– st ip u lat es in t h e m an u fact u rer’s d eclarat io n t h at t h e co m p o n en t co m p lies as far as p o ssible wit h t h e ECMD,
– h as co m p iled an d arch ived t h e req u ired d o cu m en t at io n as laid d o wn by an n ex V, p o in t 3,
– st ip u lat es t h e ap p lied safet y st an d ard s an d – h as m ad e referen ce in t h e o p erat in g in st ru ct io n s t o t h e safet y regu la-
t io n s fo r t h e m an u fact u rer o f t h e lin e in t o wh ich h is co m p o n en t s are t o be in t egrat ed .
All t h o se in vo lved assu m e t h at t h e p rescribed m in im u m st at em en t , as in d icat ed in an n ex II B, is in su fficien t an d t h e m ach in e can n o t be co m -
m issio n ed u n t il t h e o verall lin e h as been p ro ven t o co m p ly wit h t h e ECMD. Freq u en t ly, an d in p art icu lar in t h e case o f large-scale p resses,
p art o f t h e eq u ip m en t o rigin at es fro m t h e u ser an d p art o f it fro m t h e p u rch aser o f t h e p ress. As t h e ECMD req u ires st at ic st abilit y an d safe
access t o all p o in t s o f p o ssible in t erven t io n , wit h t h e d eclarat io n o f co n fo rm it y t h e p ro d u ct io n lin e m an u fact u rer assu m es resp o n sibilit y
also fo r t h e st ru ct u ral wo rk carried o u t fo r t h e p ress, fo r exam p le t h e co n st ru ct io n o f t h e n ecessary fo u n d at io n s. Th e id en t it y o f t h e m an u -
fact u rer o r co n st ru ct io n fo rem an as d efin ed by ECMD m u st be co n t rac- t u ally laid d o wn in t h e case o f t h is t yp e o f p ro d u ct io n lin e. Th e resp o n -
sible p art y t h en h as t h e o t h er co n t ract u al p art n ers co n firm co m p lian ce wit h h ealt h an d safet y st an d ard s t o t h e ext en t o f t h eir resp ect ive p er-
fo rm an ce.
3.6.4 CE marking
Th e flo w ch art in Fig. 3.6.3
in d icat es wh at is req u ired o f t h e m an u fac- t u rer wish in g t o ap p ly t h e CE m ark t o h is m ach in e. An u n d erlyin g d if-
feren ce is d rawn bet ween t wo cases. Acco rd in g t o an n ex IV o f t h e ECMD, p resses in t en d ed fo r m an u al feed o p erat io n h ave been classified
as h azard o u s m ach in es sin ce Jan u ary 1, 1995. In t h is case, a C st an d ard – t h e EN692 fo r m ech an ical an d EN693 fo r h yd rau lic p resses – m u st
exist , an d t h e p ress m u st be co n st ru ct ed wit h o u t rest rict io n s in acco r- d an ce wit h t h is st an d ard . If t h is is n o t t h e case, o r if t h e relevan t C st an -
d ard d o es n o t yet exist , t h e m an u fact u rer is req u ired t o co m m issio n a t yp e t est o f t h e m ach in e by a n o t ified bo d y i. e. an ap p ro p riat e t est in g
111
Press safety and certification
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
112
Fundamentals of press design
Fig. 3.6.2
Sample Declaration of Conformity
EG-Declaration of Conformity
per specifications of the machine directive 89392EEC, annex II A
Applied EC-directives : x
machine directive 89392EEC and 91368EEC x
electromagnetic compatibility directive 89336EEC and 9331EEC x
low -voltage directive 7323EEC … … … … … … … … … … … …
We herew ith declare that the follow ing identified machine line … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … …
make, type designation, year of manufacturing, order number as marketed by us meets the essential health and safety requirements of the EC machinery
directive 89392EEC relating to the design and construction. This declaration w ill become invalid in case of modifications of the machine line, not accepted by us.
Applied harmonized standards: x
DIN EN 292 x
DIN EN 294 x
DIN EN 60204 T1 x
DIN EN 692 x
DIN EN 418 x
E DIN EN 953 x
DIN EN 954 x
DIN EN 982 x
DIN EN 983 x
DIN EN 1037 Applied national German standards and technical specifications :
… … … … … … … … … … … … … A technical construction file has been compiled and w ill remain available.
