Repositorio Institucional de Documentos
Abstract
En esta tesis se habla de los diferentes cambios que se sugieren en la nueva Directiva 2006/42/CE de la ultima 98/37/CE. Cambios como responsabilidades legales, manera de hace unas evaluaciones de riesgo y qué tipo de problemas y cómo resolverlos, ejemplos de documentación y cómo llenarla y más temas acerca de esta nueva Directiva. La nueva Directiva se aplicara a partir del 29 de diciembre de 2009. Durante este tiempo entre 2006 y 2009 era el momento de hacer los cambios en las máquinas y los fabricantes adaptar sus máquinas a la nueva Directiva. Esta Directiva se creó mediante la Comision Europea, y más tarde el Parlamento y el Consejo Europeo aprobaron estos textos como las Directivas de Normalización Europea. Esta Directiva 2006/42/CE ha sido creado para el uso de los diferentes países de Europa. Los países incluidos son los 27 países que participan en la Unión Europea y también Liechtenstein, Islandia y Noruega. Uno de los cambios más importantes propuestos por la presente Directiva es que en el caso de nadie sepa quién es el fabricante de las máquinas, automaticamente el propietario en ese momento va a tiene la responsabilidad legal de esa máquina. Muchos dispositivos se incluyen en esta nueva Directiva, pero la principal diferencia es la inclusión de ascensores. También muchos dispositivos están excluidos del ámbito de aplicación de la Directiva como dispositivos eléctricos y electrónicos y equipos de alta tensión, así. Es muy importante hablar de normas, porque son la manera de hacer que una máquina o equipo de seguridad y después de que saben qué tipo de opciones se puede tomar para asegurarse de que la maquina es de seguridad o en el caso del mosto ¿cuál es el grado de daño que la máquina puede dar a nosotros. Egido Echeverría, María Aránzazu; Aznar Colino, Eduardo
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28. 05. 2013 Savonia University of Applied Sciences Analytical guide of the changes suggested by Directive 2006/42/EC on the safety of machines Maria Aranzazu Egido Echeverria Ingenieria Tecnica Industrial, esp. Electronica Industrial Coordinadores: Eduardo Aznar y Arto Toppinen
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3 Field of Study Technology, Communication and Transport Degree Programme Degree Programme in Information Technology Author(s) Maria Aranzazu Egido Echeverria Title of Thesis Analytical guide of the changes suggested by Directive 2006/42/EC on the safety of machines. Date 28/05/2013 Pages/Appendices 160 Supervisor(s) Mr. Arto Toppinen Client Organisation/Partners Savonia University of Applied Sciences Abstract This thesis talks about the different changes that are suggested by the new Directive 2006/42/EC from the last one 98/37/EC. Changes like legal responsabilities, way to makes a risk evaluations and what kind of problems and how to solve, examples of documentation and how to fill it and more topics about this new Directive. The new Directive was effective from 29 of December of 2009. Time between 2006 and 2009 was time to makes changes at machines and manufacturers adapt their machines to the new Directive. These Directives was created by the European Comision, and later Parliament and European council pass this texts like Directives for European standarization. This Directive 2006/42/EC is created for the use of the different countries of Europe. Countries included are the 27 countries that take part at the European Union and also Liechtenstein, Island and Norway. One of the most important changes suggested by this Directive is that in the case of noone know who is the manufacturer of the machines, automately the owner at that moments is going to has the legal responsability of that machine. Many devices are included in this new one Directive but the main difference is the inclusion of Lifts. Also many devices are excluded from the scope of the Directive like electric and electronic devices and high voltage equipments as well. Is very important to talk about standards, because are the way to make a machine or equipment safety and after that know what kind of options can you take to be sure that a machines is safety or in the wort case what is the grade of damage that the machine can give to us. At the last part of this Thesis I uncluded squematic examples of the different electronic devices that are used for the safety at machines.
4 Keywords Changes safety machine directive
5 Koulutusala Technology, Communication and Transport Koulutusohjelma Degree Programme in Information Technology Telijä Maria Aranzazu Egido Echeverria Työn nimi Analyyttinen ohje muutoksista koneiden turvallisuuteen direktiivin 2006/42/EC nojalla Päiväys 28/05/2013 Sivumäärä/liitteet 160 Työn valvoja Mr. Arto Toppinen Yritys Savonia University of Applied Sciences Tiivistelmä Tämä työ käsittelee erilaisia muutoksia uuden Direktiivin 2006/42/EC ja vanhan Direktiivin 98/37/EC välillä. Käsittelen aiheita tavat tehdä riskiarvioita, erilaiset ongelmat ja ratkaisut, esimerkkejä dokumentoinnista ja muuta tietoa uudesta direktiivistä. Uusi direktiivi astui voimaan 29. Joulukuuta 2009. Vuosien 2006 ja 2009 välisenä aikana valmistajien tuli muokata koneista uuden direktiivin mukaisia. Direktiivi valmisteltiin Euroopan komissiossa ja myöhemmin Euroopan parlamentti ja Eurooppa-neuvosto hyväksyi sen. Direktiivi on luotu useiden eri maiden käyttöön Euroopassa. Direktiivi on käytössä EU-maiden lisäksi Liechtensteinissä, Islannissa ja Norjassa. Yksi tärkeimpiä ehdotuksia tässä direktiivissä on, että jos koneen valmistajaa ei tiedetä on koneen senhetkinen omistaja laillisesti vastuussa kyseisestä koneesta. Monia laitetta on lisätty direktiivin piiriin, mutta tärkein muutos on hissien liittäminen direktiiviin. Myös monia laitteita on suljettu soveltamisalan ulkopuolelle kuten sähkölaitteet, elektroniset laitteet ja korkeajännite varusteet. On erittäin tärkeää puhua standardeista koska sillä tavoin saadaan koneista ja varusteista turvallisempia. Lisäksi käyttäjä tietää minkälaisilla asetuksilla kone on turvallinen sekä tiedetään minkälaista vahinkoa kone voi aiheuttaa pahimmassa tapauksessa. Viimeisessä osiossa esittelen esimerkki kaavioita erilaisista elektronisista turvalaitteista koneissa.
