En 201 Rubber and Plastics Machines Injection Moulding Machines

BRITISH STANDARD BS EN 201:1997IncorporatingAmendments Nos. 1 and 2

Rubber and plastics machines Injection moulding machines Safety requirements

The European Standard EN 201:1997, with the incorporation of amendments A1:2000 and A2:2005, has the status of a British Standard

ICS 83.200

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BS EN 201:1997

This British Standard, having been prepared under the direction of the Engineering Sector Board, was published under the authority of the Standards Board and comes into effect on 15 July 1997

BSI 27 March 2006

The following BSI references relate to the work on this standard: Committee reference MCE/3/2 Draft for comment 96/703746 DC

ISBN 0 580 27947 2

Committees responsible for this British Standard

The preparation of this British Standard was entrusted by Technical Committee MCE/3, Safety of machinery, to Subcommittee MCE/3/2, Rubber and plastics machine Safety, upon which the following bodies were represented:

British Footwear Manufacturers FederationBritish Plastics FederationPackaging and Industrial Films AssociationPlastics Machinery Distribution

Amendments issued since publication

Amd. No. Date Comments

10932 February 2001 See national foreword

15766 March 2006 See national foreword

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BS EN 201:1997

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Contents

PageCommittees responsible Inside front coverNational foreword ii

Foreword 2Text of EN 201 4

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National foreword

This British Standard is the official English language version of EN 201:1997, including Amendment Nos. 1 and 2, Rubber and plastics machines Injection moulding machines Safety requirements. It supersedes BS 6679:1985 which is withdrawn.The start and finish of text introduced or altered by CEN amendment is indicated in the text by tags . Tags indicating changes to CEN text carry the number of the amendment. For example, text altered by CEN amendment A1 is indicated by .The UK participation in its preparation was entrusted to by Technical Committee MCE/3, Safety of machinery, to Subcommittee MCE/3/2, Rubber and plastics machine Safety, which has the responsibility to:

A list of organizations represented on this subcommittee can be obtained on request to its secretary.Cross-referencesThe British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled International Standards Correspondence Index, or by using the Search facility of the BSI Electronic Catalogue or of British Standards Online.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard does not of itself confer immunity from legal obligations.

aid enquirers to understand the text;

present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep UK interests informed;

monitor related international and European developments and promulgate them in the UK.

Summary of pagesThis document comprises a front cover, an inside front cover, pages i to ii, the EN title page, pages 2 to 47 and a back cover.

The BSI copyright notice displayed in this document indicates when the document was last issued.

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EUROPEAN STANDARD

NORME EUROPENNE

EUROPISCHE NORM

EN 201February 1997

+ A1February 2000

+ A2July 2005

ICS 83.200 Supersedes EN 201:1985 + A1:2000 + A2:2005

Descriptors: Plastic moulding, rubber, injection machines, accident prevention, safety requirements, equipment specifications, design, dangerous areas, hazards, safety measures, safety devices, inspection, human factors engineering

English version

Rubber and plastics machines Injection moulding machines Safety requirements

(includes amendments A1:2000 and A2:2005)

Machines pour le caoutchouc et les matires plastiques Machines injecter Prescriptions de scurit (inclut les amendements A1:2000 et A2:2005)

Gummi- und Kunststoffmaschinen Spritzgiemaschinen Sicherheitsanforderungen (enthlt nderungen A1:2000 und A2:2005)

This European Standard was approved by CEN on 1996-10-12. Amendment A1 was approved by CEN on 3 January 2000 and amendment A2 was approved by CEN on 20 June 2005. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

CENEuropean Committee for Standardization

Comit Europen de NormalisationEuropisches Komitee fr Normung

Central Secretariat: rue de Stassart 36, B-1050 Brussels

1997 Copyright reserved to CEN membersRef. No. EN 201:1997 + A1:2000 + A2:2005 E

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EN 201:1997

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ForewordThis European Standard has been prepared by Technical Committee CEN/TC 145, Rubber and plastics machines Safety, the secretariat of which is held by UNI.This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by August 1997, and conflicting national standards shall be withdrawn at the latest by August 1997.This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s).For relationship with EU Directive(s), see informative annex ZA, which is an integral part of this standard.In addition to the previous version of EN 201, requirements for carousel machines, shuttle and turntable machines, and multistation machines with mobile injection unit, are included. Furthermore safety requirements for the interaction between injection moulding machines and ancillary equipment are specified.According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom.

Foreword to amendment 1This Amendment EN 201:1997/A1:2000 to EN 201:1997 has been prepared by Technical Committee CEN/TC 145, Rubber and plastics machines Safety, the secretariat of which is held by UNI.This Amendment to the European Standard EN 201:1997 shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by August 2000, and conflicting national standards shall be withdrawn at the latest by August 2000.This Amendment to the European Standard EN 201:1997 has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s).

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom.This Amendment updates the requirements related to safety distances.

Foreword to amendment 2This European Standard (EN 201:1997/A2:2005) has been prepared by Technical Committee CEN/TC 145 Plastics and rubber machines, the secretariat of which is held by UNI.This Amendment to the European Standard EN 201:1997 shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by January 2006, and conflicting national standards shall be withdrawn at the latest by January 2006.This amendment updates EN 201:1997 with regard to injection moulding machines with one or more electrical axes. The following movements, driven by an electrical axis, are not considered:

vertical movements of the platen; horizontal movements of the platen where the guards for the mould area are not interlocking guards with guard locking.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

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Contents

PageForeword 20 Introduction 41 Scope 42 Normative references 43 Terms and definitions 64 List of significant hazards 105 Safety requirements and/or measures 146 Verification of the safety

requirements and/or measures 287 Information for use 29Annex A (normative) Additional requirements for protection devices type III 32Annex B (informative) Use of proportional valves for the platen movement 33Annex C (normative) Single acknowledgement system 33Annex D (normative) Noise measurement for injection moulding machines 34Annex E (normative) Size indication of injection moulding machines 36Annex F (normative) Test block 37Annex G (normative) Interlocking of guards for injection moulding machines with one or more electrical axes 40G.1 Principle of interlocking corresponding to type III, using electromechanical components 40G.2 Principle of interlocking corresponding to type III, using one electromechanical component and the motor control unit 41G.3 Principle of interlocking corresponding to type III, using the motor control unit 42G.4 Principle of interlocking corresponding to type I, using one electromechanical component 43G.5 Principle of interlocking corresponding to type I, using the motor control unit 44G.6 Principle of interlocking corresponding to type II, using one electromechanical component 45G.7 Principle of interlocking corresponding to type II, using the motor control unit 46Annex ZA (informative) Clauses of this European Standard addressing essential requirements or other provisions of EU Directives 47Figure 1 Example of a carousel machine 7Figure 2 Examples of shuttle table machines shown without guards for the movements of the table 8

