliance Management

Management of conformance with the ISO, IEC, ANSI and/or other standards

� ESPE Inspection

Operational safety of ESPE used to protect against mechanical hazards on

production plants

� Safety Training

Comprehensive range of training in relation to compliance and safety

11

� The CompanyApprovals and Certification

Your trust is confirmed through external Accreditation

� EN 61508 through TUV� Machinery inspection through

DATech (Notified inspection body, type “C“)

Your expectations are met through internal management systems

� Competence Management� Service Quality Management� Project Management

12

03-06-2013

7

� Topics

Legislation

CE Marking

Safety Standards and Applications

Risk Assessments

Safe Guarding

Introduction to Safety

Safety Components

13

Safety Validation

� Topics


Motivation for SafetyKey Safety QuestionsBehavioural Based Safety

14

03-06-2013

8

� Motivation for Safety

General Benefits of Safety

15



16

03-06-2013

9



17



� A company performing strongly in safety has a better marketing image

� Increased Safety improve relationship with between workers, unions and the

employer

� Increased Safety improve individual and team morale

� Increased Safe practices reduces downtime and increases efficiency

� Reduced need for troubleshooting / reactive maintenance

� Creates a culture of accountability and care

� Best performing companies have best safety

18

03-06-2013

10


Economic: The total cost of accidents is like a floating iceberg

10% is visible and above sea level– Cost of recovering from injury– Employers liability– Third party / public liability– Product liability

90% is not visible and below sea level

Accident Costs

– Cost of recovering from injury– Product and material damage– Plant and building damage– Tool and equipment damage– managers’ time diverted– Emergency supplies– Clearing the site

– Production delays– Fines & Legal costs– Overtime work– Substitute labour– Investigation time– Clerical effort– Loss of expertise

19



Risk Management Cost

Risk Reaction Cost Latency Cost Risk Reduction Cost

Insurance Premiums Emergency Healthcare Inspection fines and sanctions

Safeguarding Measures

Legal cost Accident compensation Loss of skilled workforce Safety Services

Heathcare On site Fines and sanction Loss of Image Safety Procedures

Loss of resourcesIncrease maintenance cost

Training

Direct Production loss Internal conflicts

Hidden production loss Production inefficiencies

Addional resourcesExtra Labour

Recover from loss of image Less Safety incentives

20

03-06-2013

11

� Topics



21

� Key Safety Questions

Questions to Address

1. Why should machinery/ plant be safe?

2. What is (machinery/ plant) safety?

3. What is the workers perspective?

4. What is an accident?

5. What is a hazard? What is a risk?

6. What are safety components?

7. Who should be carrying out safety functions?

8. When can a system / machine / plant be considered to have an acceptable level

of safety?

9. How much should be invested in safety?

22

03-06-2013

12


Question 1 Why should machinery/ plant be safe?

� It is the moral obligation of employers to provide safe work equipment, according to article 23.1 from the:

� UNIVERSAL DECLARATION OF HUMAN RIGHTS*Everyone has the right to work, to free choice of employment, to just and favourable conditions of work and to protection against unemployment

*Adopted by UN General Assembly Resolution 217A (III) of 10 December 1948

23


24

� Safety is the freedom of unacceptable risk

Question 2 What is (machinery / plant) safety?

03-06-2013

13


25

Question 3 What is the workers perspective?

As a:� Machine manufacturer, Safety manager, Maintenance manager, Production

manager, Engineering manager or Plant engineeryou should be aware that the worker at the machine assumes that the machine is safe

However employee safety responsibilities include:� Recognizing safety hazards� Maintaining good housekeeping� Reporting safety hazards� Working safely� Using personal protective equipment (PPE)� Making the most of safety training


Workers Perspective??

26

03-06-2013

14


27

An accident is any unforeseen or unexpected event that may or may notresult in injury or damage to property or equipment

FACT: In the time it took you to read this slide, about 10 Europeans suffered disabling injuries in accidents in industry

Question 4 What is an accident?


28

Question 4 Accidents Primary Causes

Primary Causes = Unsafe Acts and Unsafe Conditions

� Management need to concentrate on the nature of the accident rather than the outcome

� It must be clearly understood that the primary cause of the accident is not always necessarily the most important feature; secondary causes, usually in the form of system failures can continue unless action is taken

03-06-2013

15


29

Unsafe Acts

� Working without authority� Failure to warn others of danger� Using unsafe equipment� Using wrong equipment� Failure to issue control measures� Horseplay � Etc…

Unsafe Conditions

� Inadequate or missing machine guards

� Defective tools or equipment� Fire Hazards� Ineffective housekeeping� Excessive noise� Poor ventilation and lighting� Etc…

Question 4 Accidents Primary Causes


30

Management System Pressures

� Financial restrictions� Lack of commitment� Lack of policy� Lack of standards� Lack of training

Social Pressures

� Group attitude� Tradition� Society attitudes to risk taking� ‘Acceptable’ behaviour in the

workplace

Question 4 Accidents Secondary Causes

03-06-2013

16


31

Question 5 What is a hazard? What is a risk?

Hazard:� ‘hazard’ means a potential source of injury or damage to health

Risk:� ‘risk’ means a combination of the probability and the degree of an injury or damage

to health that can arise in a hazardous situation


32

Question 6 What are Safety Components?

Safety Control System

E-Stop

Light Curtain

Safety Sensors

Safety Mat and Bumper

Two Hand Control

03-06-2013

17


33

Question 6 What are Safety Components?

Fixed and Mobile Guard Systems


34

Question 7 Who should be carrying out safety functi ons?

Competence means having the necessary qualifications, experience and training to be able to: � Identify all hazards, � To assess the risk related to them and � To know what control measures will reduce risk to an acceptable level

According to European Legislation personnel responsible for safety “should be able to demonstrate competence”. � Qualifications, Example: Occupational Safety and Health (MIOSH)� Training: Demonstrates knowledge specific to particular machinery, products or

processes � Experience: Demonstrates knowledge gained through experience

03-06-2013

18


35

Question 8 When is there an acceptable level of saf ety?

When can a system / machine / plant be considered to have an acceptable level of safety?� The machine/ system/ plant has been assessed� All hazards have been identified� Appropriate safety meassures have been designed to reduce the risk to an

acceptable level� A theoretical test and analysis of the performance of the new safety system has

been calculated� Safety system has been implemented� Practical tests of the safety system and fault simulation on original components,

especially in areas where doubt exists, have been performed� Validated components and principles have been used� All safety system, test, components etc... are properly documented� All of above has been done by competent people strictly following current

standards and directives


36

Question 9 How much should be invested in safety?