6 Avainsanat Muutokset turvallisuus kone direktiivi
7 Summary INTRODUCTION.......................................................................................................................10 CHAPTER 1. DIFFERENCES BETWEEN USER DIRECTIVE AND MANUFACTURE DIRECTIVE................................................................................................................................12 CHAPTER 2. NEW MACHINES DIRECTIVE (2006/42/EC)..................................................15 1. Legal analysis......................................................................................................................15 2. Territorial scope for the application of the new directive...................................................17 3. Scope for the technic application of the new directive........................................................17 3.1 Excluded from the application scope............................................................................18 3.2 Machine definition........................................................................................................19 3.3 Partlycompletedmachinery definition........................................................................20 3.4 Interchangeable equipment definition...........................................................................20 3.5 Safety component definition.........................................................................................20 3.6 Lifting accessory definition...........................................................................................20 3.7 Boilers ropes and webbing definition............................................................................21 3.8 Removable mechanical transmission device definition................................................21 4. Partlycompletedmachinery...............................................................................................22 5. Security components...........................................................................................................26 6. Responsibilities...................................................................................................................27 6.1 Market surveillance – article 4......................................................................................28 7. Annex I. News.....................................................................................................................28 7.1 General beginnings. News.............................................................................................29 7.2 Essentials of Safety and health. Paragraph 1. News......................................................31 7.3 Supplementary essential requirements safety and health for some categories of machinery. Paragraph 2. News............................................................................................36 7.4 Supplementary essential to neutralize safety and health hazards due to mobility of the machines. Paragraph 3. News.............................................................................................36 7.5 Supplementary essential requirements of safety and health to neutralize the dangers of lifting operations. Paragraph 4. News.................................................................................38 7.6 Additional essential requirements of safety and health to neutralize the dangers of lifting operations. Paragraph 6. News.................................................................................40 8. Annex IV.............................................................................................................................42 9. Conformity assessment procedures...............................................................................43 9.1 Annex IV procedure......................................................................................................44 9.2 Full quality assurance in accordance with Annex X.....................................................45 9.3 Internal production control in accordance with Annex VII...........................................46
8 9.4 EC type-examination in accordance with Annex IX.....................................................46 10. Frequently asked questions regarding the transition from the Machinery Directive (98/37/CE) to the revised new directive (2006/44/CE)..................................................47 CHAPTER 3. SUBSTANCIAL CHANGES IN MACHINES...................................................51 CHAPTER 4. MACHINERY INSTALATION..........................................................................54 1. General responsibility.........................................................................................................54 2. Installation formed by new and old machines.....................................................................54 3. Is the integration only one machine?...................................................................................55 CHAPTER 5. OTHER APPICALY DIRECTIVES....................................................................58 CHAPTER 6. EN HARMONIZED STANDARDS....................................................................59 1. A new approach...................................................................................................................59 2. Concept...............................................................................................................................60 3. Classification of European harmonized standards............................................................61 4. List of EN standards in type A and B into force.................................................................63 CHAPTER 7. RISK ANALYSIS EN 14121-1...........................................................................65 1. Machine limits definition. Chapter 5 of the standard..........................................................67 2. Identifying dangers, situations and danger events. Chapter 6 of the standard....................67 3. Risk estimation. Chapter 7 of the standard..........................................................................68 3.1 Risk elements................................................................................................................68 3.2 Aspects to consider during the risk estimation..............................................................68 4. Risk assessment. Chapter 8 of the standard........................................................................69 5. Documentation. Chapter 9 of the standard..........................................................................69 CHAPTER 8. RISK EVALUATION. FUNCTIONAL SAFETY BY EN 62061 AND EN 13849...........................................................................................................................................70 CHAPTER 9. EN ISO 13859. SECURITY DISTANCES.........................................................81 1. Safety distances to prevent the access of upper limps. Point 4.2 of the standard...............81 1.1 Reach upwards..............................................................................................................81 1.2 Scope over protective structures...................................................................................81 1.3 Scope in all directions with movement limit.................................................................83 1.4 Scope through openings................................................................................................84 CHAPTER 10. STOP FUNCTION.............................................................................................86 CHAPTER 12. COMERCIAL ELEMENTS OF SAFETY........................................................87 1.Safetyswitches....................................................................................................................87 1.1Safetyswitcheswithoutlockingservices......................................................................87 1.2Non‐contactswitches....................................................................................................88
9 2.Securitymodules.................................................................................................................89 3.Sensibleedges.....................................................................................................................89 4.Safetymats..........................................................................................................................90 5.Safetylasersscanners.........................................................................................................91 6.Handdetectionsafetysensor.............................................................................................91 7.Sensitivecontrols................................................................................................................92 ANEX I . DIRECTIVE 2006/42/CE...........................................................................................93 ANEX II. ELECTRIC SCHEMAS. SAFETY CIRCUITS TYPES BASED ON ROCKWELL EQUIPMENT APPROVED, ESTABISHED BY STANDARD EN ISO 13849.....................155 ANEXIII.REFERENCES................................................................................................................159
16 COMPARATIVEBETWEENOLDANDNEWDIRECTIVE DIRECTIVE98/37/ECDIRECTIVE2006/42/EC Preamblewith25recitals 16articlesin4chapters 9annexes Preamblewith30recitals 29articles 11annexes TABLE1.ComparativebetweenoldandnewDirective. FIGURE 5. Annexes of the Directive 2006/42/EC. ANNEXI Esential requirements aboutsafetyand healthy ANNEXII Conformity statements ANNEXIII CEmarked ANNEXIV Specialmachine requirements ANNEXV Security components ANNEXVI Mount instructionsof machines ANNEXVII Technical reportof machines ANNEXVIII Intermediate control p rocedure ANNEXIX TestCE ANNEXX Totalquality surement ANNEXXI Criterion notification a g enc y ANNEXVI Mount instructionsof machines
17 2. Territorial scope for the application of the new directive The new Directive is beginning in all European countries which take part at the European Union (27 countries), including Romania and Bulgaria from 2007 and also Switzerland, Island, Liechtenstein and Norway. This community of 31 countries is going to be denominated like EES (European Economical Space). FIGURE 6.Application scope of the Directive 2006/42/EC. 3. Scope for the technic application of the new directive The scope for the technic application of the new directive is: Machines Interchangeable equipment Safety components Lift accessories Chains, ropes and webbing Removable devices of mechanic transmission Partly completed machinery Hoists for the lift of people of people and materials
18 With this new Directive, lifts are totally include and will have to comply all the requirements and conditions for machines. This one means that all machines that have the same function of lifts at work have to comply also all the same rules of them. From the point of view about legal systematic, in the future will be only machines and quasi machines, consequently two declarations: from one hand the EC in according to annex II A and on the other hand the incorporation declaration of quasi machines in according to annex II B. In the future the EC declaration will be used by the products which being inside the Directive, like safety components. 3.1 Excluded from the application scope In the new Directive there are more specifications about machines or hardware which are excluded from the application scope. These are: Safety components intended to be used as spare parts to replace identical components and supplied by the manufacturer of the original machinery. Specific equipment which are going to use at fairs and amusement parks. Machines specific for nuclear uses and which fails can emit radioactivity. Arms, included fire arms. Seagoing vessels and mobile offshore units, and machinery installed on board such vessels and units. Machines designed or manufacturing to military or police use. Machines designed or manufacturing which will be temporary used in laboratories. Lifts at mine wells. Machines which are used to lift actors at artistic representations. Are excluded of application these electrical and electronic products: Appliances Audiovisual equipment Information technology equipment Office machines Connection apparatus and low voltage control Electric engines Are excluded also high voltage equipment: Connection apparatus and low voltage control Transformers
19 About transport are excluded: Agricultural and forestry tractors for the risks covered by the Directive 2003/37/EC are excluded machines installed inside them. Motor vehicles and their trailers covered by Directive 70/150/CEE, of 6 of February in 1970 about homologation of engine vehicles and their trailers. Are excluded machines installed inside them? Vehicles covered by Directive 2002/24/EC of Parliament and Council, of 18 of March in 2002 about homologation of engine vehicles with two or three wheels, and their modifications. Are excluded machines installed inside them? Engine vehicles which are used only for competition. Air, water and rail transports, with exclusion of machines that are installed inside them. 3.2 Machine definition An assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application, An assembly referred to in the first indent, missing only the components to connect it on site or to sources of energy and motion, An assembly referred to in the first and second indents, ready to be installed and able to function as it stands only if mounted on a means of transport, or installed in a building or a structure, Assemblies of machinery referred to in the first, second and third indents or partly completed machinery referred to in point which, in order to achieve the same end, are arranged and controlled so that they function as an integral whole, An assembly of linked parts or components, at least one of which moves and which are joined together, intended for lifting loads and whose only power source is directly applied human effort; FIGURE 7.Machine.