Figure 3 Example of a turntable machine shown without guards for the movements of the table 8Figure 4 Examples of multistation machines with mobile plasticizing and injection units 9Figure 5 Injection moulding machine with horizontal clamping unit and horizontal plasticizing and injection unit, shown without guards 12Figure 6 Injection moulding machine with vertical clamping unit and horizontal plasticizing and injection unit, shown without guards 12Figure 7 Protection devices types I, II, III 16Figure 8 Examples of the positioning of movable guards and dimensions e1, e2 for machines with tiebars 18Figure 9 Dimensions a, e1, e2 for tiebarless machines 21Figure 10 Dimensions of the discharge area 22Figure D.1 Injection moulding machine with vertical clamping unit (plan view) 34Figure D.2 Injection moulding machine with horizontal clamping unit (plan view) 34Figure F.1 Hollow cylinder type test block 37Figure F.2 Four bar type test block 37Figure G.1 Principle of interlocking corresponding to type III, using electromechanical components 40Figure G.2 Principle of interlocking corresponding to type III, using one electromechanical component and the motor control unit 41Figure G.3 Principle of interlocking corresponding to type III, using the motor control unit 42Figure G.4 Principle of interlocking corresponding to type I, using one electromechanical component 43Figure G.5 Principle of interlocking corresponding to type I, using the motor control unit 44Figure G.6 Principle of interlocking corresponding to type II, using one electromechanical component 45Figure G.7 Principle of interlocking corresponding to type II, using the motor control unit 46Table 1 Verification methods 29Table D.1 Machine data for test cycle 35Table F.1 Test block dimensions (mm) 38Li

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0 IntroductionThis European standard is a type C standard as defined in EN 292-1:1991 and has been elaborated by CEN/TC145/WG1.The extent to which hazards are covered is indicated in the scope of this standard. In addition, machinery shall comply, as appropriate, with EN 292 for hazards which are not covered by this standard.

1 ScopeThis standard specifies the essential safety requirements for injection moulding machines for the processing of plastics and/or rubber. All hazards listed in clause 4 are covered by this standard.The following machines are excluded:

machines on which the clamping unit can only be operated by the physical force of the operator; machines for reaction injection moulding (RIM, see prEN 1612-1 and prEN 1612-2); compression and transfer moulding machines (see EN 289); direct on sole injection moulding machines and full boot injection moulding machines (Wellington type boots with textile inserts) (see prEN 1845).

The safety requirements for the interaction between injection moulding machines and ancillary equipment are specified. The safety requirements for the ancillary equipment itself are not specified.This standard does not cover requirements for the design of an exhaust system.This standard applies to injection moulding machines manufactured after the date of issue of the standard.

2 Normative referencesThis standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies.EN 292-1:1991, Safety of Machinery Basic concepts, general principles for design Part 1: Basic terminology, methodology.EN 292-2:1991/A1:1995, Safety of Machinery Basic concepts, general principles for design Part 2:Technical principles and specifications.EN 294:1992, Safety of Machinery Safety distances to prevent dangerous zones being reached by the upper limbs.EN 418, Safety of Machinery Emergency stop equipment, functional aspects Principles for design.EN 563:1994, Safety of Machinery Temperature of touchable surfaces Ergonomic data to establish limit values for hot surfaces.prEN 574:1995, Safety of Machinery Two-hand control devices, functional aspects Principles for design.prEN 953:1992, Safety of Machinery General requirements for the design and construction of guards (fixed, movable).!EN 954-1:1996, Safety of machinery Safety related parts of control systems Part 1: General principles for design."prEN 982:1992, Safety requirements for fluid power systems and components Hydraulics.prEN 983:1992, Safety requirements for fluid power systems and components; Pneumatics.EN 1088:1995, Safety of Machinery Interlocking devices associated with guards Principles for design and selection.prEN 1760-1:1994, Safety of Machinery Pressure sensitive protective devices Part 1: General principles for the design and testing of pressure sensing mats and pressure sensing floors.EN 10025:1993, Hot rolled products of non-alloy structural steels Technical delivery conditions.EN 20286-1:1993, ISO System of limits and fits Part 1: Bases of tolerances, deviations and fits.Li

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EN 23741:1991, Acoustics Determination of sound power levels of noise sources Precision methods for broad-band sources in reverberation rooms.EN 23742:1991, Acoustics Determination of sound power levels of noise sources Precision methods for discrete-frequency and narrow-band sources in reverberation rooms.prEN 50100-1:1994, Safety of Machinery Electro-sensitive protective equipment Part 1: General requirements and tests.EN 60204-1:1992, Safety of Machinery Electrical equipment of machines Part 1: General requirements.!EN 60204-1:1997, Safety of machinery Electrical equipment of machines Part 1: General requirements (IEC 60204-1:1997)."EN 61131-1:1994, Programmable controllers Part 1: General information.EN ISO 3743-1:1995, Acoustics Determination of sound power levels of noise sources Engineering methods for small, movable sources in reverberant fields Part 1: Comparison method for hard-walled test rooms.prEN ISO 3743-2:1995, Acoustics Determination of sound power levels of noise sources using sound pressure Engineering methods for small movable sources in reverberant fields Part 2: Methods for special reverberation test rooms.EN ISO 3744:1995, Acoustics Determination of sound power levels of noise sources Engineering methods for free-field conditions over a reflecting plane.EN ISO 3746:1995, Acoustics Determination of sound power levels of noise sources using sound pressure Survey method employing an enveloping measurement surface over a reflecting plane.EN ISO 9614-1:1995, Acoustics Determination of sound power levels of noise sources using sound intensity Part 1: Measurement at discrete points.EN ISO 11201:1995, Acoustics Noise emitted by machinery and equipment Measurement of emission sound pressure levels at the workstation and at other specified positions Engineering method in an essentially free field over a reflecting plane.EN ISO 11202:1995, Acoustics Noise emitted by machinery and equipment Measurement of emission sound pressure levels at the workstation and at other specified positions Survey method in situ.EN ISO 11203:1995, Acoustics Noise emitted by machinery and equipment Determination of emission sound pressure levels at the workstation and at other specified positions.EN ISO 11204:1995, Acoustics Noise emitted by machinery and equipment Measurement of emission sound pressure levels at the workstation and other specified positions Method requiring environmental corrections.!EN ISO/IEC 17025:2005, General requirements for the competence of testing and calibration laboratories(ISO/IEC 17025:2005)."ISO 3745:1977, Acoustics Determination of sound power levels of noise sources Precision methods for anechoic and semi-anechoic rooms.ISO 3747:1987, Acoustics Determination of sound power levels of noise sources Survey method using a reference sound source.ISO/DIS 9614-2:1994, Acoustics Determination of sound power levels of noise sources using sound intensity Part 2: Measurement by scanning.

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3 Terms and definitionsFor the purpose of this standard the following definitions apply:

3.1 injection moulding machine

a machine for the discontinuous production of moulded parts from thermo-plastics, thermo-setting plastics, thermo-plastic rubber or rubber compounds. The plasticized material is injected through a nozzle into a mould containing a cavity in which the article is formedNOTE If the plasticized material is not injected through a nozzle into the mould then see EN 289.an injection moulding machine essentially consists of one or more clamping units, one or more plasticizing and/or injection units, drive and control systems

3.2 mould area

the area between the platens

3.3 clamping mechanism

a mechanism attached to the mobile platen to move that platen and to apply the clamping force

3.4 plasticizing and/or injection unit

a unit for plasticizing and subsequently injecting material through a nozzle

3.5 carousel machine

a machine consisting of two or more clamping units mounted on a carousel in either a vertical or horizontal configuration to index to one or more fixed plasticizing and/or injection units (see Figure 1)

3.6 multistation machine with mobile injection unit

a machine consisting of a mobile plasticizing and/or injection unit which indexes between two or more stationary clamping units (see Figure 4)

3.7 ancillary equipment

equipment which interacts with the injection moulding machine, e.g. pick and place device, robot, mould changing equipment, mould clamping device or a conveyor

3.8 shuttle/turntable machine

a machine designed to contain one or more lower parts of moulds attached to a table. The table indexes the lower parts of the mould by a sliding or rotary motion between the loading/unloading station and the injection position (see Figure 2 and Figure 3)

3.9 !electrical motorany type of motor using electrical energy, e.g. servo or linear motor

3.10 motor control unit

unit to control the movement and standstill of an electrical motor, with or without an integrated electronic device, e.g. frequency converter, contactor

3.11 electrical axis

system consisting of an electrical motor, a motor control unit and any additional contactors "

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3.12 !standstillcondition under which there is no movement of a machine part with an electrical axis

3.13 safe standstill

standstill during which additional measures are taken to prevent unexpected start-up

3.14 safety related input

input to a motor control unit used to interrupt the energy supply to the drive of the electrical axis."

