Bsi bs en 12981 2005 + a1 2009

BRITISH STANDARD BS EN 12981 2005 Coating plants — Spray booths for application of organic powder coating material — Safety requirements ICS 87 100 �� ������ ���� � ��� ���������� ������ �� ���������[.]

This British Standard was

published under the authority

of the Standards Policy and

Strategy Committee

on 20 June 2005

© BSI 2009

This British Standard is the UK implementation  EN 12981:2005+A1:2009

It supersedes BS EN 12981:2005, which is withdrawn

The UK participation in its preparation was entrusted by Technical Committee MCE/3, Safeguarding of machinery, to Subcommitee MCE/3/8,

Thermoprocessing equipment — Safety

A list of organizations represented on this subcommittee can be obtained on request to its secretary

This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application

Compliance with a British Standard cannot confer immunity from legal obligations.

Amendments/corrigenda issued since publication

The start and finish of text introduced or altered by amendment is indicated

in the text by tags Tags indicating changes to CEN text carry the number ofthe CEN amendment For example, text altered by CEN amendment A1 isindicated by    

31 May 2009 Implementation of CEN amendment A1:2009

NORME EUROPÉENNE

EUROPÄISCHE NORM

English Version

Coating plants - Spray booths for application of organic powder

coating material - Safety requirements

Installations d'application Cabines d'application par

projection de produit de revêtement en poudre organique

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä IS C H E S K O M IT E E FÜ R N O R M U N G

Management Centre: Avenue Marnix 17, B-1000 Brussels

Contents

Foreword 4



0





1





2





3





4





4.1





4.2





4.2.1





4.2.2





4.2.3





4.3





4.3.1





4.3.2





4.3.3





4.3.4





4.4





4.5





4.5.1





4.5.2





4.6





4.7





5





5.1





5.2





5.2.1





5.2.2





5.2.3





5.2.4





5.2.5





5.3





5.3.1





5.3.2





5.3.3





5.3.4





5.3.5





5.4





5.5





5.5.1





5.5.2





5.6





5.6.1





5.6.2





5.7





6





6.1





6.2





6.2.1





6.2.2





6.3





6.3.1





6.3.2





6.3.3





6.3.4





6.4





6.5





6.5.1





6.5.2





6.6





6.6.1





6.6.2





6.7





7





7.1





7.2





7.2.1





7.2.2





7.2.3





7.3





Annex A (normative) Diagrams relative to hazardous zones of potentially explosive atmosphere 37



Annex B (normative) Determination of concentration of combustible coating powder in terms of LEL 39



B.1





B.2





Annex C (informative) Diagrams relative to powder spray booths classification 43



Annex D (informative) Classification of construction material’s reaction to fire - National standards 45



Annex E (informative) References to National Exposure Limit Values 46



Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC !, amended by 98/79/EC" 47



Annex ZB (informative) !Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC " 48



Bibliography 49



This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s)

!For relationship with EU Directive(s), see informative Annexes ZA and ZB, which are integral parts of this document."

This document includes Amendment 1, approved by CEN on 2009-02-22

This document supersedes EN 12981:2005

The start and finish of text introduced or altered by amendment is indicated in the text by tags ! "

NOTE Although a spray booth, as an integral whole, formally does not fall under the scope of the ATEX Directive 94/9/EC, the standard is based upon a fundamental risk analysis according to this directive

This European Standard includes a Bibliography

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom

0 Introduction

This European Standard is a Type C standard as stated in EN ISO 12100

The machinery concerned and the extent to which hazards, hazardous situation and events are covered are indicated in the scope of this European Standard

When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards, for machines that have been designed and built according to the provisions of this European Standard

The specific requirements which manufacturers shall include in the information for use are given in Clause 7

1 Scope

1.1 This European Standard is applicable to spray booths for spray application of organic coating powder,

called in this European Standard “powder spray booths”, i.e machinery and related equipment for automated and/or manual powder coating application processes

This European Standard covers powder spray booths consisting of the following equipment:

⎯ forced ventilation system;

⎯ air filtering and coating powder recovery system;

⎯ coating powder recycling system;

⎯ delivery and circulating systems for coating powder (for instance hopper or tank, preparation and transfer new powder feeding);

⎯ air conditioning system;

⎯ automatic cleaning system;

⎯ monitoring and/or control systems;

⎯ fire detection and interlocking system;

⎯ explosion protection system;

⎯ mechanical aspects of product handling systems and reciprocators inside the powder spray booth;

⎯ electrical equipment;

⎯ powered doors and gates

joined together within or at a partially or totally enclosed structure (limited by walls, called space) for the controlled processing of spray application of organic coating powder

This European Standard deals with the significant hazards, hazardous situations and events relevant to powder spray booths when they are used as intended and under the conditions foreseen by the manufacturer (see Clause 4)

NOTE Powder spray booths are classified in Annex !C"

In addition, it defines:

⎯ the content of marking;

