Bsi bs en 00528 2008

3 Annex B informative Means of separation within racking...54 Annex C normative Safety levels according to EN ISO 13849-1...55 Annex D informative Examples for the design of load entr

Introduction

Machinery shall comply with the safety requirements and/or protective measures of this clause, Clause 6,

Clause 7 and Clause 8 In addition, the machine shall be designed according to the principles of

EN ISO 12100 (all parts) for relevant but not significant hazards, which are not dealt with by this standard

Controls and other electrical components shall be in accordance with EN ISO 13849-1, EN ISO 13850 and

EN 60204-32 apart from the deviations stated in the following clauses

Machines and sub-assemblies shall be provided with lifting points unless these are not required by design.

Control position

S/R machines equipped with one or more onboard operators must include an onboard control position This control position can be located on the lifting carriage, be mobile and independent of the lifting carriage, or be fixed in a designated area on the machine.

In the case of fully automatically controlled machines an onboard control position may be dispensed with, but an emergency control position shall be provided for each machine.

Control equipment

The text of 5.3 and its sub-clauses fully replaces and deviates from the text of 9.4 in EN 60204-32:1998 and its subclauses

Safety related parts and safety related functions are listed in Table C.1 and Table C.2 respective of Annex C

Performance levels shall be in accordance with the performance levels required in these tables

Adjustable safety related parts (e g electronic control circuitry, software, safety devices) shall be protected against access by unauthorised persons (e g by the use of access codes, seals, enclosures, tools).

Safety related parts shall be designed, located or protected to withstand foreseeable strain or damage

The switching contacts of mechanically actuated electrical safety devices shall be the positive opening type as defined in Clause 3 of EN 60947-5-1:2004 (i.e “safety switches”)

5.3.2 Prevention of unauthorised operation (equipment switch)

Each machine's control panel must include a key-operated switch to prevent unauthorized use When the key switch is in the "off" position, all machine movements are disabled, and the key can only be removed when the switch is off.

The key for manual machines enables the operator to take control, while for automatic machines, it works alongside the key in section 5.3.3 to facilitate manual operation during commissioning, fault finding, or other tasks requiring manual control.

5.3.3 Changing mode of operation (mode switch)

To ensure safety during the transition between manual and automatic control of automated machines, it is essential to implement key-operated mode switches or equivalent safety measures These mode switches are linked to the safety principle of limited access When activated, they will halt all powered motion, keeping the machinery stationary Additionally, separate start devices should be positioned externally, ideally within direct sight of the machine, to facilitate safe restarts from an emergency control position or onboard control position.

The key can only be removed from the mode switch when the machine is set to "automatic" or from a control position outside the operating area when the switch is in the "manual" or "off" position.

For manual machines, the door key must match the specifications outlined in section 5.3.2 or be permanently attached to it In the case of automatic machines, the door key should conform to the requirements in section 5.3.3 or be permanently affixed Additionally, equivalent key-dependent systems, such as key transfer systems detailed in Annex E of EN 1088:1995, are permissible.

Where one machine is dedicated to one enclosed aisle, then each key shall be unique to a machine and the access door associated with the machine operating area

In environments where machines are not confined to a single aisle, such as those equipped with transfer devices or curved pathways, it is essential to have a unique key for each dedicated aisle entrance door While the keys for the machines themselves may be identical, they should be permanently attached to the corresponding entrance door key for security and accessibility.

5.3.5 Control devices for powered movements

Control devices for all movements shall be designed and arranged so that they may be actuated easily and safely and so that the possibility of unintended actuation is avoided

Machines equipped with fully enclosed on-board control positions may have a stop category of 2 Upon receiving a stop command, powered motion will halt, and the equipment will remain stationary until the start control device is activated again.

All control devices must be clearly identifiable and marked to indicate the direction of movement, using the local language or appropriate pictograms Additionally, the method of actuating these control devices should ideally align with the specific movement they control.

NOTE The application of EN 61310-3 is recommended

The stop function shall comply with 9.2.5.3 of EN 60204-32:1998 and 5.2 of EN ISO 13849-1:2008 and shall be:

 category "2" stop, as required by the design (see 9.2.2 of EN 60204-32:1998)

5.3.7.2 Initiation of the stop-function

When a stop function is activated, powered motion will immediately halt If the stop control fails to disconnect the energy supply (known as a "category 2" stop), the stop condition must be continuously monitored and upheld The equipment will stay stationary until a start device is activated.

The emergency stop function must adhere to EN ISO 13850:2008 and section 5.3 of EN ISO 13849-1:2008, ensuring that the machine can be halted safely without introducing further risks The selection of stop category 0 or 1 should be based on the design of the drives.

NOTE Stop category 1 may be used for machines with electronically controlled drives (this deviates from 9.2.5.4.2 of

In addition to the requirements of 10.7.1.1 of EN 60204-32:1998 the actuators for the emergency stop function shall be located in all control positions as a minimum

NOTE The provision of actuators for emergency stop function should be considered for other working positions, e g hoist platforms, maintenance platforms, etc

In the event that an emergency stop device is activated, the emergency stop function will automatically engage, halting all powered motion The equipment will remain stationary until the emergency stop device is reset and the start device is activated again.

Programmable electronic equipment, including electronic devices and sub-assemblies, can be utilized for emergency stop functions, provided they meet the standards outlined in Annex C.

NOTE This is not in accordance with 11.3.4 of EN 60204-32:1998

5.3.9 Safety requirements related to EMC

NOTE This clause is related to the Machinery Directive

The machine must possess adequate immunity to electromagnetic disturbances, ensuring safe operation as intended It should not pose any danger when subjected to specified levels and types of disturbances.