Figure 1 Example of a carousel machine

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Figure 2 Examples of shuttle table machines shown without guards for themovements of the table

Figure 3 Example of a turntable machine shown without guards for themovements of the tableLi

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Figure 4 Examples of multistation machines with mobile plasticizing and injection units

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4 List of significant hazardsThis clause lists the significant hazards associated with injection moulding machines. This standard differentiates between:

general hazards; additional hazards associated with specific machine areas; additional hazards associated with specific design; additional hazards associated with the interaction between the injection moulding machine and ancillary equipment.

4.1 General hazards

4.1.1 Mechanical hazards

4.1.1.1 Crushing and/or shearing and/or impact hazards caused by:

movements of power operated movable guards; whiplash of flexible hoses with pressures higher than 5 MPa.

4.1.1.2 Hazards due to release of fluids under pressure

Injuries to the eyes or skin due to unintended release of fluids under pressure from hydraulic or pneumatic systems, or heat conditioning system, in particular from flexible hoses and their connections with pressures higher than 5 MPa.

4.1.2 Electrical hazards

Electric shock or burns due to direct or indirect contact with live conductive parts.

4.1.3 Thermal hazards

Burns and/or scalds due to operating temperatures of: hoses of the heat conditioning system and their fittings; escaping fluids from the heat conditioning system.

4.1.4 Hazards generated by noise

Hearing impairment caused by noise. The main noise sources are: the hydraulic system especially during injection; the pneumatic system e.g. exhaust of gases.

4.1.5 Hazards generated by gases, vapours and dusts

Hazards resulting from contact with or inhalation of gases, vapours and dusts harmful to health: during plasticizing of the material and subsequent injection into the mould or purging; during curing or vulcanizing of the article in the mould; after the mould is open.

4.1.6 Slip, trip and fall hazards

Injury caused by slipping, tripping and falling from designated access positions above the reference plane.

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4.2 Additional hazards associated with specific machine areas

The principal danger areas are shown in Figure 5 and Figure 6:

4.2.1 Mould area

4.2.1.1 Mechanical hazards

Crushing and/or shearing and/or impact hazards caused by: closing movement of the platen; movements of the injection cylinders through the registers of the fixed platen; movements of cores and ejectors and their drive mechanisms.

4.2.1.2 Thermal hazards

Burns and/or scalds due to operating temperatures of: the moulds; heating elements of the moulds and plasticizing and/or injection cylinders; plasticized material released from the moulds or plasticizing and/or injection cylinders.

4.2.2 Clamping mechanism area

Mechanical hazards of crushing and/or shearing: by movements of the drive mechanism of the platen; where the guard for the mould area allows access behind the mobile platen during its opening; movements of core and ejector drive mechanisms.

4.2.3 Area of movement of core and ejector drive mechanisms outside the mould area and outside the clamping mechanism area (see Figure 6 item 3)

Mechanical hazards of crushing and/or shearing caused by the movements of core and ejector drive mechanisms.

1 mould area;

2 clamping mechanism area;

3 area of movement of core and ejector drive mechanisms outside areas 1 and 2;

4 nozzle area;

5 plasticizing and/or injection unit area;

5.1 feed aperture area;

5.2 area of the heater bands of the plasticizing and/or injection cylinders;

6 discharge area.

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Figure 5 Injection moulding machine with horizontal clamping unit and horizontal plasticizing and injection unit, shown without guards

Figure 6 Injection moulding machine with vertical clamping unit and horizontal plasticizing and injection unit, shown without guards

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4.2.4 Nozzle area


Crushing and/or shearing hazards caused by: forward movement of the plasticizing and/or injection unit including nozzle; movements of parts of the power operated nozzle shutoff and their drives.

4.2.4.2 Hazards due to ejection of parts caused by:

incorrect mounting of the nozzle; use of an incorrect type of nozzle.


Burns and/or scalds due to operating temperatures of: the nozzle; plasticized material egressing from the nozzle.

4.2.5 Plasticizing and/or injection unit area


Crushing and/or shearing and/or drawing in hazards caused by: unintentional gravity movements, e.g. for machines with plasticizing and/or injection unit positioned above the mould area; the movements of the screw and/or the injection plunger in the cylinder, accessible through the feed opening.


Burns and/or scalds due to operating temperatures of: the plasticizing and/or injection unit; the heating elements e.g. heater bands, heat exchangers; the plasticized material egressing from the vent opening.

4.2.5.3 Mechanical and/or thermal hazards

Hazards due to the reduction in mechanical strength of the plasticizing and/or injection cylinders due to overheating.

4.2.6 Discharge area

Mechanical hazards of crushing and/or shearing and/or impact due to moving parts in the mould area accessible through the discharge aperture.

4.3 Additional hazards associated with specific design

4.3.1 Machines where whole body access is possible between the movable guard for the mould area and the mould area itself

Mechanical hazards of crushing and/or shearing if operators can stand between the movable guards and the mould area.

4.3.2 Machines where whole body access is possible to the mould area

Mechanical hazards of crushing and/or shearing if operators can enter the mould area.

4.3.3 Machines with downstroking platen

Mechanical hazards of crushing and/or shearing caused by platen closing movement due to gravity.

4.3.4 Carousel machines

Mechanical hazards due to impact by the carousel and/or crushing and/or shearing and/or drawing in between the carousel and fixed parts.

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4.3.5 Shuttle/turntable machines

Mechanical hazards of crushing and/or shearing and/or impact and/or drawing in caused by the movements of the table.Mechanical hazards of crushing and/or shearing and/or impact caused by unintentional gravity descent of a shuttle table with possible vertical movement.

4.3.6 Multistation machines with mobile plasticizing and/or injection unit

Mechanical hazards of crushing and/or shearing and/or impact due to movements of the plasticizing and/or injection unit between the clamping units.

4.3.7!Machines with one or more electrical axesMechanical hazards connected with the movement of machine parts with electrical axes.Electrical or electromagnetic disturbances generated by the motor control unit which are liable to create failures in the control system."4.4 Additional hazards associated with the interaction between the injection moulding machine and ancillary equipment

4.4.1 Power operated mould changing equipment

Mechanical hazards caused by crushing and/or shearing between the moving mould and/or transfer unit and fixed parts of the machine.Mechanical hazards caused by impact by the moving mould and/or transfer unit within the immediate vicinity of the mould area.

4.4.2 Power operated mould clamping devices


Crushing and/or shearing and/or impact hazards caused by: movements of the mould clamping device; falling of the mould or parts of the mould due to failure of the power supply or, in the case of magnetic clamping, due to the loss of magnetic force, or due to unintentional declamping or unsuccessful clamping.