⎯ the minimum requirements for use

1.2 This European Standard does not cover:

a) powder spray booths in which the coating is applied by immersion in a fluidised bed;

b) powder spray booths for application of non combustible and inorganic coating powder and flock; c) spraying equipment as covered by EN 1953, EN 50050, EN 50177;

d) machinery for the supply or circulation of coating material under pressure as covered by prEN 12621; e) all loading and unloading systems;

f) automatic systems, e.g robots as covered by EN 775 and control systems of powder spray booths influencing these systems (e.g teaching of the spraying process);

g) powder spray booths for application of coating powder for food-stuffs and pharmaceuticals;

h) spraying areas characterized by an open space for application of organic powder coating material which is limited only by one side wall used for extraction of exhaust ventilation;

i) limiting walls of powder spray booths if they are constituent parts of a building

1.3 This European Standard is not applicable to powder spray booths which are manufactured before the date of publication of this European Standard by CEN

The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 179, Building hardware — Emergency exit devices operated by a lever handle or push pad !, for use on

escape routes " — Requirements and test methods

EN 294, Safety of machinery — Safety distance to prevent danger zones being reached by the upper limbs

EN 349, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body

EN 418, Safety of machinery — Emergency stop equipment, functional aspects — Principles for design

EN 619, Continuous handling equipment and systems — Safety and EMC requirements for equipment for

mechanical handling of unit loads

EN 775, Manipulating industrial robots — Safety (ISO 10218:1992, modified)

EN 811, Safety of machinery — Safety distances to prevent danger zones being reached by the lower limbs

EN 842, Safety of machinery — Visual danger signals — General requirements, design and testing

EN 953, Safety of machinery — Guards — General requirements for the design and construction of fixed and

EN 971-1:1996, Paints and varnishes — Terms and definitions for coating materials — Part 1: General terms

EN 981, Safety of machinery — System of auditory and visual danger and information signals

EN 999, Safety of machinery — The positioning of protective equipment in respect of approach speeds of

parts of the human body

EN 1037, Safety of machinery — Prevention of unexpected start-up

EN 1088:1995, Safety of machinery — Interlocking devices associated with guards — Principles for design

EN 13463-5, Non-electrical equipment intended for use in potentially explosive atmospheres — Part 5:

Protection by constructional safety "c"

EN 13478, Safety of machinery — Fire prevention and protection

!EN 14462:2005, Surface treatment equipment — Noise test code for surface treatment equipment

including its ancillary handling equipment — Accuracy grades 2 and 3 "

!EN 14986", Design of fans working in potentially explosive atmospheres

EN 50015, Electrical apparatus for potentially explosive atmospheres — Oil immersion "o"

EN 50017, Electrical apparatus for potentially explosive atmospheres — Powder filling "q"

EN 50020, Electrical apparatus for potentially explosive atmospheres — Intrinsic safety "i"

EN 50050, Electrical apparatus for potentially explosive atmospheres — Electrostatic hand-held spraying

equipment

EN 50177:1996, Automatic electrostatic spraying installations for flammable coating powder

EN 50281-1-2, Electrical apparatus for use in the presence of combustible dust — Part 1-2: Electrical

apparatus protected by enclosures — Selection, installation and maintenance

EN 60079-0, Electrical apparatus for explosive gas atmospheres — Part 0: General requirements

EN 60079-17, Electrical apparatus for explosive gas atmospheres — Part 17: Inspection and maintenance of

electrical installations in hazardous areas (other than mines) (IEC 60079-17:2002)

EN 60079-18, Electrical apparatus for explosive gas atmospheres — Part 18: Construction, test and marking

of type of protection encapsulation “m” electrical apparatus (IEC 60079-18:2004)

EN 60204-1:1997, Safety of machinery — Electrical equipment of machines — Part 1: General requirements

(IEC 60204-1:1997)

EN 60529, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)

EN 61000-6-1, Electromagnetic compatibility (EMC) — Part 6-1: Generic standards — Immunity for residential,

commercial and light-industrial environments (IEC 61000-6-1:1997, modified)

EN 61000-6-3, Electromagnetic compatibility (EMC) — Part 6-3: Generic standards — Emission standard for

residential, commercial and light-industrial environments (IEC 61000-6-3:1996, modified)

EN 61000-6-4, Electromagnetic compatibility (EMC) — Part 6-4: Generic standards — Emission standard for

industrial environment (IEC 61000-6-4:1997, modified)

EN 61010-1, Safety requirements for electrical equipment for measurement, control and laboratory use —

Part 1: General requirements (IEC 61010-1:2001)

EN 61310-1, Safety of machinery — Indication, marking and actuation — Part 1: Requirements for visual,

auditory and tactile signals (IEC 61310-1:1995)

EN 61310-2, Safety of machinery — Indication, marking and actuation — Part 2: Requirements for marking

(IEC 61310-2:1995)

EN 61310-3, Safety of machinery — Indication, marking and actuation — Part 3: Requirements for the

location and operation of actuators (IEC 61310-3:1999)

EN 61496-1:2004, Safety of machinery — Electro-sensitive protective equipment — Part 1: General requirements and tests (IEC 61496-1:2004, modified)

!deleted text"

EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic

terminology, methodology (ISO 12100-1:2003)

EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:

Technical principles (ISO 12100-2:2003)

EN ISO 14122-1, Safety of machinery — Permanent means of access to machinery — Part 1: Choice of fixed

means of access between two levels (ISO 14122-1:2001)

EN ISO 14122-2, Safety of machinery — Permanent means of access to machinery — Part 2: Working

platforms and walkways (ISO 14122-2:2001)

EN ISO 14122-3, Safety of machinery — Permanent means of access to machinery — Part 3: Stairs,

stepladders and guard-rails (ISO 14122-3:2001)

ISO 3864-1, Graphical symbols — Safety colours and safety signs — Part 1: Design principles for safety signs

in workplaces and public areas

IEC 61496-2, Safety of machinery — Electro-sensitive protective equipment — Part 2: Particular requirements

for equipment using active opto-electronic protective devices (AOPDs)

3 Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN 971-1:1996,

EN ISO 12100-1:2003 and the following apply

3.1

powder spray booth

assembly of linked components such as forced ventilation by one or more fans, air filtering and coating powder recovery system, coating powder recycling system, measuring and control devices (e.g interlocking of forced ventilation and spraying device), fire detection and interlocking, explosion protection system, automatic cleaning system, air conditioning system, warning devices, electrical apparatus, joined together within or at a partially or totally enclosed structure (limited by walls, called space) for the controlled processing of spray

NOTE Different kind of powder spray booth are described in Annex !C", e.g.:

⎯ powder spray booth with operator inside the booth (see Figure !C.1" of Annex !C");

⎯ powder spray booth with operator outside the booth (see Figure !C.2" of Annex !C");

⎯ powder spray booth without operator but with supports for automatic spraying device outside the booth (see !C.3");

⎯ powder spray booth with operator and supports for automatic spraying device outside the booth (see Figure !C.4");

⎯ powder spray booth with operator and automatic spraying device inside the booth (see Figure !C.5" of Annex !C")

⎯ This kind of powder spray booth can also be designed as a multizone powder spray booth

3.2

powder coating material; coating powder

solvent-free coating material in powder form which, after fusing and possible curing, gives a continuous film (see 1.41 of EN 971-1:1996)

forced ventilation system

ensures the air exchange by fan(s) or by other powered means

NOTE Forced ventilation systems are using exhaust air units with devices for material separation and – optional – automatic cleaning, and, in addition, if applicable a supply air unit with devices for filtering, air conditioning and automatic powder recycling

3.7

supply air

consists either totally of outside air or by energetic reasons of a mixture of outside air with recirculation air The recirculation airflow may consist of exhaust air and/or recirculated clean air Air introduced in the powder spray booth serves to replace the collection air, to reduce the concentration of air pollutants in the work region and to supply air for technological processes

3.8

explosive atmosphere

mixture with air, under atmospheric conditions, of flammable substances in the form of gases, vapours, mists

or dusts, in which, after ignition has occurred, combustion spreads to the entire unburned mixture (see 3.17 of

EN 1127-1:1997)

NOTE In this European Standard, explosive atmosphere is only due to dust resulting from used coating powder

lower explosion limit (LEL)

lower limit of the explosion range (see 3.8 of EN 1127-1:1997)

3.11

average concentration of coating powder

mass of coating powder introduced into the powder spray booth divided by the volume of air extracted by the forced ventilation system during the same period of time

3.12

exposure limits

concentration limits of dangerous substances in air required by worker health legislation

NOTE Limits are different according to the countries (see Annex !E")

3.13

reciprocator

alternating moving device holding guns

3.14

powder recovery system

system which collects overspray from the powder coating process which has not been deposited on the workpiece

3.15

enclosed recovery system

separate enclosed coating powder collector (e.g filter and/or cyclone) which is connected through ductwork to the powder spray booth

3.16

open recovery system

coating powder collector usually fitted with filters integrated to the powder spray booth in open arrangement

3.17

explosion relief venting

protective measure at which an area of the panelwork of the enclosure (for example of the coating powder collection unit) is designed and constructed to release the excess pressure in the event of an explosion to prevent injury to persons and further damage to equipment

fire detection system

fire alarm system comprising components for automatically detecting a fire, initiating an alarm of fire and initiating other action as appropriate (see 3.1.3 of ISO 8421-3:1989)

3.21

hazardous areas

areas where hazards due to explosive atmosphere may exist The probability of occurrence of explosive atmosphere is classified in zones

Limits of hazardous zones are given in Annex A

NOTE For this European Standard, only the zones 20 and 22 (as defined in 3.22 and 3.24) are suitable

3.24

zone 22

area in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation, but if it does occur, it will persist for a short period only (see 6.3.3 of EN 1127-1:1997 and 6.2 of EN 50281-3:2002)

NOTE This zone can include, among others, areas in the vicinity of equipment containing combustible dust, from which dust can escape from leaks and form dust deposits

3.25

Equipment category

NOTE Equipment for potentially explosive atmospheres is divided into groups and categories Group II: Equipment for places with a potentially explosive atmosphere, other than mines susceptible to firedamp; this group comprises three categories according to the level of safety provided