According to EN 61000-6-2, machine manufacturers must design, install, and wire equipment and sub-assemblies while adhering to the recommendations from sub-assembly suppliers This ensures that electromagnetic disturbances do not result in unsafe operations or potential failures that could pose a danger.

Performance must remain consistent without any degradation that could pose a risk Specifically, there should be no instances of performance loss or degradation that could lead to dangerous situations.

 unexpected start-up (see EN 1037);

 blocking of an emergency stop command, or resetting of the emergency stop function (see EN ISO 13850 and EN 60204-32);

 inhibition of the operation of any safety related circuit including safety related fault detection capabilities

Information on measures to reduce the effects of electromagnetic disturbances on the machine is given in 4.4.2 of EN 60204-32:1998.

Hoist unit

All hoist units must have brakes that can safely halt the hoist's movements with its test load at the rated speed and keep it securely in a stopped position.

In emergency situations, a holding brake, when used alongside other equivalent devices, must effectively halt all movements under the same conditions It is acceptable for the holding brake to have a limited lifespan in this context.

Brakes shall be applied automatically when the power supply is interrupted

The hoist unit shall be arranged so that the connection between the brake and the drum or sprocket cannot be disengaged

When a manual brake release lever is provided, the brake shall be operational when the lever is released

5.4.2 Limitation of the lifting and lowering movement

To prevent abrupt shocks during lifting and lowering movements, it is essential to implement upper and lower limit stops that define the vertical travel range This includes the installation of preliminary devices to ensure a controlled stop at the upper and lower hoist limits, particularly when using variable or multi-step drives Additionally, control devices such as limit switches or proximity sensors must be utilized to prevent incorrect hoist direction at the travel limits.

Ultimate limit switches must be of the positive operating type with direct mechanical actuation, conforming to EN 60947-5-1 standards When activated, these switches automatically trigger an emergency stop function as specified in section 5.3.6 Additionally, the actuators of these switches should operate independently of other switches.

1) Machines with slack rope, chain or belt protection do not require ultimate limit switches for the bottom limit except for continuous rope and chain drives;

Time delays in the control functions of electrical drives, such as DC motors or frequency-controlled motors, are acceptable as long as they do not exceed the time required for the system's stop function Additionally, S/R machines with liftable onboard control positions must be equipped with buffers or equivalent devices The maximum allowable deceleration for vertical movement should not exceed 3 g for individuals in the liftable onboard control position, with this deceleration calculated based on the tripping speed of the overspeed governor.

NOTE Regarding the equivalent function see 5.5.2 together with an additional (redundant) braking system

5.4.3 Overload and slack condition protection

5.4.3.1 Overload protection a) Rated load equal or greater than 1 000 kg:

Machines shall be equipped with an overload protection system when the rated load is greater than or equal to 1 000 kg b) Rated load less than 1 000 kg:

Where the rated load is less than 1 000 kg, an overload protection system shall be provided:

1) machines that are practicable to lift person(s);

2) where there is a risk to persons e.g due to rack collapse by the machine or breakage of suspension elements (see also 6.4.1)

In the event of an overload condition, an automatic stop function will be triggered as per section 5.3.7.1 It is important for the manufacturer to establish the settings and testing methods for the overload protection device.

Hoist units with suspension elements must include a device that detects slack conditions, which, when triggered, halts all operations except for lifting at the machine's slowest speed However, this safety feature is not required if endless chains or belts are utilized.

Provisions shall be made to prevent the restarting of the machine until the fault has been cleared by an authorised person

5.4.4 Safety gear and overspeed governor

Machines designed to lift individuals and capable of raising more than 1.5 meters, excluding those with self-sustaining lead-screw drives or direct acting hydraulic drives, must be fitted with an independent working safety gear and an overspeed governor for enhanced safety.

The characteristics of the safety gear and overspeed governor shall be compatible with the relevant characteristics of the machine

Safety gear is not required for machines other than those in 5.4.4.1 unless there is danger to persons

When a person is on the lifting carriage solely for fault clearing without vertical movements, additional safety measures, such as mechanical devices to prevent the carriage from falling, are permitted However, these devices must be used safely, and the lifting carriage should be secure at any height.

5.4.4.3 Operation of the safety gear

The safety gear shall operate by means of an overspeed governor at a speed not higher than 0,7 m/s or 1,4 times the rated speed, whichever is the greater

The safety gear must operate at a tripping speed exceeding 1 m/s without causing an average design retardation greater than 3 g, considering the mass of the machine parts, the rated load, and the operator(s).

The tensile force generated in the overspeed governor rope upon tripping must meet or exceed the greater of two specified values: a minimum of 300 N or double the force required to activate the safety gear.

The breaking load of the rope shall be at least 8 times the tensile force produced in the rope of the overspeed governor when tripped

5.4.4.4 Function of several safety gears

When there is more than one safety gear, their actuators shall be connected (e g by mechanical means) to ensure they operate simultaneously

5.4.4.5 Operation of the safety gear

Operation of the safety gear shall automatically initiate an emergency stop function in accordance with 5.3.7

5.4.4.6 Breakage of or slackness in the overspeed governor rope or chain

The safety device must detect any breakage or slackness in the overspeed governor rope or chain, and if triggered, it will automatically activate an emergency stop function as outlined in section 5.3.7.