An instruction manual for the machinery has been composed and delivered in : x
community language of the manufacturers country original version x
community language of the user country … … … … … … … … … … … … …
Place, date … … … … … … … … … … … … …
M anager design services … … … … … … … … … … … … …
title and designation of the undersigned Legally binding signature
of the manufacturer
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
au t h o rit y in acco rd an ce wit h an n ex VI. Th e m an u fact u rer is o n ly en t i- t led t o issu e t h e d eclarat io n o f co n fo rm it y an d ap p ly t h e CE m ark o n
t h e basis o f an EC t yp e t est cert ificat e. If t h e p ress h as been co n st ru ct ed o n t h e basis o f t h e t yp e C st an d ard , t h e m an u fact u rer m ay ch o o se an y
o n e o f t h ree fu rt h er p ro ced u res. Eit h er h e sen d s t h e t ech n ical d o cu - m en t at io n t o t h e t est in g au t h o rit y, wh ich o n ly co n firm s receip t , o r h e
arran ges fo r a review o f t h e t ech n ical d o cu m en t at io n , o r h e co m m is- sio n s an EC t yp e t est o f t h e m ach in e.
In cert ain m ach in es it is n ecessary t o reach d irect ly wit h t h e h an d s bet ween t h e t wo h alves o f t h e d ie aft er each st ro ke. Th ese m ach in es are
cat ego rized as m ach in es wit h m an u al feed o r rem o val. Even m ach in es in wh ich p art s are in sert ed m an u ally d u rin g set -u p
are n o t cat ego rized as an n ex IV m ach in es. In t h e case o f m ach in es n o t d esign ed t o p erm it m an u al feed o r rem o val, t h e m an u fact u rer issu es
t h e d eclarat io n o f co n fo rm it y an d ap p lies t h e CE m ark at h is o wn risk. Co n seq u en t ly, a p ress in t en d ed exclu sively fo r au t o m at ic o p erat io n
113
Press safety and certification
Fig. 3.6.3
Sequence for the conformity declaration and the CE mark
Notified body
Equipment
M anufacturer
M anufacturer Declaration of conformity certifies compliance w ith underlying requirements of the directive
Declaration of conformity certifies compliance w ith tested model Remark:
Not in accordance w ith annex IV
Art. 82a
Not fully in compliance w ith
standards Art. 82b Compile documents
in accordance w ith annex V
M anufacturer draw s up declaration of
conformity and applies CE mark
M anufacturer draw s up declaration of
conformity and applies CE mark
M anufacturer draw s up declaration of
conformity and applies CE mark
M anufacturer draw s up declaration of
conformity and applies CE mark
M anufacturer draw s up declaration of
conformity and applies CE mark
Notified body carries out EC type
test on model Notified body
issues EC type certificate
Notified body issues EC type
certificate Notified body
issues certificate
Notified body retains
documents Notified body checks
w hether standards have been correctly
applied Notified body
performs EC type test on model
Notified body confirms
receipt Compile documents in
accordance w ith annex VI, send w ith
model to notified body Compile documents in
accordance w ith annex VI, send w ith
model to notified body Compile documents in
accordance w ith annex VI, send to
notified body Compile documents in
accordance w ith annex VI, send to
notified body Fully in compliance
w ith standards Art. 82c
In accordance w ith annex IV
Art. 82a, c
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
Table 3.6.2: Extract from a hazard analysis w ith risk assessment
Hazardous situation,
danger area
Active area, die
mounting area
Type of danger
Crushing, shearing
1.1, 1.2
1, 2
x 3
3 4
Part event Reaching
in from front and
other hazards in
active area during
operation 1.1.2a,f,
1.3.7, 1.3.8, 1.4.2.2B,
1.4.1, 1.6.1 5.3.3, 5.3.5.,
5.3.6, 5.3.10,
5.3.12, 5.3.15,
5.5.6, 5.5.7, 5.5.8
EN294 EN999
EN954 EN953
EN1088 89392,
annex I Applied
standards EN692 Others
Protective shield 1st safeguarding to category 4, n.o. and n.c. contacts,
early opening tS, safety distance 320 mm to match stopping time 0.2 s to EN999.
Together w ith sw ivelling gripper box prevention of access to danger zones
EN294 see draw ing Safety gear remark
1
2
N um
be r o
f h az
ar d
in a
cc or
da nc
e w
ith E
N 41
4
Co nt
in uo
us o
pe ra
tio n
Se t-
up M
ai nt
en an
ce Re
pa irs
D eg
re e
of s
ev er
ity O
ve ra
ll fr
eq ue
nc y
ca te
go ry
B yp
as sa
bl e
Pr ot
ec tio
n ca
te go
ry D
oc . N
o.