3.25.1

Equipment Group II Category 1D

equipment in this category is intended for use in areas in which explosive atmospheres caused by air/dust mixtures are present continuously for long periods or frequently (see 3.2.3 of EN 13463-1:2001)

NOTE Equipment of category 1D is suitable for use in zone 20, 21 and 22

3.25.2

Equipment Group II Category 2D

equipment in this category is intended for use in areas in which explosive atmospherescaused by air/dust mixtures are likely to occur (see 3.2.4 of EN 13463-1:2001)

NOTE Equipment of category 2D is suitable for use in zone 21 and 22

3.25.3

Equipment Group II Category 3D

equipment in this category is intended for use in areas in which explosive atmospheres caused by air/dust mixtures are unlikely to occur, or, if they do occur, are likely to do so only in frequently and for a short period only (see 3.2.5 of EN 13463-1:2001)

NOTE Equipment of category 3D is suitable for use in zone 22

3.26

multi-zone powder spray booth

spray booth including a number of sections for manual and/or automatic spraying and forced ventilation flash off space

NOTE In flash off space no spraying takes place

⎯ workpieces or parts of workpieces

NOTE Danger points can exist, for example, on gear, chain drives, V-belt, flat belt, pulling and supporting elements

on continuous conveyors, spoke wheels, shafts and shaft ends, slides, push rods and similar parts, tools and clamping devices

Particular points of danger are:

⎯ crushing and shearing points;

⎯ trapping points;

⎯ inrunning nips;

⎯ cutting, punching and impact points

3.28

accessible danger zone

"accessible danger zones" are areas where, for example, area guards or ESPDs allow whole-body access The objective is to prevent anyone starting the machine while persons are within the danger zone

3.29

hold-to-run control device

control device where the actuator automatically returns to the start position when released and where machine operation is started and maintained only as long as the actuator is hold depressed

3.30

integrated feeding system

feed mechanism for the workpiece which is integrated with the powder spray booth and where the workpiece

is held and controlled mechanically during the processing

3.31

loading / unloading

operation where the workpiece is put on / taken from the integrated feeding system

4 List of significant hazards

4.1 General

This clause contains the significant hazards, hazardous situations and events as far as they are dealt with in this European Standard, identified by risk assessment as significant for these types of powder spray booths and which require action to eliminate or reduce the risk

NOTE 1 Examples for the classification of powder spray booths are given in Annex !C"

NOTE 2 Hazards can also occur from combinations of ancillary equipment (e.g atomising and spraying equipment, robots, reciprocators, conveyors, power driven turntables for workpieces) and other parts of the powder spray booth

NOTE 3 Information on the method of risk analysis is given in EN 1050

4.2 Mechanical hazards

4.2.1 Shearing, crushing, cutting, entanglement, drawing-in, impact hazards

These hazards may result from the mechanical interfaces of the following equipment especially with powder spray booths:

⎯ product handling systems (e.g hazard from inrunning nip);

⎯ fans and automatic damper adjusters (e.g injuries caused by over-running of fan blades);

⎯ powered doors and gates;

⎯ automatic equipment or systems (e.g reciprocator, atomising and spraying system and power driven turntables for workpieces)

4.2.2 Entrapment hazard

This hazard may occur, for instance:

⎯ when obstacles or obstructions can impede a quick evacuation of the operator(s) from the powder spray booth in case of mechanical accident or fire;

⎯ when there is an accidental significant lowering of pressure inside an enclosed spray booth (i.e obstruction of air inlet) capable to increase the door opening effort beyond human capability

4.2.3 Personnel's slip, trip and fall hazards

Such hazards may occur, for instance, on gangways, platforms, ladders, stairs, gratings and excavations equipping the powder spray booths

These hazards may be increased as a result of poor lighting

4.3 Electrical hazards

4.3.1 Electrical shock (by direct or indirect contact)

Such hazards may occur, for instance, by touching:

⎯ electrically live parts that are non insulated for operational reasons;

⎯ conductive parts, which are not at dangerous voltage under normal operation, but in case of failure could be;

⎯ electrically live parts when insulation is insufficient or damaged by mechanical influences

4.3.2 Faulty earthing

Such hazards may occur, for instance:

⎯ by defective bonding to the protective earth system;

⎯ when resistance to earth is too high

4.4 Hazards generated by noise

Such hazards may occur inside and outside the powder spray booths

They can be originated from noises emitted for instance by:

⎯ fans;

⎯ excessive air velocity in ducts and accessories;

⎯ compressed air operating equipment (noises generated by reverse jet filter device, etc.)

