BS EN 983 1996
Short Description
Safety of machinery Safety requirements for fluid power systems andtheir components Pneumatics...
Description
BRITISH STANDARD
I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
Safety of machinery Ð Safety requirements for fluid power systems and their components Ð Pneumatics
The European Standard EN 983 : 1996 has the status of a British Standard
ICS 23.100; 23.140
NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW
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BS EN 983 983 : 1996 1996
BS EN 983 : 1996
Committees responsible for this British Standard I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h This British Standard, having s been prepared under the n direction of the Engineering u Sector Board, was published d l under the authority of the e i f f Standards Board and comes into e effect on h 15 November 1996 s : y © BSI 1996 p o C d e s n e c i L
The following BSI references relate to the work on this standard: Committee reference MCE/18 Draft for comment 93/700546 DC
ISBN 0 580 26252 9
The preparation of this British Standard was entrusted to Technical Committee MCE/18, Fluid power systems and components, upon which the following bodies were represented:
Association of British Mining Equipment Companies British Compressed Air Society British Fluid Power Association British Hydrodynamics Research Association Department of Trade and Industry (National Engineering Laboratory) Ministry of Defence University of Bath The following bodies were also represented in the drafting of the standard, through subcommittees and panels: British Iron and Steel Producers' Association Engineering Equipment and Materials Users' Association Health and Safety Executive
Amendments issued since publication Amd. No.
Date
Text affected
BS EN 983 : 1996
Contents I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
Page Committees responsible
Inside front cover
National foreword
ii
Foreword
2
Text of EN 983
3
i
BS EN 983 : 1996
National foreword I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
ii
This British Standard has been prepared under the direction of the Technical Committee MCE/18 and is the English language version of EN 983 : 1996 Safety of machinery ± Safety requirements for fluid power systems and their components ± Pneumatics, published by the European Committee for Standardization (CEN). EN 983 was produced as a result of international discussion in which the United Kingdom took an active part. Cross-references Publication referred to
Corresponding British Standard
EN 286-1
BS EN 286 Simple unfired pressure vessels designed to contain air or nitrogen Part 1 : 1991 Design, manufacture and testing BS EN 292 Safety of machinery. Basic concepts, general principles for design Part 1 : 1991 Basic terminology, methodology Part 2 : 1991 Technical principles and specifications BS EN 418 : 1992 Safety of machinery. Emergency stop equipment, functional aspects. Principles for design BS EN 50081 Electromagnetic compatibility. Generic emission standard Part 2 : 1994 Industrial environment BS EN 60529 Specification for degrees of protection provided by enclosures (IP code.) BS 2917 Graphic symbols and circuit diagrams for fluid power systems and components Part 1 : 1993 Specification for graphic symbols
EN 292-1 EN 292-2 EN 418
EN 50081-2 EN 60529 ISO 1219-1
The Technical Committee has reviewed the provisions of prEN 954-1, prEN 1050, ENV 1070, prEN 1127-1, prEN 50081-2, ISO/DIS 1219-2, ISO 5598 and ISO/TR 11688-1 to which normative reference is made in the text and has decided that they are acceptable for use. Compliance with a British Standard does not of itself confer immunity from legal obligations.
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EN 983
EUROPEAN STANDARD Â ENNE NORME EUROPE È ISCHE NORM EUROPA I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
April 1996
ICS 23.100.00; 23.140 Descriptors: Hydraulic fluid power, pneumatic fluid power, pneumatic equipment, directional control valves, fluid circuits, components, safety, accident prevention, hazards, design, equipment specifications, specifications, protection, verification, marking
English version
Safety of machinery Ð Safety requirements for fluid power systems and their components Ð Pneumatics
Se curite des machines ± Prescriptions de se curite relatives aux systeÁmes et leurs composants de transmissions hydrauliques et pneumatiques ± Pneumatique
Sicherheit von Maschinen ± Sicherheitstechnische Anforderungen an fluidtechnische Anlagen und deren Bauteile ± Pneumatik
This European Standard was approved by CEN on 1996-03-09. 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, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
CEN European Committee for Standardization Comite EuropeÂen de Normalisation Europa È isches Komitee fu È r Normung Central Secretariat: rue de Stassart 36, B-1050 Brussels
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1996 Copyright reserved to CEN members Ref. No. EN 983 : 1996 E
