BRITISH STANDARD BS EN 1218 4 2004 Safety of woodworking machines — Tenoning machines — Part 4 Edge banding machines fed by chain(s) ICS 79 120 10 ��������� � ���� ������������������������������������[.]
General
For the purposes of this document, the terms and definitions given in #EN ISO 12100-1:2003$ apply Additional definitions specifically needed for this document are shown in 3.2 and 3.3.
Terms
The main parts of a single end machine and a double end machine and their terminology are illustrated in Figures 1 and 2
Figure 1 — Terminology of a single end machine
8 Trip wire at out feed
10 Trip device at in feed
11 Device to prevent involuntary access between machine halves e.g trip wire
13 Preceding sizing/milling zone (optional)
Definitions
The edge banding machine, which can be either a single end or double end model, is specifically designed to bond edge banding to one or both ends of a workpiece in a single pass This machine features an edge banding zone equipped with various units for heating, bonding, and pressing, suitable for both flexible and solid edges Additionally, it includes a zone for supplementary operations such as snipping, trimming, milling, sanding, polishing, and chamfering Often, the edge banding zone is preceded by a sizing or profiling zone to enhance the overall process.
The integrated feed mechanism is designed to hold and control the work-piece or tool mechanically during machining operations, ensuring precise interaction with the machine.
3.3.3 ejection unexpected movement of the work-piece or parts of it or part of the machine from the machine during processing
3.3.4 run-up time time elapsed from the actuation of the start control device until the spindle reaches the intended speed
3.3.5 run-down time time elapsed from the actuation of the stop control device to spindle stand still
3.3.6 machine actuator power mechanism used to effect the motion of the machine
3.3.7 dynamic processing unit unit which moves with the work-piece during processing and returns to its starting position ready for the following (succeeding) work-piece (see Figure 3)
1 Dynamic processing unit (e.g sniper saw)
Figure 3 — Example of a dynamic processing unit
The machine is divided into two halves, each comprising a frame, chain beam, top pressure beam, and working units Each half is designed to process a distinct end of the workpiece Additionally, one or both halves can adjust their positions to accommodate workpieces of varying dimensions.
Integral enclosures for double and single end machines are designed to closely fit the machinery, offering sound attenuation while allowing for certain setting adjustments to be made externally Each half of the machine is equipped with individual guarding, and the guarding on the adjustable half moves in tandem with the machine when modifications are made for work-piece width.
A complete machine enclosure is specifically designed to reduce noise while allowing the operator to move freely within the space This enclosure ensures that all machine settings and adjustments are easily accessible from inside, enhancing both safety and convenience.
#displaceable machine$$$$ machine which is located on the floor, stationary during use and equipped with a device, normally wheels, which allow it to be moved between locations
Supplier information includes statements, sales literature, and leaflets where a manufacturer declares the characteristics of a material or product, as well as its compliance with relevant standards.
This document identifies significant hazards and hazardous situations related to machines, as outlined in EN 1050:1996, which require action to mitigate risks It addresses these hazards by establishing safety requirements and measures or referencing relevant standards A comprehensive list of these hazards can be found in Table 1, in accordance with Annex A of EN 1050:1996.
Table 1 — List of significant hazards
No Hazards, hazardous situations and hazardous events EN ISO 12100 Relevant sub- clause of this document Part 1:
- machine parts or workpieces: a) shape; 4.2 4.2.1,
5.3.7 d) mass and velocity (kinetic energy of elements in controlled or uncontrolled motion);
- accumulation of energy inside the machinery: g) liquids and gases under pressure; 4.2 4.10, 5.5.4 5.4.7, 5.4 8
1.5 Drawing-in or trapping hazard 5.3.7
1.9 High pressure fluid injection or ejection hazard 5.3.4, 5.4.7,
2.1 Contact of persons with live parts (direct contact) 4.3 4.9, 5.5.4 5.4.4, 5.4.14
2.2 Contact of persons with parts which have become live under faulty conditions
Burns, scalds, and other injuries can occur from contact with objects or materials at extreme temperatures, exposure to flames or explosions, and radiation from heat sources.
3.2 Damage to health by hot or cold working environment
4 Hazards generated by noise, resulting in:
4.1 Hearing loss (deafness), other physiological disorders (loss of balance, loss of awareness)
4.2 Interference with speech communication, acoustic signals 5.4.2
7 Hazards generated by materials and substances (and their constituent elements) processed or used by the machinery
7.1 Hazards from contact with or inhalation of harmful fluids and dusts
8 Hazards generated by neglecting ergonomic principles in machinery design related to:
8.1 Unhealthy postures or excessive effort 4.9 4.7, 4.8.2,
8.2 Hand-arm or foot-leg anatomy 4.9 4.8.3 5.2.2, 5.4.5, 6.3
8.7 Design, location or identification of manual controls 4.8.7,
4.11.8 5.2.2 8.8 Design or location of visual display units 4.8.8, 6.2 5.2.2
10 Unexpected start up, unexpected overrun/overspeed (or any similar malfunction) from:
10.1 Failure/disorder of the control system 4.11, 5.5.4 5.2.1, 5.2.11
10.2 Restoration of energy supply after an interruption
10.3 External influences on electrical equipment 4.11.11 5.4.4, 5.4.11
10.6 Errors made by the operator (due to mismatch of machinery with human characteristics and abilities, see 8.6)
11 Impossibility of stopping the machine in the best possible conditions 4.11.1,
13 Failure of the power supply 4.11.1,
14 Failure of the control circuit 4.11, 5.5.4 5.2.11
17 Falling or ejected objects or fluids 4.2.2 4.3, 4.10 5.3.5, 5.4.14
18 Loss of stability / overturning of machinery 4.2.2 5.2.6 5.3.1
19 Slip, trip and fall hazards in relationship with machinery (because of their mechanical nature)
5 Safety requirements and/or measures
General
The machine must adhere to the safety requirements and protective measures outlined in this clause Furthermore, it should be designed following the principles of Clause 5 of EN ISO 12100-1:2003, addressing relevant but not significant hazards, such as sharp edges, that are not covered by this document.
