3 Fundamentals of press design

114 Fundamentals of press design
cannot be used for manual feed operation. This possibility is excluded
in the operating instructions – as far as possible, it should be possible
for the control system to prevent manual production.
Certificates issued by the manufacturer himself, however, must satisfy
certain conditions. In addition to adhering to the major health and
safety requirements of the ECMD, the manufacturer is required to draw
up a document prior to issuing the declaration of conformity in which
he provides written proof of compliance with these safety requirements.
The statutory retention period for this document is 10 years.
The documentation, intended for the customer, comprises the operating
instruction manual, which contains the necessary information for
the machine user. The focal point of the documentation is the hazard
analysis and risk assessment (Table 3.6.2). This involves a systematic
evaluation of the machine by the manufacturer concerning potential
hazards, an evaluation of the risk involved, and the appropriate measures
for their minimization. These must be described in the documentation.
The outcome takes on the form of a list of solutions undertaken
to comply with the points derived from annex I of the ECMD. In addition,
the documentation includes plans and diagrams – circuit diagram,
hydraulic and pneumatic diagrams and functional characteristics –, calculations,
test results, certificates and manufacturer’s declarations from
suppliers in as far as these are necessary for verification of the required
safety standard. This documentation does not need to be physically
Table 3.6.2: Extract from a hazard analysis with risk assessment
1
2
Hazardous
situation,
danger
area
Active
area, die
mounting
area
Type of
danger
Crushing,
shearing
Number of hazard
in accordance with EN414
1.1,
1.2
Part event
Reaching
in from
front and
other
hazards in
active area
during
operation
Continuous operation
Set-up
Maintenance
Repairs
Degree of severity
Overall frequency category
Bypassable
Protection category
x 3 3 0 4
Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Applied
89/392, standards
Safety gear / remark
annex I EN692 Others
Doc. No.
Protective shield 1st safeguarding to
5.3.3, 5.3.5.,
category 4, n.o. and n.c. contacts,
5.3.6,
early opening tS, safety distance 320 mm
5.3.10, EN294
to match stopping time 0.2 s to EN999.
1.1.2a,f, 5.3.12, EN999
Together with swivelling gripper box
1.3.7, 1.3.8, 5.3.15, EN954
prevention of access to danger zones 1, 1.4.2.2B, 5.5.6, 5.5.7, EN953
(EN294) (see drawing)
2
1.4.1, 1.6.1 5.5.8 EN1088