CEN/TC 198 Date: 2010-05 EN 1010-5:2005/FprA1:2010 CEN/TC 198 Secretariat: DIN Safety of machinery Safety requirements for the design and construction of printing and paper converting machines Part 5: Machines for the production of corrugated board and machines for the conversion of flat and corrugated board Sicherheit von Maschinen Sicherheitsanforderungen an Konstruktion und Bau von Druck- und Papierverarbeitungsmaschinen Teil 5: Wellpappenerzeugungs-, Flach- und Wellpappenverarbeitungsmaschinen Sécurité des machines Prescriptions de sécurité pour las conception et las construction de machines d impression et de transformation du papier Partie 5 : Onduleuses et machines de transformation fu carton plat et du carton ondulé ICS: Descriptors: Document type: European Standard Document subtype: Amendment Document stage: Unique Acceptance Procedure Document language: E T:\DUP\76 NORMUNG\CEN\TC198\WG1\Normenreihe_1010\1010-5 Wellpappenmaschinen\NewMachDir\12_Änderung_Mai2010\FprEN_1010-5_May2010.doc STD Version 2.3a
Foreword This document (EN 1010-5:2005/FprA1:2010) has been prepared by Technical Committee CEN/TC 198 Printing and paper machinery - safety, the secretariat of which is held by DIN. This document is currently submitted to the Unique Acceptance Procedure. 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 EC Directive(s). For relationship with EC Directive(s), see informative Annex ZB, which is an integral part of this document. 2
Replace in the whole document All references to EN 1010-1 (including references to pren 1010-1) By EN 1010-1:2004+A1:2010 1 Scope Replace the 4 th and 5 th indent hand-fed platen machines for cutting and creasing; automatic platen machines for cutting and creasing; with stand-alone platen presses, for single stroke mode, dwell mode and continuous operation mode, for cutting and creasing; automatic flatbed punching machines; 2 Normative references Normative reference EN 418:1992, Safety of machinery Emergency stop equipment, functional aspects Principles for design. shall be replaced by EN ISO 13850:2007, Safety of machinery Emergency stop. Principles for design Normative reference Replace "EN 1050:1996, Safety of machinery Principles for risk assessment" with "EN ISO 14121-1:2007 Safety of machinery Risk assessment Part 1: Principles". Add the following references Add "EN 983:2009, Safety of machinery - Safety requirements for fluid power systems and their components - Pneumatics;" Add "EN 953:1997+A1:2009, "Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards 3
Add "EN ISO 13849-1:2008, Safety of machinery Safety related parts of control systems General principles for design". Add "EN 1760-2+A1:2009, Safety of machinery - Pressure sensitive protective devices - Part 2: General principles for the design and testing of pressure sensitive edges and pressure sensitive bars". Add "EN ISO 13857:2008, Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs (ISO 13857:2008)". Add "ISO 14120, Safety of machinery Guards General requirements for the design and construction of fixed and movable guards" Add "ISO 14121-1, Safety of machinery Risk assessment Part 1: Principles". Add "EN 62061:2005, Safety of machinery Functional safety of safety-related electrical, electronic and programmable electronic control systems (IEC 62061:2005)". 3 Terms and definitions Add the following terms 3.23 point of operation area of the press in which the process (such as diecutting, embossing, foil stamping, printing, etc.) is being performed 3.24 protective device safeguard other than a guard NOTE etc.) Examples of protective devices include, but are not limited to, hold-to-run controls, two-hand controls, ESPDs, 3.25 trip bar protective bar that, when pushed, activates the interlocking safety system of the machine NOTE A trip bar can be a metal bar or a pressure sensitive edge 3.26 stand-alone platen press self contained machine not intended to be used as part of an integrated manufacturing system 4
4 List of significant hazards Substitute the following sections of table 1: Safety measures: reference to clauses in Hazards Danger zone This standard EN ISO 12100-1: 2003 Mechanical hazards crushing shearing cutting or severing entanglement drawing-in trapping impact ejection of high-pressure fluids EN 1010-1: 2004 Manually-fed platen presses danger points created by closing movement impacts caused by platen 5.5.1 excess of stopping time 5.5.4.3 5.5.1, 5.5.3 5.2.10, 5.2.10.2, 5.2.6.1.1 Avoiding direct or pending hazardous situations Corrugating board production machines Folding box gluer machines Inline machines Manually-fed platen presses Automatic flatbed punching machines Tube winding machines 5.2.1.3 to 5.2.1.5, 5.2.16.2, 5.2.3.9 5.3.6.4 5.4.1.2, 5.4.1.6 5.5.3, 5.5.4, 5.5.6, 5.5.7, 5.5.8 5.6.6.3, 5.6.6.7, 7.1.5.1 5.7.8 5.2.7.2 Failure, malfunction of control system Faults or failures in safety Manually-fed platen presses control system laser scanners 5.5.1 5.5.4 5