For guidance in connection with risk reduction by design, see Clause 4 of EN ISO 12100-2:2003, and for safeguarding measures, see Clause 5 of EN ISO 12100-2:2003.
Controls
Safety and reliability of control systems
A safety-related control system encompasses everything from the initial manual control or position detector to the input of the final actuator, such as a motor This document specifically addresses the safety-related control systems associated with this machine.
interlocking with guard locking (see 5.3.7);
trip device, limiting device and hold-to-run control devices (see 5.3.7);
provided to satisfy the requirements of 5.4.1;
provided to satisfy the requirements of 5.3.2 for avoiding contact between tools and parts of the machine
Unless otherwise stated in this document these control systems shall, as a minimum, be designed and constructed in accordance with category 1 as defined in #EN ISO 13849-1:2008$
For the purposes of this document "well tried components and principles" means: a) electrical components if they comply with relevant standards including the following as:
1) #EN 60947-5-1:2004$ (Section 3) for control switches with positive opening operation used as mechanical actuated position detectors for interlocking guards and for relays used in auxiliary circuits;
2) #EN 60947-4-1:2001$ for electromechanical contactors and motor-starters used in main circuits;
3) #HD 22.1 S4:2002$ for rubber-insulated cables;
The #HD 21.1 S4:2002$ standard applies to polyvinyl chloride cables that are protected against mechanical damage through proper positioning, such as within frames Electrical principles must adhere to the first four measures outlined in 9.4.2.1 of #EN 60204-1:2006$ Circuits should be either hardwired or, if using electronic components in safety-related control systems, must meet the "well tried" criteria as specified in 9.4.2.2 (redundancy with cross-monitoring) or 9.4.2.3 (diversity) of #EN 60204-1:2006$, with examples provided in Annex A Mechanical components should operate in positive mode as described in section 4.5 of EN ISO 12100-2:2003 Additionally, mechanically actuated position detectors for guards must be actuated in positive mode, with their arrangement, fastening, and cam design adhering to the requirements of sections 5.2 and 5.3.
EN 1088:1995; e) interlocking devices with guard locking if they satisfy the requirements of 5.3.7.1; f) pneumatic and hydraulic components and systems if they comply with the requirements of EN 983:1996 and EN 982:1996 respectively
Time delay devices in hardwired safety-related control circuits, designed for a minimum of 1 million actuations, may be classified as category B This classification applies to components involved in the initial manual control of the hold-to-run function, in accordance with the requirements of EN ISO 13849-1:2008.
In addition the control system for step less speed changing shall be as a minimum designed and constructed in accordance with the following principles:
The actual speed or exit frequency can be converted using a comparator, such as an electronic system, allowing for comparison either by the inverter or an external comparator with the chosen frequency.
Verification: By checking the relevant drawings and/or circuit diagrams and inspection on the machine
#NOTE For components characteristics the information from the component supplier can be useful.$
Position of controls
The primary electrical control devices for operating the tool spindle and other processing spindles, as well as for normal stopping, integrated feed, top pressure beam movement, machine half movement, and mode selection, should be grouped together in a visible location for the loading position If the controls are placed on a separate control desk, their location must be clearly indicated in the instruction manual.
Hold-to-run control devices shall be located so that the operator, when actuating them, can see the controlled movements (also see 5.2.7.2d))
For the position of the emergency stop controls see 5.2.5
Where a mobile set of controls is used, it shall be connected by cable to the machine
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing on the machine.
Starting
Before operating or reactivating the machine, it is essential to ensure that all safety measures are in place and operational This is accomplished through the interlocking systems outlined in section 5.3.7 The machine can only be started or restarted by using the designated start control device.
Power supply to the tool spindle drive motor and other processing spindle drive motors must be clearly indicated, either permanently or upon the operator's request This can be achieved through a light signal located near the start control, integrated into the start button, or by utilizing a two-position switch Additionally, operators can verify the status by querying the control computer.
The shearing and crushing zone between the workpiece and machine components must be clearly visible from the main control position, either directly or through indirect means such as mirrors or television cameras.
It shall be possible to start each tool motor and the feed mechanism separately (see 5.2.6)
For electrically started machines see 9.2.5.2 of #EN 60204-1:2006$
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing on the machine.
Stop controls
A stop control shall be fitted which, when actuated, stops all machine actuators and cuts power to them once stopping is complete
The category of this stop function (category 0 or 1) shall be in accordance with the requirements of 9.2.2 of
The EN 60204-1:2006 standard ensures that the safety and functional requirements of machinery are met by preventing collisions between the workpiece, tools (both moving and stationary), and dynamic processing units This standard also stipulates that power must be maintained to the electrical brake, if available, until the braking sequence is fully completed.
Control circuits must meet specific requirements, including the use of a time-delay device This device should have a time delay that exceeds the machine's maximum run-down time, and it must either be fixed or have a sealed adjustment mechanism.
If the emergency stop outlined in section 5.2.5 meets the specified criteria, it can be considered equivalent to the normal stop control requirements In such instances, measures must be implemented to prevent any automatic or unintentional restarting, as referenced in section 7.5.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
Any other stop controls provided shall be of category 0, 1 or 2 in accordance with the requirements of
The EN 60204-1:2006 standard outlines that a category 2 stop control must meet all safety requirements based on its intended function When active in the setting mode for all movements or in machining mode specifically for the feed, it is essential that the control adheres to these safety standards.
To initiate the stopping sequence, first halt the movement of the axes, then stop the spindle rotation and engage the brake if available Once the braking sequence is finished, disconnect the power to the brake if it is electrically operated.