This model links the cost of accidents and the cost of risk reduction.At point A the total costs are the lowest.

Safety resources

Cost

Total Cost

Total Accident Cost

Total Safety Cost

A

SAFETY IS AN OBLIGATION.

NOT AN OPTION!!!!!!!

03-06-2013

19


37

Safety Costs Model for Decision Making

Safety

Level

CostRisk

Reduction

Cost

Risk

reaction

Cost

Risk

Management

Cost

High

High

Latency

Risk Cost

Optimal Economic Result

TOTAL

Cost

Current Situation


Safety First

You should quantify

the safety first !

There is always a safer way !!!!There is always a safer way !!!!

Or more ………

38

03-06-2013

20

� Topics



39

� Behavioural Based Safety

Figure 1: The Safety Triad

Person Environment

Behaviour

Knowledge, Skills, Abilities,

Intelligence, Motives,

Personality

Equipment, Tools, Machines,

Housekeeping, Heat/Cold,

Engineering, Standards, Operating

Procedures

Complying, Coaching, Recognizing, Communicating,

Demonstrating “Actively Caring”

40

03-06-2013

21


41

Identifying barriers to safety

Safety behaviour is often uncomfortable, less convenient, and less fun.


42

Seven Basic Principles of Behaviour Based Safety

� Focus Intervention on Observable Behaviour

� Look for External Factors to Understand and Improve Behaviour

� Direct with Activators and Motivate with Consequences

� Focus on Positive Consequences to Motivate Behaviour

� Apply the Scientific Method to Improve Intervention

� Use Theory to Integrate Information, not to Limit Possibilities

� Design Interventions with Consideration of Internal Feelings and Attitudes

03-06-2013

22


43

“Beneficial change results from acting people into thinking differently rather than targeting internal awareness or attitudes so as to think people into acting differently”

Principle 1: Focus Intervention on Observable Behav iour


44

� Place focus on external factors –

environmental conditions and

behaviours – which can be changed

upstream from a potential injury.

� Internal person factors are difficult to

identify, and if defined, they are even

more difficult to change directly.

Principle 2: Look for External Factors to Understan d and Improve Behaviour

03-06-2013

23


45

� We do what we do because of the

consequences we expect to get for

doing it

� Activators (or signals preceding

behaviour) are only as powerful as the

consequences supporting them

� This principle is referred to as the ABC

model (three-term contingency)

Principle 3: Direct with Activators and Motivate wi th Consequences


46

� We perform behaviour to receive

positive consequences or to avoid or

escape negative consequences

� The type of consequences (positive or

negative) controlling our behaviour

influences our attitude towards the

task

Principle 4: Focus on Positive Consequences to Moti vate Behaviour

03-06-2013

24


47

� Objective and systematic observation

enables the kind of feedback needed

to know what works and what doesn’t

work to improve behaviour

� Behaviour can be observed and

measured before and after an

intervention process is put into effect

� Feedback can be used to improve

process

Principle 5: Apply the Scientific Method to Improve Intervention


48

DO IT - Behavioural Based safety is a continuous 4-s tep process

DEFINE - Behaviour(s) to target

OBSERVE - To collect baseline data

INTERVENE - To influence target behaviour(s)

TEST - To measure impact of intervention

DOIT

03-06-2013

25


49

Principle 6: Use Theory to Integrate Information, n ot to Limit Possibilities

� Theory – driven research can narrow the perspective of an investigator and limit

the breadth of findings possible from the scientific method

� Many important findings in behavioural science have resulted from exploratory

investigation – “I wonder what will happen if…”

� An intervention process that works well in one situation will not necessarily be

effective in another setting

� Summarise the relationships you observe between intervention results and certain

situational or interpersonal characteristics, thereby developing a research based

theory


50

Principle 7: Design Interventions with Consideratio n of Internal Feelings and Attitudes

� Internal feelings or attitudes are influenced indirectly by the type of behaviour-

based intervention procedure implemented

� The way we implement an intervention process can increase or decrease feelings

of empowerment, build or destroy trust, or cultivate or stifle a sense of teamwork or

belongingness

� Implementing/refining intervention procedures should be based on both objective

behavioural observation and subjective evaluations of internal feeling states

03-06-2013

26

� True or False…

Inadequate or missing machine guards is a secondary cause of accidents.

Management need to concentrate on the nature of the accident rather than the outcome.

Emergency Stops, Light Curtains and Safety Signs are not forms of Safety Components.

Primary Causes of accidents are Unsafe Acts and Social Pressures.

A machine has an acceptable level of safety when all hazards have been identified and adequately controlled.

�

�

�

�

�

51

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

52

Safety Validation

03-06-2013

27

� Topics

Legislation

Introduction to Safety LegislationAdvantages of Compliance

53

� Introduction to Safety Legislation

54

European Legislation

How has European Legislation come about?

� 1957 Treaty of Rome

� Old approach Directives

� Mid 1980’s Article 100a of Treaty of Rome introduced New approach Directives (now Article 95 of Amsterdam 1999)

� Objective: To promote freedom of goods, services, finance and people

03-06-2013

28


55

European Legislation

� The EU Commission issues Directives� Approved Authorised Bodies (e.g. CEN, CENLEC) issue EU Normatives� A State sponsored body exists in each member state to secure Safety, Health and

Welfare at work, e.g. the HSA in Ireland� The Government transpose these Directives into Laws, while the HSA enforce the

Laws and issue Guidance Documentation

RECOMMENDATIONS

LAWS

EU NORMATIVES

AUTHORISED BODIES

EU DIRECTIVES

EU CommissionHealth & Safety

Authority


Machinery Directive must be implemented in law by all states in the European Economic Area. The directive deals with the requirements to achieve CE Marking

European Directives Geographical Scope

Austria

Belgium

Bulgaria

Cyprus

Czech Republic

Denmark

Estonia

Finland

France

Germany

Greece

Hungary

Iceland

Ireland

Italy

Latvia

Liechtenstein

Lithuania

Luxembourg

Malta

Netherlands

Norway

Poland

Portugal

Romania

Slovakia

Slovenia

Spain

Sweden

United Kingdom

56

03-06-2013

29


57

� Machinery Directive

� Low voltage Directive

� EMC Directive

� PED Directive

� ATEX Directive

(Note: There are 21 product directives issued that require CE marking of products.)