can n o t be u sed fo r m an u al feed o p erat io n . Th is p o ssibilit y is exclu d ed in t h e o p erat in g in st ru ct io n s – as far as p o ssible, it sh o u ld be p o ssible
fo r t h e co n t ro l syst em t o p reven t m an u al p ro d u ct io n . Cert ificat es issu ed by t h e m an u fact u rer h im self, h o wever, m u st sat is-
fy cert ain co n d it io n s. In ad d it io n t o ad h erin g t o t h e m ajo r h ealt h an d safet y req u irem en t s o f t h e ECMD, t h e m an u fact u rer is req u ired t o d raw
u p a d o cu m en t p rio r t o issu in g t h e d eclarat io n o f co n fo rm it y in wh ich h e p ro vid es writ t en p ro o f o f co m p lian ce wit h t h ese safet y req u ire-
m en t s. Th e st at u t o ry ret en t io n p erio d fo r t h is d o cu m en t is 10 years. Th e d o cu m en t at io n , in t en d ed fo r t h e cu st o m er, co m p rises t h e o p erat -
in g in st ru ct io n m an u al, wh ich co n t ain s t h e n ecessary in fo rm at io n fo r t h e m ach in e u ser. Th e fo cal p o in t o f t h e d o cu m en t at io n is t h e h azard
an alysis an d risk assessm en t Table 3.6.2
. Th is in vo lves a syst em at ic evalu at io n o f t h e m ach in e by t h e m an u fact u rer co n cern in g p o t en t ial
h azard s, an evalu at io n o f t h e risk in vo lved , an d t h e ap p ro p riat e m ea- su res fo r t h eir m in im izat io n . Th ese m u st be d escribed in t h e d o cu m en -
t at io n . Th e o u t co m e t akes o n t h e fo rm o f a list o f so lu t io n s u n d ert aken t o co m p ly wit h t h e p o in t s d erived fro m an n ex I o f t h e ECMD. In ad d i-
t io n , t h e d o cu m en t at io n in clu d es p lan s an d d iagram s – circu it d iagram , h yd rau lic an d p n eu m at ic d iagram s an d fu n ct io n al ch aract erist ics –, cal-
cu lat io n s, t est resu lt s, cert ificat es an d m an u fact u rer’s d eclarat io n s fro m su p p liers in as far as t h ese are n ecessary fo r verificat io n o f t h e req u ired
safet y st an d ard . Th is d o cu m en t at io n d o es n o t n eed t o be p h ysically
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Fundamentals of press design
Metal Forming Handbook Schuler c Springer-Verlag Berlin Heidelberg 1998
p resen t , bu t co m p rises an in d ex wh ich m akes referen ce t o t h e vario u s sect io n s by m ean s o f an id en t ificat io n n u m ber.
In th e case of a h azard an alysis, safety is m on itored over each p h ase of th e m ach in e’s life, from assem bly th rou gh to com m ission in g, u tiliza-
tion , rep air an d fin al scrap p in g. Protective m easu res m u st ap p ly eq u ally to m ach in e op erators, set-u p an d m ain ten an ce staff. Dep en d in g on th e
risk, safety m u st also be gu aran teed in case of m ach in e m alfu n ction s. As, for exam p le, th e failu re of a brake valve an d th u s th e u n ch ecked m ove-
m en t of th e slid e cou ld lead to seriou s in ju ry, d yn am ically m on itored p ress safety valves m u st be u sed u n less it is p ossible to p rovid e an eq u iv-
alen t d egree of safety by keep in g safety d evices closed . Th e m on itored valves are red u n d an t d ou ble valves an d , d ep en d in g on th e req u ire-
m en ts of th eir resp ective fu n ction s, th ey are self-m on itorin g. Th is m ean s th at d esp ite a brake valve failu re, th e “brakin g” fu n ction is still
p erform ed , accom p an ied by a m essage in d icatin g wh eth er th e two valves h ave op erated correctly or n ot. A p ositive “fu n ction OK” sign al is
u sed for self-m on itorin g of th e sign allin g m od u le cf. Sect. 3.5
. In an alysin g p o t en t ial h azard s, t h e m an u fact u rer m u st also co n sid er
“fo reseeable u n u su al sit u at io n s”, e. g. su rp rise sit u at io n s o f t h e t yp e p reviou sly m en tion ed . Th e op eratin g in stru ction s m u st accord in gly
in clu d e a statem en t on m ach in e u tilization in accord an ce with th e in ten d ed p u rp ose of th e m ach in e, an d also p roh ibit an y foreseeable cas-
es o f vio lat io n , fo r exam p le o p erat io n o f t h e p ress wh ile o bservers are lo cat ed beh in d t h e clo sed p ro t ect ive gear in o rd er t o o bserve t h e
m ach in e o p erat io n . In d icat io n s o f p o ssible vio lat io n o f o p erat in g regu - lat io n s are o ft en o n ly p o ssible aft er o bservat io n o f o p erat in g, set -u p
an d m ain t en an ce st aff. Th e resu lt s o f t h e h azard an alysis are reflect ed in t h e d esign o f p ro t ect ive gear, rem arks relat in g t o resid u al risk at t h e
m ach in e an d in t h e o p erat in g in st ru ct io n m an u al. Th u s, t h ey are m ad e kn o wn t o t h e m ach in e u ser.
3.6.5 M easures to be undertaken by the user