To prevent unexpected startup of movements during setting or feed operations, compliance with EN 1037:1995 is essential If cutting power to all machine actuators is not feasible, implementing standstill monitoring as per section 6.4 of EN 1037:1995 is required In the event of a failure, the standstill monitoring system must ensure that power to these movements is cut off.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine.
Emergency stop
Shall be according to #EN ISO 13850:2008$ and in addition:
Machines must be equipped with emergency stop controls that meet the specifications outlined in sections 9.2.5.4 and 10.7 of EN 60204-1:2006 It is important to note that the stipulations in section 10.7.5 of EN 60204-1:2006 are not applicable Additionally, the normal stopping requirements detailed in section 5.2.4 must be adhered to.
Emergency stop controls must be installed at key locations, including both ends of each machine half at loading and unloading positions, on all mobile or fixed control sets, within 0.5 meters of each hold-to-run device, and inside enclosures with a mode selection switch These controls should be positioned to ensure accessibility from any operational position.
A single emergency stop control can fulfil, by virtue of its installed position, the function of more than one of the above requirements
Verification: By checking the relevant drawings and/or circuit diagrams, measurement, inspection and relevant functional testing of the machine.
Integrated feed
The integrated feed operates only when all tool spindles in the sizing/profiling zone are powered on or when the non-powered spindles are retracted to a non-cutting position suitable for the machine's maximum tool diameter This can be accomplished through a limit switch meeting at least category B standards as per #EN ISO 13849-1:2008, or by utilizing a programmable electronic system.
See 6.3 for tools which are adjusted manually, this manual adjustment includes a hold-to-run control
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine.
Mode selection
A mode selection switch must be included to allow the guard(s) to be opened for adjustments while specific machine parts are in motion This control mode will take precedence over all other control systems, except for the emergency stop.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
5.2.7.2 Mode selection for adjustment of tools and other processing units
A mode selection switch may be included for tools and processing units, with specific requirements: a) the normal (automatic) control mode must be disabled in adjustment mode; b) its use should not trigger any adjustments; c) switching to the adjusting position must stop the feed, tool spindles, and other processing units; d) it must be lockable, such as with a key-operated switch, in compliance with the requirements of 4.11.10.
According to EN ISO 12100-2:2003, the movement of the feed must be regulated by a hold-to-run control device, which should be positioned solely on a mobile set of controls Additionally, if the hold-to-run control for the feed is continuously activated for over 5 minutes, both the feed and the tool spindles are required to stop.
The EN 60204-1:2006 standard mandates that powered adjustments must be managed by a hold-to-run control device It specifies that some or all tool spindles may continue to operate after intentional activation, requiring that the area around the tool remains visible to the operator during adjustments Additionally, necessary deterring or impeding devices must be installed to prevent horizontal access to any rotating tools from within the enclosure For dynamic processing units, it is crucial that tool spindles and dynamic movements are disabled when the relevant guards are open.
Verification: By checking the relevant drawings and/or circuit diagrams, measurement, inspection and relevant functional testing of the machine
5.2.7.3 Mode selection for fine adjustment of the tool and other processing units whilst they and the feed are running during machining
A mode selection switch is essential for fine-tuning tools and processing units When implemented, it must meet specific criteria: a) the normal automatic control mode must be disabled during fine adjustment; b) activating the switch should not trigger any adjustments; c) it must be lockable, such as with a key-operated switch, in compliance with the requirements outlined in section 4.11.10.
According to EN ISO 12100-2:2003, the interlocking of a single door, not exceeding 2.0 m in length, may be overridden once for a maximum duration of 3 minutes, after which the feed, tools, and other processing units must cease operation Additionally, appropriate deterring or impeding devices must be installed to prevent horizontal access to any rotating tools from within the enclosure For specific materials and properties of these devices, refer to section 5.3.2 Furthermore, for dynamic processing units, the operation of tool spindles and dynamic movements must be disabled when the relevant guards are open.
Verification: By checking the relevant drawings and/or circuit diagrams, measurement, inspection and relevant functional testing on the machine.
Speed changing
Machines equipped with a frequency inverter for stepless speed adjustment must ensure that the actual speed does not exceed the selected speed by more than 10% The actual speed or exit frequency can be compared to the selected value through an electronic system, either by the inverter itself or an external comparator, as outlined in section 9.4.2 of EN 60204-1:2006 and its annex A.4.
Verification: By checking the relevant drawings and/or circuit diagrams #and$ inspection #deleted text$
#NOTE For the component characteristics a confirmation from the component manufacturer can be useful.$
Failure of the power supply
14 Failure of the control circuit 4.11, 5.5.4 5.2.11
17 Falling or ejected objects or fluids 4.2.2 4.3, 4.10 5.3.5, 5.4.14
18 Loss of stability / overturning of machinery 4.2.2 5.2.6 5.3.1
19 Slip, trip and fall hazards in relationship with machinery (because of their mechanical nature)
5 Safety requirements and/or measures
The machine must adhere to the safety requirements outlined in this clause and be designed according to Clause 5 of EN ISO 12100-1:2003, addressing relevant but not significant hazards, such as sharp edges, that are not covered by this document.