5 Safety requirements and/or measures Replace entire clause 5.5 by the following 5.5 Manually-fed stand-alone platen presses, for single stroke mode, dwell mode and continous operation mode for cutting and creasing Safeguarding shall be provided in those areas where it is recognized that operators are exposed to significant hazards. The guarding requirements of EN 1010-1 apply. Guard construction shall meet the requirements of EN 953. All platen presses shall have trip bar(s) (see 5.5.3) or other protective devices (see 5.5.4) located where access to a hazard is possible. 5.5.1 General safeguarding requirements On machines wider than 1.6 m the impact hazard created by the movable platen while opening shall be guarded by the use of a knee bar (See Figure 21, Item 7).The length of the knee bar shall be equal to or greater than the width of the movable platen. The knee bar shall be constructed such that it will retain its shape to ensure actuation of the trip function throughout its length. With the movable platen in the open position, the clearance between the knee bar and front surface of the movable platen shall be at least 120 mm (see figure 21). All mechanical trip bars shall be provided with a switch mounted on each end of the trip bar. The signals of the switches allocated to the individual trip device shall be processed separately. The conductor cables connecting the switches shall be physically separated and shall be located outside the electrical cabinet. Pressure sensitive protective devices shall satisfy the requirements of EN 1760-2. Trip functions using mechanical devices (including knee bars) shall satisfy the requirements of ISO 13856-2 and PL r e of ISO 13849-1 or SIL3 of IEC 62061. Trip functions or presence sensing functions using laser scanners shall satisfy the requirements of PL r d of ISO 13849-1 or SIL2 of IEC 62061. The safety system that controls trip devices and their related signal processing, which safeguard routine and regular access to a hazard point on a manually-fed machine, shall comply with PL r e of ISO 13849-1 or SIL3 of IEC 62061. 5.5.2 Safeguarding side access Various means may be used to prevent access from the sides of the press. Those means include, but are not limited to, the following measures: a) Fixed protective barriers, interlocking guards and/or interlocking tables that prevent access, from any side of the press according to tables 2 and 4 of ISO 13857 Tables shall extend 1000mm from the side frame outward and over the length of the press, reaching from the front edge of the open position of the moveable platen to at least 250 mm behind the backward edge of the trip device. See figure 21 and 24. b) Laser scanners meeting the requirements of 4.3. provided on both sides of the platen with the scanned area being at a distance of 200 mm minimum and 250 mm maximum (measured from the beginning of the scanned area). The size and shape of the scanned areas on the sides shall be as shown in Figure 25a. Access between the laser scanners and the machine housing from the front and rear of the platen press to the danger zones shall be prevented by fixed guards (see Figure 25b). 6
Means of preventing access to the dangerous zone between the movable platen and punching plane other than those defined at a) and b) shall provide an equivalent level of protection. 5.5.3 Additional requirements for manually-fed platen presses in dwell or continuous operation mode One of the following configurations shall be provided: a) An interlocked protective device (U-shaped trip bar) that covers both the sides and the top of the point of operation shall be provided, (see Figure 21 and Figure 22). The platen trip bar shall pass under the U- shaped trip bar in its operating position with a clearance of 12 mm maximum (see Figure 23). The minimum distance shall be maintained throughout the range of all operating temperatures. If the stopping distance specified by the manufacturer is exceeded, the control system shall prevent an additional cycle until the brake/clutch system is adjusted. This requirement shall be met at all speeds of the machine. The stopping distance shall be monitored at the end of each cycle. NOTE A cycle begins in the stopped position and is completed when the platen returns to the stopped position. The U-shaped trip bar pivot shall be rated such that a force of 20 N is sufficient for actuation and triggering of the clutch/brake device. The pivot of the U-shaped trip bar shall be below the punching plane (see Figure 24). For manually-fed machines operated in the automatic (timer-controlled) mode an additional trip bar, usually located on the top edge of the movable platen, shall also be provided. This trip bar, when actuated, stops platen motion. For machines greater than 1 m wide, a presence-sensing device that will detect the presence of a person on the moveable platen shall be provided. If a person is detected, start-up shall be prevented. b) Laser scanner in accordance with 5.5.4. Dimensions in millimetres Key 1 trip bar on movable platen 5 front edge of interlocking table 2 U-shaped trip bar on fixed platen 6 interlocking table 3 punching plane 7 knee bar 4 lower edge of punching plane Figure 21 Interlocking tables 7
Dimensions in millimetres Key 1 platen 2 platen trip bar 3 die mounting surface 4 protective device Figure 22 Safety protection for point of operation (press open) Dimensions in millimetres Key 1 platen trip bar 2 protective device in operating position Figure 23 Relationship between safety device and platen trip bar 8
Dimensions in millimetres Key 1 trip bar on movable platen 4 horizontal part of trip bar 2 U-shaped trip bar on fixed platen 5 knee bar 3 punching plane Figure 24 Trip bars 5.5.4 Laser scanners 5.5.4.1 General Three laser scanners, one on each side and one on the top, shall be used to detect entry from the top and sides and shall be integrated with the safety system of the machine. For the presence-detection of person at presses with a platen wider than 1m, a laser scanner mounted on the top of the fixed platen (see scanned area on the top (3) in Figure 25) shall be provided. The gap between the scanned area and the movable platen in fully open position shall be a maximum of 350 mm. When the press is in motion and the presence of a person is detected, the machine shall stop with a stopping distance, measured at the top of the platen, not exceeding 120 mm. The further movement of the platen shall require a reset and not automatically restart. When the platen press is stopped, and the presence of the person is detected by the laser scanner, an unexpected start-up shall be prevented and the press shall not automatically start. Laser scanners shall meet the requirements of IEC 61496-1 and IEC 61496-3. Dimension in millimetres 9