4.5 Hazards generated by dangerous substances

4.5.1 Hazards resulting from contact with coating powder

Such hazards may be generated by contact with coating powder causing allergic irritation of skin and also dermatitis

4.5.2 Hazards resulting from inhalation of coating powder

Such hazards may be generated by inhalation of coating powder causing respiratory tract damage

4.6 Fire and explosion hazards

Such hazards may occur if coating powder clouds (produced by spraying equipment or turbulences of deposits or other means) are ignited Fire and explosion are possible if effective ignition sources are present and if the concentration of coating powder in air exceeds the lower explosion limit (LEL)

Examples of ignition sources are:

⎯ electrical sparks;

⎯ hot surfaces;

⎯ sparks created by mechanically induced sources;

⎯ sources of thermal energy used during maintenance;

⎯ flames propagation by the forced ventilation into the powder recovery system

LEL can be exceeded for example:

⎯ if forced ventilation of the powder spray booth breaks down;

⎯ if coating powder deposits are distributed within the powder spray booth;

⎯ in powder recovery systems during automatic filter cleaning

4.7 Hazards caused by failure of the energy supply and malfunction of the control system

Failure of energy supplies may lead to:

⎯ reduction of ventilation flow rate;

⎯ unexpected shutdown of control devices;

⎯ increase of powder concentration;

⎯ reduction of recirculation flow rate;

⎯ loss of lighting

Failure or malfunction of the control system (unexpected start-up, overrun) which can lead to:

⎯ increase of powder concentration;

⎯ wrong sequence of essential control functions

5 Safety requirements and/or protective measures

5.1 General

Machinery shall comply with the safety requirements and/or protective measures of this clause In addition, the machine shall be designed according to the principles of EN ISO 12100-2 for hazards relevant but not significant which are not dealt with by this European Standard (e.g sharp edges)

5.2 Mechanical safety requirements

5.2.1 Safeguarding of danger points

5.2.1.1 General

Inrunning nips on cylinders, drums, rolls and similar parts shall be safeguarded e.g by guards or by applying the safety distances specified in EN 349

Guards shall be designed as follows:

As guards without openings or with openings for feeding the material (for example work pieces): The safety distances shall be established in relation to the width of the opening in accordance with EN 294 Movable guards shall be interlocked with the dangerous movements in accordance with 5.2.1.3 or they shall be fixed to the machine Movable guards shall satisfy the requirements of 5.2.1.3

!When fixed guards are applied, they shall be fixed by systems that can be opened or removed only with tools Their fixing systems shall remain attached to the guards or to the machinery when the guards are removed Where possible, these guards shall be designed in such a way that they can only remain in place using their fixing system."

For machines constituting moving parts (e.g moving devices holding spraying equipment) see 7.2.2 first indent

5.2.1.2 Prevention of crushing and shearing

Moving parts of a powder spray booth such as power driven turntables, agitation system, powder feeding system and ventilation system shall be designed in such a way that in normal operation and maintenance crushing, shearing, cutting, entanglement, drawing-in, impact cannot occur EN 349, EN 294, EN 811, EN 842, ISO 3864-1, EN 619 shall be taken into account

The manual shall contain a warning against residual risks resulting from the presence of non-guarded product fixing devices, e.g hooks (see 7.2)

Starting of handling systems and reciprocators shall be preceded by an acoustic or optical signal with a duration of at least 5 s EN 61310-1 and EN 61310-2 shall be taken into account

5.2.1.3 Guards and interlocks

Guards shall satisfy the requirements of EN 953 Interlocking shall satisfy the requirements of Clauses 5 and 6

of EN 1088:1995

For interlocking, see 5.2.4 (control system)

For fence-type enclosures, the safety distances according to EN 294 apply A further requirement is that the distance between floor and lower edge of the fence is 200 mm maximum and between floor and upper edge 1,4 m

Guards and doors giving access to moving parts that need to be accessed frequently shall be safeguarded by interlocking with the hazardous movement (see 5.2.4)

Guards that do not have to be opened frequently shall either be fixed in such a way that their removal necessitates the use of a tool or they shall be interlocked with the hazardous movement (see 5.2.4)

For the purpose of this European Standard guards and doors are removed "frequently", including for maintenance purposes, if they are to be removed at least once per work shift

NOTE Guards and doors are removed for "setting-up" purposes, for example:

⎯ to supply workpieces to be processed;

⎯ to supply the cleaning liquid;

⎯ for make-ready

Automatic travel of movable guards shall not create danger points

⎯ If robots are installed of the type covered by EN 775 the powder spray booth may function as safeguarding enclosure under the condition that access to the powder spray booth is safeguarded in the same way as required in EN 775 for fence-type enclosures

⎯ ESPDs shall be interlocked with the hazardous movement ESPDs shall satisfy the requirements of type 2 of EN 61496-1 and IEC 61496-2

5.2.1.4 Moving parts

Access to power driven turntables shall be prevented by a fence-type enclosure or ESPD or be safeguarded

in a way resulting in the same level of safety Access-doors and openings for feeding products which are accessible by persons shall be interlocked with the turntable rotation

The travel when opening automatic powered doors if installed shall be guarded in such way that the hazard from crushing between the door leaf and fixed adjacent machinery parts or walls is prevented

An emergency stop control shall be located at the main control panel

5.2.1.6 Devices for setting-up, make-ready, cleaning and trouble-shooting during the work process

When access to the powder spray booth is needed during the work process for setting-up, make-ready, cleaning and trouble-shooting, hold-to-run devices shall be provided for controlling hazardous movements inside guarded areas A lockable selector switch shall be provided to allow only normal operation or hold-to-run operation at a time Where both hold-to run devices and two-hand controls are present, the selector switch shall enable the choice between hold-to-run mode with one actuator and the two-hand control mode