For guidance in connection with risk reduction by design, see Clause 4 of EN ISO 12100-2:2003, and for safeguarding measures, see Clause 5 of EN ISO 12100-2:2003
5.2.1 Safety and reliability of control systems
A safety-related control system encompasses everything from the initial manual control or position detector to the input of the final actuator, such as a motor This document specifically addresses the safety-related control systems associated with this machine.
interlocking with guard locking (see 5.3.7);
trip device, limiting device and hold-to-run control devices (see 5.3.7);
provided to satisfy the requirements of 5.4.1;
provided to satisfy the requirements of 5.3.2 for avoiding contact between tools and parts of the machine
Unless otherwise stated in this document these control systems shall, as a minimum, be designed and constructed in accordance with category 1 as defined in #EN ISO 13849-1:2008$
For the purposes of this document "well tried components and principles" means: a) electrical components if they comply with relevant standards including the following as:
1) #EN 60947-5-1:2004$ (Section 3) for control switches with positive opening operation used as mechanical actuated position detectors for interlocking guards and for relays used in auxiliary circuits;
2) #EN 60947-4-1:2001$ for electromechanical contactors and motor-starters used in main circuits;
3) #HD 22.1 S4:2002$ for rubber-insulated cables;
For polyvinyl chloride cables, compliance with #HD 21.1 S4:2002$ is required, provided they are protected against mechanical damage, such as being positioned within frames Electrical principles must adhere to the first four measures outlined in 9.4.2.1 of #EN 60204-1:2006$ Circuits should be “hardwired,” or if electronic components are utilized in safety-related control systems, they must meet the “well tried” criteria as specified in 9.4.2.2 (redundancy with cross-monitoring) or 9.4.2.3 (diversity) of #EN 60204-1:2006$ (refer to Annex A for examples) Mechanical components should operate in positive mode as described in 4.5 of EN ISO 12100-2:2003 Additionally, mechanically actuated position detectors for guards must be actuated in positive mode, with their arrangement, fastening, and cam design/mounting conforming to the requirements of 5.2 and 5.3.
EN 1088:1995; e) interlocking devices with guard locking if they satisfy the requirements of 5.3.7.1; f) pneumatic and hydraulic components and systems if they comply with the requirements of EN 983:1996 and EN 982:1996 respectively
Time delay devices in hardwired safety-related control circuits, designed for a minimum of 1 million actuations, may be classified as category B This classification applies to components involved in the initial manual control of the hold-to-run function, in accordance with the requirements of EN ISO 13849-1:2008.
In addition the control system for step less speed changing shall be as a minimum designed and constructed in accordance with the following principles:
The actual speed or exit frequency can be converted using a comparator, such as an electronic system, allowing for comparison either by the inverter or an external comparator with the chosen frequency.
Verification: By checking the relevant drawings and/or circuit diagrams and inspection on the machine
#NOTE For components characteristics the information from the component supplier can be useful.$
The primary electrical control devices for operating the tool spindle and other processing spindles, as well as for normal stopping, integrated feed, top pressure beam movement, machine half movement, and mode selection, should be grouped together in a visible location for the loading position If the controls are placed on a separate control desk, their location must be clearly indicated in the instruction manual.
Hold-to-run control devices shall be located so that the operator, when actuating them, can see the controlled movements (also see 5.2.7.2d))
For the position of the emergency stop controls see 5.2.5
Where a mobile set of controls is used, it shall be connected by cable to the machine
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing on the machine
Before operating or reactivating the machine, it is essential to ensure that all safety measures are in place and operational This is accomplished through the interlocking systems outlined in section 5.3.7 The machine can only be started or restarted by using the designated start control device.
Power supply to the tool spindle drive motor and other processing spindle drive motors must be clearly indicated, either permanently or upon the operator's request This can be achieved through a light signal located near the start control, integrated into the start button, or by utilizing a two-position switch Additionally, operators can verify the status by querying the control computer.
The shearing and crushing zone between the workpiece and machine components must be clearly visible from the main control position, either directly or through indirect means such as mirrors or television cameras.
It shall be possible to start each tool motor and the feed mechanism separately (see 5.2.6)
For electrically started machines see 9.2.5.2 of #EN 60204-1:2006$
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing on the machine
A stop control shall be fitted which, when actuated, stops all machine actuators and cuts power to them once stopping is complete
The category of this stop function (category 0 or 1) shall be in accordance with the requirements of 9.2.2 of
The EN 60204-1:2006 standard ensures that the safety and functional requirements of machinery are met by preventing collisions between the workpiece, tools (both moving and stationary), and dynamic processing units This standard also stipulates that power should remain supplied to the electrical brake, if available, until the braking sequence is fully completed.
To meet the specified requirements, control circuits must be properly configured If a time-delay device is implemented, its delay must exceed the machine's maximum run-down time, and the delay should either be fixed or have a sealed adjustment mechanism.
If the emergency stop outlined in section 5.2.5 meets the specified criteria, it can be considered equivalent to the normal stop control In such instances, measures must be implemented to prevent any automatic or unintentional restarting, as referenced in section 7.5.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
Any other stop controls provided shall be of category 0, 1 or 2 in accordance with the requirements of
The EN 60204-1:2006 standard outlines that a category 2 stop control must meet all safety requirements based on its intended function When active in the setting mode for all movements or in machining mode specifically for the feed, it is essential that the control adheres to these safety standards.
To initiate the stopping sequence, first halt the movement of the axes, then stop the spindle rotation and engage the brake if available Once the braking sequence is finished, disconnect the power to the brake if an electrical brake is installed.
To comply with EN 1037:1995, it is essential to prevent any unexpected startup of movements during the setting mode or feed movement in machining mode If cutting power to all machine actuators is not feasible, implementing standstill monitoring as per section 6.4 of EN 1037:1995 is required In the event of a failure, the standstill monitoring system must ensure that power to these movements is cut off.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
Shall be according to #EN ISO 13850:2008$ and in addition:
Failure of the control circuits
The requirements of EN 1037:1995 apply and in addition:
Control circuits must be designed to ensure that a line rupture, such as a broken wire, pipe, or hose, does not compromise safety functions, including the risk of involuntary starts, in accordance with standards EN 60204-1:2006, EN 982:1996, and EN 983:1996.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing on the machine.
Protection against mechanical hazards
Stability
Stationary machines and auxiliary equipment e.g additional work-piece supports shall be provided with the facility, e.g holes in the frame, for fixing them to a suitable stable structure e.g floor (also see 6.3 e))
#Displaceable$ machines fitted with wheels shall have facilities to make them stable during machining e.g brakes for the wheels or a device to retract the wheels from the floor
Verification: By checking the relevant drawings and inspection of the machine.