Key 1 movable platen 4 fixed guard 2 scanned area on the top 5 scanner for the scanned areas on the sides 3 scanner for the scanned areas on the top 6 scanned areas on the sides Figure 25a,b Platen press equipped with laser scanner 5.5.5 Platen presses with dwell mode (timer-controlled operation) On platen presses with timer-controlled operation, the open dwell time shall not exceed 10 s. The warning requirements of 5.5.11.1 shall be met. 10
5.5.6 Stopping distance The stopping distance of the platen press shall not exceed 120 mm. This shall be measured between the top edges of the moveable and fixed platens. On manually-fed platen presses, if the stopping time or stopping distance specified by the manufacturer to meet the requirement of the previous paragraph is exceeded, start-up shall be prevented. The stopping distance shall be monitored at the end of each cycle. 5.5.7 Main drive braking and clutch/brake mechanism Manually-fed platen presses shall be equipped with a fail-safe clutch/brake mechanism to disconnect the stored energy in the flywheel from the moving platen and bring the platen to a stop thereby preventing press motion. On presses with flywheels, this mechanism shall be located on the fly-wheel shaft. When using a clutch/brake mechanism, electric power supply failure, or loss of pneumatic or hydraulic pressure, shall activate the brake and disengage the clutch (i.e. fail-safe). The brake shall be of sufficient strength to maintain the platen in the position in which it stopped due to the failure. If a pneumatic system is used for the combined clutch and brake system (stopping closing movement of the platen) two pneumatic valves shall be provided. The pneumatic system shall meet PL r e of ISO 13849-1. The pneumatic system shall comply with the requirements of EN 983. 5.5.8 Flywheels Flywheels shall be enclosed or otherwise guarded in accordance with EN 1010-1. A flywheel retention device shall be provided to ensure that the flywheel will not come off its shaft unexpectedly. NOTE A key in a keyway is not considered to be a flywheel retention device. 5.5.9 Controls 5.5.9.1 Pushbuttons 5.5.9.1.1 General Pushbuttons shall meet the requirements of EN 1010-1 and 5.5.9.1.2 5.5.9.1.2 Emergency stop On manually-fed platen presses, an emergency stop pushbutton shall be provided on the motion control station. The emergency stop control shall meet the requirements of EN 1010-1. 5.5.9.2 Other controls 5.5.9.2.1 Control to permit manual movement of machine A control shall be provided to release the brake and engage the clutch, if necessary, to permit manual movement of the press. This control shall only function when the motion of the main drive motor is inhibited. 5.5.9.2.2 Selector switches Multiple-position selector switches may be used in conjunction with another motion control, and shall not be an alternative or substitute for the pushbutton controls defined in EN 1010-1. 11
5.5.10 Automatic stop After an automatically-initiated stop, the press shall not automatically start. The operator shall go through the normal starting sequence, in order to initiate press motion. NOTE An automatically-initiated stop may be the result of the activation of a guard interlock, stop after the scanner detects an obstruction. 5.5.11 Signals and warning devices 5.5.11.1 Indicator light for automatic mode A flashing red indicator light shall be provided in the operator's view clearly indicating when the machine is in dwell mode. 6 Verification of safety requirements and/or measures Replace in clause 5 "Table 2" with "Table 3". Replace in table 3 "Hand-fed platen machines" with "manually-fed platen presses" 7 Instruction for use Replace the entire clause 7.1.4 by the following 7.1.4 Manually-fed platen machines 7.1.4.1 The instruction handbook shall state: that safety devices (e.g. trip bars and laser scanners) and brake shall be checked daily for proper operation, removable safety test trip with the press set at its maximum operating speed; that test results of the daily testing of the safety devices should be recorded; that checking shall be carried out when the operating temperature of the machine is reached; that where the function of the devices is inappropriate, the machine shall be closed down until defects have been eliminated; procedures for safe routine adjustment, cleaning, inspection and maintenance of equipment, including power isolation procedures). 12
Add a new Annex ZB: Annex Z (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association to provide a means of conforming to Essential Requirements of the New Approach Directive 2006/42/EC on machinery. Once this standard is cited in the Official Journal of the European Communities under that Directive and has been implemented as a national standard in at least one Member State, compliance with the normative clauses of this standard confers, within the limits of the scope of this standard, a presumption of conformity with the relevant Essential Requirements of that Directive and associated EFTA regulations. WARNING Other requirements and other EU Directives may be applicable to the product(s) falling within the scope of this standard. 13