4.4.2.2 Hazards caused by magnetic fields

Interference with the operation of e.g. heart pacemakers and hearing aids.

4.4.3 Other ancillary equipment

Hazards are dependent on the type of ancillary equipment.

5 Safety requirements and/or measuresSafety distances shall be in accordance with EN 294:1992, table 1. These distances shall be taken from the reference planes (see also 5.1.6).Emergency stop equipment shall be in accordance with EN 418. Stop category 0 or stop category 1 may be selected unless otherwise specified (see 5.3.1 !, 5.3.2 and 5.3.7.1").The following specific protection devices are used on injection moulding machines:

a) Protection device type I (see Figure 7)Movable interlocking guard (see EN 292-1:1991, 3.22.2 and 3.22.4) with one position switch (see EN 1088:1995, 6.2) acting on the main shut-off device of the power circuit (e.g. valve, contactor) via the control circuit.When the guard is closed the position switch:

shall not be operated; shall have closed contacts or function in an equivalent mode; shall authorize the control signal initiating the dangerous movement.

When the guard is opened, the position switch shall be positively and directly operated by the guard and shall positively interrupt the control signal initiating the dangerous movement.

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In general safety shall be maintained in the case of a single fault. For example if relays, controlled by the position switch, are used for the purpose of contact multiplying, monitoring of these relays is necessary. This monitoring may be realized by the use of a programmable electronic system. The single fault safety requirement does not apply to the position switch or main shutoff device since it is assumed that these are well tried components.b) Protection device type II (see Figure 7)Movable interlocking guard with two position switches both acting on the main shutoff device of the power circuit via the control circuit.The first position switch shall act in accordance with protection device type I.When the guard is closed, the second position switch:

shall be operated by the guard; shall have closed contacts or function in an equivalent mode; shall authorize the control signal initiating the dangerous movement.

When the guard is opened the second position switch shall no longer be operated and shall interrupt the control signal initiating the dangerous movement.The correct functioning of the two position switches shall be monitored at least once during each movement cycle of the guard, so that a fault in one of the two position switches shall be automatically recognized and commencement of any further dangerous movement shall be prevented.c) Protection device type III (see Figure 7)Movable interlocking guard with two interlocking devices independent of one another. One device shall act via the control circuit in accordance with protection device type II. The other interlocking device shall act directly or indirectly on the power circuit using a position detector (see EN 1088:1995, 5.1 and 5.2).When the guard is closed the position detector:

shall not be operated; shall have closed contacts or function in an equivalent mode; shall enable the power circuit.

When the guard is opened the position detector shall be positively and directly operated by the guard and shall interrupt the power circuit via the second shutoff device.The correct functioning of the two interlocking devices shall be monitored at least once during each movement cycle of the guard, so that a fault in one of the two interlocking devices shall be automatically recognized and commencement of any further dangerous movement shall be prevented.Additional requirements are given in annex A.

In addition to the protection devices described above, fixed guards in accordance with EN 292-1:1991, 3.22.1 and safety devices in accordance with EN 292-1:1991, 3.23 may be used.Guards shall be designed in accordance with prEN 953:1992. They shall preferably be mounted on or close to the machine.The requirements for movable guards also apply to access doors in fences.NOTE According to prEN 953:1992, access doors in fences are regarded as movable guards in fixed guards.

From the selection of guards or safety devices see the following subclauses, where minimum requirements are specified.

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Figure 7 Protection devices types I, II, III

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5.1 General

5.1.1 Mechanical hazards

5.1.1.1 Crushing and/or shearing and/or impact hazards

If the movement of power operated guards can cause injury (see prEN 953:1992, 5.2.4.2) then trip devices (see EN 292-1:1991, 3.23.5) shall be fitted which will immediately either arrest or reverse the closing movement of the power operated guard. Reversing the movement shall not create further hazards.To prevent whiplash, flexible hoses with pressures higher than 5 MPa and their connections shall be designed to prevent tearing from the fittings and unintentional detachment from connection points.Tearing can be prevented by the use of tear proof fittings e.g. firm fit connection between hose and fitting. Alternatively dangerous whiplash of flexible hoses can be prevented by fixed enclosing guards (see prEN 953:1992, 3.2.1) and/or additional attachment of the hoses e.g. by a chain.To prevent unintentional detachment from connection points, cutting ring type connectors shall not be used. Appropriate connections are for example flanged joints, flared unions or conical nipple connections.See also 7.1.6.

5.1.1.2 Hazards due to release of fluids under pressure

To prevent the uncontrolled release of fluids under pressure hydraulic and pneumatic equipment shall be designed in accordance with EN 292-2:1991/A1:1995, 3.8, prEN 982:1992 and prEN 983:1992.To prevent release of pressurized fluids from hose assemblies, the requirements listed in 5.1.1.1 for flexible hoses and their connections shall be met.

5.1.2 Electrical hazards

Electrical equipment shall be in accordance with EN 60204-1:1992.

5.1.3 Thermal hazards

To prevent burns through unintentional contact with heat conditioning hoses and fittings, fixed guards or insulation shall be provided at accessible parts outside of the guarded area where the maximum operating temperature can exceed the limit values determined in accordance with EN 563:1994. In addition warning signs shall be fitted (see 7.2).To prevent injury from escaping fluids, uncovered heat conditioning hoses and fittings shall be covered by guards able to contain these fluids.

5.1.4 Hazards generated by noise

The machine shall be designed in accordance with EN 292-2:1991/A1:1995, annex A, 1.5.8.For the hydraulic system, noise reduction shall be achieved by selecting low noise components and/or by partial or complete insulation using the state of the art. Noise reduction for the pneumatic system shall be achieved by the application of vent silencers according to the state of the art.NOTE In both cases detailed information on the state of the art is available from numerous publications. Also B type standards are in preparation, e.g. ISO/TR 11688-1:1995 Acoustics Recommended practice for the design of low noise machinery and equipment Part 1: Planning.

See also 7.1.2.

5.1.5 Hazards generated by gases, fumes and dust

The machine shall be so designed that an exhaust system can be fitted or positioned, for the extraction of harmful substances. This standard does not cover the requirements for the design of an exhaust system (see clause 1).See also 7.1.3.

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5.1.6 Slip, trip and fall hazards

Designated access positions on the machine shall be permanently marked.Marked positions shall be:

safe against slipping and tripping; safe against falling (for heights 1 000mm above floor level); provided with safe means of access.

See also 7.1.7 and 7.2.See also EN 292-2:1991/A1:1995, 6.2.4.

5.2 Additional safety requirements and/or measures in specific machine areas

5.2.1 Mould area


5.2.1.1.1 Hazards due to the closing movement of the platen

Access to the mould area shall be prevented by protection devices type III for the platen closing movement complemented by fixed guards where necessary.A movable guard may not require interlocking if it is mechanically connected to a protection device type III, provided reliable connecting elements are used.Where proportional valves are used for the control of the platen movement, see annex B.