Risk of break-up during operation
The guards for the tools must be made from materials that meet specific criteria: a) steel with a minimum ultimate breaking strength of 350 N/mm² and a wall thickness of at least 2 mm; b) light alloy that conforms to the specifications outlined in Table 2.
Table 2 — Light alloy tool guard thickness and tensile strength
Polycarbonate should have a minimum wall thickness of 5 mm, or alternatively, other plastic materials must match or exceed the impact strength of 5 mm thick polycarbonate Additionally, cast iron must possess an ultimate tensile strength of at least 200 N/mm² and a wall thickness of no less than 5 mm.
To prevent contact between tools and machine parts during powered spindle adjustments, it is essential to utilize a manually adjustable mechanical restraint device or numeric control It is important to note that adjustments do not encompass controlled movements during machining processes.
Verification: By checking the relevant drawings, measurement #and$ inspection of the machine
#NOTE For the ultimate tensile strength a confirmation from the manufacturer of the material can be useful.$
Tool holder and tool design
All tool spindles shall be manufactured to at least the requirements given in Annex B
The part of the spindle upon which the saw-blades are located shall have a minimum tolerance of g6 in accordance with the requirements of ISO 286-2:1988
Verification: By checking the relevant drawings and by measurement
The tool spindles shall be manufactured from steel with a minimum ultimate tensile strength of 580 N mm -2
Verification: By checking the relevant drawings #deleted text$
#NOTE For the ultimate tensile strength a confirmation from the manufacturer of the material can be useful.$
5.3.3.3 Dimensions for spindles and tools
According to section 6.2.4 of #EN 847-1:2005$, manufacturers must specify the maximum speed, weight, and dimensions of tools compatible with each spindle (refer to section 6.3 for additional details).
Verification: By calculation or other method, e.g test, accepted standards, proven experience
Spindle units that remain stationary during machining must be securely held in place This can be achieved through various means: a securing device for manual adjustments, a brake or self-locking transmission for electric motor adjustments, a non-return valve for pneumatic power adjustments, or a control circuit for Numeric Control settings.
NOTE In the context of this requirement “adjustment” does not include controlled movement during machining
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
To facilitate tool changes, a spindle holding device must be used to keep the spindle stationary This device can take the form of a double spanner or an integral locking bar that is inserted through the spindle.
Verification: By checking the relevant drawings, inspection and relevant functional testing of the machine
Spindle rings must have bores with a tolerance of at least H8, as specified by ISO 286-2:1988 Additionally, the clamping surfaces of the spindle rings should be parallel within a tolerance of 0.02 mm.
Spindle rings shall be manufactured in steel with an ultimate tensile strength of at least 350 N mm -2
For spindle rings with a bore size ≥ 30 mm the wall thickness shall be ≥ 9,5 mm Where the bore size is < 30 mm the wall thickness shall be ≥ 4 mm
Verification: By checking the relevant drawings, inspection #and$ measurement #deleted text$
#NOTE For the ultimate tensile strength a confirmation from the manufacturer of the material can be useful.$
Tool spindles must be equipped with one of the following tool fixing devices: a positive connection between the tool and the spindle, a positive connection between the front flange or spindle ring (locking collar) and the spindle, or a cone connection.
Where saw flanges are provided, they shall conform to the following requirements:
1) the diameter of both flanges (or flange for flush mounted saw-blades) shall be at least D/6 (where D is the diameter of the largest saw-blade for which the machine is designed);
2) for flanges other than those for flush mounted saw-blades, the clamping surface at the outside part of the flange shall be flat over a width of at least 5 mm and recessed to the centre (see Figure 4) Both outside diameters shall be within a tolerance of ± l mm
When fitted with a hydraulic tool fixing system, there shall be a device which prevents axial movement of the tool in the case of hydraulic system failure
Verification: By checking the relevant drawings, inspection, measurement and relevant functional testing of the machine.
Braking
Automatic brakes are required for tool spindles with an un-braked run-down time exceeding 10 seconds, ensuring that the braked run-down time is under 10 seconds Additionally, if the run-up time surpasses 10 seconds, the braked run-down time must be less than the run-up time but cannot exceed 30 seconds For sanding belt units, an automatic brake is necessary when the un-braked run-down time is over 30 seconds, with the braked run-down time also being less than 30 seconds.
For electrical braking, reverse current injection braking shall not be used
Verification: For the determination of the run-up time, the braked and un-braked run-down time see the appropriate test given in 5.3.4.3
5.3.4.2 Conditions for all tests a) the spindle unit shall be set in accordance with the manufacturer’s instructions (e.g belt tension); b) when selecting the speed and the tools, conditions shall be chosen which create the greatest kinetic energy for which the machine is designed; c) before beginning the test the spindle unit shall be running for at least 15 min at idle speed; d) verify that the actual spindle speed is within 10 % of the intended speed; e) when testing a unit provided with manual star delta starting, the motor manufacturer's instruction for starting shall be observed; f) the speed measuring equipment shall have an accuracy of at least ± 1 % of full scale; g) the time measuring equipment shall have an accuracy of at least ± 0,1 s
5.3.4.3.1 Un-braked run-down time
To measure the un-braked run-down time, first, operate the spindle drive motor at the intended speed without load for one minute Next, disconnect the power to the spindle drive motor and record the unbraked run-down time This process should be repeated two additional times for accurate results.
The un-braked run-down time is the average of the three measurements taken
The braked run-down time is determined by first operating the spindle drive motor at the intended speed without any load for one minute Next, power to the spindle drive motor is cut, and the duration of the braked run-down time is measured Finally, the spindle is allowed to remain stationary for a specified period.