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I S B Foreword ) c ( This European Standard has been prepared by CEN/TC , y 114, Safety of machinery, the Secretariat of which is p held by DIN. o C This European Standard shall be given the status of a d national standard, either by publication of an identical e l l text or by endorsement, at the latest by October 1996, o r and conflicting standards shall be withdrawn at the t n latest by October 1996. o c n This European Standard has been prepared under a U mandate given to CEN by the European Commission , 6 and the European Free Trade Association and supports 0 essential requirements of EC Directive(s). 0 2 According to the CEN/CENELEC Internal Regulations, 0 the national standards organizations of the following 0 : 0 countries are bound to implement this European 0 Standard: Austria, Belgium, Denmark, Finland, France, + T Germany, Greece, Iceland, Ireland, Italy, Luxembourg, MNetherlands, Norway, Portugal, Spain, Sweden, G Switzerland and the United Kingdom. 5 4 : It was developed to contribute towards unification of 5 safety regulations and procedures in the various 1 : member countries for each aspect within the field of 1 0 pneumatics for fluid power systems and their 3 components. This standard utilizes the most recently 2 validated technical information from established t c technical sources (e.g. CEN, ISO, national standards O and European documents). n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
Contents Page Foreword
2
0
Introduction
3
1
Scope
3
2
Normative references
3
3
Definitions
4
4
List of hazards
4
5
Safety requirements and/or measures
4
5.1
Basic requirements for the design and specification of pneumatic systems
4
Additional requirements
7
5.2
5.2.1 Site conditions
7
5.2.2 Component removal
7
5.2.3 Preparation for transportation
7
5.3
Specific requirements for components and controls
8
5.3.1 Motors and rotary actuators
8
5.3.2 Cylinders
8
5.3.3 Valves
8
5.3.4 Energy transmission and conditioning
9
5.3.5 System protection
10
5.3.6 Sequence control
10
5.3.7 Control systems with servo or proportional valves
10
5.3.8 Silencers
10
Verification of safety requirements and/or measures
10
6.1
Inspection
10
6.2
Testing
10
7
Information for use
11
7.1
Final data
11
7.2
Maintenance data
11
7.3
Marking
11
7.3.1 Components
11
7.3.2 Components within a system
11
7.3.3 Ports
11
7.3.4 Valve control mechanisms
11
7.3.5 Internal devices
11
Annex A (informative) Bibliography
12
6
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I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
0 Introduction This standard is a type B2 standard (according to EN 292-1) and contains the general requirements for pneumatic systems and their components on machinery. For type C standard makers, it is a basis for the development of specific requirements on dedicated machines. If no type C-standards are available, it is a basis for the manufacturers when constructing machines that include pneumatic systems and their components. In developing this standard, safety related requirements out of ISO 4414 were selected as well as additional safety related requirements. Equivalent safety requirements for hydraulic systems are defined in EN 982 Safety of machinery Ð Safety requirements for fluid power systems and their components Ð Hydraulics.
1 Scope This standard applies to pneumatic systems and their components on machinery. It identifies hazards and factors which affect the safety of systems and their components when they are put to their intended use. Gas bottles and receivers are excluded from the scope of this standard. For receivers see EN 286-1. The principles specified apply to the design, construction and modification of new systems and their components and aspects of use including: ± assembly;
EN 286-1
Simple unfired pressure vessels designed to contain air or nitrogen ± Part 1: Design, manufacture and testing
EN 292-1 : 1991
Safety of machinery ± Basic concepts, general principles for design ± Part 1: Basic terminology, methodology
EN 292-2 : 1991
Safety of machinery ± Basic concepts, general principles for design ± Part 2: Technical principles and specifications
EN 418
Safety of machinery ± Emergency stop equipment, functional aspects ± Principles for design
prEN 954-1 : 1992 Safety of machinery ± Safety related parts of control systems ± Part 1: General principles for design prEN 1050 : 1992 Safety of machinery ± Risk assessment ENV 1070
Safety of machinery ± Terminology
prEN 1127-1 : 1993
Safety of machinery ± Fire and explosions Part 1: Explosion prevention and protection
EN 50081-2
Electromagnetic compatibility ± Generic emission standard ± Part 2: Industrial environment
prEN 50082-2
Electromagnetic compatibility ± Generic immunity standard ± Part 2: Industrial environment
EN 60204-1 : 1992
Safety of machinery ± Electrical equipment of machines ± Part 1: General requirements (IEC 204-1 : 1992, modified)
EN 60529
Degrees of protection provided by enclosures (IP code) (IEC 529 : 1989)
ISO 1219-1
Fluid power systems and components ± Graphic symbols and circuit diagrams ± Part 1: Graphic symbols
± installation; ± adjustment; ± operation; ± cleaning; ± maintenance. Components are covered in the standard, but only to the extent that safety requirements are given to allow the components to be safely integrated into a system's design. The standard applies to systems and their components on machinery that are manufactured after the date of the adoption of this standard.