Key Legislation for CE Marking


58

European Directives

90/396/EEC Appliances burning gaseous fuels

00/9/EC Cableway installations designed to carry persons

89/106/EEC Construction products

2004/108/EC Electromagnetic compatibility

94/9/EC Equipment and protective systems in potentially explosive atmospheres

93/15/EEC Explosives for civil uses

95/16/EC Lifts

2006/95/EC Low voltage equipment

2006/42/EC Machinery safety

2004/22/EEC Measuring instruments

90/385/EEC Medical devices: Active implantable

03-06-2013

30


59

European Directives

93/42/EEC Medical devices: General

98/79/EC Medical devices: In vitro diagnostic

92/42/EEC New hot-water boilers fired with liquid or gaseous fluids (efficiency requirements)

90/384/EEC Non-automatic weighing instruments

94/62/EC Packaging and packaging waste

89/686/EEC Personal protective equipment

97/23/EC Pressure equipment

99/5/EC Radio and telecommunications terminal equipment

94/25/EC Recreational craft

87/404/EEC Simple pressure vessels

88/378/EEC Toys safety


60

European Directives

Machinery Directive 2006/42/EC

The Machinery Directive is the instrument that all EU member states have adopted to establish the safety requisites machinery must posses in order to be introduced into the Community Market

Objectives� To ensure the free movement of goods in all the member states

� To ensure identical Safety requirements for machinery in every country

� To ensure a high level of safety

03-06-2013

31


61

Machinery Directive

Responsibilities- Manufacturer

� A manufacturer is the person who is responsible for designing and manufacturing a product with a view to placing it on the Community market on his own behalf

� The manufacturer has an obligation to ensure that a product intended to be placed on the Community market is – Designed – Manufactured– Conformity assessedto the essential requirements in accordance with the provisions of the applicable Directives


62

� To aid a supplier to fulfill the requirement of functional safety of machinery supplied to LEGO

� Based on the requirements of the MD 2006/42/EC

� The directives listed are not an exhaustive list.

LEGO Law and Standards Requirement Specification

03-06-2013

32


63

� Member States shall also provide for penalties for infringements, which may include criminal sanctions for serious infringements.

� Penalties include– The illegal machine shall be recalled or replaced,– monetary penalties, (up to 20 000 € in Belgium, up to 5000 £ in the

UK) or even imprisonment – Equipment insurance coverage may be invalid.– In case of accidents or of controls from the authorities, the machine

may be blocked and withdrawn from the worksite, therefore causing a delay in the work and financial losses.

– The non-compliant machine may not be compatible with standard spare parts and/or accessories available in the EU.

Penalties for Non Compliance

� Topics

Legislation

Introduction to Safety LegislationAdvantages of Compliance

64

03-06-2013

33

� Advantages of Compliance

� Compliance with legislation. Legal protection

� Safe products make good business sense. Market perception

� Organizational culture

� Natural link between safety and reliability

� Employee well-being

� Points to other management failures

� Diagnosis easily possible

� Direct costs: compensation, insurance costs

� Indirect costs: downtime, investigation, replacement of staff, etc.

65

� True or False…

The machinery directive ensured the free movement of goods throughout the world

The EU Commission issues Directives

Member states health and safety bodies transpose directives in to law

�

�

�

66

03-06-2013

34

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

67

Safety Validation

� Topics

CE Marking

Regulatory OverviewOverview of Life ExampleCE Marking Examples

68

03-06-2013

35

� Regulatory Overview

69

What is CE Marking?

CE marking is a documented physical examination and inspection of a machine, process or piece of work equipment carried out under the legislative framework of EU directives.


CE Marking Principles

� CE marking symbolises the conformity of the product with the applicable Community requirements imposed on the manufacturer

� The CE marking affixed to products is a declaration by the person responsible that:– The product conforms to all applicable Community provisions– The appropriate conformity assessment procedures have been completed

� Specific directives had been put in place providing the legal regulation for the affixing of the CE marking

� The CE marking is not a mark of origin, as it does not indicate that the product was manufactured in the European Community

� CE is only a claim by the manufacturer that the machinery is safe and that they have met relevant supply law. The user, also has to check that it is, in fact, safe before the machinery is used.

70

03-06-2013

36


71

Scope of machinery that requires CE Marking

� Machines that are placed or put into service in the EU market for the first time

� In-house machinery where manufacturers put their own machinery into service

� Machinery Imported from outside the EU irrespective of age

� Machinery operating in the EU that was built prior to 1995 but has had significant modifications since being installed

� Machines altered beyond their original limits (e.g. Potential to Run Faster) where the Risk has increased from the original installation

.


72

Who Does It Affect ?

The responsibility for demonstrating that the machinery satisfies the Machinery Directive rests on the machine manufacturer or the importer into the European Community.

This could affect: � Original Equipment Manufacturers (OEM’s)� Machines Imported into the European Union� Machines built for own use� Machines built for sale into the European Union� Machines altered beyond their original limits� New machines (currently being place in the market or put into service)� Old machines (if being place into the market or substantially modified)

03-06-2013

37


CE Method Flowchart

73


74

Requirements of the CE Marking Process

The Manufacturer (or other) must:

� Assess Machinery/ Plant against current legislation to establish which directives are applicable i.e. Machinery Directive, LVD, EMC, ATEX, etc.

� Carry out Risk Assessment� Carry out Risk Reduction (Correct and validate any failures)� Validate the machinery against the Essential Health and Safety Requirements

(E.H.S.R’s)� Verify that machine/ plant is compliant� Compile a Technical Construction File� Draw up an EC Declaration of Conformity stating which directives are applicable� Affix CE Plate

03-06-2013

38


75

CE Plate Example

2009Year:

Type:

Serial Number:

Pilz-Ident-No.:

Manufacturer: Authorised Representative:

Plastic Extrusion

E320-450-348

P.13849.CH

Pilz IrelandModel Farm Road

Cork, IrelandTel: +353 21 4804940Tel: +353 21 4804994

DanGyo MachineryNan Chenglou

325234 Wenzhou, ChinaTel: +353 21 4804940Tel: +353 21 4804994

� Topics

CE Marking

Regulatory OverviewHow To Comply with DirectiveCE Marking Examples

76

03-06-2013

39

� How to Comply with the Directive

77

Overview

Risk Assessment at the Design Stage:

� Apply safety at the design stage� Identify the risk to health and safety posed by the Machine � Reduce risks as far as possible by design

Self Assessment Procedure:

� For most items of machinery (with certain exceptions of those listed in Annex IV –more dangerous machinery with special requirements), the manufacturer can self-certify that they design their products to meet the requirements of the Directive and sign a Declaration of Conformity.