The motor power (rated input) is denoted as P in kW, and the re-start interval must be at least 1 minute The spindle drive motor should be restarted and operated at no-load for 1 minute, followed by repeating this process, including the previous steps, a total of 9 additional times.
The braked run-down time is the average of the 10 measurements taken
The run-up time is determined by starting the tool spindle drive motor and measuring the duration until it reaches full speed Next, power is cut to the motor, allowing the spindle to stop completely This process is repeated two additional times to ensure accuracy in the measurements.
The run-up time is the average of the three measurements taken.
Devices to minimise the possibility or the effect of ejection ! ! ! ! or kick-back " "
Deflectors must be installed to redirect off-cuts away from the saw blade, preventing contact with subsequent tools and avoiding ejection from the machine Alternatively, off-cuts should be hogged and extracted effectively.
Verification: By checking the relevant drawings, inspection and relevant functional testing of the machine
Machines intended for banding solid edges must include a pressure device, such as pressure rollers, to prevent the ejection of solid edges when the milling units, positioned after the gluing units, operate in climb cutting mode.
A pressure device with pressure rollers must fulfill specific criteria: it should have two rollers with a non-damaging surface, such as rubber, that press against the upper and lower faces of the workpiece and its banded solid edge Additionally, it must include one roller with a hard surface, like steel, that applies horizontal pressure to the banded solid edge The device should be positioned on the machine between the outfeed end and the milling tools The pressure from the rubber rollers must be at least 50 N, applied perpendicularly to the upper and lower surfaces, while the steel roller must exert a pressure of at least 300 N, also at right angles to the banded solid edge.
3 Soft faced rollers (upper and lower)
Figure 5.3.5 — Pressure device installation at the outfeed end of the machine
To ensure safety during milling operations, a pressure device must be installed to prevent kick-back of the workpiece's solid edge when the milling unit cuts against the feed This device should be positioned between the edge banding zone and the milling tools, unless alternative kick-back prevention methods, such as roller assemblies and feeding systems, are in place If an additional pressure device is required, it must comply with the specifications outlined in section 5.3.5a), b), and d).
Verification: By checking the relevant drawings, inspection and measurement."
Work-piece supports and guides
The work-piece shall be guided and supported by the track and the top pressure beam
Verification: By checking the relevant drawings, inspection and relevant functional testing of the machine.
Prevention of access to moving parts
To ensure safety, access to rotating tools, such as sanding tools, must be restricted by a guard or guards that form a complete enclosure, except for the slot between the feed chain and the top pressure beam where the workpiece moves.
Access for maintenance, adjustment, or setting must be facilitated through a movable interlocking guard that complies with the guard locking requirements of EN 1088:1995, with exceptions noted in section 5.2.7.2.
When the run-down time of a tool exceeds 10 seconds, it is essential to implement an interlocking device with a spring-applied or power-released guard locking mechanism, as specified in Annex M of EN 1088:1995, for that section of the enclosure.
The integral enclosure must be designed to prevent a person from standing inside with the access doors closed If the machine's design or door size makes this unfeasible, the enclosure should ensure that: a) a person's movement along the machine is restricted; b) emergency stop(s) are available for anyone inside; and c) access doors can be opened from within.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection, measurement and relevant functional testing of the machine
To ensure safety during sanding operations, fixed guards must prevent access to all parts of the sanding belt except for the area used for sanding the workpiece These guards should facilitate the changing or adjusting of the sanding belt, as well as cleaning or dust removal, through a non-interlocking hinged cover that can be securely locked in the closed position during normal operation.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine
5.3.7.3 Guarding of the edge banding zone
Access to snipping knives, spiked rollers, and pressure or loading rollers must be restricted through fixed guards, ensuring that these components are only accessible via the designated slot between the feed chain and the top pressure beam where the workpiece moves.
Other hazards e.g trapping or crushing, shall be minimised by means of a deterring/impeding device preventing direct horizontal access
Verification: By checking the relevant drawings, inspection and relevant functional testing of the machine
5.3.7.4 Guarding of the chain or other feed mechanisms
To ensure safety, access to chains and pressure devices must be restricted by the enclosure specified in section 5.3.7.1 Additionally, fixed guards should be used for any parts outside the enclosure, except for the sections of the chain and pressure device that are essential for holding and feeding the workpiece.
To minimize the risk of crushing between the closing pads of the chain at the in feed and out feed, it is essential to implement adequate chain design or provide proper guarding Additionally, the danger of being drawn in between the chain and a fixed part of the machine can be reduced by utilizing a work support piece or a suitable casing extension to cover potential trapping points.
Verification: By checking the relevant drawings, inspection, measurement and relevant functional testing of the machine
Figure 5 — Example of adequate feed chain design
Figure 6 — Work support at in feed
Figure 7 — Example of guarding of feed chain at the in feed 5.3.7.4.2 Trapping at the in feed end of the machine
To ensure safety at the in-feed end of each top pressure beam, access to the trapping points for guiding and holding the workpiece must be restricted This can be achieved by implementing either a fixed guard that moves vertically with the top pressure beam, maintaining a gap of 4 mm or less between the workpiece and the guard, or by utilizing a mechanically actuated trip device that complies with specified requirements.
EN 1760-2:2001, which shall meet the following additional requirements:
1) the width of the sensor of each trip device shall extend at least over the full width of the beam;
2) the bottom edge of the trip device shall be no more than 12 mm above the surface of the work-piece during normal feeding;
3) having regard to the gap between this trip device and the work-piece, the horizontal distance from the trip device to the trapping point, the response time of the trip device and the stopping time of the chain, the trip device shall be designed and positioned so that when operated it shall stop the feed before a hand resting on the work-piece and moving at the maximum feed speed for which the machine is designed can reach the trapping point;
4) the trip device shall not in itself create a trapping hazard
Verification: By checking the relevant drawings and/or circuit diagrams, measurement, inspection and relevant functional testing of the machine
A Width of sensor (A ≥ width of top pressure beam)
Figure 8 — Trip device at the in feed end of the machine 5.3.7.4.3 Crushing between machine halves (double end machines)
To avoid the risk of a person being crushed between chain beams, it is essential for the machine to be equipped with a mechanically actuated trip device, as outlined in the relevant safety standards.