2 Normative references This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the 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.
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ISO/DIS 1219-2 : Fluid power systems and 1993 components ± Graphic symbols and circuit diagrams ± Part 2: Circuit diagrams ISO 5598
Fluid power systems and components ± Vocabulary
ISO/TR 11688-1
Acoustics ± Recommended practice for the design of low-noise machinery and equipment ± Part 1: Planning
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3 Definitions
5 Safety requirements and/or measures
I When designing pneumatic systems for machinery, all S For the purpose of this standard, the definitions of B ENV 1070 and the following apply. Other definitions intended operations and use of systems shall be ) considered. Risk assessment in accordance with c not included are given in ISO 5598. ( prEN 1050 shall be carried out to determine the , y 3.1 fluid power foreseeable risks associated with systems when they p o The means whereby signals and energy can be are used as intended by their design. So far as it is C transmitted, controlled and distributed using a practicable, the risks identified shall be eliminated by d pressurized fluid as the medium. design and, where this is not practicable, the design e l l shall incorporate safeguards against such risks. See o r 3.2 system t EN 292-2. n Arrangement of interconnected components which o Where systems or parts of systems have safety related c transmits and controls fluid power energy. n control functions, they should be designed and U 3.3 component constructed to meet specified categories of , 6 An individual unit (e.g. cylinder, motor, valve, filter) performance, as given in prEN 954-1. 0 0 comprising one or more parts designed to be a 5.1 Basic requirements for the design and 2 functional part of a fluid power system. specification of pneumatic systems 0 0 : 3.4 pneumatics 5.1.1 All components in the system shall be selected 0 0 Science and technology which deals with the use of air or specified to provide for safety in use, and they shall + operate within the design limits when the system is put T or neutral gases as the fluid power medium. M to its intended use. Components shall be selected or G 3.5 maximum working pressure specified so that they have adequate characteristics to 5 The highest pressure at which the system or part of allow them to operate reliably under all intended uses 4 : the system is intended to operate in steady-state of the system. Particular attention shall be paid to the 5 conditions. 1 reliability of components that could create a hazard, in : 1 the event of their failure or malfunction. 0 3.6 rated pressure The components shall be selected, applied and 3 The highest pressure at which the component is 2 installed in accordance with the manufacturer's t intended to operate for a number of repetitions c recommendations. O sufficient to assure adequate service life. n 3.7 operating device o MDevice that provides an input signal to a control , a mechanism (e.g. cam, switch). n , 3.8 control mechanism n u A device that provides an input signal to a component d l (e.g. lever, solenoid). e i f f e 3.9 actuator h s Component that transforms fluid energy into n mechanical energy (e.g. motor, cylinder). u d l 3.10 piping e i f f Any combination of fittings, couplings or connectors e h with pipes, hoses or tubes which allows fluid flow s between components. : y p 3.11 neutral gas o C A gas which has properties similar to air and does not d react to the effects of pressure and/or temperature in a e manner different to air. s n e c i L 4 List of hazards The possible hazards associated with the use of pneumatic power in a machine are given in table 1.
NOTE. It is recommended that wherever practicable components should be made in conformance with recognized international or national standards.
5.1.2 All parts of the system shall be designed or otherwise protected against pressures exceeding the maximum working pressure of a system or any part of the system or the rated pressure of any specific component. The preferred means of protection against excessive pressure are one or more pressure relief valves located to limit the pressure in all parts of the system. Alternative means, such as pressure regulators, may be used, provided those means satisfy the application requirements. Systems shall be designed, constructed and adjusted to minimize surge pressures and intensification pressures. Surge pressure and intensified pressure shall not cause hazards. Loss of pressure or critical drops in pressure shall not expose persons to a hazard. 5.1.3 Leakage (internal or external) shall not cause a hazard.