Figure 8 Examples of the positioning of movable guards and dimensions e1, e2for machines with tiebars

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For machines with platen movements in one horizontal axis, access via the top side shall be prevented by protection devices type II. A movable top guard is not required where safety distances from designated access positions are achieved by design or by fixed guards. The movable guards shall preferably be designed so that it is not possible for persons to stay between the guards and the mould area. This requirement is met e.g. if the dimensions in Figure 8 ( 150 mm) are achieved. Where it is possible for persons to stay between the guards and the mould area or to gain whole body access into the mould area (see 5.3.2, a, b, c, d) the requirements of 5.3.1 and/or 5.3.2 shall be met.

5.2.1.1.2 Sides of the machine where a cycle cannot be initiated

Alternatively to protection devices type III, an interlocking guard with two position switches may be used at sides where a cycle cannot be initiated provided that whole body access to the mould area, or between the mould area and the guard, is not possible.When the guard is opened the two position switches shall:

switch off the main drive for the closing movement of the platen; and shut off the energy accumulator for the closing movement of the platen.

To fulfil these requirements, only hardwired circuits using electro-mechanical components shall be used.When the guard is returned to its closed position manual resetting of the controls shall be necessary at the side of the machine where a cycle can be initiated.

5.2.1.1.3 Hazards due to the other movements listed in 4.2.1.1

The movable guards as specified in 5.2.1.1.1 or 5.2.1.1.2 shall also protect against these other movements. For these movements the guards shall act as protection devices type II.When a guard is opened it shall:

interrupt the cycle; plasticizing may continue if escape of the plasticized material is prevented and the nozzle contact force cannot lead to a hazardous situation; arrest and prevent forward movement of the screw or plunger; arrest and prevent forward movement of the injection unit; arrest and prevent dangerous movements of cores and ejectors; and their drive mechanisms.

The machine may be equipped with a lockable switch to allow manual operation of cores and ejectors when the guards for the mould area are open, using a hold to run control device (see EN 292-1:1991, 3.23.3), or a two hand control device (see EN 292-1:1991, 3.23.4), in accordance with prEN 574:1995, type IIIB, or a limited movement control device (see EN 292-1:1991, 3.23.8). See 7.1.5.

5.2.1.1.4 Use of control guards

As an alternative to movable interlocking guards, control guards in accordance with EN 292-1:1991, 3.22.6 may be used providing:

the requirements of EN 292-2:1991/A1:1995, 4.2.2.5 are met; and the requirements of 5.2.1.1.1 and 5.2.1.1.3 are met; and the position of the manual controls for the power operated guards affords a clear view of the mould area and meets the distances given in EN 294:1992, Table 2 in relation to that area; and the distances e1, e2 between tiebars (see Figure 8) or the corresponding distances e1, e2 for a tiebarless machine (see Figure 9) do not exceed 630 mm; and it is not possible to gain whole body access between the mould area and the guard (see 5.2.1.1.1, last paragraph); and closing of power operated guards is manually initiated.

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Warning notices shall be displayed drawing attention to the hazards caused by hot moulds and/or heating elements. See 7.2.Fixed and movable guards shall be designed to contain any ejected plasticized material.When the mould area guards are open forward movement of the screw or injection plunger shall be prevented (see 5.2.1.1.3).In addition machine manufacturers shall advise on the need for personal protective equipment. See 7.1.1.

5.2.2 Clamping mechanism area

To prevent access to dangerous movements in the clamping mechanism area protection devices type II shall be provided.When the movable guards are opened the two position switches shall:

interrupt the cycle; interrupt all movements of the platen.

Where access is required only for machine repair or maintenance, fixed guards are permitted.An opening movement of the platen when the guards for the mould area are open shall only be possible if access to crushing and/or shearing points behind the mobile platen is prevented.Access to the area of dangerous movements of the core and ejector drive mechanisms is already prevented by the above described guards for the clamping mechanism area. For these movements, the guards, if movable, shall act as protection devices type I.Alternatively, additional fixed guards may be used.

5.2.3 Area of movement of core and ejector drive mechanisms outside the mould area and outside the clamping mechanism area (see Figure 6, item 3)

Access to this area shall be prevented by: protection devices type I; or fixed guards.

5.2.4 Nozzle area


A protection device type I shall be provided.When the guard is opened the following shall be interrupted in all positions of the injection unit excluding maintenance positions:

the forward movement of the injection unit, including nozzle; the movements of parts of power operated nozzle shutoff and their drives.

In the case of horizontal injection units, an opening in the guard underneath the nozzle is permissible.

5.2.4.2 Hazards due to ejection of parts

See 7.1.1.


Warning notices shall be displayed drawing attention to the hazards associated with the hot nozzle. See 7.2.Hazards generated by hot plasticized material egressing from the nozzle shall be prevented by the guard described in 5.2.4.1. Additionally, this guard shall, when it is opened, act as a protection device type I to stop the forward movement of the screw or injection plunger.The design of the guards shall take into consideration the hazards of splashing from hot plasticized material and the extreme positions of the nozzle excluding maintenance positions.In all positions of the injection unit for maintenance (outside the guard for the nozzle area), purging of plasticized material shall only be possible by means of manual control according to EN 292-2:1991/A1:1995, 3.7.8 and 3.7.10 and, when processing plastics, at reduced speed.

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5.2.5 Plasticizing and/or injection unit area


In order to prevent unintentional gravity descent, injection units positioned above the mould area shall be provided with a restraint device e.g. for a vertical hydraulically operated movement with a restraint valve, fitted preferably directly on the cylinder, or as close as possible to the cylinder using flanged (flared or welded) pipework or flared unions only.The feed opening shall be designed so that access to the crushing and/or shearing points is prevented (for safety distances see EN 294:1992, Table 4).


The requirements according to 5.2.4.3 shall be met.Heat insulation of the plasticizing and/or injection cylinders shall be provided. The insulation shall be designed so that for a cylinder temperature of 240 C, the temperature of the outer surface of the insulation does not exceed the limit values according to EN 563:1994.Hazards due to the plasticized material egressing from the vent opening shall be prevented by a guard able to contain this plasticized material.

5.2.5.3 Mechanical and/or thermal hazards

The temperature of the plasticizing and/or injection cylinders shall be automatically monitored to ensure that the maximum permissible limit value is not exceeded. This limit shall be set by the manufacturer (see 7.1.1). The energy supply to all heating elements shall be automatically interrupted:

if the maximum permissible limit value is exceeded; or in case of a fault in the temperature control.

The requirements given in 5.2.5.3 do not apply to injection moulding machines designed exclusively for processing rubber.

Figure 9 Dimensions a, e1, e2 for tiebarless machines

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5.2.6 Discharge area

The discharge aperture shall be designed or safeguards shall be provided to prevent access to any dangerous movement through this aperture, even when conveyors are installed.Preferably the dimensions in Figure 10 should be met if necessary by using fixed guards.Alternatively the following protective devices may be used:

protection devices type I; and/or electro-sensitive protective equipment in accordance with prEN 50100-1:1994, type 2. This protective equipment shall not be used to control the machine.

When conveyors are used, see also 5.4.3.

Figure 10 Dimensions of the discharge area

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5.3 Additional safety requirements and/or measures associated with specific design

5.3.1 Machines where whole body access is possible between the movable guard for the mould area and the mould area itself

For these machines, safety devices additional to those specified in 5.2.1.1.1 shall be provided to detect the presence of persons between the movable guard for the mould area and the mould area itself, e.g. electro-sensitive protective equipment according to prEN 50100-1:1994, type 2 or pressure sensing mats or floors according to prEN 1760-1:1994, category 2.These additional safety devices shall become effective when the machine is switched on and, when persons are standing in this area, shall:

interrupt the control circuit for the platen closing movement, and, in the case of a power operated guard, interrupt the control circuit for the guard closing movement; and prevent injection into the mould area; and prevent initiation of a further cycle.