EN 1760-2:2001, which complies with the following additional requirements:
1) it shall extend at least over the full length of the chain beam;
2) it shall have a maximum tripping force of 50 N;
3) it shall be fitted to the moving chain beam(s) and positioned such that its sensor is at least 50 mm in front of the chain beam and not more than 70 mm below the lowest crushing point of the chain beam (see Figure 9);
4) when the trip device is triggered, the beam shall stop before the trip device is fully compressed; or b) an active opto-electronic protective device (light barrier) in accordance with the requirements of
The CLC/TS 61496-2:2006 standard specifies that an active opto-electronic protective device must utilize one or more beams that meet the criteria outlined in sections a) 1) and a) 3) of the previous requirements Additionally, the residual stroke of the chain beam after actuation must not exceed 50 mm, ensuring compliance with at least category 2 safety standards.
The CLC/TS 61496-2:2006 standard requires an automatic test each time the machine is powered on Additionally, a limiting device must be implemented to ensure that the machine halves do not come closer than 500 mm, as specified in section 3.26.8 of EN ISO 12100-1:2003 If closer proximity is necessary, it must be achieved using a hold-to-run control device that allows for a clear view along the length of the machine halves.
Where the distance between the chain beams is ≤ 150 mm, the device required in a) or b) can be overridden
Verification: By checking the relevant drawings and/or circuit diagrams, measurement, inspection and relevant functional testing of the machine
5 Trip device sensor extending over full length of chain beam
Figure 9 — Trip device on moving chain beam
5.3.7.4.4 Crushing between machine halves and fixed parts of the machine
Protection against non-mechanical hazards
Fire
To #deleted text$ minimise fire hazards, the requirements of 5.4.3 and 5.4.4 shall be fulfilled
To prevent overheating of stationary workpieces or machine components, it is essential to implement interlocking mechanisms, such as linking workpiece heaters with the feed Additionally, heat can be diverted or the heating power reduced to a safe level that avoids combustion, considering the specific characteristics of the workpiece.
This interlocking device shall be a minimum of category B in accordance with the requirements of
Verification: By checking the relevant drawings, and/or circuit diagrams, inspection and relevant functional testing on the machine.
Noise
5.4.2.1 Noise reduction at the design stage
When designing machinery, the information and technical measures to control noise at source given in
EN ISO 11688-1:1998 shall be taken into account The most relevant noise sources are the rotating tools
The machine must include noise enclosures, which, if integrated into the guarding system, must meet the interlocking requirements specified in section 5.3.7 However, if the noise enclosure solely addresses noise hazards while other guards manage mechanical hazards, interlocking is not necessary, as noted in section 6.3.
The noise enclosure must feature sound-absorbing linings that cover at least 75% of its internal surface area, with a noise absorption factor (α) of at least 0.7 at 1 kHz, as per EN ISO 354:2003 standards Additionally, the dimensions of the in-feed and out-feed openings should exceed the maximum allowable work-piece dimensions by no more than 20 mm.
Verification: By checking the relevant drawings, measurement, inspection and confirmation from the component manufacturers
Operating conditions for noise measurement shall comply with the requirements of Annexes F or G of ISO 7960:1995
Mounting and operating conditions of the machine shall be identical for the determination of emission sound pressure levels at the work station and sound power levels
Emission sound power levels must be measured using the enveloping surface method outlined in EN ISO 3746:1995, with specific modifications: the environmental indicator K 2A should not exceed 4 dB, and the sound pressure level difference between background and machine at each point must be at least 6 dB, with a correction formula applicable up to 10 dB Measurements should only utilize the parallelepiped surface at 1 m from the reference surface, and if the machine is within 2 m of an auxiliary unit, that unit must be included in the reference surface The 30-second measuring time requirement is waived, the test method's accuracy must be within 3 dB, and nine microphone positions are required as per Annexes F or G of ISO 7960:1995.
Alternatively, where the facilities exist and the measurement method applies to the machine type, emission sound power levels may also be measured in accordance with a method of higher precision i.e
EN ISO 3743-1:1995, EN ISO 3743-2:1996, EN ISO 3744:1995 and EN ISO 3745:2003 without the preceding modifications
For determination of sound power level by sound intensity method, use EN ISO 9614-1:1995 (subject to agreement between the supplier and the purchaser)
Emission sound pressure level at the workstation shall be measured in accordance with the requirements of
The EN ISO 11202:1995 standard has been modified to include specific requirements: the environmental indicator K 2A and local environmental factor K 3A must not exceed 4 dB; the difference between the background emission sound pressure level and the workstation sound pressure level should be at least 6 dB; and the correction for the local environmental factor K 3A must be calculated according to A.2 of EN ISO 11204:1995, referencing EN ISO 3746:1995, rather than the method in Annex A of EN ISO 11202:1995, or in accordance with EN ISO 3743-1:1995.
EN ISO 3743-2:1996, EN ISO 3744:1995 or EN ISO 3745:2003 where one of these standards has been used as the measuring method
Emission of chips, and dust
Provision shall be made for the extraction of chips and dust from the machine and it shall be able to be connected to a separate chip and dust collection system
The design of hoods, ducts, and baffles must ensure that chips and dust are effectively conveyed to the collection system, utilizing a calculated conveying velocity for the extracted air within the duct.
20 m s -1 for dry chips and 28 m s -1 for wet chips (moisture content 18 % or above)
Verification: By checking the relevant drawings and inspection of the machine.