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Table 1. List of hazards Hazard type
Relevant clauses EN 292-1 : 1991
4.1 Mechanical hazards
EN 292-2 : 1991
4.2
± shape
Annex A of EN 292-2 : 1991
Relevant type B standard or clause in this standard
1.3, 1.4,
5.1.1, 5.1.2,
1.3.7
5.1.3, 5.1.5,
± relative location
5.1.7, 5.2.1,
± mass and stability (potential energy of elements)
5.2.2, 5.2.3,
± mass and velocity (kinetic energy of elements)
5.3.1, 5.3.2,
± inadequacy of the mechanical strength
5.3.3, 5.3.4.2,
± accumulation of potential energy by:
5.3.4.3, 5.3.4.4,
± elastic elements (springs), or
5.3.5.1, 7.2,
± liquids or gases under pressure, or
7.3.1
± vacuum ± leakage 4.2 Electrical hazards
5.1.6, 5.2.1, 5.3.3.3.2 a, EN 60204-1
4.3 Thermal hazards resulting in burns and scalds, by a possible contact of persons, by flames or explosions and also by the radiation of heat sources
5.1.8, 5.2.1
4.4 Hazards generated by noise
5.1.8, 5.2.1, 5.3.8
4.5 Hazards, especially unintended movements caused by electromagnetic fields 4.6 Hazards generated by materials and substances processed, used and exhausted by machinery
3.7.11
1.5.10, 1.5.11
EN 50081-2, prEN 50082-2
1.5.13
4.6.1 Hazards resulting from contact with or inhalation of harmful fluids, gases, mists, fumes and dusts
5.1.9, 5.3.2.6, 7.1
4.6.2 Fire or explosion hazards
5.2.1
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Page 6 EN 983 : 1996
Table 1. List of hazards ( continued) I Relevant clauses S Hazard type B EN 292-1 : 1991 ) c ( , y 5.2.2 p 4.7 Hazards caused by failure o of energy supply, breaking C d down of machinery parts and e other functional disorders l l o r 4.7.1 Failure of energy supply 3.16 t n (of energy and/or control o c circuits) n U ± variation of energy , 6 0 0 ± unexpected start 2 0 ± prevention from stopping if 0 : the command has already been 0 given 0 + T ± falling or ejecting of moving M parts or pieces held by the G machinery 5 ± impeded automatic or manual 4 : 5 stopping 1 : 1 ± protection device remains not 0 fully effective 3 2 4.7.2 Unexpected ejection of 4.2.1 t c machine parts or fluids O 3.1.5, n 4.7.3 Failure, malfunction of o control system (unexpected 3.1.6, M start up, unexpected overrun) 3.1.7 , a n , n u d l e i f f 4.7.4 Errors of fitting e h s n u d l e i f f e 4.8 Hazards caused by h temporarily missing and/or s : incorrectly positioned safety y p related measures/means, for o C example
EN 292-2 : 1991
Annex A o f EN 292-2 : 1991
3
1.2
3.7
1.2.6
Relevant type B standard or clause in this standard
5.1.4, 5.1.6, 5.2.1, 5.3.3.3.2 c, 5.3.3.3.2 d
3.8, 4
1.3.2, 1.3.3
5.2.1, 5.3.4.3.2
3.7
1.2.7, 1.6.3
prEN 954-1, 5.1.4, 5.1.6, 5.3.3.2, 5.3.5, 5.3.6, 5.3.7
1.5.4
5.2.1, 5.2.3, 5.3.3.1, 5.3.4.2, 5.3.4.3, 7.3
4
d 4.8.1 Starting and stopping e s devices n e 4.8.2 Safety signs and signals c i L
3.7
1.2.3, 1.2.4
5.1.4
3.6.7, 5.2, 5.3, 5.4
1.7.2, 1.7.3
7.2
4.8.3 All kinds of information or warning devices
5.4
1.7.0, 1.7.1
5.3.4.1.1c, 5.3.5.8, 7.3
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Page 7 EN 983 : 1996
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Table 1. List of hazards ( continued) Hazard type
Relevant clauses EN 292-1 : 1991
EN 292-2 : 1991
Annex A of EN 292-2 : 1991
Relevant type B standard or clause in this standard
4.8.4 Energy supply disconnecting devices
6.2.2
1.6.3
5.1.6, 7.2
4.8.5 Emergency devices
6.1
1.2.4
EN 418
3.12, 6.2.1, 6.2.3, 6.2.6
1.1.2 f, 1.1.5
5.1.5, 5.3.1, 5.3.2.3, 5.3.4.3.2, 5.3.4.4, 5.3.5.2, 5.3.5.3
4.8.6 Essential equipment and accessories for safe adjusting and/or maintaining
3.3, 3.11
5.1.4 Whatever the type of control or power supply used (e.g. electrical, pneumatic, etc.), the following actions or occurrences (unexpected or by intention) shall not create a hazard: ± switching the supply on or off; ± supply reduction; ± supply cut-off or re-establishment.
5.2 Additional requirements 5.2.1 Site conditions When designing systems, it shall be ensured that the following influences that can lead to a hazard are considered: ± vibration, contamination, humidity, range of ambient temperatures;
5.1.5 The system shall be designed and constructed so that components are located where they are accessible and can be safely adjusted and serviced.