As an alternative to presence detection a single acknowledgement system (see annex C) or a mechanical latch in accordance with the conditions stipulated in 5.3.2 may be used.At least one emergency stop conforming to category 0 according to EN 418 shall be provided between the movable guard for the mould area and the mould area itself.

5.3.2 Machines where whole body access is possible to the mould area

For the following machines, safety devices additional to those specified in 5.2.1.1.1 and, where relevant, to those specified in 5.3.1 shall be provided:

a) machines with horizontal clamping unit and tiebars (see Figure 8) where there is a standing plane in the mould area; and e1 or e2 > 1 200 mm.

b) machines with horizontal clamping unit without tiebars (see Figure 9), where: a < 850 mm and e1 > 400 mm and e2 > 400 mm; or e1 > 1 200 mm; or e2 > 1 200 mm.

c) machines with vertical clamping unit and tiebars where: e1 or e2 > 1 200 mm; and maximum opening between the platens > 1 200 mm.

d) machines with vertical clamping unit without tiebars where: one of the platen dimensions > 1 200 mm; and maximum opening between the platens > 1 200 mm.

These additional safety devices shall be:a) devices such as mechanical latches which prevent the unintentional closing of movable guards. These devices shall become effective with each opening movement of the guard. It shall be necessary to separately reset these safety devices before another cycle can be initiated. The position from which the safety devices are reset shall afford a clear view of the mould area, if necessary with the use of aids to vision.The correct functioning of these devices shall be monitored by position switches at least once during each movement cycle of the guard, so that a fault in these devices or their position switches will be automatically recognized and commencement of all further platen closing movements shall be prevented.For all power operated guards fitted with such additional safety devices, the closing movement of the guard shall be operated by a hold to run control device which is positioned to give a clear view of the mould area.

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b) additionally, at least one emergency stop conforming to Category 0 according to EN 418, readily accessible from inside the mould area, at all sides of the machine where protection devices type III are fitted;c) additionally:

for machines with horizontal clamping unit, devices which detect the presence of persons in the mould area, e.g. electro-sensitive protective equipment according to prEN 50100-1:1994, type 2, or pressure sensing mats or floors according to prEN 1760-1:1994, category 2. These devices shall operate in accordance with the conditions stipulated in 5.3.1; for machines with vertical clamping unit, a single acknowledgement system (see annex C) as an alternative to presence sensing devices as described in 5.3.1.

5.3.3 Machines with downstroking platen

Hydraulic or pneumatic downstroking injection moulding machines shall be equipped with two restraint devices, which may for example be hydraulic valves to prevent unintentional gravity descent of the platen. Such valves shall be fitted preferably directly on the cylinder, or as close as possible to the cylinder using flanged (flared or welded) pipework or flared unions only.Where the platen is greater than 800 mm in one of its dimensions and the opening stroke can exceed 500 mm at least one of the restraint devices shall be mechanical. Such mechanical restraint devices shall automatically become effective over the complete stroke of the platen when the movable guards of the mould area are opened or when other safety devices for the mould area are actuated. Where it is not possible to open the movable guard of the mould area until the platen has reached its maximum opening stroke, mechanical restraint devices which only become effective in that position are permitted.In the event of a failure of one of the restraint devices the other device shall arrest the gravity descent of the platen. The restraint devices shall be automatically monitored so that in the case of a failure of one of these devices:

this failure is automatically recognized; and the initiation of any further downward movement of the platen is prevented.

5.3.4 Carousel machines

Access to dangerous movements of the carousel shall be prevented by fixed guards and/or protection devices type II.However where protection devices type II allow access to the mould area then the requirements specified in 5.2.1.1 and where applicable 5.3.1 and 5.3.2 shall also apply.

5.3.5 Shuttle/turntable machines

Access to dangerous movements of the table shall be prevented by one or more of the following: fixed guards; protection devices type II; electro-sensitive protective equipment in accordance with prEN 50100-1:1994, type 2; two hand control devices in accordance with prEN 574:1995, type IIIB.

Where protection devices type II are used which also allow access to the mould area then the requirements specified in 5.2.1.1 shall also apply.Where vertical movement of the shuttle table is possible gravity descent of the shuttle table shall be prevented e.g. by a hydraulic restraint as described in 5.3.3.

5.3.6 Multistation machines with mobile injection unit

Access to dangerous movement of the injection unit as it moves between the clamping units shall be prevented by fixed guards and/or protection devices type II.However where the protection devices type II allow access to the mould area, then the requirements specified in 5.2.1.1 and where applicable 5.3.1 and 5.3.2 shall also apply.

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!5.3.7 Machines with one or more electrical axes5.3.7.1 Emergency stop

The emergency stop shall function as a category 1 stop of EN 60204-1:1997, 9.2.2. Emergency stop devices shall be in accordance with EN 60204-1:1997, 10.7.

5.3.7.2 Electrical axis for the horizontal movement of the platen

5.3.7.2.1 Safe standstill when a guard for the mould area is open

When one of the interlocking guards with guard locking for the mould area specified in 5.3.7.2.2.1 is open, safe standstill shall be achieved by interrupting the energy supply to the movement of the platen by two channels according to G.1, G.2 or G.3 or according to category 4 of EN 954-1:1996.The interruption by both channels shall be independent from the programmable controller. The following shall be used:

contactor(s) in the power supply to the electrical motor or the motor control unit; and/or safety related input(s) to the motor control unit.

Automatic monitoring of the safety related components is required so that in case of a fault in one of those components, it is not possible to initiate the next movement. Automatic monitoring shall be carried out at least once during each movement cycle of the movable guard.

5.3.7.2.2 Prevention of access to hazardous areas created by the movement of the platen

5.3.7.2.2.1 Mould area

Access to the area between the platens shall be prevented by interlocking guards with guard locking.Guard locking shall remain effective until standstill has been detected (see Annex G).For the guard locking device well tried components according to category 1 of EN 954-1:1996 shall be used. The components shall be designed to withstand a minimum force of 1 000 N, applied e.g. when trying to open one of the guards when the guard locking is still effective.Detection of standstill shall be safe against single fault. This shall be done by:

monitoring two independent standstill signals; or standstill detection according to category 3 of EN 954-1:1996; or permanent monitoring of the change of position of the platen by means of a motor encoder.

5.3.7.2.2.2 Clamping mechanism area

Where access to the platen and its drive mechanism is prevented by movable guards (see 5.2.2), these shall be interlocking guards according to G.6 or G.7 or according to category 3 of EN 954-1:1996.In the case of dangerous run-down, i.e. t (access time) < T (overall system stopping performance as defined in EN 999:1998, 3.2), the guards for the clamping mechanism area shall be interlocking guards with guard locking.Guard locking shall remain effective until standstill has been detected. Detection of standstill shall be safe against single fault, as specified in 5.3.7.2.2.1, 4th paragraph.In the case of an interlocking guard without guard locking for the clamping mechanism area the access time (t) shall be calculated as follows:

where

t is the access time in s;

d is the distance between guard and dangerous point in m;

v is 1,6 m/s, approach speed see EN 999:1998;

#t is 100 ms, to take into account the time necessary to open the guard sufficiently to gain accessto the protected area."

t dv--- t+=

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!When calculating or measuring the overall system stopping performance for the movement of the platen and its drive mechanism, the worst case shall be taken into account related to speed, mass, temperature. See 7.1.9.