20 3.3 Partlycompletedmachinery definition Assemblieswhichisalmostmachinerybutwhichcannotinitselfperformaspecificapplication. Adrivesystemispartlycompletedmachinery.Partlycompletedmachineryisonlyintendedto beincorporatedintoorassembledwithothermachineryorotherpartlycompletedmachinery orequipment,therebyformingmachinerytowhichthisDirectiveapplies. 3.4 Interchangeable equipment definition Adevicewhich,aftertheputtingintoserviceofmachineryorofatractor,isassembledwith thatmachineryortractorbytheoperatorhimselfinordertochangeitsfunctionorattributea newfunction,insofarasthisequipmentisnotatool. 3.5 Safety component definition Arethecomponentswhichservetofulfillasafetyfunction? whichisindependentlyplacedonthemarket, thefailureand/ormalfunctionofwhichendangersthesafetyofpersons,and Whichisnotnecessaryinorderforthemachinerytofunction,orforwhichnormal componentsmaybesubstitutedinorderforthemachinerytofunction. 3.6 Lifting accessory definition Componentorequipmentnotattachedtotheliftingmachinery,allowingtheloadtobeheld, whichisplacedbetweenthemachineryandtheloadorontheloaditself,orwhichisintended toconstituteanintegralpartoftheloadandwhichisindependentlyplacedonthemarket;
21 slings and their components are also regarded as lifting accessories. FIGURE 8. Different lifting accessories. 3.7 Boilers ropes and webbing definition Are designed for lifting purposes as part of lifting machinery or lifting accessories. FIGURE 9. Boilers. 3.8 Removable mechanical transmission device definition Aremovablecomponentfortransmittingpowerbetweenself‐propelledmachineryoratractor andanothermachinebyjoiningthematthefirstfixedbearing.Whenitisplacedonthe marketwiththeguarditshallberegardedasoneproduct.
22 4. Partlycompletedmachinery In according to the definition, the partly completed machinery has not undergone an assembly process so long as that it can perform by itself a particular application, including management and safe operation of the same. In these levels, it is left to the next level of the value creation chain, making a safety and complete machine which comply all the conditions set by the Directive. So, the partly completed machinery manufacturer or agent are exempt from the comply of other obligations that the Directive don’t set (in exception of the manufacturer declaration). A consequence of the new policy is that this will mean a significant increase in work in each of the cases. FIGURE 10. Partly completed machine. Through individual provisions is stabled that the machines must also be safe, to the extent that is feasible, and that in this case, the manufacturer has also allocated the relevant documentation and reporting obligations. In this sense, it will not be necessary in the future to adopt any contractual arrangement individual or voluntary.
23 FIGURE 11. Partly completed machines procedure regarding based on article 13 of Directive 2006/42/EC. In the future, machines manufactures must comply the next three requirements according to the Directive. 1. PREPARE TECHNICAL DOCUMENTATION: The content of the technical documentation to develop are defined at the VIIB Annex of the Directive. Seeing the extend of documentation to prepare (risk test, comply safety object according to the annex I,), is clear that the manufacturer of a partly completed machine have the same obligations like a manufacturer of a machine. 2. MOUNTING INSTRUCTIONS. Mounting instructions of a partly completed machine are similar of the instructions manual for the working of a machine but these instructions must be clearer. PARTLYCOMPLETEDMACHINESPROCEDUREREGARDINGBASED ONARTICLE13OFDIRECTIVE2006/42/EC TECHNICALDOCUMENTATION: Setplane Connectiondiagrams Riskassessmentdocumentation INSTRUCTIONS: Indicationsthathavetocomplyto enabletheassemblysoasnotto compromisethesafetyandhealth CONFORMITYDECLARATION: Manufacturer Identity Indicationstostart Personaldata ANNEXVIIB ANNEXVI ANNEXIIB
24 Mounting instructions can be writing in the language that the customer wants, and this is the most difference to the instructions manual. 3. INCORPORATION DECLARATION Content and structure of the incorporation declaration are included at annex II B of Directive. Subject commissioning is maintaining, known as the manufacturer's declaration of force today. Attach the statement is recommended as an annex, if applicable, as Annex I of Directive, and describe here that security objectives have been addressed in the design and manufacture of the partly completed machinery. In the case of a manufacturer manufacture partly completed machines in series, is going to apply also the requirement of a quality assurance system at Annex X. The declaration of incorporation must contain the following particulars: 1. Business name and full address of the manufacturer of the partly completed machinery and, where appropriate, his authorised representative; 2. Name and address of the person authorised to compile the relevant technical documentation, which must be established in the Community; 3. Description and identification of the partly completed machinery including generic denomination, function, model, type, serial number and commercial name; 4. A sentence declaring which essential requirements of this Directive are applied and fulfilled and that the relevant technical documentation is compiled in accordance with part B of Annex VII, and, where appropriate, a sentence declaring the conformity of the partly completed machinery with other relevant Directives. These references must be those of the texts published in the Official Journal of the European Union; 5. An undertaking to transmit, in response to a reasoned request by the national authorities, relevant information on the partly completed machinery. This shall include the method of transmission and shall be without prejudice to the intellectual property rights of the manufacturer of the partly completed machinery; 6. A statement that the partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive, where appropriate; 7. The place and date of the declaration; 8. The identity and signature of the person empowered to draw up the declaration on behalf of the manufacturer or his authorised representative.
25 FIGURE 12. Example of Declaration of incorporation.
32 The requirement mentioned only in paragraph 3 (…special hazards derived from the mobility of machines – 3.2.1 driving position) now is a general requirement for all machines. Points 1.2.1 and 1.2.7 are mixed like only one 1.2.1 and has expanded his reach. Handing systems should be designed and manufacturing for avoiding dangerous situations. Novelty is the requirement that in wireless control systems should occur automatically stop when not receiving the correct control signals. At the point 1.2.2 control devices, is particularly prevalent in the unintentional start indicating the need to implement commissioning organs in defined positions with adequate visualization of all risk areas. At the point 1.2.3 is signaled that if for safety reasons it is necessary for starting or stopping must be performed according to a specific sequence, there mechanisms to ensure that these operations are performed in the correct order. 1.2.4.2 Operational stop. Directive 98/37/EC requires that when there will be a stop, the supply of organs must be stop. When for operational reasons, a stop is required that does not disrupt the energy supply to the actuators, is monitored and maintained stop conditions. In contrary of normal stops, at stops for operational functions not the supply to actuators is stop. 1.2.4.3 Emergency stop In according to international hazards, `` emergency switch of devices´´ are going to be ``emergency stop devices´´. Stop function has to be available and operational permanently. Devices for emergency stops are used to improve security protective operations, not to replace them. 1.2.5 Selection of control or operating mode If, for certain operations, the machinery must be able to operate with a guard displaced or removed and/or protective device disabled, the control or operating mode selector must simultaneously: — disable all other control or operating modes. — permit operation of hazardous functions only by control devices requiring sustained action.