± fire or explosion hazard (see prEN 1127-1);
5.1.6 The system shall be designed to facilitate positive isolation from energy sources and also to facilitate dissipation of the fluid pressure in the system in order to prevent unexpected start-up. In pneumatic systems this can be done by, e.g.:
± protection for electrical devices;
± isolation of the supply by a suitable shut-off device, which may need to be lockable; or ± isolation and dissipation of pressure from the system with a suitable shut-off device(s) having a pressure release feature, which may need to be lockable; ± release or support of mechanical loads when the system is depressurized; ± isolation of the electrical supply (see 5.3 of EN 60204-1 : 1992). Precautions should be taken when the supply is reinstated after isolation or depressurization. 5.1.7 Mechanical movements, whether intended or unintended (including effects from e.g. acceleration, deceleration or lifting/holding of masses), shall not result in a situation hazardous to persons. 5.1.8 For the design of low noise machinery and systems, see ISO /TR 11688-1. 5.1.9 Systems shall be so designed, constructed and/or equipped that hazards due to airborne hazardous substances included in the exhausting air can be minimized.
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± electrical network (voltage and its tolerances, frequency, available power); ± requirements for guarding; ± legal and other environmental limiting factors (e.g. noise emission level); ± space required for access, use and maintenance as well as the location and mounting of components and systems to ensure their stability and security in use; ± specification of pneumatic supply available; ± other safety requirements. 5.2.2 Component removal Components should be located such that their removal for maintenance should not necessitate extensive disassembly of adjacent parts. 5.2.3 Preparation for transportation 5.2.3.1 Identification of piping Whenever systems have to be dismantled for transportation, the piping and connections shall be clearly identified. The identification shall correspond and not conflict with the data on any appropriate drawings. 5.2.3.2 Packaging All systems/components shall be packaged in a manner that protects them from damage and distortion and preserves their identification during transportation.
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5.2.3.3 Protection of openings I Exposed openings in components shall be covered, S B and male threads shall be protected during ) transportation. These covers shall only be removed c ( , immediately before reassembly. Only covers that y require their removal before reassembly can take place p o shall be used. C d 5.3 Specific requirements for components and e controls l l o r 5.3.1 Motors and rotary actuators t n Rotating shafts and couplings shall be guarded to o c prevent hazard to personnel. n U 5.3.2 Cylinders , 6 0 5.3.2.1 Resistance to buckling 0 2 Attention shall be given to stroke length, loading, and 0 cylinder mountings in order to avoid bending or 0 : buckling of the cylinder piston rod in any position. 0 0 5.3.2.2 Resistance to shocks and vibrations + T Any components mounted on or connected to a Mcylinder shall be attached in a way that resists G 5 loosening caused by shocks, vibrations, etc. 4 : 5 5.3.2.3 Stroke end stops 1 : If stroke length is determined by external stroke end 1 stops, means shall be provided for locking adjustable 0 3 end stops. 2 t 5.3.2.4 Alignment c O Mounting surfaces shall be designed to prevent n distortion of the cylinder when installed. The cylinder o shall be mounted in a way that avoids unintended side M , loads during operation. a n 5.3.2.5 Mounting fasteners , n Mounting fasteners for cylinders and attachments shall u d l be designed and installed to accommodate all e predictable forces. As far as possible the fasteners i f f should be free from shear forces. Foot-mounted e h cylinders should have means to absorb shear loads, s rather than depending on mounting fasteners. The n u mounting fasteners shall be adequate to absorb d l overturning moments. e i f f 5.3.2.6 Air vent e h A single acting piston type cylinder shall have its air s : vent port designed and/or positioned to avoid hazards y to persons when displaced air is exhausted. p o C 5.3.2.7 Rod protection d Piston rods should be protected against foreseeable e s damage from dents, scratches, corrosive fluids etc. n e 5.3.3 Valves c i L 5.3.3.1 Mounting 5.3.3.1.1 Method Valve type and method of mounting shall be selected to ensure correct function, adequate leak tightness and resistance against foreseeable mechanical and/or environmental influence.