5.4.4.7 Lead-screw drives or direct acting hydraulic drives

Safety gear is unnecessary for hoist units equipped with self-sustaining lead-screw drives or direct acting hydraulic drives; however, equivalent safety measures must be implemented For further details, refer to sections 5.4.6.5 and 5.4.7.3.

According to ISO 4308-1, the diameters of wire ropes, drums, and pulleys must be calculated accordingly For hoist units designed to carry individuals, the minimum breaking load must be at least ten times the maximum static force, while for other hoist units, this ratio should be at least five The use of a single rope is permitted.

5.4.5.1.2 Size, strength and construction of wire ropes

All wire ropes used in a single lifting unit must be uniform in size, strength, and construction For ropes designed to carry individuals, compliance with EN 12385-4 is mandatory Alternatively, other ropes that do not meet this standard may be utilized, provided they maintain an equivalent safety level through regular inspections for aging, fatigue, and wear.

Travel unit

The machine must safely decelerate and stop from its rated speed with the rated load and operator(s) without causing undue shock during normal operation and emergencies, such as overspeed This is achieved through: a) an electrical or mechanical braking system for regular operation; b) a mechanical braking system that activates automatically if the power supply is interrupted; and c) an effective braking system for machines with an onboard or emergency control position and an indirect drive unit, ensuring functionality even if the rope, belt, or chain fails This brake may be combined with the previously mentioned mechanical braking system.

An automatic additional braking system is essential in situations where the normal operational braking system may fail This includes scenarios such as negotiating curves at reduced speeds, approaching end stops designed for speeds below 70% of the rated speed, and preventing collisions when multiple machines operate on the same rail without additional safety measures like onboard bumpers.

The additional braking system shall be able to operate even in the event of gear failure in the travel unit

5.5.1.3 Machines with front and rear drive units

In machines equipped with both front and rear drive units featuring distinct electrical and mechanical braking systems, the additional braking system outlined in section 5.5.1.2 may be omitted if each braking system fulfills the criteria specified in section 5.5.1.1 Furthermore, it is essential that each braking system can be tested independently.

All machines must have a self-acting parking brake to ensure they do not move unintentionally, particularly during maintenance This parking brake can be integrated with the braking systems outlined in sections 5.5.1.1 b) and 5.5.1.1 c).

Automatic speed reduction is essential for safety in specific situations, such as when negotiating curves at limited speeds, when end stops cannot halt the machine at its rated speed, and when there is a risk of collision with other machines operating on the same rail without additional safety measures like onboard buffers.

The function of this system shall be automatically monitored In case of failure, the machine shall be stopped automatically

To ensure safe machine operation at the limit of travel, several safety measures must be implemented: a) Buffers or equivalent devices must be installed to absorb travel movement energy, with a maximum deceleration not exceeding 10 m/s²; b) An operational device in the control circuit should stop the machine before it contacts the buffers, unless the buffers are designed for continual use and are automatically monitored to return to their initial position, allowing travel only when the buffers are reset; c) Additionally, a safety-type ultimate limit switch with direct mechanical actuation must be included, which, when triggered, will automatically initiate an emergency stop function as per section 5.3.8 The actuator for this switch must operate independently from other switches.

A permissible time delay in the control function for electrical drives, such as DC motors or frequency-controlled motors, should not exceed the duration needed for the control system's stop function Additionally, it is essential to implement measures that prevent collisions, which could pose risks to personnel or cause damage to machinery, especially when multiple machines operate on the same rail.

To enhance safety and prevent derailment, a profile plate must be installed around the head of the rail on the machine This device will remain effective even if there is a failure of the travel wheels or guide rollers.

Rail junctions shall include interlocking devices to prevent derailment

Rail sweeps shall be provided in front of travel wheels

Means shall be provided to prevent the machine from dropping more than 10 mm if a travel wheel or axle fails

The machine and the rails shall be designed and built in such a way that the machine will not overturn even during operation of the safety devices

The stability factor ( υ s ) is calculated as follows:

The stabilizing effects from the rated load, including personnel and horizontal forces from the machine's mass, can only be considered when they are present under specified load combinations If stability relies on additional equipment, that equipment must be specifically designed for the intended task.

Anti-tipping devices that engage rail heads must ensure that the rails, their fixings, guides, and related components can withstand the generated forces.

Horizontal forces resulting from the rated load and personnel on the machine, along with all components above the lower carriage, must be multiplied by a factor to account for oscillation effects However, this factor is not applicable in cases of buffer impact.

Under standard operating conditions, a machine is deemed safe from overturning when its stability factor, νs, is equal to or greater than 1.5 This assessment must consider the most unfavorable tipping axis, the moments generated by the machine and its rated load, including personnel, as well as horizontal forces from the mass and, if relevant, wind loading, for each load scenario under the least favorable loading combinations.

In emergency situations, mechanical braking may occur due to the activation of an emergency stop or power loss Under these circumstances, the speed (\$v_s\$) must be at least 1.1, without considering the influence of any anti-tipping devices.

The oscillation factor must be selected and implemented based on the specific electrical and mechanical drive system, taking into account both acceleration and deceleration This factor is determined by calculating the maximum dynamic stress caused by abrupt changes in acceleration and deceleration, as well as the worst-case amplitude of the mast.

If machines without anti-tipping devices, with or without load, hit the buffers, the wheel loading shall remain positive.

Load handling devices

The load handling device, such as forks or platforms, must be designed to ensure that all parts of the specified load remain stable during normal operation.

All movements must be restricted by mechanical means to prevent undue stresses in the drive system when reaching end stops Therefore, limiting devices should be incorporated into the control circuit.