Hold-to-run control devices shall have a displacement limited to a maximum of 75 mm or with a maximum operating speed of 5 m/min For the application of hold-to-run devices designed as two-hand control device, the same limitations of displacement and operating speed shall apply The movement shall come to a stop in

a time that, taking into consideration the hand approach speed, ensures there is no danger for the operator The hand approach speeds specified in EN 999 shall be taken as a basis

Where hold-to-run controls are being used to allow safe control of hazardous movements, starting the machine in the hold-to-run mode after opening the corresponding interlocking guard shall only be possible when all other interlocked guards are closed

5.2.2 Protective measures against entrapment

Powder spray booths shall be designed so that in case of an emergency all persons entrapped can find their way out of the powder spray booth in the quickest time possible, without being hindered by obstructions The doors provided for personnel:

⎯ shall be capable of being opened and closed from inside and outside;

⎯ shall always open outwards;

⎯ shall be capable of being opened from inside by a mere push, independent of the air pressure (high or low) within the spray booth according to EN 179;

⎯ shall be self-closing;

⎯ shall have a minimum 800 mm width and 2 000 mm height

For access and egress of operators, powder spray booths for manual application shall be designed so that the operator does not need to travel more than 10 m to reach a door

If the powder spray booth is longer than 5 m, a second door shall be provided If the loading door complies with the requirements for operators' doors an additional door for operator access is sufficient

In multizone powder spray booth doors for workpieces located between manual spraying area and automatic spraying area shall not be operator's doors

If a permanent opening for loading of workpieces is used at the same time as personnel exit, a clearance of

800 mm exceeding maximum workpiece width shall be provided

Powder spray booths with operator inside the booth and powder spray booths with operator and with reciprocator automatic spraying device inside the booth shall be equipped with a pressure control device which is interlocked with the forced ventilation to prevent an accidental severe lowering of pressure inside the powder spray booths, capable of hindering the opening of the doors either by increase of opening effort or by deformation of the structure (see 5.5.2.3 a))

5.2.3 Protective measures against personnel’s slip, trip and fall

Gangways and guard-rails that are part of the powder spray booths shall comply with EN ISO 14122-1,

EN ISO 14122-2 and EN ISO 14122-3

The floor of powder spray booths with operator inside shall be non-skid (e.g by applying floor gratings)

Where floor gratings are used, they shall be joined in a way that no projections or cavities can cause a risk to slip, trip or fall

The powder spray booth shall be provided with adequate lighting of 600 lux minimum

5.2.4 Control system

5.2.4.1 General

The following control systems are considered safety-related:

⎯ monitoring of air velocity;

⎯ monitoring of recirculated air;

⎯ monitoring of minimum exhaust flow rate;

⎯ monitoring of spraying equipment activation before forced ventilation is working effectively;

⎯ detection of fire and fire alarm; interlocking circuits as dealt with in 5.6.1.3;

⎯ mode selector circuit;

⎯ main control circuit for each type of energy used

Control switches for starting hazardous movements shall be in accordance with the requirements of

⎯ the safety related part of a electric/electronic control system shall satisfy at least category 3 (see 6.2.4 of

EN 954-1:1996) It is allowed to provide single main contactors

NOTE 2 Category 3 means that faults in the safety related part of a control system (e.g auxiliary relays, auxiliary contactors, computers for safety-related functions or special PLCs (Programmable Logic Control) for monitoring) are detected and that measures are taken to bring the controlled equipment into a safe state (e.g stop of hazardous movements) According to EN 60204-1 programmable electronic control functions are not allowed considered safe in all cases

5.2.5 Warning devices, indicators, markings and actuating devices

The requirements of EN 61310-1, EN 61310-2 and EN 61310-3 shall be satisfied

5.3 Electrical safety requirements

5.3.1 General

Electrical equipment shall comply with EN 60204-1 and EN 50281-1-2

5.3.2 Protective measures against contact with electrically live parts

Protection against electrical shock shall comply with requirements of Clause 6 of EN 60204-1:1997

Electrical devices and conductors shall be installed in such a way that damages from mechanical stresses and environmental influences are prevented

All mechanical conductive parts of the installation shall be earthed (see Clause 8 of EN 60204-1:1997)

Emergency stopping devices shall fulfil the requirements of EN 418 and shall be designed in accordance with

EN 60204-1 as category 1 stop

When it is necessary to prevent access to high voltage areas, the requirements of 5.2.6 of EN 50177:1996 shall be met

All electrical equipment shall be designed such that it will withstand the testing specified in 19.2 to 19.6 of

EN 60204-1:1997 Voltage tests as specified in 19.4 of EN 60204-1:1997 are not required for electronic control circuits

NOTE 1 EN 50050 and EN 1953 specify requirements for spraying equipment (hand-held electrostatic guns)

NOTE 2 EN 1953 specifies requirement for powder equipment and conductive pipes

NOTE 3 IEC 60364 and IEC 60384 for risk of explosion (code BE3) specify requirements for electrical conducts