Electricity
The requirements of #EN 60204-1:2006$ apply unless otherwise stated in this document
Refer to section 6.2 of EN 60204-1:2006 for guidelines on preventing electric shock from direct contact, section 6.3 for measures against electric shock from indirect contact, and Clause 7 for requirements on protection against short circuits and overloads.
To prevent electric shock from indirect contact, automatic isolation of the electrical power supply is typically implemented, as detailed in the manufacturer's instruction handbook.
The degree of protection for electrical components shall be in accordance with the requirements of #11.3 of
The standard EN 60204-1:2006 specifies that, with certain exceptions, three-phase motors must have a minimum protection degree of IP 5X as per EN 60529:1991, and the final statement of section 11.3 is not applicable.
#In accordance with test 1 in 18.2 and 18.6 of EN 60204-1:2006 the test for the continuity of the protective bonding circuit and functional tests apply.$
Single phase motors with a rated input ≤ 1 kW, manufactured in accordance with the requirements of
Verification: #By checking the relevant drawings and/or circuit diagrams, inspection and relevant continuity of the protective bonding circuit and functional tests (specified in test 1 of 18.2 and 18.6 of
#NOTE For electrical components characteristics the information from the electrical component supplier can be useful.$
Ergonomics and handling
#The requirements of EN 614-1:2006 shall apply and in addition:$
The height of the work-piece support shall be between 750 mm and 900 mm above the floor level
#The machine and its controls shall be designed according to ergonomic principles in accordance with
EN 1005-4:2005 for work posture which is not fatiguing
The positioning, marking and illumination (if necessary) of control devices, and facilities for materials and tool set handling shall be in accordance with ergonomic principles in accordance with EN 894-1:1997,
EN 894-2:1997, EN 894-3:2000, EN 1005-1:2001, EN 1005-2:2003, EN 1005-3:2002
Tanks containing compressed air drainers and oilers shall be placed or oriented in such a way that the filler and drain pipes can be easily reached
Machine components weighing over 25 kg must be equipped with appropriate attachments for lifting devices, such as lugs, strategically placed to prevent overturning, falling, or uncontrolled movement during transport, assembly, disassembly, disabling, and scrapping.
If the machine is fitted with a movable control panel, this panel shall be fitted with a facility to move it in the desired position
If graphical symbols related to the operation of actuators are used, they shall be in accordance with Table A.1 of EN 61310-1:2008
NOTE Further guidance is given in EN 60204-1:2006, EN 614-1:2006 and EN 614-2:2000
Also see 5.2.2 for position of controls, 5.2.5, 6.3, EN 894-3:2000 and EN 1005-3:2002.$
Verification: By checking the relevant drawings, measurement and inspection of the machine
Lighting
Where lighting is required as determined by reference to EN 1837:1999, it shall be provided in accordance with the requirements of #16.2 of EN 60204-1:2006$
Verification: By checking the relevant drawings and/or circuit diagrams and inspection of the machine.
Pneumatics
Hydraulics
Heat
Where there are hazards caused by contact of a hand with any hot surfaces, the requirements of 5.3 of
According to EN 563:1994, inadvertent contact is defined as lasting 1 second or less, while voluntary contact, such as with a handle, exceeds 30 seconds To prevent contact, a fixed enclosing guard must be used, which can be made of wire mesh with a maximum mesh size of 40 mm or insulating material.
This does not apply to the internal surfaces of the open glue-pot and glue-pot lid during filling
For hydraulic and pneumatic equipment see EN 982:1996 and EN 983:1996 respectively
Verification: By checking the relevant drawings, inspection and measurement of temperature.
Substances
Machines intended for use with Polyurethane (PU) glues must include measures to contain glue vapors or gases, such as an enclosed system, or allow for connection to a dedicated extraction system.
Verification: By checking the relevant drawings and visual inspection
#The machine shall have sufficient immunity to electromagnetic disturbances to enable it to operate correctly in accordance with EN 60439-1:1999, EN 50370-1:2005 and EN 50370-2:2003
Machines that use CE-marked electrical components, installed according to the manufacturers' guidelines, are typically safeguarded against external electromagnetic interference.
For control systems with electronic components see Clause 1
Verification: By checking the relevant drawings and/or circuit diagrams and inspection of the machine.$
Static Electricity
If the machine is fitted with flexible hoses for chip and dust extraction the hoses shall be able to lead charge to earth potential
Verification: By checking the relevant drawings and inspection of the machine.
Errors of fitting
It shall not be possible to fit a tool of greater diameter than the largest tool for which the machine is designed.Also see 5.4.14, 6.2 and 6.3
Verification: By checking the relevant drawings and inspection of the machine.
Isolation
#The requirements of Clause 5 of EN 1037:1995 apply and in addition:$
The electrical isolator shall be in accordance with the requirements of 5.3 of #EN 60204-1:2006$ except that the isolator shall not be of type d) as described in 5.3.2 of #EN 60204-1:2006$
Machines equipped with a pneumatic system must have an isolation device, such as a valve, that allows for secure locking in the off position, for instance, using a padlock.
To ensure safety in machines with hydraulic systems, isolation can be accomplished by either disconnecting the electrical supply to the hydraulic drive motor, as outlined in section 5.3 of #EN 60204-1:2006, or by installing a disconnection device, such as a valve with mechanical locking in the off position.
Verification: By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional testing of the machine.
Maintenance
#The basic principles of 4.15 of EN ISO 12100-2:2003 shall be observed and in addition at least the information for maintenance listed in 6.5.1 e) of EN ISO 12100-2:2003 shall be provided See also 6.3.$
Residual energy storage, such as in a reservoir or pipe, requires the implementation of pressure dumping mechanisms, typically through the use of a valve It is important to note that pressure should not be released by simply disconnecting a pipe.
Verification: By checking the relevant drawings, instruction handbook, inspection and relevant functional testing of the machine