� The conformity process will involve using harmonised norm standards.


78

Self-Assessment Procedure

Machinery manufactured in conformity with specified transposed harmonized standards will be presumed to comply with the essential health and safety requirements covered by those standards.

03-06-2013

40


79

Structure of Standards

The structure of the European harmonised standards contains many interlinking standards, which allow the build of a machine without special designed machine safety standards.

� Topics

CE Marking

Regulatory OverviewOverview of LifecycleCE Marking Examples

80

03-06-2013

41

� CE Marking Examples

81

Introduction Article 2 of Machinery Directive

The different scenarios for certification:

� Machines imported from outside the EEA with manufacturers knowledge� Machines imported from outside the EEA without manufacturers knowledge� Machines designed and built in the EEA� Subassemblies built in the EEA� Assembly's of machines built in the EEA� Machines built for customers own use in the EEA


82

CE Marking Example 1

A non-EEA manufacturer wishes to market machinery in the EEAMade outside EAA

03-06-2013

42


83

CE Marking Example 1Requirements

� When a manufacturer of a non-EEA country sells machinery for use on the territory of the European Union, he must comply in full with the technical and administrative requirements of the Directive in Article 5.


84


The origin non-EEA manufacturer does not wish to market machinery in the EEAMade outside EAA

03-06-2013

43


85


� A company located in the EEA may buy new machinery directly from a non-EEA country without the non-EEA manufacturer even knowing where it is going.

� This is also the case when an “old” machine would be moved inside a company from a plant outside the EEA to a plant inside the EEA.

� In this case this “old” machinery has to be regarded as “new”.

� The machinery directive stipulates that in this case, the user who places the product on the market is regarded as a manufacturer. He will be responsible for modifying the machinery if it does not comply with the technical requirements.


86


Building a Machine or partly completed machine for Manufacture either within or outside the EEA

03-06-2013

44


87


� The machinery directive treats anyone assembling machinery or machinery parts from various origins, or a user building a new machine for his own use, as a manufacturer .

� Whether or not the subassemblies come from a supplier established in the EEA is immaterial here.


88


Design of a new assembly from part ly completed machines

+ +

03-06-2013

45


89


� The assembler, who may be a manufacturer, assembler, engineering company or the end-user himself, designs a new assembly from several machines.

� If the assembler controls the whole project, he is regarded as responsible for supervising safety. He may buy or import subassemblies which may or may not be compliant and bear CE marking.


90


� It is very important that the project manager takes care of safety from the moment the orders are placed and specifications drawn up for the components.

� It is unrealistic to assume that an assembly of machines that comply individually with the Directive will form an assembly that also conforms.

� Safety is not cumulative. The project manager must anticipate putting together an overall technical file. This overall technical file is not the sum of the documents provided by the various suppliers.

� The technical file has to describe the overall risk analysis which by definition is beyond each subassembly supplier. In fact a large part of the suppliers’ technical documentation is irrelevant to the objectives of the technical file set out by the Directive.

03-06-2013

46


91

� The purchase order placed with the supplier from the project manager should clearly define the nature of the safety information to carry out his overall risk analysis. There are probably many operating parameters or technical features of the subassemblies which can influence the final result.

� This information must be available or at least kept at his disposal. The same applies to instruction manuals. A manual for a complex assembly is more than a compilation of the subassembly manuals.



92


Development of complex assemblies including (retrofit/upgrading)

+

03-06-2013

47


93

� "EC" declaration of conformity for assemblies of machines– In the case of assemblies of machines resulting from the joining of several

machines, the "manufacturer" may be the prime contractor who coordinates and supervises the production of the assembly.

– The end user will often be this prime contractor. An "EC" declaration of conformity might be signed jointly by several parties. In this case, it is safe to assume that the latter have committed themselves to being jointly and severally liable.



94


� The project manager may also come onto the scene several years after the machinery has been put into service if, for example, he is modernizing a production line by installing a common control system for several machines.

� The problem lies with the use of machinery covered by Directive 2009/104/EC , as amended.

� It stipulates that “the employer shall take the measures necessary to ensure that, throughout its working life, work equipment is kept, by means of adequate maintenance, at a level such that it complies with” the European Directive applicable to it when it was first put into service or, failing this, with the technical annex to Directive 2009/104/EC, as amended”.

In the case of an “essential modification” Pilz can take over the responsibility for the conformity assessment procedures. In this case access to all safety related documents has to be guaranteed or Pilz may prepare missing documents.

03-06-2013

48


95


Users building machinery for their own use made in the EEA


96


� Article 2 of the machinery Directive requires users building machinery for their own use to comply with the Directive.

� This does not concern modification of machinery in service but rather design of entirely new equipment.

� Although there is no problem of freedom of movement since the machinery is not being placed on the market, the machinery Directive is applicable to ensure that this type of new machinery is as safe as that available on the market.

03-06-2013

49


97


� “Where neither the manufacturer nor his authorised representative established in the Community fulfils the obligations of Article 5 (completing the CE process), these obligations shall fall to any person placing the machinery or safety component on the market in the Community. The same obligations shall apply to any person assembling machinery or parts thereof or safety components of various origins or constructing machinery or safety components for his own use”.


98

Key Points

� “No manufacturer, whether domiciled in the EEA or not, can invoke the previous paragraph to artificially discharge himself from his responsibilities to a third party (retailer, wholesaler, user, etc.). This would be a clear misuse of the law intended to circumvent the application of the Directive. Only the person who places the machinery on the market can avail themselves of their own risk”.

� This person decides to assume the full responsibility of a manufacturer even though they are not one.

� Since the possibilities for initiating legal proceedings against a manufacturer established outside the EEA are relatively limited, it is likely that the direct importer or user will have to face the consequences alone of non-conformity or an accident.

03-06-2013

50

� Who of the following are responsible for CE Marking Machinery?