33 — permit the operation of hazardous functions only in reduced risk conditions while preventing hazards from linked sequences. — prevent any operation of hazardous functions by voluntary or involuntary action on the machine's sensors. 1.2.6 Failure of the power supply Has been added as a new feature that power supply failures should not change the machine parameters in an uncontrolled way when such change can lead to dangerous situations. 1.3.8.1 Moving transmission and 1.3.8.2 Moving parts involving in the process Some of the changes of both sections are the result of the amendment to paragraph 1.4.2.2 in Annex I. Is a new need to decide if you need a receipt or not, what should be valued in the context of a risk assessment. In paragraph 1.3.8.1 may be necessary also interlocked guards, and in the case of paragraph 1.3.8.2 may be waived under certain circumstances. 1.3.9 Risk of uncontrolled movements. When a part of the machinery has been stopped, any drift away from the stopping position, for whatever reason other than action on the control devices, must be prevented or must be such that it does not present a hazard. 1.4.2.1 Fixed regards. Has been added as a new feature that fixing systems must remain attached to the guards or to the machinery when the guards are removed. 1.4.2.2 Interlocking movable guards. The distinction of movable guards A and B were disappeared and is replaced with the requirements for guards with interlocking device, with or without locking device. 1.5.8 Noise The level of noise emission may be assessed with reference to comparative emission data for similar machinery. 1.5.9 Vibration The level of vibration emission may be assessed with reference to comparative emission data for similar machinery.
34 1.5.10 Radiation Have developed more detailed requirements, differentiating unwanted radiation and functional radiation, ionizing and non-ionizing. 1.5.15 Risk of slipping, tripping or falling. Is added it is necessary, that machines must be equipped with fixed handles. Must be adapted to the user and ensure stability. 1.5.16 Lightning. Machinery in need of protection against the effects of lightning while being used must be fitted with a system for conducting the resultant electrical charge to earth. 1.7.1 Information and warnings on the machinery. Information and warnings on the machinery should preferably be provided in the form of readily understandable symbols or pictograms. Any written or verbal information and warnings must be expressed in an official Community language or languages. Also is a new, that information may be submitted in any official language understood by the operators. 1.7.1.1 Information and information devices. The new is that display screens or other means of interactive communication between the operator and the machine must be easily understood and used. 1.7.3 Marking of machinery. All machinery must be marked visibly, legibly and indelibly with the following minimum particulars: — the business name and full address of the manufacturer and, where applicable, his authorised representative. — designation of the machinery. — the CE Marking (see Annex III). — designation of series or type. — serial number, if any. — the year of construction, that is the year in which the manufacturing process is completed. —It is forbidden to pre-date or post-date the machinery when affixing the CE marking.
35 —Furthermore, machinery designed and constructed for use in a potentially explosive atmosphere must be marked accordingly. 1.7.4 Instructions. — All machinery must be accompanied by instructions in the official Community language or languages of the Member State in which it is placed on the market and/or put into service. The instructions accompanying the machinery must be either ‘Original instructions’ or a ‘Translation of the original instructions’, in which case the translation must be accompanied by the original instructions. By way of exception, the maintenance instructions intended for use by specialized personnel mandated by the manufacturer or his authorised representative may be supplied in only one Community language which the specialized personnel understand. —Extending the concept of machine in Article 1 at Directive means that these products must also possess an instruction manual completed as requirements of the directive: o Security components o Loading means o Chains, robes and webbing o Removable mechanical transmission devices Besides, requirements about instructions content have these precisions and have been amplify with this information: o The EC declaration of conformity, or a document setting out the contents of the EC declaration of conformity, showing the particulars of the machinery, not necessarily including the serial number and the signature. o Warnings concerning ways in which the machinery must not be used that experience has shown might occur. o Information about the residual risks that remain despite the inherent safe design measures, safeguarding and complementary protective measures adopted; o Instructions on the protective measures to be taken by the user, including, where appropriate, the personal protective equipment to be provided. o Information on airborne noise emissions.
36 7.3 Supplementary essential requirements safety and health for some categories of machinery. Paragraph 2. News Requirements of section 2.1 is applied to machinery for food and also machines for cosmetics and pharmaceuticals. 2.2 Portable handheld and/or handguide machinery. 2.2.1 Generalities. The handles of portable machinery must be designed and constructed in such a way as to make starting and stopping straightforward. 2.2.1.1 Instructions. o Should indicate the value of the vibration to the system is exposed to hand arm o The indicated values should be accompanied by the corresponding uncertainty o Laying down conditions for the measurement methods 2.2.2 Portable fixing and other impact machinery. This point is new and inside this kind of machines are warhead machines introduced in the field of application of Directive. 2.3 Machinery for working wood and material with similar physical characteristics. Projection risk refers not only to the parts but also parts of them. 7.4 Supplementary essential to neutralize safety and health hazards due to mobility of the machines. Paragraph 3. News Seating. Is required to implement a system of retention also on machines equipped with FOPS (non falling objects). Shouldn’t implement a retention system if this one improve risk.
37 Control systems If necessary, steps must be taken to prevent unauthorized use of controls. In the case of remote controls, each control unit must clearly identify the machinery to be controlled from that unit. The remote control system must be designed and constructed in such a way as to affect only: — the machinery in question, — the functions in question. Remote controlled machinery must be designed and constructed in such a way that it will respond only to signals from the intended control units. o 3.3.1 Control devices The sixth paragraph of section 1.2.2 about audible and visual warning signals will be applied only in the case of reverse gear. o 3.3.3 Travelling function Remote-controlled machinery must be equipped with devices for stopping operation automatically and immediately and for preventing potentially dangerous operation in the following situations: — if the driver loses control, — if it receives a stop signal, — if a fault is detected in a safety-related part of the system, — if no validation signal is detected within a specified time. o 3.4.3 Rollover and tipover Where, in the case of self-propelled machinery with a ride-on driver, operator(s) or other person(s), there is a risk of rolling or tipping over, the machinery must be fitted with an appropriate protective structure, unless this increases the risk. o 3.4.4 Falling objects Where, in the case of self-propelled machinery with a ride-on driver, operator(s) or other person(s), there is a risk due to falling objects or material, the machinery must be designed and constructed in such a way as to take account of this risk and fitted, if its size allows, with an appropriate protective structure.
38 3.4.7 Transmission of power between selfpropelled machinery ( or tractor) and recipient machinery. It must be possible to open this guard for access to the removable transmission device. Once it is in place, there must be enough room to prevent the drive shaft damaging the guard when the machinery (or the tractor) is moving. 3.5.3 Emission of hazardous substances. The operator must be protected against the risk of exposure to such hazardous emissions. 3.6.1 Sings, signals and warnings. Where necessary, there must be an appropriate connection between a trailer and the machinery for the operation of signals. 3.6.3.1 Vibrations. The instructions must give the following information concerning vibrations transmitted by the machinery to the hand-arm system or to the whole body: — the vibration total value to which the hand-arm system is subjected, if it exceeds 2,5 m/s2. Where this value does not exceed 2,5 m/s2, this must be mentioned, — the highest root mean square value of weighted acceleration to which the whole body is subjected, if it exceeds 0,5 m/s2. Where this value does not exceed 0,5 m/s2, this must be mentioned, — the uncertainty of measurement. 7.5 Supplementary essential requirements of safety and health to neutralize the dangers of lifting operations. Paragraph 4. News 4.1.2.8 Machinery serving fixing landing. o 4.1.2.8.1 Movements of the carrier. The movement of the carrier of machinery serving fixed landings must be rigidly guided to and at the landings. Scissor systems are also regarded as rigid guidance. o 4.1.2.8.2 Access to the carrier.