The drive unit for load handling devices must include a friction clutch or similar mechanism to restrict the drive force, thereby reducing the potential for injury to individuals and preventing damage to the machine and related storage equipment.

The racking supplier shall be advised of the kinetic energy and additional forces to be able to calculate the resulting forces

To ensure the safety of stationary load handling devices, it is essential to equip the drive unit with a reliable braking system or a self-sustaining gear, such as a worm gear, that functions effectively in all operational modes.

Interlocks must be installed to ensure that the load handling device can only move laterally when the machine is at a complete stop Additionally, when the load handling device is extended, both lifting and traveling movements should be restricted to the designated slow speed.

Automatic machines must be equipped with interlocks, such as positional sensors for forks or loads, to prevent accidental contact with racks or other objects Key considerations include ensuring the machine is correctly positioned both horizontally and vertically, maintaining central alignment of the load and forks, and ensuring that the aperture is not occupied.

Auxiliary lifting and pulling devices must be designed to prevent loads from being moved into or over the onboard control position, ensuring the operator's safety from falling load parts.

For automatic machines the load shall be checked for correct positioning on the load handling device before lift or travel movements take place

Satellite/channel vehicles shall comply with the requirements of 5.5.1.1, 5.5.4.1, 5.5.4.3, 5.5.4.4, 5.6.1 to 5.6.3

5.6.8.2 Position of the satellite vehicle

The correct position on the lifting carriage shall be monitored.

Electrical equipment

The electrical equipment for the machines shall be provided in accordance with the applicable clauses of

EN 60204-32 together with the particular requirements below Deviations are stated in the respective clauses

Electrical equipment encompasses a variety of components such as materials, fittings, devices, appliances, fixtures, and apparatus that are integral to the electrical installation of machinery This category includes electronic equipment, disconnection means from the power supply, and all wiring associated with the machinery leading to the disconnection point.

If the equipment is intended for use in electrical supply conditions outside the range of 4.3 of

According to EN 60204-32:1998, if the supply voltage falls outside the specified tolerances, the manufacturer is required to implement necessary design modifications, ensure appropriate safety measures, and clearly outline any operational restrictions in the "information for use."

Electrical equipment must be chosen and installed according to the specific working environment If the equipment is to be used in conditions that fall outside the parameters outlined in section 4.4 of EN 60204-32:1998, such as extreme ambient temperature, humidity, altitude, or corrosive atmospheres, the relevant environmental design parameters must be clearly specified in the user information.

In accordance with the requirements outlined in EN 60204-32:1998, the disconnection and switching of the energy supply will be achieved through two key devices: a main switch, which serves as a supply disconnecting device for each S/R machine and also controls the fixed supply such as bus-bars and festoon cables, and an on-board switch, which acts as an additional disconnecting device for each machine equipped with onboard control systems like motor starters and inverters.

Main switch: The main switch shall be either type a), type c) or type d) according to 5.3.2 of

On-board switch: the on-board switch shall be either type a), type b) or type c) according to 5.3.2 of

5.7.4.3 Means of disconnection for maintenance areas

Where a separate maintenance or repair area is provided, it shall be possible to interrupt the power supply in the same way as in 5.7.4.1 and 5.7.4.2

An unintended connection between a live and disconnected supply line (e g by double current collectors across two bus-bar-sections) caused by the S/R machine or transfer device shall be prevented

5.7.4.5 Unexpected start up, disconnection and unauthorised, inadvertent and/or mistaken connection

The requirements of 5.4, 5.5 and 5.6 of EN 60204-32:1998 apply to all devices listed in 5.7.4.1

Devices that do not comply with section 5.3.2 of EN 60204-32:1998, such as contactors, can be utilized for entering aisles, accessing machines, or performing minor tasks as outlined in section 5.4 of the same standard.

The specifications of Clause 6 of EN 60204-32:1998 shall apply

According to EN 60204-32:1998, maintenance and inspection requirements include the use of hold-to-run control devices for dangerous movements, ensuring relevant movements operate at reduced speeds, and providing an emergency stop device at the control station Additionally, if the work environment restricts escape, the powered movement's travel distance must be limited, or three-position enabling devices should be utilized.

This applies also to portable control stations (see also 5.3.5 and 5.9.3)

In accordance with EN 60204-32:1998, section 9.3.2, a restart after the activation of a safety device must only occur in the safe direction, achieved through a combination of a key-operated switch and a hold-to-run control device This requirement is applicable to specific safety functions.

 safety gear and overspeed governor.

Transfer device

The safety of the transfer device shall be ensured under all operating conditions using the applicable requirements from 5.2 through 5.7 For the environment see 5.10

To safely drive the machine onto or off the transfer device, it is essential that the device is securely restrained in its proper position, either through mechanical interlocking or braking systems, and is continuously monitored.

Movement of the transfer device shall only be possible if the machine is either fully on or fully off the transfer device

To ensure safety during machine transfers, measures must be implemented to prevent the machine from exiting the aisle when the transfer device is misaligned This should be done in accordance with a risk assessment, utilizing devices as outlined in section 5.5.3 or their equivalents.

The machine shall be interlocked to prevent travel in the direction of transfer unless the means of travel limitation are in a position to act as a positive stop

Stability during transfer shall be ensured under all operating situations in accordance with 5.5.5.

Maintenance repair and fault clearance

The following minimum requirements shall be provided to ensure safe maintenance, repair and fault clearance

For this purpose, temporary or permanent means shall be available either on or off the machine

For significant maintenance tasks such as servicing brakes, gearboxes, and control panels, the use of maintenance platforms is essential When the platform's floor height exceeds 1 meter above ground level, it is crucial to implement fall protection measures, including guard rails, in compliance with section 6.2.2.4.