5.3.7.3 Electrical axis for the movement of the plasticizing and/or injection unit

For this movement, the interlocking of the guard for the nozzle area shall be according to G.4 or G.5 or according to category 1 of EN 954-1:1996 and the interlocking of the guards for the mould area shall be according to G.6 or G.7 or according to category 3 of EN 954-1:1996.In the case of dangerous run-down, i.e. t (access time) < T (overall system stopping performance as defined in EN 999:1998, 3.2), the guard for the nozzle area shall be an interlocking guard with guard locking. Guard locking shall remain effective until standstill has been detected. The detection of standstill shall be according to category B of EN 954-1:1996. In the case of an interlocking guard without guard locking for the nozzle area the access time shall be calculated as specified in 5.3.7.2.2.2.When calculating or measuring the overall system stopping performance for the movement of the plasticizing and/or injection unit, the worst case shall be taken into account related to speed, mass, temperature. See 7.1.9.

5.3.7.4 Electrical axis for the rotation of the plasticizing screw

For this movement, the interlocking of the guard for the nozzle area shall be according to G.4 or G.5 or according to category 1 of EN 954-1:1996 and the interlocking of the guard for the mould area shall be according to G.6 or G.7 or according to category 3 of EN 954-1:1996. Guard locking is not required because the run-down is not dangerous. If the machine is designed for processing rubber only, a motor control unit according to category B of EN 954-1:1996 without a contactor is sufficient.

5.3.7.5 Electrical axis for the linear movement of the injection screw or plunger

For this movement, the interlocking of the guard for the nozzle area shall be according to G.4 or G.5 or according to category 1 of EN 954-1:1996 and the interlocking of the guard for the mould area shall be according to G.6 or G.7 or according to category 3 of EN 954-1:1996. Guard locking is not required because the run-down is not dangerous.

5.3.7.6 Electrical axes for the movement of cores and ejectors

For the movement of cores and ejectors and/or their drive mechanisms, the interlocking of the guards outside the mould area shall be according to G.4 or G.5 or according to category 1 of EN 954-1:1996 and the interlocking of the guards for the mould area shall be according to G.6 or G.7 or according to category 3 of EN 954-1:1996. In the case of dangerous run-down, i.e. t (access time) < T (overall system stopping performance as defined in EN 999:1998, 3.2), the guards shall be interlocking guards with guard locking. Guard locking shall remain effective until standstill has been detected. The detection of standstill shall be according to category B of EN 954-1:1996. In the case of interlocking guards without guard locking, the access time shall be calculated as specified in 5.3.7.2.2.2.When calculating or measuring the overall system stopping performance for the movement of cores and ejectors, the worst case shall be taken into account related to speed, mass, temperature. See 7.1.9.

5.3.7.7 Requirements for the automatic monitoring circuit

5.3.7.7.1 Requirements for the automatic monitoring circuit where Annex G is applied

The following shall be automatically monitored at least once during each movement cycle of the movable guard:

change of state of the position detectors of the guard (not applicable to Figure G.4 and Figure G.5 if S1 is a well tried component); position of the contactors or the information given by the motor control unit; position of the guard locking device, if applicable; information given by the standstill detection, if applicable. "L

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!If a single fault occurs, the automatic monitoring shall prevent the initiation of any further movement. The monitoring circuit shall not produce a direct control signal for the shutoff devices e.g. contactors, motor control unit. Monitoring may be performed via the programmable controller. In that case the monitoring programme shall be in permanent memory protected against electrical interference and the monitoring system shall be equipped with a start-up test. In addition, for position detectors, contactors and/or motor control unit to control the same safety function:

each one of those components shall be connected to its own input module; or if a common input module is used, either the inverse signals from each one of those components shall be input as well, or any fault in the input circuits shall be automatically recognised; or if an input unit (input card) consists of several input modules, the signals from each one of those components to be monitored for antivalence shall be separated by at least the input module bit distance (e.g. 4 bits, 8 bits or 16 bits). In addition, signals from each one of those components which are not antivalent and are connected to the same input module shall not occupy adjacent bits.

The enable signal for the control circuit of the machine shall be produced by the monitoring circuit.

5.3.7.7.2 Requirement for the automatic monitoring circuit where Annex G is not applied

Where Annex G is not applied, the monitoring system shall be designed so that the required category of EN 954-1:1996 is achieved.

5.3.7.8 Movements caused by gravity

Movements caused by gravity shall be prevented by spring-loaded parking brakes. See also 7.1.10.

5.3.7.9 Electrical or electromagnetic disturbances

The motor control units shall be installed and used in accordance with the specifications of the motor control units manufacturers."5.4 Additional safety requirements and/or measures when using ancillary equipment

5.4.1 Power operated mould changing equipment

Access to the mould change area shall be prevented by protection devices type I for the movements of the mould changing equipment, in conjunction with fixed guards where necessary.Where it is possible to gain whole body access into the mould change area, additional devices, e.g. electro-sensitive protective equipment according to prEN 50100-1:1994, type 2, or pressure sensing mats or floors according to prEN 1760-1:1994, category 2 shall be fitted. These additional devices when actuated shall interrupt the control circuit for movements of the mould changing equipment.Movements of the mould and/or mould transfer device may be initiated manually without the existence of guards or with guards open or with additional safety devices being ineffective using a selector switch lockable in all positions and by actuation of:

a hold to run control device, provided the maximum speed cannot exceed 75 mm/s; or a limited movement control device.

The manual control device shall be positioned to give a clear view of the danger area.

5.4.2 Power operated mould clamping devices


The movable guard as specified in 5.2.1.1.1 or 5.2.1.1.2 shall also provide protection against the movements of the power operated mould clamping device. For these movements, the guard shall act as a protection device type II.Falling of the mould or its parts shall be prevented e.g. by additional mechanical restraint devices or by self retaining clamping elements.In the case of magnetic clamping the correct location of the mould halves shall be automatically monitored so that in the event of either mould half being or becoming dislocated, further movement of the platen shall be prevented.

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5.4.2.2 Hazards caused by magnetic fields

See 7.1.8.

5.4.3 Other ancillary equipment

The connection of ancillary equipment shall not reduce the level of safety specified in this standard for injection moulding machines. This means:

the connection of ancillary equipment which results in the modification of the guarding of the machine shall not allow unprotected access to danger areas of the machine. if opening a movable guard of the ancillary equipment gives access to a danger area of the machine, this movable guard shall perform to the same standard as a guard which is required for that danger area of the machine. In the case of whole body access as defined in 4.3.1 and/or 4.3.2 additional safety devices as specified in 5.3.1 and/or 5.3.2 shall be provided; ancillary equipment the presence of which prevents access to a danger area of the machine and which can be removed without the use of a tool shall be interlocked with the machine control circuit in the same way as the movable guard for the danger area concerned; if opening a movable guard of the machine gives access to a danger area of ancillary equipment this guard shall also meet the requirements specified in the standard applicable to that ancillary equipment; stopping devices including emergency stopping devices shall function as described in EN 292-2:1991/A1:1995, annex A, 1.2.4, Complex installations.

If the machine is intended to be used together with ancillary equipment it shall be so designed that the machine can only be operated if the ancillary equipment is connected in accordance with the above listed requirements.