39 Where persons have access to the carrier, the machinery must be designed and constructed in such a way as to ensure that the carrier remains stationary during access, in particular while it is being loaded or unloaded. The machinery must be designed and constructed in such a way as to ensure that the difference in level between the carrier and the landing being served does not create a risk of tripping. o 4.1.2.8.3 Risk due to contact with the moving carrier. Where necessary in order to fulfill the requirement expressed in the second paragraph of section 4.1.2.7, the travel zone must be rendered inaccessible during normal operation. When, during inspection or maintenance, there is a risk that persons situated under or above the carrier may be crushed between the carrier and any fixed parts, sufficient free space must be provided either by means of physical refuges or by means of mechanical devices blocking the movement of the carrier. o 4.1.2.8.4 Risk due to the load falling off the carrier. Where there is a risk due to the load falling off the carrier, the machinery must be designed and constructed in such a way as to prevent this risk. o 4.1.2.8.5 Landings. Risks due to contact of persons at landings with the moving carrier or other moving parts must be prevented. Where there is a risk due to persons falling into the travel zone when the carrier is not present at the landings, guards must be fitted in order to prevent this risk. Such guards must not open in the direction of the travel zone. They must be fitted with an interlocking device controlled by the position of the carrier that prevents: — hazardous movements of the carrier until the guards are closed and locked, — hazardous opening of a guard until the carrier has stopped at the corresponding landing. 4.1.3 Fitness for purpose. The static and dynamic tests referred to in section 4.1.2.3 must be performed on all lifting machinery ready to be put into service.
40 4.4.1 Lifting accessories. In the instruction should also indicate how new the static test coefficient is used. 4.4.2 Lifting machinery. In instructions should also indicate where appropriate, a report that details the static and dynamic tests conducted by or for the manufacturer or his authorized represented. 7.6 Additional essential requirements of safety and health to neutralize the dangers of lifting operations. Paragraph 6. News 6.1.1 Mechanical strength. The carrier, including any trapdoors, must be designed and constructed in such a way as to offer the space and strength corresponding to the maximum number of persons permitted on the carrier and the maximum working load. If ropes or chains are used to suspend the carrier, as a general rule, at least two independent ropes or chains are required, each with its own anchorage. 6.1.2 Loading control for machinery moved by power other than human strength The requirements of section 4.2.2 apply regardless of the maximum working load and overturning moment, unless the manufacturer can demonstrate that there is no risk of overloading or overturning. 6.2 Control devices. The control devices for these movements must be of the hold-to-run type except where the carrier itself Is completely enclosed. 6.3.2 Risk of persons falling from the carrier. When the carrier is designed as a work station, provision must be made to ensure stability and to prevent hazardous movements. Any trapdoor in floors or ceilings or side doors must be designed and constructed in such a way as to prevent inadvertent opening and must open in a direction that obviates any risk of falling, should they open unexpectedly. 6.3.3 Risk due to objects falling on the carrier. Where there is a risk of objects falling on the carrier and endangering persons, the carrier must be equipped with a protective roof.
41 6.4 Machinery serving fixed landing. NEW POINT. For cover the new Directive about lifts and lower has been created this point. o 6.4.1 The carrier must be designed and constructed in such a way as to prevent risks due to contact between persons and/or objects in or on the carrier with any fixed or moving elements. Where necessary in order to fulfill this requirement, the carrier itself must be completely enclosed with doors fitted with an interlocking device that prevents hazardous movements of the carrier unless the doors are closed. The doors must remain closed if the carrier stops between landings where there is a risk of falling from the carrier. The machinery must be designed, constructed and, where necessary, equipped with devices in such a way as to prevent uncontrolled upward or downward movement of the carrier. These devices must be able to stop the carrier at its maximum working load and at the foreseeable maximum speed. The stopping action must not cause deceleration harmful to the occupants, whatever the load conditions. o 6.4.2 Controls at landings Controls, other than those for emergency use, at landings must not initiate movements of the carrier when: — the control devices in the carrier are being operated, — the carrier is not at a landing. o 6.4.3 Access to the carrier. The guards at the landings and on the carrier must be designed and constructed in such a way as to ensure safe transfer to and from the carrier, taking into consideration the foreseeable range of goods and persons to be lifted. 6.5 Markings. The carrier must bear the information necessary to ensure safety including: — the number of persons permitted on the carrier, — the maximum working load.
48 - From the formal, legal point of view, machinery can only be placed on the market with reference to Directive 2006/42/EC as from 29th December 2009. 3. QUESTION: When shall a manufacturer establish an EC Declaration of conformity according to Directive 2006/42/EC? ANSWER: A manufacturer shat establish an EC Declaration of conformity according to Directive 2006/42/EC for products first placed on the market as from 29th December 2009. In cases where the manufacturer cannot be certain on what date individual products will be first placed on the market, providing the products concerned comply with both the current and the new Directives, he may establish an EC Declaration of conformity referring to both Directive 98/37/EC and Directive 2006/42/EC. The reference to Directive 98/37/EC should be removed from the EC Declaration of conformity after the 29th December 2009. 4. QUESTION: Can the current harmonized standards be used to comply with Directive 2006/42/EC? ANSWER: Since there have been some modifications to the essential health and safety requirements set out in Annex I, it cannot be assumed that the current harmonized standards comply fully with Directive 2006/42/EC. The European commission is issuing a mandate to CEN and Cenclec to develop the necessary new standards and ensure that the current standards are checked against Directive 2006/42/EC and adapted as necessary. Furthermore, all harmonized standards must include a reference to the new Directive. The Commission intends to publish a list of harmonized standards supporting Directive 2006/42/EC before the Directive becomes applicable.
49 5. QUESTION: When will manufacturers be able to use the new full quality assurance procedure for Annex IV machinery? ANSWER: The Member States will first have to assess, appoint and notify Notified Bodies for the new full quality assurance procedure set out in Annex X of the new Directive. This can be done as soon as Directive 2006/42/EC has been transposed into national law. As soon as Bodies have been notified for this procedure, they will be able to carry out the necessary audits and inspections and issue approvals of manufacturers full quality assurance systems. However, products cannot be placed on the market on the basis of such approvals until Directive 2006/42/EC becomes applicable on 29th December 2009. 6. QUESTION: Will the existing Notified Bodies be able to carry out EC typeexaminations according to Directive 2006/42/EC? ANSWER: Bodies that are notified to carry out EC typeexaminations under Directive 98/37/EC will be able to continue to carry out EC typeexaminations under Directive 2006/42/EC, providing their notification covers the product categories concerned. For product categories included in Annex IV of Directive 2006/42/EC that are not listed in Annex IV of Directive 98/37/EC, the Member States will have to notify new Bodies or extend the scope of the notification of existing ones. 7. QUESTION: Will EC typeexamination certificates established according to Directive98/37/EC remain valid for Directive 2006/42/EC?? ANSWER: Since there have been some modifications to the essential health and safety requirements set out in Annex I, it cannot be assumed that EC typeexamination certificates issued according to Directive 98/37/EC remain valid for Directive 2006/42EC. Furthermore, such certificates must be updated to refer to Directive 2006/42/EC. Notified Bodies will thus have to review existing EC typeexamination certificates to ensure that they remain valid in light of the requirements of the new Directive and update them to refer to Directive 2006/42/EC. Manufactures are encouraged to request this review without delay in order to avoid a bottleneck in the months preceding December 2009.