5.3.3 Protective measures regarding earthing

All conductive parts of the installation and all conductive structures such as floors, walls, ceilings, screens, fences, conveyors, workpieces, spraying material containers, automatic moving devices etc within the powder spray booth except for those parts which are under high voltage in normal operation, shall be bonded together with one another and with the earth terminal of the high voltage supply system to the protective earth system

of the electrical supply (see also 5.5.1 of EN 50177:1996)

NOTE More information on the earthing of electrostatic powder guns is given in EN 50050 and EN 50177

5.3.4 Protective measures on electromagnetic influences

Electrical and electronic components of the powder spray booths shall be resistant against electromagnetic influences Every interference of control systems of powder spray booths that can lead to an unsafe situation shall be prevented (see EN 61000-6-1, EN 61000-6-3, EN 61000-6-4)

5.3.5 Protective measures against electrostatic phenomena

Where walls of thin non-conductive materials are used the occurrence of electrostatic discharges which could ignite coating powders (propagating brush discharges) shall be avoided The minimum thickness of walls made of plastic materials shall be 9 mm, if they are in contact with conductive material, unless the breakdown voltage of plastic material is lower than 4 kV

When operator is working inside the powder spray booth, the floor shall be electrostatically conductive

The resistance to earth of booth floor with operator inside shall be less than 1MΩ

NOTE 1 For more information see Figures !C.1" and !C.5" of Annex !C"

NOTE 2 Information on propagating brush discharges is given in 5.2.5 of EN 50177:1996

5.4 Safety requirements and protective measures against noise

A powder spray booth as defined in 3.1 shall be so designed and constructed that risks resulting from the emission of airborne noise are reduced to the lowest level, taking account of technical progress and the availability of means of reducing noise in particular at the source

For example the following measures can be adopted:

⎯ choice of the filter cleaning system(s) emitting minimum noise;

⎯ equipment set on anti-vibratory supports;

⎯ flexible connections between the ducts and especially between fans and ducts;

⎯ choice of fan speed according to most favourable noise curves;

⎯ use effective silencer(s) on air operated equipment;

⎯ ducts soundproofing;

⎯ ancillary equipment permanently installed and connected to the powder spray booth shall not propagate noise to the powder spray booth structure through vibration, resonance etc

NOTE 1 This list is not exhaustive

The determination, declaration and verification of airborne noise emission of powder spray booths shall be carried out as stated in !EN 14462:2005"

NOTE 2 EN ISO 11688-1 gives general technical information on widely recognised technical rules and means to design low-noise machinery

!NOTE 3" EN ISO 11688-2 gives useful information on noise generation mechanisms in machinery

!NOTE 4" Concerning noise emitted by air compressors and spraying equipment refer to EN 1012-1 and

EN 1953

5.5 Safety requirements against dangerous substances

5.5.1 Protective measures against contact with coating powder

Contact with or absorption of dangerous substances sprayed shall be reduced by forced ventilation as far as possible (see 5.5.2.1 and 5.6.2) See also the provisions for the content of the instructions for use in 7.2.2

5.5.2 Protective measures against inhalation of coating powder

5.5.2.1 General

Powder spray booths shall be equipped with a forced ventilation system to reduce the concentration of coating powder in the operator's working area below exposure limits

Forced ventilation systems shall be designed according to type of application, size and shape of workpieces to

be coated, amount of coating powder used and exposure limits

Forced ventilation systems shall prevent escape of coating powder from powder spray booths through entrance and exit openings of workpieces, openings for manual application, reciprocators and conveyors slots, where existing

Air exhausted from the powder recovery system recirculated into the powder spray booth shall not contain particle concentrations above exposure limits

NOTE For information about exposure limit values see informative Annex !E"

5.5.2.2 Airflow direction

The airflow direction shall always keep coating powder away from the breathing zone of the operator and thus reducing inhalation of coating powder Information shall be given about required use of respiration protective devices, see 7.2

When it is required that the operator moves around a workpiece positioned at a fixed spot, the forced ventilation shall be directed vertically downwards

The length and the width of vertically ventilated powder spray booths with operator inside shall be at least one metre more on each side than the length and the width of the biggest workpiece to be coated

In the plane of the opening of the powder spray booths, airflow direction shall be from outside to inside to avoid powder escaping from the powder spray booths

5.5.2.3 Air velocity

a) General

In order to avoid coating powder escape from any opening of the powder spray booths the following air velocities are required under normal operating conditions, but without any workpiece inside the powder spray booth

1) Powder spray booth with operator inside (example given in Figure !C.1" of Annex !C") The average of measured vertical air velocities shall be at least 0,3 m/s

Single measured values shall be at least 0,25 m/s

Corresponding measurement points are specified in 6.5.2.3 a) 1)

2) Powder spray booth with operator outside (example given in Figure !C.2" of Annex !C") The average of measured air velocities through each opening shall be at least 0,4 m/s with a minimum air velocity of 0,3 m/s

Corresponding measurement points are specified in 6.5.2.3 a) 2)