5.3.3.1.2 Orientation There shall be means to avoid incorrect mounting of valves. 5.3.3.1.3 Attitude The effects of gravity, impact or vibration on the main elements of a valve shall be considered when mounting any valve. 5.3.3.1.4 Back pressure When stacked or manifold valves or common exhaust lines are used, then special consideration needs to be given to the design of the system to avoid the influence of back pressure which could affect safe use. 5.3.3.2 Spring biased or detent located valves Any actuator required to maintain its position or to adopt a specific position for safety, in the event of a control system failure, shall be controlled by a valve which is either spring biased or detent located to a safe position. 5.3.3.3 Valve operating devices 5.3.3.3.1 Mechanically operated valves Mechanically operated valves shall be installed so that they cannot be damaged by the operating device. 5.3.3.3.2 Electrically operated valves a) Electrical connections Electrical connections to a supply shall be in accordance with appropriate standards, e.g. EN 60204-1. For hazardous operating conditions, the appropriate degree of protection (e.g. explosion proofing, water proofing) shall be employed. b) Terminal block housing Where terminal blocks and housings are specified in the valves, the terminal block housing shall be constructed as follows: ± the appropriate degree of protection in accordance with EN 60529; ± adequate space for permanently located terminals and for the terminal cable including an additional length of cable; ± captive fasteners for the electrical access cover to prevent loss, e.g. screws with retaining washer; ± suitable securing device for the electrical access cover, e.g. a chain; ± cable connections with strain relief. c) Solenoids Solenoids shall be sized so that they are capable of operating the valves reliably at the nominal voltage 10 %. d) Manual override If an electrically operated valve needs to be operated for safety reasons when electrical control is not available, then it should be fitted with manual override means. These shall be designed so that they cannot be operated inadvertently, and they should reset when the manual control is removed unless otherwise specified.
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Page 9 EN 983 : 1996
I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
5.3.4 Energy transmission and conditioning
5.3.4.2.5 Piping runs across access ways
5.3.4.1 Fluids
Piping runs across access ways shall not interfere with the normal use of the access way. They should be located either below or well above the floor level, and in accordance with site conditions. These piping runs shall be readily accessible, rigidly supported, and where necessary, protected from external damage.
5.3.4.1.1 Filtration a) Filters, drains and dryers Means shall be provided to remove detrimental solid, liquid and gaseous materials from the compressed air or neutral gas. The degree of filtration shall be consistent with the requirements for the components and environmental conditions.
5.3.4.2.6 Characteristics of piping The safe use of piping within a system shall take into account site conditions. Where plastic piping is selected, it shall not be adversely affected by any fluids associated with the system.
c) Filter condition monitoring
5.3.4.2.7 Quick action (release) couplings
If deterioration of filter performance could lead to a hazardous situation, clear indication of such deterioration shall be given.
Quick action (release) couplings shall be selected so that when they are coupled or uncoupled:
b) Degree of filtration
5.3.4.1.2 Compatibility of lubricating fluids Where necessary, appropriate lubricating fluids should be recommended for use in systems. The fluids should be compatible with all components, elastomers, plastic tubing and flexible hoses in the system. 5.3.4.2 Pipes, fittings and fluid passages 5.3.4.2.1 Design of layout Piping should be designed to discourage its use as a step or ladder. External loads should not be imposed upon piping. 5.3.4.2.2 Piping location To avoid incorrect connections which might cause a hazard, pipes should be identified and located accordingly. Piping, both rigid and flexible, shall be located to protect against foreseeable damage and not restrict access for adjustment, repairs, replacement of components or work in process. 5.3.4.2.3 Foreign matter Pipes, fittings, and fluid passages, including cored and drilled holes, shall be free of detrimental foreign matter such as scale, burrs, swarf, etc., that may restrict flow or be dislodged and cause malfunction of and/or damage to any component including seals and packings. 5.3.4.2.4 Supports If necessary, piping shall be securely supported both at its ends and at intervals along its length by correctly designed supports. Pipe supports shall not damage the piping or reduce the flow. Piping shall not be used to support components where they would impose undue loads on the piping. Undue loads may arise from component mass, shock, vibration and surge pressure.
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± the coupling shall not be forced apart in a hazardous manner; ± compressed air or particles shall not be expelled in a hazardous manner; ± a controlled pressure release system shall be provided where a hazard may exist. 5.3.4.3 Flexible hose assemblies Flexible hose assemblies shall not be constructed from hoses which have been previously used as part of a hose assembly. Flexible hose assemblies shall fulfill all performance requirements specified in the appropriate European and/or international standard(s). Recommendations on storage time for the flexible hose assemblies given by the hose manufacturers shall be considered. Consideration should be given to recommending a service life for hose assemblies. 5.3.4.3.1 Installation Installation of flexible hose assemblies shall: ± have the minimum length necessary to avoid sharp flexing and straining of the hose during the component operation. Flexible hoses should not be bent with a radius smaller than the recommended minimum bending radius; ± minimize torsional deflection of the hose during the installation and use, e.g. as the result of a rotating connector jamming; ± be located or protected to minimize abrasive rubbing of the hose cover; ± be supported, if the weight of the hose assembly could cause undue strain. 5.3.4.3.2 Failure of flexible hose assemblies and plastic piping If the failure of a flexible hose assembly or plastic piping constitutes a whiplash hazard, it shall be restrained or shielded. If the failure of a flexible hose assembly or plastic piping constitutes a fluid ejection hazard, it shall be shielded.