For minor maintenance tasks, such as addressing faults in load handling devices, standing positions are adequate When the standing position is over 1 meter above ground level, a safety harness with a restraint lanyard provides sufficient fall protection.

In all cases a safe means of access shall be provided

In on-board maintenance roles where personnel are present while the machine is in motion, it is essential to implement additional protective measures as outlined in section 6.3.2 to mitigate risks of crushing, shearing, or trapping hazards.

In the absence of alternative measures for identifying and addressing faults, designated emergency control positions must be established to ensure safe and direct observation and control of machine movements These positions can be either fixed or mobile, permanent or temporary, and may be located inside or outside the machine's operating area.

To prevent falls from heights exceeding 1 meter, safety measures such as handrails must comply with Clause 7 of EN ISO 14122-3:2001 Additionally, safety harnesses with restraint points are essential Emergency control positions on the lifting carriage should feature a platform with minimum dimensions of 0.35 m by 0.35 m.

 means to protect persons at the emergency control position if they are at risk from falling objects from the lifting carriage (see 6.2.2.8);

 safe means of access (e g ladder with climb protection according to EN 363 and fixing means Class A1 of EN 795 at the transition points);

 portable or fixed control devices complying with 5.3.5, 5.3.6 and 5.3.7

For loads exceeding 50 kg that cannot be managed manually, it is essential to have an emergency control position or at least an approval button nearby the load handling devices to facilitate the release of pre-selected movements.

For machines where accessing the load handling device is impractical, such as light good S/R machines or miniload machines, operators can control the machine from a ladder It is essential to implement safety measures that allow the operator to secure themselves while keeping both hands free for controls, such as using short safety belts fixed horizontally around the hips and attached to the vertical stringers.

Where the emergency control position is inside the machine operating area the requirements of the key dependence system (see 5.3.4) shall apply

If the emergency control position has no protection, a maximum speed of 0,05 m/s in the x and y direction is permitted

In emergency positions with crushing and shearing guards, such as side protection or enclosures at least 1.1 meters high, a maximum speed of 0.5 m/s is allowed in the x and y directions.

If the emergency position is designed according to Clause 6, no speed reduction is necessary

Effective communication must be guaranteed, such as through direct voice, telephone, or two-way radio, to ensure that maintenance and repair personnel can communicate while positioned at a maintenance site, especially when the machine is being operated from the on-board operator's position or an emergency control location.

5.9.6 Protection from operating machines (S/R machines and transfer equipment)

During repair or maintenance in areas with operating machines or transfer devices, it is essential to implement protective measures for personnel These measures must adhere to the requirements outlined in section 5.5.3, such as the use of temporary buffers, and must also mitigate hazards related to the electrical supply.

To protect maintenance and repair personnel from injuries caused by moving machinery, access to danger zones must be restricted through compliant measures such as barriers, fencing, or other appropriate methods.

When conducting maintenance in areas where machines or transfer equipment will continue to operate, it is essential to implement measures as outlined in section 5.5.3, such as using temporary buffers, to ensure personnel safety from moving machinery and electrical hazards Alternatively, safe shutdown devices, including limit switches, light barriers, and laser scanners, can be employed alongside an additional brake system as specified in section 5.5.1.2.

A ladder for access along the complete height of the mast shall be provided for all S/R machines with a height over 5 m

Over the height of 5 m a ladder has to be fitted with a safety cage or a fall arrest system in accordance with

EN 363 and Class A1 anchor points at transfer positions in accordance with EN 795.

Machine environment

The following covers specific requirements for interfaces with buildings and racks in the context of S/R machines in as much as they are relevant for machine safety

The forces produced by the machine, which are transferred to the travel and guide rails, racking, and buffers, must be considered for both normal and emergency operating conditions The manufacturer of the machine is responsible for determining these forces, including an effective dynamic factor, and must communicate this information to the supplier of the racking and/or building.

Machines and transfer devices must be designed and installed to prevent collisions with fixed objects, such as racks or building components, by considering factors like tolerances, deflections, vibrations, and wear.

5.10.3 Safeguarding of persons (Limiting access)

To ensure safety from injuries caused by moving machines, access to machine operating areas must be restricted or equipped with sensors A typical setup includes an aisle with an access door and a rail-dependent S/R machine, as illustrated in Figure A.3 Protection can be implemented through various methods outlined in sections 5.10.3.2 to 5.10.3.4, along with the requirements specified in section 5.10.3.5.

5.10.3.2 Enclosure, doors and/or removable panels

Perimeter enclosures must comply with EN ISO 13857:2008, being at least 2 meters high Access for operation, repair, or maintenance is facilitated by doors and/or removable panels, which should only open outward and can be opened from the inside without a key The key for these doors must be the same as or permanently connected to the key for specific switches When a door is open, machine movement in the operating area must be prevented, and restarting can only occur from within the machine or from an external control station with the door closed, in accordance with EN 1037 Additionally, access doors located more than 1 meter above ground must be locked to ensure they only open when the machine is correctly positioned, and removable panels that are frequently accessed or tool-free must be constructed and secured similarly to doors.

5.10.3.3 Means of separation within racking

A means of separation is required to deter access from one machine operating area into an adjacent machine operating area through the racking

No additional means of separation is required where the physical gaps through the racking are less than 0,3 m wide

For physical gaps exceeding 0.3 m, an additional separation method is necessary, which must include a barrier at least 1.0 m above floor level and an intermediate barrier that restricts the clear space to less than 0.5 m Acceptable materials for the barrier include racking members, chain, wire mesh, or wire cable, and it should be positioned between the respective aisles (refer to Annex B).