O.E.M’s

Plant Operators

Direct Machine Importers

Maintenance Departments

Machines Designed by Manufacturers for own use

Yes

Yes

Yes

No

No

99

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

100

Safety Validation

03-06-2013

51

� Standards

Definitions

� Standards ensure minimum desirable characteristics of products and services such as quality, environmental friendliness, safety, reliability, efficiency and interchangeability - and at an economical cost

� Standards are formal documents containing technical specifications or other precise criteria to be used consistently as rules, guidelines, or definitions of characteristics, to ensure that materials, products, processes and services are fit for their purpose

101

� Standards

The main reasons are: � Worldwide progress in trade

liberalisation� Interpenetration of sectors� Worldwide communications systems� Global standards for emerging

technologies� Developing countries worldwide.

Why Standards?

For example, the format of the credit cards, phone cards, and "smart" cards that have become commonplace is derived from an ISO International Standard. Adhering to the standard, which defines such features as an optimal thickness (0,76 mm), means that the cards can be used worldwide

102

03-06-2013

52

� Standards

Standards for Safe Construction of Machines & Plant s

� INTERNATIONAL � EUROPE � NATIONAL

� IEC / ISO Standards � EN / ISO / IEC Standards

� DIN / EN / ISO IEC Standards

103

� Standards

104

Application of Legislation and Standards

Training (Additional measures)

Inform and warn (Residual Risk)

Risk Reduction Safeguards

Risk Reduction Design

Limits of Acceptable Risk

Risk Assessment

Machine Limits

ISO 3864

ISO 11428

ISO 14120

ISO 13854

EN ISO 12100

EN ISO12100

EN ISO 12100

03-06-2013

53

� Topics


Key Machine Safety StandardsCase examples

105

� Key Machine Safety Standards

� European Normatives provide a presumation of conformity to the Machinery Directive

� Application of appropriate Normatives can be used for complaince with specific EHSR‘s

� Type C standards can allow a presumption of conformity for a whole machine

Overview

106

03-06-2013

54


A Type Standard ExampleEN ISO 12100

EN ISO 12100 Safety of machinery- General principles for design – Risk Assessment

The standard covers:

� Safeguarding and complimentary protective measures

� Selection and implementation of guards and protective devices

� Requirements for the design of guards and protective devices

� Safeguarding for reducing emissions

107


A Type Standard ExampleEN ISO 12100

Safeguarding for reducing emissions (examples)

� NoiseAdditional protective measures include, for example:

– enclosures– screens fitted to the machine;– Silencers

� VibrationAdditional protective measures include, for example, damping devices for vibration isolation between the source and the exposed person such as resilient mounting or suspended seats.

108

03-06-2013

55


B Type Standard ExampleEN ISO 13857

Safety of Machinery - Safety distances to prevent hazard zones being reached by the upper and lower limbs.

This standard is used to establish adequate safety distances to be determined to prevent danger zones being reached based on the upper limbs of persons of 3 and/or 14 years old and above.

The distances detailed in the standard are based on persons who try to reach danger zones without additional aid and under the conditions specified for the different reaching situations.

109


C Type Standard ExampleEN ISO 10218-1/2

� Movements (normal or unexpected) of any part of the robot arm (including back)

� End-effector failure (separation)� Hot surfaces associated with the end-

effector; or associated equipment or workpiece

� The rotational motion of any robot axes

Robots and Robotic Devices - Safety Requirements for Industrial Robots

These standards have been created in recognition of the particular hazards that are presented by industrial robots and industrial robot systems.

These can include

110

03-06-2013

56


111

� EN 953 - General requirements for design and construction of Guards.

� EN 349 - Minimum gaps to avoid crushing parts of the human body.� EN ISO 13849 - Safety-Related Parts of Control Systems� EN ISO 13850 - Emergency Stop

� EN 60204 -1 - Electrical equipment on Industrial Machines� EN ISO 13857 - Safety distances to prevent hazard zones being reached by upper

and lower limbs.

� EN 1088 - Interlock devices associated with Guards.� EN 1037 - Safety of machinery - prevention of unexpected start up.

Common Standards to Consider with Machinery

� Topics


Key Machine Safety StandardsCase example

112

03-06-2013

57

� Case Example

Injection Moulding Machine

113

� Case Example

114

� Specifies the essential safety requirements for injection mouldingmachines for the processing of plastics and/or rubber.

� The safety requirements for the interaction between injection mouldingmachines and ancillary equipment are specified.

EN 201 Plastics and rubber machines - Injection Moul ding Machines -Safety requirements

03-06-2013

58

� Case Example

115

Contents� Scope� Normative references� Terms and definitions� List of significant hazards� Safety requirements and protective

measures� Verification of the safety requirements

and/or protective measures� Information for use


� Case Example

116


Normative ReferencesThe following are some standards which are indispensible for the application of EN201� EN 349 Minimum gaps to avoid crushing of parts of the human body� EN 574 Two-hand control devices — Functional aspects — Principles for design� EN 953 Guards — General requirements for the design and construction of fixed

and movable guards� EN 983 Safety requirements for fluid power systems and their components —

Pneumatics� EN 1088 Interlocking devices associated with guards – Principles for design and

selection� EN ISO 13732-1:2008 Ergonomics of the thermal environment — Methods for the

assessment of human responses to contact with surfaces — Part 1: Hot surfaces� EN 60204-1:2006 Electrical equipment of machines — Part 1: General

requirements

03-06-2013

59

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

117

Safety Validation

� Topics

Risk Assessments

Risk Assessment Methods

118

03-06-2013

60

� Risk Assessment Definitions

119

What is a Risk assessment?