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5.3.4.4 Non-metallic bowls on fluid conditioning 5.3.5.8 Monitoring of system parameters I units Where changes in system operating parameters could S To protect personnel from the hazard of a non-metallic constitute a hazard, clear indication shall be provided. B ) bowl failure on filters, separators, filter-regulators and c 5.3.6 Sequence control ( , lubricators when the product of the pressure in bar Sequencing by position sensing shall be used wherever y and the volume in litres of the bowl is greater than 1 p practicable and shall always be used when a o bar litre the bowl should be capable of being shielded. sequencing malfunction of a pressure or time lapse C d 5.3.5 System protection control, on its own, could cause a hazard. e l l 5.3.5.1 Pressure regulation 5.3.7 Control systems with servo or proportional o r t Control shall be provided to maintain the system valves n o pressure within safe limits, e.g. where pressure Where actuators are controlled by servo or c n regulators are used in pneumatic circuits for safety, proportional valves and malfunction of the control U they should be of the self-relieving type. system may result in the actuators causing a hazard , 6 NOTE. Relieving type regulators are not safety relief devices and then means shall be provided to maintain or recover 0 shall not be the sole device to prevent excess pressure where control of these actuators. Actuators, speed controlled 0 their relief capability is inadequate. 2 by servo or proportional valves, shall have means to 0 5.3.5.2 Tamper-resistant protection hold or move the actuator to a safe position if 0 : unintended movement may cause a hazard. 0 Pressure and flow control devices on their enclosures 0 + shall be fitted with tamper-resistant devices where an 5.3.8 Silencers T unauthorized alteration to pressure or flow can cause a Silencers shall be used where the sound pressure level Mhazard. G caused by exhausting air is above that permitted by 5 5.3.5.3 Adjustable control mechanisms applicable codes and standards. 4 : The use of exhaust port silencers in themselves shall 5 Pressure and flow control devices shall be constructed 1 to permit adjustment within their ratings. Adjustment not constitute a hazard. : 1 beyond these ratings may be possible; the ratings are 0 3 not maximum adjustable limits. 6 Verification of safety requirements 2 t Adjustable control mechanisms shall hold their settings and/or measures c within specified limits until reset. O Since a pneumatic system may not be a complete n 5.3.5.4 Control of multiple devices machine, many verification procedures cannot be o carried out until the pneumatic system is incorporated MWhere there is more than one interrelated , automatically and/or manually controlled device on the into the machine. Appropriate instructions shall be a n equipment, and where failure of any of these devices given to the machine manufacturer by the pneumatic , could cause a hazard, protective interlocks or other system designer/manufacturer. n u safety means shall be provided. Where practical, these d l interlocks should interrupt all operations, provided that 6.1 Inspection e i f The systems and their components shall be verified by f such interruption does not of itself cause a hazard. e inspecting their identification in comparison to the h 5.3.5.5 Protection under external loads s system specifications. n Means shall be provided to prevent unacceptable In addition the connection of components on the u d pneumatic system shall be inspected to verify its l pressure build-up where high external loads are e reflected on actuators. i compliance with the circuit diagram. f f e 5.3.5.6 Unintended movement 6.2 Testing h s Control systems shall be designed to prevent The following tests shall be conducted to determine : y unintended hazardous movement and improper compliance with the applicable safety requirements: p o sequencing of actuators. This applies to all phases of ± operational tests to prove the correct operation of C the operation. the system and all safety devices; d e 5.3.5.7 Control system stability ± pressure test to test each part of the system at the s n Pressure and flow control valves shall be selected so maximum working pressure which may be sustained e c that changes in working pressure, working temperature under all conditions of intended use. i L and load do not influence the operation in a hazardous way.
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I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
7 Information for use
7.3.2 Components within a system
Information for use shall be in accordance with clause 5 of EN 292-2 : 1991.
Each pneumatic component shall be allocated an item number and/or letter. This item number and/or letter shall be used to identify the component on all diagrams, lists and layouts. It should be clearly and permanently marked on the installation adjacent to the component.
7.1 Final data A circuit diagram shall be provided. This diagram should be in accordance with ISO/DIS 1219-2. Details of any hazards associated with the specified lubrication fluids should be given. Information supplied should include: ± toxicity;
Component ports and power take-off points (test ports and bleed points) shall be clearly and distinctly identified. The identification shall correspond to the data on the circuit diagram.