5.10.3.4 Sensing devices to protect S/R machines working area a) Off-board sensors:

Light barriers, motion detectors, and similar devices on the perimeter of enclosures are essential for halting machine movements to avert collisions between humans and machines, adhering to the stopping distance outlined in EN 999 Any deviations from this standard must be justified through risk analyses These safety devices require automatic monitoring as specified in Annex C, and electro-sensitive protective equipment must meet type 2 standards of EN 61496-1 To ensure safety, at least two beams should be positioned at heights of 0.4 m and 0.9 m to restrict access, while the arrangement of beams must consider the specific hazards to prevent individuals from entering danger zones Additionally, pressure-sensitive protective devices must comply with EN 1760 (parts 1 through 3).

These may be (e g pressure sensitive safety devices or safety devices with proximity reaction) mounted on the machine to detect persons

1) Choice, installation and testing of bumpers shall be in accordance with EN 1760-3

2) People detecting sensors shall fulfil the requirements of EN 61496-1

Restarting shall only be possible by means which can be activated intentionally by an authorised person in a position from which he can observe the protected area

Machines with on board sensors according to 5.10.3.4 b) shall be equipped with a ready warning device (e g a flashing light) being activated, when machines start moving

5.10.3.5 Separation of operational areas a) Automatic machines:

Safety devices must be installed on machines that can change aisles or where individuals may transition from a safe aisle to an unsafe area, such as a transfer aisle This requirement also applies to manual machines.

An electrical monitoring system must ensure that the machine does not operate unless the proper entry and exit procedures are followed, which include mode selection outside, access, mode selection inside, and restart, or the reverse sequence.

To prevent injuries caused by machine movement, it is essential to arrange load transfer areas in a way that restricts access at entry and exit points This can be achieved by deterring access or halting the dangerous movements of the machines, as illustrated in Annex D.

When considering safety standards, it is essential to assess the risk of crushing and shearing as outlined in EN 349, particularly between the pallet and the sides of the opening If compliance with EN 349 is not achievable due to the configuration of racks and load transfer areas, alternative safety measures must be implemented.

When designing openings for the inward movement of pallets, it is crucial to consider the risk of body crushing between the pallet and the sides of the opening.

 limiting the force between load unit and obstacle to less than 150 N;

 distance in accordance with EN ISO 13857;

 space of 0,5 m in accordance with EN 349;

 using lateral wings or flaps, which are flexible or which activate sensors

Access beneath conveyors shall be prevented by limiting the height of the opening to 0,5 m A test ball of 0,5 m diameter might not pass through

Authorised access via an interlocked door (see 5.10.3.1) shall be made as convenient as possible to deter personnel seeking access by any other route

5.10.4.2 Gravity systems in pallet-racking

To ensure safe access to the machine operating area where loads are transferred via a gravity system to order picking or input positions, it is essential to meet specific requirements that restrict entry into the gravity system zone.

The gravity systems must extend a minimum length of 1.2 meters to effectively separate personnel from the machine operating area, particularly when the load handling device is in the outer position To prevent falls and unauthorized access between the tracks of the gravity system, flexible netting should be installed in compliance with EN 1263-1 and EN 1263-2 standards.

To prevent unauthorized access to gravity lanes, specific measures must be implemented, such as optimizing the arrangement of the gravity system and designing the side members appropriately, as illustrated in Annex D, Figure D.4, "Design of Frame Surface."

Access to the machine operating area must be restricted if the specified requirements are not met, utilizing one of the methods outlined in Annex D or other equivalent safety measures.

Special care shall be taken for the safe transfer of the load between the machine and other equipment (e g conveyor, automated guided vehicle, transfer car, work station, etc.)

General

This clause deals with machines that are intended to be used by an onboard operator in the normal mode, e g for onboard picking.

Onboard control position

6.2.1 Access to and egress from the onboard control position

It shall be possible to enter and leave the onboard control position safely, wherever it is, in accordance with the following sub-clauses

Access and egress must be facilitated through fixed means as specified in EN ISO 14122-4, which may include a fixed ladder paired with a safety cage or a fall arrest system compliant with EN 363 Additionally, Class A1 anchor points should be installed at transfer positions in accordance with EN 795.

6.2.1.3 Means for ladder to prevent fall

In deviation with EN ISO 14122-4 means for preventing a fall shall be fitted for ladder flights of more than 5 m starting at a height no greater than 3 m

Ladders shall be equipped with appropriate means to rest at intervals of not more than 6 m (e g resting places or devices to support persons securely)

In situations where a ladder cannot be used and access is limited to a height of 5 meters, it may be feasible, as per deviation 6.2.1.2, to install fixed access or egress points at specific locations on the machine or control area This ensures that in case of an emergency, individuals can safely exit from all positions using an alternative system, such as an inertia reel.

6.2.2 Design and dimensioning of onboard control position

Ergonomic principles shall be taken into consideration, in accordance with EN 614-1, EN 894-1 and EN 894-2

The onboard control position shall be arranged and designed so that the operator has a clear view of his/her immediate working area

6.2.2.3 Floor of the onboard control position

The floor of the onboard control position shall be within 5° of the horizontal and slip resistant (e g chequer plate)

For normal operation, the floor shall be capable of withstanding at least a pressure of 1 800 N/m² and a mass of 100 kg distributed over an area of 0,16 m² at any part of the surface

When glazing is used for flooring, it must be made of laminated safety glass that possesses strength equal to or greater than the floor itself, or it should be adequately protected to meet or exceed the floor's strength standards.