� An overall process comprising of a risk analysis and a risk evaluation. (Definition from EN ISO 12100:2010 – Safety of machinery - General principles for design -Risk assessment and risk reduction)

� EN ISO 12100:2010Risk assessment is a series of logical steps to enable, in a systematic way, the examination of the risks associated with machinery. Risk assessment is followed where necessary by risk reduction

� Risk Assessment Methods & Systems

120

Overview of Risk Assessment Methods

Risk Assessment

� A comprehensive estimation of the probability and the degree of the possible injury or damage to health in a hazardous situation in order to select appropriate safety measures

Purpose

� Identify hazards with equipment� Estimate the risk� Evaluate the risk� Determine countermeasures to reduce/ eliminate risk

03-06-2013

61


Overview of Risk Assessment Methods

121


122

Methods for Hazard Identification & Analysis

Methods for Risk Assessment can be grouped into 2 p rinciple types

� 1. Deductive methods: – The final event is assumed and the events which could cause this final event are

then sought– Fault Tree Analysis

� 2. Inductive methods: – The failure of a component is assumed. The subsequent analysis identifies the

events which this failure could cause– Preliminary Hazard Analysis– Risk Matrix– HAZOP

03-06-2013

62


123

Fault Tree Analysis

� Fault tree diagrams (or negative analytical trees) are logic block diagrams that display the state of a system (top event) in terms of the states of its components (basic events)

� An undesired effect is taken as the root ('top event') of a tree of logic

� Each situation that could cause that effect is added to the tree as a series of logic expressions


124

Preliminary Hazard Analysis

� An initial system safety study of potential system hazards

Risk = Probability x Severity = R = P x S

� Identify, for all phases of life of a machine, the hazards which could lead to an accident

� Qualitative evaluation of the degree of possible injury or damage to health� Methods which can be used to evaluate the risk include:

– Risk Matrix– Hazard Rating number

03-06-2013

63


125

Risk Matrix

� This method is based on the definition of risk (A combination of the probability and the degree of the possible injury or damage to health) and the principle of Iso-risk contour

Risk = Probability x Severity = P x S

Iso – Risk Contours

PROBABILITYNEVER

0

SE

VE

RIT

Y

R1

R2

R3


126

� The aim with this WRA is to improve your working environment during the change-over and the maintenance which also prevents that you will develop a work-related nuisance.

� Yes/No Questionnaire with the following sections:– Machines– Other kinds of Hazards– Internal transport– Impact on movements, fall– Working positions – Working environment

LEGO Workplace Risk Assessment

03-06-2013

64

� Risk Assessment

127

Points to Remember

� The machine’s risk assessment should cover all phases of its life.

� It should also cover all personnel who will interface with the machine during this life span.

� Take into account correct use and reasonably foreseeable misuse.

– Reasonably foreseeable misuse is defined in EN ISO 12100 as use of a machine in a way not intended by the designer, but which may result from readily predictable human behaviour.

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

128

Safety Validation

03-06-2013

65

� Topics

Safe Guarding

Introduction

129

� Safe Guarding

130

Finding a BalanceReduce Risks as far as is reasonably practical

Machinery

Tolerability Factors

Quality/Rigour

Safety FunctionsProbability

(assuming failure of safety function)

Consequences

Safety Requirements

03-06-2013

66

� Safe Guarding

131

� Safe Guarding

132

03-06-2013

67

� Safe Guarding

Die

Stripper plate

133

� Safe Guarding

134

03-06-2013

68

135

� Safe Guarding

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

136

Safety Validation

03-06-2013

69

� Safety Components

137

� Safety components are the means by which we can apply appropriate safety to machinery in a practical sense

� Through on-going technological advancements we have more and more flexibility in the way we apply safety to machinery

� This allows us to produce more productive and user friendly machinery and production lines

� More importantly we can now manufacture SAFER machinery and production lines

Overview

Safeguarding

Guards

Safety Devices


Safeguards are provided to protect persons from hazards which cannot be removed or designed out

Two types of safeguards exist, guards and protective devices

Guards are defined as:� “physical barrier, designed as part of the machine, to

provide protection.” EN ISO 12100

Protective Devices are defined as:� “safeguard other than a guard” EN ISO 12100

Overview

138

Safeguarding

Guards

Safety Devices

03-06-2013

70


139

Safety component means a component:

� Which serves to fulfil a safety function, and

� Which is independently placed on the market, and

� The failure and/or malfunction of which endangers the safety of persons, and

� Which is not necessary in order for the machinery to function, or for which normal components may be substituted in order for the machinery to function.

� Annex V Provides a list of Safety components

Machinery Directive 2006/42/ECNew Definition: Safety Component Article 2(c)

Safeguarding

Guards

Safety Devices


140

� Removable mechanical transmission devices guards� Persons detection protective devices d� Power-operated interlocking movable guards� Logic units to ensure safety functions� Valves with additional means for failure detection

intended for the control of dangerous movements on machinery

� Guards and protective devices designed to protect persons against moving parts involved in the process on the machinery

� Monitoring devices for loading and movement control in lifting machinery

� Restraint systems to keep persons on their seats� Emergency stop devices� Two-hand control devices

Indicative listing of Safety Components covered by the Machinery Directive 2006/42/EC in Annex V:

Safeguarding

Guards

Safety Devices

03-06-2013

71


141

This standard has been modified to take into consideration the changes to the fixing requirements of the new Machinery Directive.The standard defines the types of Guards as:� Fixed Guards� Enclosing Guards� Distance Guards� Movable Guards� Power Operated Guards� Self Closing Guards� Control Guards� Adjustable Guards� Interlocking Guards� Interlocking Guards with Guard Lock

EN 953 Safety of Machinery - General requirements fo r the Design of Fixed and Movable Guards

Safeguarding

Guards

Safety Devices


142

� Climbing on guards shall as far as practicable be inhibited by design

� Guards must offer adequate viewing to minimise the need to remove them

� Guards must be designed to prevent parts of the body from reaching danger zones

� Verification that guards comply shall be by measurement

� Safety Distance Tables– Low Risk

– Where there is a low risk from a friction or abrasion hazard

– High Risk– Where there is a high risk from an

entanglement hazard

General Requirements

Safeguarding

Guards

Safety Devices

03-06-2013

72


143

Fixed Guard� Must be kept in place permanently e.g. welded� Held with fasteners making it impossible to remove

without the use of tools (not with a coin or nail file)� Where possible be unable to remain in place without

their fixings

Fixed Guard Types� Enclosing Guard� Distance Guard

Fixed Guard

Fixed Guarding

Interlocking Guards

Adjustable Guards

Moveable Guards

Interlocking Guards with Guard Locking

Guards


144

Fixed Guard Example

03-06-2013

73


145

Movable Guard � Guard generally connected by mechanical means

(hinges or slides) to the machine frame or an adjacent fixed element

� Can be opened without the use of tools

Movable Guard Types� Power Operated Guard � Self Closing Guard� Control Guard

Moveable Guard

Fixed Guarding

Interlocking Guards

Adjustable Guards

Moveable Guards


Guards


146

Moveable Guard Example

03-06-2013

74


147

Adjustable Guard� A guard which is adjustable as a whole or

incorporates adjustable parts� Allow access to areas only where it is strictly

necessary� Adjustable manually or automatically� Reduces the risk of ejection� Not be easily removed� Easily adjustable

without the use of tools

Adjustable Guard

Fixed Guarding

Interlocking Guards

Adjustable Guards

Moveable Guards


Guards


148

Adjustable Guard Example

03-06-2013

75


149

Guard associated with an interlocking device so that:

� Hazardous machine functions covered by the guard cannot operate until the guard is closed

� A stop command must be given when the guard is open

� Closing the guard does not itself initiate the operation of the moving parts within the danger zone

Interlocking Guard

Fixed Guarding

Interlocking Guards

Adjustable Guards

Moveable Guards


Guards


150

Interlocking Guard Example

03-06-2013

76


151

Guard associated with an interlocking device and a guard locking device so that:

� Parts must be prevented from moving while the danger zone is being accessed

� A stop command must be given when the guard is open

� Closing and locking the guard does not itself initiate the operation of the moving parts within the danger zone

Interlocking Guard with Guard Locking

Fixed Guarding

Interlocking Guards

Adjustable Guards

Moveable Guards


Guards


Interlocking Guard with Guard Locking Example

152

03-06-2013

77


153

� Interlocking Devices

� Light Curtains

� Safety Mats

� Two Hand Control

� Safety Scanners

� Mechanical Trip Devices

� Safety Strips

Safety Devices

Safeguarding

Guards

Safety Devices


154

“Mechanical, electrical or other type of device, the purpose of which is to prevent the operation of machine elements under specified conditions (generally as long as a guard is not closed)”

Guarding Associated with Interlocking Devices

� Movable Guard

� Interlocking Guard

� Interlocking Guard with Guard Locking

Interlocking Devices


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop

Safety Control Systems

Safety Devices

03-06-2013

78


Interlocking Devices Examples

155


156

Application

� Regular Access is required to hazardous areas� Only suitable if there is no risk of material being

ejected from the machine

Light Curtains


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices

03-06-2013

79


157

Three types available

� Type I� Type II� Type III

Two Hand Controls are only of value to one operator

Other safeguards should be considered when appropriate

Two Hand Control


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices


Two Hand Control

158

03-06-2013

80


159

Pressure Sensitive Mats� Cease dangerous functions of machinery when

pressure is applied� Placed around hazardous areas of machines� Used in conjunction with other safety measures� Can withstand large forces

Safety Sensors - Safety Mats


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices


160

Safety Laser Scanners � 180 degree scan� Safe zone� Warning zone� Trip zone� 2 Dimensional Scan� Programmed to “see” static objects in its path� Suitable for unmanned guided vehicles or areas

around large machinery

Safety Sensors - Safety Scanners


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices

03-06-2013

81


161

Emergency StopOverview


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices� Positive Mechanical Action� An actuator that performs an emergency stop

command must remain latched-in� To reset emergency stop command the actuator will

need to be (unlatched)� The control device that generates the emergency

stop signal must maintain the emergency stop command until it is reset

� Resetting the control device shall only be by a manual action

� Resetting the control device shall not by itself create a restart


162

Emergency StopThree Categories of Stops (IEC 60204-1 & NFPA 79)


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices� Category 0

“Stopping by immediate removal of power to the machine actuators (I.e. an uncontrolled stop)”

� Category 1“a controlled stop with power available to the

machine actuators to achieve the stop and then removal of power when the stop is achieved”

� Category 2“a controlled stop with power left available to the

machine actuators”

Category 0 & Category 1 are Emergency Stops

03-06-2013

82


163

Emergency StopActuators Types


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety DevicesDifferent forms of Emergency Stop Actuators� Mushroom push-buttons� Wires, Ropes� Foot pedals� Handles


164

Emergency StopColours


Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety DevicesEmergency Stop Colours

� Actuator Colour – Red� Background Colour – Yellow

Additional Items to consider:� Labels� Marker flags on wires or ropes

03-06-2013

83


165

Safety Relays� Suitable for all safety levels

Safety PLC� Complex Safety Solutions

SafetyBUS� Simplifies the implementation of safety systems



Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices


166

Safety Relays� Suitable for all safety levels of lower complexity

Safety PLC� Complex Safety Solutions� Extremely Flexible, with diagnostic value

Safety Fieldbus systems � Simplifies the implementation of safety systems� De-centralised network of safety inputs and outputs



Safety Sensors

Two Hand Control

Light Curtains

Emergency Stop


Safety Devices

03-06-2013

84


Safety Control Systems Examples

167


168

Additional Measures

03-06-2013

85


169

On Completion of a Risk Reduction it may be:� Necessary to provide additional safety

measures due to residual risk

Additional Measures can include:� Personal Protection Equipment� Safe Working Procedures� Fixed Warning Signs� Training

Additional Measures

“Okay, I’ve put the warning signs inside the grinder. You can turn it on now.”


170

Additional Measures

03-06-2013

86

� Can you identify each guard type?

Fixed Distance Guard Self-Closing Guard

Adjustable Guard Tunnel Guard

171

� Topics

Legislation

CE Marking


Risk Assessments

Safe Guarding


Safety Components

172

Safety Validation

03-06-2013

87

� Topics

Safety Validation

Introduction to Safety Validation

173

� Introduction to Safety Validation

Overview

Definition:A Safety Validation process is a documented examination of a machine, process or piece of work equipment carried out under the guidelines of national and/ or international standards comparing the actual status with a desired result

Purpose:The purpose of the Safety Validation is to check for proper implementation of safety design by verifying the machine safety functions with the requirement specifications

Validation can be delivered as a service as part of system implementation project or as a stand-alone service assuring machinery safety

174

03-06-2013

88


Requirements for Validation

Tasks performed for validation depend on the machine in question and the life cycle but may include:

� Review of machine risks

� Mechanical guarding examination

� Safety related Control-circuit examination

– Electrical examination

– Fluid power system examination

� Safety related Software examination

� Functional safety test

� CE Marking Validation

– Installation examination (EMC, LVD, other EU directives)

– EHSR examination (Noise, Ergonomic,…)

175


Relevant Standards

IEC 62061: Safety of machinery – Functional safety of safety-related electrical,electronic and programmable electronic control systems

ISO 13849-1 Safety of machinery - Safety related parts of control systems Part 1: General Principles for Design

ISO 13849-2 Safety of machinery - Safety related parts of control systems Part 2: Validation

EN 60204-1:2006 Safety of machinery – Electrical equipment of machines – Part 1: General requirements

IEC 61508-2 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems

176

03-06-2013

89


Relevant Legislation

� Europe

– EC Directive 2006/42/EC Annex I (Machinery Directive)

– EC Directive 2009/104//EC Annex I (Use of Work Equipment Directive)

– EC Directive 2006/95/EC (Low Voltage Directive)

– EC Directive 2004/108/EC (EMC Directive)

177


178

Machinery Directive

� All machinery being placed into Service in the EC must comply with the essential health and safety requirements (EHSR’s) listed in Annex I of the Machinery Directive 2006/42/EC.