50 Since Directive 2006/42/EC requires EC typeexamination certificates to be reviewed every 5 years (see Annex IX, section 9.3), the 5 year period for existing certificates can be counted from the date on which they have been updated according to Directive 2006/42/EC. 8. QUESTION: What will happen to products certified according to one of the procedures set out in Article 8 (2,c) of Directive 98/37/EC (Receipt of technical file or Certificate of adequacy to harmonized standards)? ANSWER: The procedures set out in Article 8 (2,C) of Directive 98/37/EC will no longer exist under Directive 2006/42/EC. As from 29th December 2009, manufacturers of products placed on the market on the basis of these procedures will therefore have to apply one of the procedures set out in Article 12(3) and (4) of Directive 2006/42/EC. For products manufactured in accordance with harmonized standards that cover all the relevant health and safety requirements, the manufacturer will be able to certify the conformity of the product himself according to the procedure set out in Article 12 (3, A) of the Directive.
51 CHAPTER 3. SUBSTANCIAL CHANGES IN MACHINES At the new Directive 2006/42/EC, these concepts remain unchanged and, at this time without clarification. Consequently, also raises the question of when a substantial change in a machine is coming, when conditions of the policy are applied and when not. In this sense it is recommended to apply a decision tree, as illustrated in the flowchart shown next (based on an interpretive guide the administration of Federal Government on this issue). This does not mean in any way that in these cases is to tolerate a level of security on the machine substantially lower, rather what has to be considered is that the requirements of the new Machinery Directive cannot be met fully in practice when modifications will change machines. Anyway should apply the basic rules of safe operation of the same, it means, should apply the requirements specified in Annex I of Directive. In according with the last scheme, it should indicate: The analysis respect flow char should be a team work and it must be documented. Modifications of security systems must not be considered substantial modifications. Only at the reduction of security systems (dismantling) could constitute a substantial modification. In expert circles is discussed very intensively if the correction by simple safeguards can also be achieved by incorporating other safeguards, such as Interlocked guards or guards contactless. This question can be answer with an affirmation when the protection versus risk is dominated as well or better, and interventions of control elements are surface.
52 Powerincrease?? Functionalmodification?? Securitysystems?? Substantialmodification?? Newrisk? Isnotsafety? Probability? Cancause injury? Arepossible safeguards? Substantialamendment NO NO YES REVERSIBLE LOW NOsubstantial modifications SAFETY MACHINE NOsubstantial modifications RESTORE SAFETY
53 FIGURE 15. Flow chart about make changes, substantial changes or restore safety in machines at Directive 2006/42/EC.
54 CHAPTER 4. MACHINERY INSTALATION Sets of machinery and partly completed machinery have not undergone any change in the scope of application of the new policy and therefore no practical issues related to them. This theme requires a special consideration, particularly under three points of view: 1. General responsibility Who has overall responsibility when a machine installation does not have a single source, which can also mean that machines (regardless of whether they are completed or partly completed machinery) have been provided by third-party manufacturers (including construction machinery itself). In this case is necessary (in the best of the cases in advance) the appointment of a general contractor (a systems integrator) who respond to the Directive under the total installation. In the case of the general responsibility question don’t be regulated, the responsible by the point of view of the Directive will be the operator of machine. 2. Installation formed by new and old machines In relation to paragraph 1, may often a set of new grouping machines that are not compound only by new machines. Is more likely to be machinery or partly completed machinery with more manufacturing years old. In this case, the question arises to value the fact that one of these machines present a state of a previous technological security systems towards meeting the requirements of the directive on machines. This question raises the same dilemma that when a machine has a substantial modification and when not. Usually applies the principle that the machines conform to EC previous model years maintaining the state purchased. It means that machines in a past date were safe in the sense of the requirements and conditions of the policy effect at that time remain safe. Maintaining acquired condition also applies to the classic old machines, it means machines prior to the time of the policy, so generally these old machines can be incorporated as such in new facilities.
55 When the integration is composed with old machines prior to 98/37/EC directive, machinery subsequent to this and other more modern conform to the new policy, the general contractor, which preferably should be designated previously certified EC compliant of integration. If necessary, the conditions or requirements of EU directives which cannot be met in the old machines should be highlighted in a continuation sheet attached to the EC declaration of conformity. 3. Is the integration only one machine? A third issue which is frequently arise in connection with the machinery installation is when the group of machines is a machine installation and when not. According to this principle, there isn’t a set of machines in the sense of the directive that consists of machines capable of operating independently (or partial installations capable of operating independently) that are connected from the functional point of view and control, but it does not constitute a unit from the point of view of safety in the sense indicated above. This happens, for example, when the transition points don’t happens a risk, between machines because of their grouping. Chain connected machines can still be considered separate from the standpoint of safety. In this case, the policy states that security measures are taken only in the individual machine.
56 INDUSTRIALFACILITY Machine1+Machine2+ Machine3+… Istherea functional link? Isthere linkingof control systems? Isthere linkingof security systems? Declarationofconformityand ECmarkingofthewhole installation Declarationofconformity andECmarkingofeachof themachines YES YES YES YES NO NO NO