Where grated flooring is used, the holes or openings shall not allow a 30 mm diameter sphere to pass through The area of each opening shall in no case exceed 900 mm²

To ensure the safety of the operator, the onboard control position must be protected from falls This protection should include guardrails, as specified in Clause 7.

EN ISO 14122-3:2001 or equivalent protection

Where picking tables are used as guards, a height of 0,9 m is sufficient

To facilitate picking the height of the guard may be reduced to 0,9 m

Guards are not required at the sides of the onboard control position if the aisle sides can prevent falls, provided the machine only exits the protected area when the onboard control position floor is less than 1 meter above ground level.

To ensure safety, guards must be permanently affixed to the onboard control position If the control position floor can be elevated more than 1.5 meters above ground level, hinged or sliding guard rails should be interlocked to prevent machine movement when the guard rails are not completely closed.

Doors or gates to the onboard control position must not open outward or downward Additionally, these doors or gates should be interlocked to ensure that the machine cannot operate while any door or gate is open.

Operators in the onboard control position must have overhead protection that ensures their safety during both traveling and hoisting movements of the machine at all times.

The protection must effectively shield against falling objects based on their mass while ensuring that it does not induce shocks or excessive deformation It should withstand a load of 100 kg over an area of 0.16 m² across its surface without permanent deformation and prevent small items, such as nuts and bolts, from penetrating through.

Structural parts of the onboard control position shall be non-combustible, and any furnishings shall be difficult to ignite

If glass is used for the onboard control position it shall be of the laminated safety glass type

The onboard control position shall be fitted with a distinctive warning device to attract attention (e g a horn)

NOTE The onboard control position may be fitted with a system for external communication where direct communication is impossible

The onboard control position and adjacent areas shall have sufficient lighting for the operator to do his work safely

The lighting system shall be protected from shocks and risk of falling; particular care shall be taken to prevent any fragments from shattered lamps from falling on persons

Emergency lighting (e g., emergency aisle lighting, a torch) shall be provided to enable the operator to leave the onboard control position safely

In areas where machines can switch aisles and individuals may transition from a safe aisle to an unsafe zone, such as a transfer aisle, it is essential to implement automatic audible and/or visible warning signals.

Control equipment

One of the mode switches in 5.3.3 shall be positioned on the machine

Means shall be provided to safeguard the operator(s) against injuries due to contact with objects outside of the onboard control position during movement of the machine

NOTE Especially it should not be attractive to reach dangerous places until the S/R machine comes to a complete stop (e g to pick during positioning)

For this purpose, the onboard control position may be fully enclosed

Two-hand control of type IIIA, as per EN 574, or equivalent safety measures, can be utilized, ensuring that no body part is at risk when the operator maintains the correct posture within their driving position Additionally, any other individuals on the machine must also be adequately protected.

Hoist unit

When using an elevating onboard control position alongside a lateral handling device, it is essential for the machine to have a suitable overload protection system This system must detect overload conditions based on the forces from the working load in the suspension elements, even if the load's mass is monitored If an overload is detected, all lifting movements must cease immediately.

Protection of operators in an aisle containing two or more manually operated machines

containing two or more manually operated machines

10.4.6 Operator check of aisle 10.4.7 No unauthorised access to the aisles 10.4.8 Permit to work system

10.5.2.9 No danger from second machine

Access door interlock 4.1.7 Slip, trip or fall on operator's platform

8.1 Erection and dismantling 5.4.7.2 No separation of lifting carriage 5.4.8.2 No rack and pinion disengagement

6.2.2.8 Overhead protection 6.2.1.4 Prevention of falls from access means 6.2.2.3 Floor design

6.2.2.4 Safe guard 6.2.2.5 Guards 6.2.2.6 Permanent fixed guards 6.2.2.7 Operator's position door opening

10.4.15 Operator entering or leaving the machine in position

4.1.10 Fall of person from elevated operator position

10.4.20 Person on load handling device 4.1.11 Defective stopping 5.5.1.1.c) Emergency braking system

5.3.5 Control devices for powered movements 5.3.9 Safety requirements related to EMC

4.1.12 Uncontrolled movements (including unintended movements)

5.4.6.5 Prevention of lowering of the onboard control position

5.4.2 Limitation of lifting and lowering movement 5.4.6.7 Auxiliary hoist valve 5.6.1 Load stability 5.6.6 Auxiliary handling equipment 5.6.7 Load position monitoring

5.10.5 Load movement over persons 5.10.7 No unintentional load movement 5.10.8 Protection from falling loads 7.4.3 Lead-screw drives (safety nut) 10.4.10 No overloading

10.4.11 Load remains on load handling device 10.4.12 No projection of goods into aisle

10.4.18 No handling of faulty loads 5.5.2.c) Speed reducing system

5.5.3.d) Limitation of travel 4.1.15 Tipping of machine 5.4.3.1 Overload protection

5.5.2 Speed reducing system 5.5.4 Anti-derailment device 5.5.5 Stability

5.6.5 Load handling interlocks 5.8.1 Machine position on transfer device 5.8.3 Transfer device movement

5.8.4 Machine interlocking before transfer 5.8.5 Stability of transfer device

5.4.6 Hydraulic lowering control valve 5.4.7 Lead-screw drives (safety nut) 5.4.8 Rack and pinion drives 5.9.2 Protection of maintenance position 6.2.2 Onboard control position design