� This applies to assemblies of machines, complete machines and partly completed machines.

� The manufacturer or the authorised representative is responsible for the compliance of the machine.

� The Essential Health and Safety Requirements (ESHR) validation list outlines the requirements listed in Annex I of the Machinery Directive

03-06-2013

90


179

Use of Work Equipment Directive (UWED)

� A UWED Validation is an assessment of a machine to ensure conformance to the requirements of the Use of Work Equipment Directive (UWED) 2009/104/EC.

� The directive states that users of machinery must establish compliance of all work equipment irrespective of age.

� It is especially applicable to machines equipment put into service before January 1995 (pre Machinery Directive) or work equipment that is not subject to the Machinery Directive.

� The UWED has been transposed into national law in the EU member states. However, each state is free to increase local requirements and add additional obligations. Therefore, check compliance of the checklist with the applicable national law also.

� Technical documentation of the machine is required for the Validation.


180

Electro Magnetic Compatibility (EMC)

� Compliance verification of each relevant component� Adequate installation according to the manufacturers’ requirements� Validated on site at the existing machine� A checklist can be created for use on site

Critical issues may be:� Grounding and filtering on frequency converters� Surge suppressors on contactors and valves� Grounding on electronic components like controller, HMI� Shielding � Separated cables for run of power and control signals � Proper size and star topology on grounding and bonding� Grounding of metal components (wiring duct, cabinets, …)� Shielding of high frequency cables of drives/ motors� Correct fixation of electrical connections and earth� Large-area connection of shielding

03-06-2013

91


181

Low Voltage Directive (LVD)

Can Be used for Machinery Directive 2006/42/EC or LVD 2006/95/ECAccording to IEC 60204-1: chapter 18 the following verifications shall be completed:,

The verifications shall always include the items a), b) and f) and may include one or more of the items c) to e):

a) verification that the electrical equipment complies with its technical documentation;

b) in case of protection against indirect contact by automatic disconnection, conditions for protection by automatic disconnection shall be verified according to 18.2;

c) insulation resistance test (see 18.3);d) voltage test (see 18.4);e) protection against residual voltage (see 18.5);f) functional tests (see 18.6).


182

Other Validation Requirements

Pneumatic Validation� The construction and design of the pneumatic equipment shall be validated against

the requirements of the Machinery Directive (MD), the standard ISO 4414: Pneumatic fluid power - general rules and safety requirements for systems and their components, and may also include the additional pneumatic requirements of the specific machinery standard(s)

Hydraulic Validation� The construction and design of the hydraulic equipment shall be validated against

the requirements of the Machinery Directive (MD), the standard ISO 4413: Hydraulic fluid power - general rules and safety requirements for systems and their components: and the additional hydraulic requirements of the specific machinery standard(s)

03-06-2013

92


183


Mechanical Safety Guarding Validation� The construction and design of the mechanical safety gates and fences shall be

validated against the requirements of the Machinery Directive (MD) and the applicable standards – EN 953: Safety of machinery – Guards – General requirements for the design

and construction of fixed and movable guards– ISO 13857: Safety of machinery - Safety distances to prevent hazard zones

being reached by upper and lower limbs– EN 349: Minimum gaps to avoid crushing of parts of the human body– The additional requirements of the specific machinery standard(s) may also be

required


184


Ergonomics Validation� Assesses the construction and design of the machine and the working issues and

positions will be validated. All negative body burdens and stresses for the operator shall be discovered. (EN 13861 Safety of machinery - Guidance for the application of ergonomics standards in the design of machinery)

Noise Validation� Noise measurements can be completed according to several standards also

depending on the size of the machine and the environment it is located(EN 11200, EN ISO 3744)

PL/SIL Validation� Verification that the installed Safety Control system meets the required PL/SIL.

(PL : ISO 13849-1, SIL: IEC 62061)

03-06-2013

93


185

EN 13861 Table A.1 Example

CM

SE

®, I

ndur

aNE

T p®

, PA

S40

00®, P

AS

cal®

, PA

Sco

nfig

®, P

ilz®, P

IT®,

PLI

D®, P

MC

prot

ego®

, PM

D®, P

MI®

, PN

OZ

®,

Prim

o®, P

SE

N®, P

SS

®, P

VIS

®, S

afet

yBU

S p

®, S

afet

yEY

E®, S

afet

yNE

T p®

, the

spi

rit o

f saf

ety®

are

regi

ster

ed a

nd p

ro-

tect

ed tr

adem

arks

of P

ilz G

mbH

& C

o. K

G in

som

e co

untr

ies.

We

wou

ld p

oint

out

that

pro

duct

feat

ures

may

var

y fr

om

the

deta

ils s

tate

d in

this

doc

umen

t, de

pend

ing

on th

e st

atus

at t

he ti

me

of p

ublic

atio

n an

d th

e sc

ope

of th

e eq

uipm

ent.

We

acce

pt n

o re

spon

sibi

lity

for t

he v

alid

ity,

accu

racy

and

ent

irety

of t

he te

xt a

nd g

raph

ics

pres

ente

d in

this

info

rmat

ion.

P

leas

e co

ntac

t our

Tec

hnic

al S

uppo

rt if

you

hav

e an

y qu

estio

ns.

Keep up-to-date on Pilzwww.pilz.com.mx

Date post:	13-Dec-2015
Category:	Documents
Upload:	desiderio-cast
View:	224 times
Download:	3 times

Step 1_Lego_Day Training Vers 1.pdf

Documents