57 FIGURE 16. Flow chart describing how a machine is composed.
64 FIGURE 21. List of Different standards into force between A and B.
65 CHAPTER 7. RISK ANALYSIS EN 14121-1 FIGURE 22. Different standards to measure risk. Withthis purpose machine standardsare goingtobe applied ENISO13849‐1 ``Partsofcontrol systemsrelating tosafety´´ ENISO12100‐1 ``Generaldesign principlesfor machinessafety´´ ENISO14121‐1 ``Riskassessment ofthemachine´´ ALLMANUFACTURERSHOULDTOREALIZEANRISK EVALUATIONTOKNOWWHATSTANDARDSHAVETO BEAPPLYANDINWHATMEASURE
66 FIGURE 23. Evaluation process that the manufacturer must to comply to reduce risk. IDENTIFYINGLIMITS MACHINE(CHAPTER5 ENISO14121) IDENTIFICATIONOF HAZARDS,SITUATIONS ANDHAZARDOUSEVENTS (CHAPTER6ENISO 14121 ) RISKVALUATION( CHAPTER8ENISO 14121) ISTHERISK ADECUATELY REDUCED? RISKREDUCTION( CHAPTER5ENISO 12100‐1) RISKESTIMATION (CHAPTER7ENISO 14121) END EVALUATIONPROCESSTHAT THEMANUFACTURERMUST TODOTOREDUCERISK START
67 1. Machine limits definition. Chapter 5 of the standard EXTRACTS OF EN ISO 14121-1 The risk assessment begins with the determination of the limits of the machine, taking into account all stages of the life cycle of the machine. This means that you should identify the characteristics and performance of the machine or series of machines included in an integrated process, as well as those of the people involved, the environment and products, in terms of limits of the machine as described in the following sections: Limits of Use Limitations in space Limits on time Other limits (environmental conservation ..) 2. Identifying dangers, situations and danger events. Chapter 6 of the standard EXTRACTS OF EN ISO 14121-1 After determination of the limits of the machine, the essential step in any risk assessment of a machine is the systematic identification of all hazards, hazardous situations and hazardous events that are reasonably foreseeable, during all phases of the life cycle the machine, it means: a) Transport, assembly and installation; b) Commissioning; c) Use; d) Decommissioning, dismantling and removal; Should also consider all the tasks that can be done during the active life of the machine: Adjustment; Tests / trials; Learning / programming; Change process or tools; Implementation; All modes of operation; Feeding the Machine; Stop the machine;
68 Stopping the machine in an emergency; After restore of a jam; Restarting after an unscheduled stop; Search / detection avveria (operator intervention); Cleaning and maintenance; Preventive maintenance; Corrective maintenance. 3. Risk estimation. Chapter 7 of the standard EXTRACTS OF EN ISO 14121-1 After identification of hazards should perform risk estimation for each dangerous situation, determining elements of risk. When determining these elements is necessary to consider the items listed in the paragraph. 3.1 Risk elements The risk associated with a particular hazard situation depends on the following: a) Its severity; b) The probability of occurrence of such damage, which is a function of: exposure of individuals to the danger; the occurrence of a hazardous event; technical and human possibilities to avoid or limit the damage. 3.2 Aspects to consider during the risk estimation People exposed Type, frequency and duration of exposure Relationship between exposure and effects Human Factors Suitability of preventive measures Ability to neutralize or circumvent the preventive measures Ability to maintain preventive measures Information for use
69 4. Risk assessment. Chapter 8 of the standard EXTRACTS OF EN ISO 14121-1 After estimating the risk should carry out risk assessment in order to determine it is necessary to reduce risk, If it is necessary to reduce the risk, then you must select and apply appropriate preventive measures, by repeating the procedure. As part of this iterative process, the designer must verify that the application of new preventive measures, will generate additional hazards or other risks are increased. If new hazards are created, these will be added to the list of hazards identified and appropriate preventive measures will be required to run them. 5. Documentation. Chapter 9 of the standard EXTRACTS OF EN ISO 14121-1 The documentation on the risk assessment should test the procedure to be followed and the results that have been reached.
70 CHAPTER 8. RISK EVALUATION. FUNCTIONAL SAFETY BY EN 62061 AND EN 13849 Currently industrial applications demand ever more security, it is easy to deduce that when an application covers all the recommendations and regulations for protection of breakdowns and security, the probability of breakdowns is reduced drastically justifying the investment in quality equipment under the strictest standards. The following standards for evaluate the level of security systems: ENISO954‐1:03‐1997:Safetyrelatedpartsofcontrolsystemsof machines.‐Part1:Generalprinciplesfordesign. ENISO13849‐1:12‐2007: Safetyrelatedpartsofcontrolsystemsof machines.‐Part1:Generalprinciplesfordesign. EN62061:10‐2005:Safetyofmachinery‐Functionalsafetyofelectrical controlsystems,electronicandprogrammableelectronicsafety‐ related. EN61508:2002‐11:Safetyofmachinery‐Functionalsafetyofelectrical controlsystems,electronicandprogrammableelectronicsafety‐ related. Part1:Generalrequirements Part2:Requirementselectrocoscontrolsystems,electronicand programmableelectronicsafety‐related Part3:Softwarerequirements Part4:TermsandAbbreviations Part5:Examplestocalculatethesafetyintegritylevel Part6:PrinciplesofapplicationofstandardsIEC61508‐2andIEC 61508‐3
71 FIGURE 24. Different standards with the main working information. The standards that define PL (performance levels) and SIL (safety integrity levels) covering the systems control safety-related electrical, and produce the same or similar results, although through different methods. This providing users the option to choose the most suitable for your application or completeness and each standard offers comparable that are appropriate for users who are going. The PL are related to the categories of security system, which first appeared in the '90s as part of the European standard EN 954-1 that supported the policy of the EU machinery. It was decided that there should be a standard for the design of safetyrelated components of the control systems. The resulting standard presented a series of categories that are used to describe the structure of a safety-related circuit. In terms of safety machinery standards of EN 954-1, Safety of machinery, parts of control systems relating to safety, the standard that has so far classified security levels, will be replaced by two standards co-exist for a while. The original standard is valid until 2010 to allow for a transition period to the new revised version. In many cases, designers and installers of electronic security systems may choose to meet the requirements of EN ISO 13849-1 or EN 62061 and fully meet the EC Machinery Directive. The following image shows the design selection process and how the two standards are related. Before these standards can be applied, you must have done a risk assessment of in accordance with the definitions in EN ISO 14121 to identify potential risks and risk reduction measures. Best practices require the document and, in many cases, assessments are drafted to supplement the operating instructions of the equipment in the technical documentation.
72 FIGURE 25. Different standards with the main information. EN954: ‐>Harmonizedunder EUmachinery directive ‐>Estucturaoriented single ‐>Noprogrammable electronic l IEC61508: ‐>Formanufacturersof controls/systems ‐>Quantitative structure‐oriented. ENISO13849‐1: ‐>Quantitativeand structure ‐>Formanufacturers/ integratorscontrols ‐>Predetermined architecturesfor electronics ‐>Qualityforhydraulic, pneumatic... EN/IEC62061: ‐>HarmonizedunderEU machinerydirective ‐>Forintegratorscontrols ‐>Quantitativeand orientedtostructure ‐>PESEuseIEC61508 Electronic equipments Usedlike reference
73 Before proceeding we should take into account certain abbreviations that are commonly used in these rules: FIGURE 26. Definition about different abreviatures. We briefly describe below the standard ``EN ISO 13849-1: 2008 - Safety of machinery: insurance components in control systems'': This standard is a revision of EN 954-1 and provides safety requirements and guidelines for the design and integration of safety-related parts of the systems of control. Introduced in 1996, EN 954-1 was seen by some as too simple and insufficient approximation when forcing designers to evaluate the reliability of safety components. The new standard adds a quantitative to qualitative requirements of the above standard and includes the possibility of component failure of the security system. As to EN 954-1, using a risk estimate to determine the level of performance required (PLR). This is done with a risk graph as shown in the image. DesignatedArchitecture:StructureofandefaultSPR/CS. B10d:Numberofswitchingoperationswhen10%ofthesamplefails. CCF:Commoncausefailure. CV:diagnosticcoverage DCavg:Coveragebydiagnosis MTBF:Meantimebetweenfailures MTTFd:Meantimetodangerousfailure PFH:Probabilityfailureperhour PFHd:Probabilityofdangerousfailureperhour PL:Reliabilitylevel PLr:Levelofreliabilityrequired SIL:SafetyIntegrityLevel SRP/CS:Safetyrelatedpartsofcontrolsystemsofmachines
80 SILs retain many of the principles of category system but also add a level of detail and definition that better addresses modern control and security architectures. are used to determine the functional safety quantifying the probability of occurrence of a fault in a device while performing its safety function. There are levels for machinery train, SIL3 is the most reliable, and SIL1 the least. Along with assessments in the background, the SIL also use a combination of technical factors to determine the level or classification, including the average probability of dangerous failure on demand (PFHD) and security features required for a process. It is the work that occurs in the background that distinguishes the SIL. With regard to functional safety, appropriate management systems should be on your side to ensure that the right people with the right level of expertise is working on the job in question. It is also necessary to deal with the specifications of security requirements. These are used to determine exactly what security requirements must be met. It deals with the components and the systems with respect to their design, validation and specification on the project life cycle, while also contemplates any environmental influence, as well as other factors that may affect the optimal system. The final addition is the way to address the systems and subsystems, with UNE standards like IEC 61508 covering complex subsystems such as safety PLCs. The first subdivision on measures to avoid systematic breakdowns and subsequent action to control the complex secondary system in the event that a malfunction occurs in the system. The second one focuses on the reliability of the system, using the probability of occurrence of dangerous breakdowns per hour (PFHD) as a measure. The end subdivision deals with architectural constraints. An example would be the combination of the features of fault tolerance in a secondary system and balance functions compared with existing diagnoses, with a high tolerance and significant diagnoses that result in the highest. There are many other factors to determine the levels of SIL, and the methods of formal software design, modification and validation techniques, however, still more highlight the major differences between the categories and SIL. In general, whether they use a PL, a SIL or a combination of both, the choice should be related to the complexities of the systems and, for this reason, perhaps could provide guidance on which method to adopt.