3) Powder spray booth without operator inside but with reciprocators for automatic spraying device outside the booth (example given in Figure !C.3" of Annex !C")

The average of measured air velocities through each opening shall be at least 0,4 m/s with a minimum air velocity of 0,3 m/s

Corresponding measurement points are specified in 6.5.2.3 a) 3)

4) Powder spray booth without operator but with reciprocators for automatic spraying devices outside the booth (example given in Figure !C.4" of Annex !C")

The average of measured air velocities through each opening of powder spray booths with manual spraying operation inside shall be at least 0,4 m/s with a minimum air velocity of 0,3 m/s (e.g in Figure !C.4" of Annex !C")

Corresponding measurement points are specified in 6.5.2.3 a) 4)

5) Powder spray booth with operator and reciprocator for the automatic spraying device inside the booth (example given in Figure !C.5" of Annex !C")

The average of measured vertical air velocities shall be at least 0,3 m/s

Single measured values shall be at least 0,25 m/s

Corresponding measurement points are specified in 6.5.2.3 a) 5)

b) Particular cases

In the case of powder spray booths with operator outside, deviation from requirements in 5.5.2.3 a) 2) and 5.5.2.3 a) 3) is acceptable only if a large distance between the spraying area and workpiece openings prevents coating powder escape from the openings

At all times the air velocity shall be maintained as required in 5.5.2.3 a) 1) to 5.5.2.3 a) 5) for the manual operator spraying area

Enclosed powder spray booths with operator inside to spray only large well-defined workpieces at a time (e.g wagons, containers) shall be vertically ventilated

When large well-defined workpieces have to be coated, the required airflow shall be based on the air velocity inside the powder spray booth accommodating the workpiece Such powder spray booths shall not be used for small workpieces

The floor area of the workpieces shall be subtracted from the floor area of the powder spray booth and the remaining area considered as in 5.5.2.3 a) 1) for conditions with operator inside Corresponding measurement points are specified in 6.5.2.3 a) 1)

5.5.2.4 Ventilation performance

Powder spray booths shall be provided with a device (e.g pressure monitoring device, vacuum switch) to monitor the performance and detect any malfunction of the ventilation system According to the air velocity of the forced ventilation specified in 5.5.2.3 this device shall be interlocked with coating powder spraying equipment according to EN 50050 and EN 50177 (see also 5.2.4.1 and 5.2.4.2)

After failure of the forced ventilation system a manual restart shall be ensured

5.6 Safety requirements and protective measures against fire and explosion

The ductwork for make-up and exhaust air shall be of material, which does not support combustion

The surface of the ductwork shall not accumulate electrostatic charges, which could lead to an ignition It shall

be rigid enough, as short as possible, smooth inside and have no bends of small radius, which cause local reductions in airflow velocity and allow hazardous amounts of coating powder deposits

Powder deposits of hazardous amount shall be avoided within the powder spray booths

NOTE Additional information is given in Annex !D"

5.6.1.3 Fire detection system and interlocking

Powder spray booths as defined in 3.1 shall be equipped with a fire detection system, independent of the type

of powder recovery system

The fire detection system shall:

⎯ fulfil the requirements of 5.2.4;

⎯ have a response time less than 0,5 s;

⎯ cut off in the following order: the power supply, coating powder supply, filter cleaning and the forced ventilation system;

⎯ initiate a visible and audible alarm according to EN 981

Additional information on fire protection systems is given in EN 50177

NOTE In the next revision special attention will be paid to applicable alarm systems and their requirements

5.6.2 Explosions

5.6.2.1 General

The requirements shall allow:

⎯ to maintain the flammable substances concentration below LEL by forced ventilation;

⎯ to eliminate or reduce ignition sources

5.6.2.2 Limitation of coating powder concentration

In powder spray booths, a forced ventilation system shall be provided, so that the average concentration of coating powder in air does not exceed 50 % of LEL Where there is no reliable value of the LEL, an average concentration of 10 g/m3 shall not be exceeded (see Annex B)

5.6.2.3 Classification in hazardous areas (according to 3.21)

The classification of hazardous zones is an integral part of the safety concept for explosion prevention The ignition prevention category of equipment and components implemented to powder spray booth is dependent

on limitation of flammable substance concentration by forced ventilation

The internal volume of the powder spray booths and open recovery systems shall be classified as zone 22 (see 3.24)

The internal volume of enclosed powder recovery system shall be classified as zone 20 (see 3.22)

The external volumes to powder spray booths but within a distance up to 1 m from permanent openings, shall

be classified as zone 22 (see 3.24), see Annex A

NOTE Doors are not considered to be permanent openings

5.6.2.4 Avoidance or reduction of ignition sources

5.6.2.4.1 General

In order to prevent hazards by explosive atmospheres, the design and selection of electrical and non electrical equipment shall ensure that ignition sources are avoided in any part of the system, where areas with explosion hazard are classified (see 5.6.2.3) If electrical and non electrical equipment is implemented according to their manufacturer’s instruction, then the completed installation is of the same category of protection

5.6.2.4.2 Electrical equipment

Electrical apparatus for use in the presence of combustible dust shall comply with EN 50281-1-2