6 Verification of the safety requirements and/or measuresVerification of the safety requirements and/or measures shall be undertaken as shown in Table 1 below The noise measurement (see 5.1.4) shall be carried out in accordance with annex D.Functional testing includes the verification of the function and efficiency of the guards and safety devices on the basis of:

descriptions given in the information for use; safety related plans and circuit diagrams; the requirements given in clause 5 of this standard and in the other quoted standards.

Functional testing of protection devices type II !, III and according to Annex G" shall also include the simulation of faults which are likely to occur.

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Table 1 Verification methods

7 Information for use7.1 Instruction handbook

Each injection moulding machine shall be accompanied by a handbook giving general instructions for use (see EN 292-2:1991/A1:1995, 5.5 and EN 292-2:1991/A1:1995, annex A, 1.7.4). In addition the instruction handbook shall contain the following:

7.1.1 Plasticizing and/or injection unit

The manufacturer shall give information for selecting and for assembly/disassembly of the injection nozzle.The manufacturer shall state that only nozzles, plasticizing and/or injection cylinders and their fastening bolts as specified by the manufacturer shall be used.The manufacturer shall state that due to insufficient pre-drying or degradation of certain plastic materials, unintentional ejection from the nozzle may occur and that in this case appropriate personal protective equipment shall be worn.

Clause

Verification methods

Visual inspection Functional test Measurement Calculation

5.1.1.1 X X

5.1.1.2 X

5.1.2 X X

5.1.3 X

5.1.4 X X X

5.1.5 X

5.1.6 X X

5.2.1.1 X X X

5.2.1.2 X X

5.2.2 X X

5.2.3 X X

5.2.4.1 X X

5.2.4.2 X X

5.2.5.1 X X X

5.2.5.2 X X

5.2.5.3 X X

5.2.6 X X X

5.3.1 X X X

5.3.2 X X X

5.3.3 X X X X

5.3.4 X X X

5.3.5 X X X

5.3.6 X X X

!5.3.7 X X X X"5.4.1 X X X

5.4.2.1 X X X

5.4.3 X X X

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The manufacturer shall declare the maximum permissible limit value of the temperature of the plasticizing and/or injection cylinders.

7.1.2 Noise emission

The instruction handbook shall indicate the conditions of installation during the noise measurements according to annex D and give the following information concerning airborne noise emission by the machinery, either the actual value or a value established on the basis of measurements made on identical machinery:

equivalent continuous A-weighted sound pressure level at workstations, where this exceeds 70 dB(A); where this level does not exceed 70 dB(A), this fact shall be indicated; peak C-weighted instantaneous sound pressure value at workstations, where this exceeds 63 Pa (130 dB in relation to 20 Pa); sound power level emitted by the machinery where the equivalent continuous A-weighted sound pressure level at workstations exceeds 85 dB(A).

In addition, for machines designed for rubber processing, information on the duration of the test cycle used (see annex D) shall be given.

7.1.3 Exhaust system

The manufacturer shall indicate that some materials likely to be processed can emit harmful gases, vapours or dusts and that exhaust system may be needed. The manufacturer shall indicate that in that case an exhaust system shall be positioned or fitted under the responsibility of the user. The manufacturer shall give information concerning the fitting or positioning of the exhaust system.

7.1.4 Ancillary equipment

It shall be stated that the manufacturer is only responsible for the interaction of the machine with ancillary equipment where the manufacturer has designed the interface system.The manufacturer shall state that if ancillary equipment is removed, the original guards or safety devices shall be replaced.

7.1.5 Lockable switch referred to in 5.2.1.1.3

The manufacturer shall state that the operator may only be allowed to use this switch provided the design of the mould, cores and ejectors, or their drive mechanisms prevents access to shearing or crushing areas.

7.1.6 Flexible hose assemblies

The manufacturer shall give information on regular inspections of flexible hose assemblies and their replacement.

7.1.7 Access positions

The manufacturer shall indicate that all positions which are not marked according to 5.1.6 are not to be used as access positions.

7.1.8 Magnetic mould clamping

The manufacturer shall give information on the safe use of the magnetic mould clamping device. This shall include instruction on the preparation and upkeep of the mould and platen contact surfaces.It shall be indicated that equipment such as heart pacemakers and hearing aids can be affected in the proximity of the magnetic field.

!7.1.9 Stopping performanceThe manufacturer shall specify the maximum stopping distance or time of the parts driven by electrical axes for which there is an interlocking guard without guard locking.

7.1.10 Parking brakes (see 5.3.7.8)

The manufacturer shall specify the frequency and procedure for testing the parking brake system. The manufacturer shall specify the maximum additional mass that can be added to the parts liable to move by gravity. The manufacturer shall also specify the replacement belts to be used. "

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7.2 Marking

The minimum markings shall include: name and address of the manufacturer and supplier; CE mark; designation of series or type; serial number if any, or machine number; year of construction; size indication according to annex E; access positions; warning notices about hot parts: heat conditioning hoses and fittings, moulds, heating elements and nozzles.

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Annex A (normative) Additional requirements for protection devices type III

A.1 Hydraulic power circuit

A.1.1 Requirements for the second shutoff device (see Figure 7, items 7 and 8)

The second shutoff device which interrupts the flow to the cylinder for the dangerous movement shall be an additional valve which is:

A.1.1.1 positively and directly actuated by the movable guard when the guard is opened; or

A.1.1.2 controlled by an additional position switch being positively and directly actuated by the movable guard when the guard is opened; or

A.1.1.3 controlled by a pilot valve being positively and directly actuated by the movable guard when the guard is opened; or

A.1.1.4 controlled by a pilot valve which is controlled by an additional position switch being positively and directly actuated by the movable guard when the guard is opened.

Where the additional valve is controlled by a position switch according to A.1.1.2 or A.1.1.4: the position switch shall have positive opening contacts; the connection between the position switch and the additional valve shall be via a hardwired circuit (possibly via a relay) and shall be independent of the programmable controller.

A.1.2 Requirements for the monitoring circuit

The following shall be automatically monitored during each cycle of the movable guard: the switching of the position switches of the guard acting on the control circuit; the switching of the position of the additional valve according to A.1.1; the switching of the position of the additional position switch (according to A.1.1.2 or A.1.1.4) and/or the pilot valve (according to A.1.1.3 or A.1.1.4). Where this is automatically monitored by the position switching of the additional valve, additional monitoring of the additional position switch and/or pilot valve is not required.

The automatic monitoring shall be effected so that if a single fault occurs, commencement of any further dangerous movement shall be prevented.The monitoring circuit shall not produce a direct control signal for the additional valve.Monitoring may be effected via the programmable controller. The monitoring programme shall be in permanent memory protected against electrical interference; the monitoring system shall have the same level of safety as defined in EN 61131-1:1994 and shall be equipped with a start-up test procedure.If monitoring is effected by a programmable controller:

each position switch shall be connected to its own input module; or if a common input module is used the inverse signals from both position switches shall be inputted as well, or any fault in the input circuits shall be automatically recognized.

The enable signal for the control circuit of the machine shall be produced by the monitoring circuit.

A.2 Pneumatic power circuit

The safety level shall be the same as that prescribed in B.1.In addition the pneumatic power circuit shall be designed to rapidly arrest the movement of the platen when the movable gu

En 201 Rubber and Plastics Machines Injection Moulding Machines

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