81 CHAPTER 9. EN ISO 13859. SECURITY DISTANCES. UNE ISO 13857:2008 Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs and lower limbs. This document is a standard type B This International Standard establishes values for safety distances, in an industrial environment such as public, in order to prevent danger zones being reached by the machines. Safety distances are appropriate for protective structures. This International Standard also gives information about the distances to prevent free access of the lower limbs. This international standard covers people aged less than 14 years. 1. Safety distances to prevent the access of upper limps. Point 4.2 of the standard 1.1 Reach upwards Figure shows the safety distances to reach upwards. FIGURE 33. Safety distance reach upwards. If the risk in the dangerous area is low, the height of the danger zone, h, must be equal to or greater than 2500mm. If the risk is high danger zone, the height of the danger zone, h, must be equal to or greater than 2700mm. 1.2 Scope over protective structures The figure shows the safety distance to reach over protective structure. Righthand=Dangerousarea andhighofthedangerousarea Floor=Reference
82 FIGURE 34. Safety distance scope over protective structures. TABLE7.Horizontaldistancetodanger. A=highofthedangerousarea B=highoftheprotective structure C=Safetydistancehorizontalto thedangerzone
83 TABLE8.Heightofperformancestructure 1.3 Scope in all directions with movement limit For upper limbs accesses table3 is used considering the following conditions: This table applies to people over 14 years measuring at least 1.4 m. Distances can be used up to 850mm lower (see Table 4) when the obstacle that restricts the movement has a length of 300mm minimum.
84 TABLE9.Scopeinalldirectionswithmovementlimit. 1.4 Scope through openings To access openings upper limb was employed by Table 4, taking into account the following conditions: This table applies to people over 14 years. For openings greater than 120mm, Table 3 should be used.
85 TABLE10.Scopethroughopenings.
86 CHAPTER 10. STOP FUNCTION UNE 60204-1 in paragraph 9.2.2 requires each machine incorporates a stop function. There are three stop categories: Category 0: stopping by immediate removal of power to the actuators Category 1: controlled stop maintaining the energy available in the actuators of the machine to allow the stop. The power supply is not disrupts until the stop has occurred. Category 2: controlled stop maintaining the energy available in the actuators Notes: o For a Category 1 stop maximum time to produce the disconnection of energies is recommended that no more than 30 seconds. This type of stop is usually applied in installations where a stop category 0 would mean a higher risk for immediate disconnection of energies could generate an accident or breakdown that could trigger it. o Solutions according to emergency stop category 2 must be applied with great caution. In fact, solutions of this type are held only with special safety systems such as a safety PLC or a programmable module.
87 CHAPTER 12. COMERCIAL ELEMENTS OF SAFETY In this chapter we will develop a series of sections which explain the security business elements that exist in the market. Its use and is essential for safety tecnic involved in modifications to adapt work equipment regulations, or to the technician who develops new equipment or automated systems. Many of these items are approved and will be precisely these that certify (if you strictly follow the manufacturer's instructions) that the security system has implemented certain security category. 1.Safetyswitches Safety switches are very important to certify the existence of movable guards in working position when the production process is in progress. 1.1Safetyswitcheswithoutlockingservices. Safety switches without locking device placed in a cell protection certify that there is in the working position when starting the production of the machine as it is not placed is impossible to start the cycle. If during the work cycle occurred opening the machine will stop. We must take into account when installing this type of switch, the opening during operation of the team should not be hazardous to the worker, for example, its installation should be done in such a way that once the opening occurs of protection, stop mobile elements is sufficiently fast so that the worker does not reach the danger zone with these elements in motion. The Rockwell Tongue Interlock Switches allow the head of the switch to rotate, offering different options on how you can operate the switch and mount it on the guard. This flexibility offers the best fit for your applications. FIGURE 35. ROCKWELL safety switches without locking services.
88 These are the different models of devices: 440K Cadet 3 440K Elf Miniature 440K MT-GD2 440K Trojan 5 & 6 Universal 440K Trojan T15 & T15-GD2 1.2Non‐contactswitches. They consist of two elements that recognize each other without contact. You can code and have great difficulty mocked. They are very useful for any type of fencing as its installation is very simple and has a high tolerance of alignment. They are used in applications where the rules requires high security category, when heavy soiling or whether to meet strict hygiene regulations. Also are used in applications that pose problems for precise guidance of doors, doors that subject to strong vibration machines and require high boot tolerances. Rockwell Non-contact Interlock Switches help you to protect personnel and equipment. At the same time, flexibility and productivity are points that you must also consider as you design your safety system. For non-contact interlocks, no physical contact (under normal conditions) takes place between the switch and actuator. FIGURE 36. ROCKWELL, non contact switch. These are the different models that Rockwell have: 440N Ferrogard 1, 2, 20, 21 440N Ferrogard 3, 4, 5 440N Ferrogard 6, 9, 10, 13, 14 440N Ferrogard GD2 440N Ferrogard GS1, GS2 440N Magnetically Coded 440N SensaGuard 440N Sipha Sensors
89 2.Securitymodules. Security modules are fundamental within the safety of a team. These security modules certify proper operation of a security system and adecuate integrated into the security level for which they are approved. Is very important for safety circuits in which you install a control module are independent of team maneuver, so that failures of this do not affect the safety of the machine. Is very important for the security level for which the device is approved safety circuits segur determined by the manufacturer. There are the following security modules. For emergency stop control To control safety switches To control sensitive mats Control of sensitive edges Control system for two-hand or desk bimanual Optoelectronic systems to control 3.Sensibleedges. Safety sensitive edges are used for the protection of moving parts in the points at which you can produce crushing, shearing or impact. Widely used in automated moving parts that can cause entrapment protection such as motorized mobile. Usually of rubber or neoprene and are variably depending on the manufacturer and the different models, but are generally as a roe pipe inside which a conductor or conductors located responsive to the contract, such that when a pressure in any edge point occurs stop element to which this partner. The new ROCKWELL sensible edge use a combination of non-conductive rubber and flexible wire-cored conductive rubber bonded together so they keep bouncing back into shape even after repeated compressions.
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