4.1.16 Lifting of persons resulting in: a) plummeting of onboard control position b) falling from onboard control position

10.4.4 Correct numbers of persons on machine 4.1.17 Derailment of machine 5.5.4 Anti-derailment device

4.1.18 Insufficient strength of parts 5 Compliance with EN standards

4.1.19 Inadequate design of pulleys and drums 5.4.5.1.4

Pulley and drum design requirements

4.1.20 Inadequate selection of suspension elements 5.4.5.1

Rope, belt and chain selection criteria

4.1.21 Lowering by friction brake 5.4.1 Hoist unit brake

5.1 Compliance with EN standards 5.7.1 Electrical supply conditions 5.7.3 Environment

4.2.1 Electrical contact with live conductors

5.7.4 Supply disconnecting device 4.2.2 Electrostatic phenomena Not applicable

4.3.1 Burns and scalds Not applicable

4.3.2 Hot or cold working environment Extreme thermal conditions: Additional risk assessment needed 4.3.3 Inadequate cab heating/ventilation Not applicable

4.3.4 Fire at the operator control position 6.2.2.9 Furnishings difficult to ignite

4.4.1 Hearing loss 5 Protection from hearing loss

4.4.2 Interference with communication 5.9.5 Means of communication

4.5 Vibration 5.10.7 Protection against unintended load movement

4.7 Materials and substances 5 Specified working environment

4.8.1 Unhealthy postures or efforts 6.2.2.1 Ergonomic principles

4.8.2 Inadequate consideration of anatomy 6.2.2.1 Ergonomic principles

4.8.3 No personal protection equipment 8.1.3 Provision of personal protection equipment 6.2.2.2 Operator view of his area

6.2.4.3 Emergency lighting for evacuation 4.8.5 Mental overload or underload Not applicable

5.3.2 Equipment switch 10.2.4 Warning signs 5.3.3 Mode switch 5.3.4 Key dependence 5.7.2 Electrical supply conditions 10.5.2.5 Switch off and lock main isolator

4.8.6 Human error resulting in: a) unauthorised persons on machines; b) dangerous change to automatic control

10.5.2.6 Avoid hazards when switching on power 4.8.7 Lack of visibility 6.2.2.2 Operator view of his area

4.8.8 Inadequate signs/signals/warnings 6.2.3 Operator's warning device

5.3.5 Control device for powered movements 5.3.6 Control device

5.9.3 Emergency controls 5.9.2 Maintenance position 5.9.7 Access along the mast 4.8.10 Means of access

6.2.1.2 Access to onboard control position

4.8.11 Use in dark places 6.2.4.1 Adequate lighting for work area

10.4.16 Immediate evacuation in emergency 8.1.1 Correct assembly information 8.2.1 Correct commissioning information 8.2.2 Instruction manual for commissioning

10.4 Conditions for the safe operation of equipment 5.3.1 Prevention of unauthorised operation 10.5.2.10 Machine recovery procedure

8.1.2 Trained personnel for erection etc

8.2.3 Trained personnel for commissioning 10.4.3 Suitable and reliable operators only

10.4.13 Removal of key for manually controlled machines

10.4.14 Only one key for automatic machines

4.10.1 Failure of energy supply 5.5.1.1.b) Automatic braking with power failure

Pipe and hose pressures 4.10.2 Unexpected ejection of fluids

5.4.6.4 Pressure relief valve 4.10.3 Malfunction of control system 5 Compliance with EN standards

4.10.4 Unexpected loss of machine stability 5.5.4.4 10 mm drop if wheel fails

4.11 Missing or incorrectly positioned safety related means

5.10.3.3 Sensing devices 5.10.4 Load entry and exit

8.2.4 Check safety devices before commissioning 10.4.5 Behaviour in case of failures 10.4.9 Safety devices to remain operational

10.5.3.5 Examination of safety components 5.5.1 Braking system

5.5.2 Speed reducing system 5.5.3 Limitation of travel

5.8.4 Stop machine from leaving aisle 4.11.3 Safety signs and signals 10.3.1 Identification plate

10.3.2 Carrying capacity 10.3.4 Warning signs 4.11.4 Information and warning devices 10.3.3 Operating instructions

4.11.5 Energy supply disconnection devices 5.7.4 Supply disconnecting (isolating) device

5.3.7 Stop function 7.3.2 Emergency stop equipment 5.5.1 Travel unit braking system

10.5.2.10 Machine recovery procedure 5.7.4 Supply disconnecting (isolating) device 5.9.2 Maintenance position

5.9.3 Emergency control position 5.9.5 Communication means

4.11.7 Equipment for safe adjustment and maintenance

8.1.3 Correct tools etc for assembly 4.11.8 Equipment for evacuating gases Not applicable

5 Safety requirements and/or protective measures for all types of S/R machines

Machinery shall comply with the safety requirements and/or protective measures of this clause, Clause 6,

Clause 7 and Clause 8 In addition, the machine shall be designed according to the principles of

EN ISO 12100 (all parts) for relevant but not significant hazards, which are not dealt with by this standard

Controls and other electrical components shall be in accordance with EN ISO 13849-1, EN ISO 13850 and

EN 60204-32 apart from the deviations stated in the following clauses

Machines and sub-assemblies shall be provided with lifting points unless these are not required by design

S/R machines equipped with one or more on-board operators must include an onboard control position This control can be located on the lifting carriage, be mobile and independent of the lifting carriage, or be fixed in a designated position on the machine.

In the case of fully automatically controlled machines an onboard control position may be dispensed with, but an emergency control position shall be provided for each machine