± asphyxiating hazards in the event of fire;
7.3.4 Valve control mechanisms
± hygiene requirements;
± biological resistance; ± method of disposal. 7.2 Maintenance data All systems shall be provided with the necessary maintenance data which shall clearly: ± indicate external lubrication points, the type and levels of lubricant required and whether or not the lubricator(s) can be filled under pressure; ± locate drains, filters, test points, strainers, magnets, etc., that require scheduled maintenance; ± identify those parts of a system that are not depressurized by the normal venting device; ± give any required depressurizing instructions. 7.3 Marking 7.3.1 Components The following particulars shall be shown, if practicable, in a permanent and readily visible form on all components: ± the manufacturer's/supplier's name and brief address; ± the manufacturer's/supplier's product identification; ± the rated pressure; ± symbols according to ISO 1219-1, and all ports correctly identified; ± for hose assemblies: date of manufacture; ± for stacking modules: their order shall be clearly indicated adjacent to, but not on, the stack.
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7.3.3 Ports
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7.3.4.1 Non-electrical control mechanisms Valve control mechanisms and their functions shall be plainly and permanently identified with the same identification used on the circuit diagram. 7.3.4.2 Electrical control mechanisms Electrical control mechanisms (solenoids and their attaching plugs or cables) shall be identified on the electrical and pneumatic circuit diagrams with the same identification. 7.3.5 Internal devices Valves and other functional devices (orifice plugs, passages, shuttle valves, check valves, etc.) located within a manifold, mounting plate, pad, or fitting, shall be identified adjacent to their access openings. Where access openings are located under a component or components, identification shall, if practicable, be provided adjacent to the component and marked `CONCEALED'.
Page 12 EN 983 : 1996
Annex A (informative)
I S Bibliography B ) c European Standards ( , y Safety of machinery ± Two-hand control device p prEN 574 : 1991 o Safety of machinery ± Safety requirements for fluid power systems and their C EN 982 components ± Hydraulics d e l l prEN 1037 : 1993 Safety of machinery ± Isolation and energy dissipation Ð Prevention of unexpected o r start-up t n o EN 50081-1 Electromagnetic compatibility (EMC) ± Generic emission standard ± Part 1: Residential, c commercial and light industry n U , prEN 50082-1 : 1994 Electromagnetic compatibility (EMC), Generic immunity standard ± Part 1: Residential, 6 commercial and light industry 0 0 International Standards 2 0 ISO 2230 Vulcanized rubber ± Guide to storage 0 : 0 ISO 2398 Industrial rubber hose for compressed air (up to 2,5 MPa) 0 + ISO 2944 Fluid power systems and components ± Nominal pressures T MISO 4400 Fluid power systems and components ± Three-pin electrical plug connector ± G Characteristics and requirements 5 4 Pneumatic fluid power ± Recommendations for the application of equipment to : ISO 4414 5 transmission and control systems 1 : Plastics hoses ± Textile-reinforced thermoplastics type for compressed air ± Specification 1 ISO 5774 0 Pneumatic fluid power ± Cylindrical quick-action couplings for maximum working 3 ISO 6150 2 pressures of 10 bar, 16 bar and 25 bar (1 MPa, 1,6 MPa and 2,5 MPa) ± Plug connecting t c dimensions, specifications, application guidelines and testing O Fluid power systems and components ± Two-pin electrical plug connector with earth n ISO 6952 o contact ± Characteristics and requirements M Rubber and plastics hoses and hose assemblies ± Ratios of proof and burst pressure to , ISO 7751 a design working pressure n , Rubber and plastics hoses and hose assemblies ± Guide to selection, storage, use and n ISO 8331 u maintenance d l e ISO 8573-1 Compressed air for general use ± Part 1: Contaminants and quality classes i f f e ISO 10099 Pneumatic fluid power ± Cylinders Acceptance test h s CETOP 1) Recommendations n u RP 5 P Specification for pneumatic cylinders d l Identification code for ports and operators of pneumatic control valves and other e RP 68 P i f f components e h s : y p o C d e s n e c i L
1)
CETOP: EUROPEAN OIL HYDRAULIC AND PNEUMATIC COMMITTEE.
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I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L
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I S B ) c ( , y p o C d e l l o r t n o c n U , 6 0 0 2 0 0 : 0 0 + T M G 5 4 : 5 1 : 1 0 3 2 t c O n o M , a n , n u d l e i f f e h s n u d l e i f f e h s : y p o C d e s n e c i L BSI 389 Chiswick High Road London W4 4AL
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