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STANDARDSIST EN 422:20001DGRPHãþD
SIST EN 422:2009
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 422June 2009ICS 83.200Supersedes EN 422:1995
English VersionPlastics and rubber machines - Blow moulding machines -Safety requirementsMachines pour les matières plastiques et le caoutchouc -Machines de moulage par soufflage - Prescriptions desécuritéKunststoff- und Gummimaschinen - Blasformmaschinen -SicherheitsanforderungenThis European Standard was approved by CEN on 13 May 2009.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial 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 STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre:
Avenue Marnix 17,
B-1000 Brussels© 2009 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 422:2009: ESIST EN 422:2009
EN 422:2009 (E) 2 Contents Page Foreword .4Introduction .51 Scope .62 Normative references .63 Terms and definitions .74 List of significant hazards .84.1 General hazards .84.2 Mechanical hazards related to power operated movements during production . 104.3 Additional hazards associated with machines of specific design . 104.3.1 Machines allowing whole body access . 104.3.2 Rotary machines . 104.4 Additional hazards when using ancillary equipment . 105 Safety requirements and/or protective measures . 105.1 General . 105.1.1 Basic requirements. 105.1.2 Safety distances. 105.1.3 Emergency stop . 115.1.4 Fluid systems . 115.1.5 Safeguards . 115.1.6 Movements caused by gravity . 125.1.7 Electrical hazards and hazards due to electromagnetic interference . 125.1.8 Thermal hazards . 125.1.9 Hazards due to harmful substances . 125.1.10 Fire hazards . 135.1.11 Hazards due to overpressure . 135.1.12 Mechanical hazards during setting . 135.2 Mechanical hazards related to power operated movements during production . 145.2.1 Basic requirements. 145.2.2 Additional requirements . 165.3 Additional hazards associated with machines of specific design . 175.3.1 Machines allowing whole body access . 175.3.2 Rotary machines . 175.4 Additional hazards when using ancillary equipment . 176 Verification of safety requirements and/or protective measures . 187 Information for use . 207.1 Instruction handbook . 207.1.1 General . 207.1.2 Safety-related components . 207.1.3 Emergency stop . 207.1.4 Thermal hazards . 207.1.5 Exhaust systems. 207.1.6 Fire hazard . 207.1.7 Setting . 207.1.8 Ancillary equipment . 217.2 Marking . 21Annex A (normative)
Acknowledgement systems . 22A.1 Single acknowledgement system . 22SIST EN 422:2009
EN 422:2009 (E) 3 A.2 Double acknowledgement system . 22Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC . 23Annex ZB (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC . 24 SIST EN 422:2009
EN 422:2009 (E) 4 Foreword This document (EN 422:2009) has been prepared by Technical Committee CEN/TC 145 “Plastics and rubber machines”, the secretariat of which is held by UNI. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by December 2009, and conflicting national standards shall be withdrawn at the latest by December 2009. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document supersedes EN 422:1995. 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 EC Directive(s). For relationship with EC Directive(s), see informative Annexes ZA, and ZB, which are integral parts of this document. 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 the United Kingdom. SIST EN 422:2009
EN 422:2009 (E) 5
Introduction This European Standard is a type C standard as defined in EN ISO 12100-1:2003. The machinery concerned and the extent to which hazards, hazardous situations and hazardous 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 type C standard. SIST EN 422:2009
EN 422:2009 (E) 6
1 Scope This European Standard covers essential health and safety requirements for the design of blow moulding machines for the processing of plastics. The significant hazards inherent in blow moulding machines are listed in Clause 4. This European Standard does not cover dip blow moulding machines. This European Standard does not cover hazards due to the use of fluorine or other toxic fluids. The safety requirements for the interaction between blow moulding machines and ancillary equipment are stipulated. The technical safety requirements for the design of this equipment are not covered. This European Standard does not cover the requirements for the design of the exhaust system. The European Standard does not cover noise hazards. This European Standard is not applicable to blow moulding machines which are manufactured before the date of its publication as an EN. A transition period until 29 December 2009 is foreseen during which the manufacturer may choose to apply either this or the previous version of the standard. 2 Normative references 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 953, Safety of machinery — Guards — General requirements for the design and construction of fixed and movable guards EN 982:1996, Safety of machinery — Safety requirements for fluid power systems and their components — Hydraulics EN 983:1996, Safety of machinery — Safety requirements for fluid power systems and their components — Pneumatics EN 999:1998, Safety of machinery — The positioning of protective equipment in respect of approach speeds of parts of the human body EN 1760-2:2001, Safety of machinery — Pressure sensitive protective devices — Part 2: General principles for the design and testing of pressure sensitive edges and pressure sensitive bars
EN 60204-1:2006, Safety of machinery — Electrical equipment of machines — Part 1: General requirements (IEC 60204-1:2005, modified) EN 60529:1991, Degrees of protection provided by enclosures (IP Code) (IEC 60529:1989) EN 61000-6-2:2001, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards; Immunity for industrial environments (IEC 61000-6- 2:1999, modified) EN 61000-6-4:2001, Electromagnetic compatibility (EMC) — Part 6-4: Generic standards; Emission standard for industrial environments (IEC 61000-6-4:1997, modified) EN 61496-1:1997, Safety of machinery — Electro-sensitive protective equipment — Part 1: General requirements and tests (IEC 61496-1:1997) SIST EN 422:2009
EN 422:2009 (E) 7 EN 61496-3:2001, Safety of machinery — Electro-sensitive protective equipment — Part 3: Particular requirements for Active Opto-electronic Protective Devices responsive to Diffuse Reflection (AOPDDR)
(IEC 61496-3:2001) 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 13732-1:2008, Ergonomics of the thermal environment — Methods for the assessment of human responses to contact with surfaces — Part 1: Hot surfaces (ISO 13732-1:2006) EN ISO 13732-3:2008, Ergonomics of the thermal environment — Methods for the assessment of human responses to contact with surfaces — Part 3: Cold surfaces (ISO 13732-3:2005) EN ISO 13849-1:2006, Safety of machinery — Safety related parts of control systems — Part 1: General principles for design (ISO 13849-1:2006) EN ISO 13857:2008, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and lower limbs (ISO 13857:2008) EN ISO 14122-1:2001, Safety of machinery — Permanent means of access to machinery — Part 1: Choice of a fixed means of access between two levels (ISO 14122-1:2001) EN ISO 14122-2:2001, Safety of machinery — Permanent means of access to machinery — Part 2: Working platforms and walkways (ISO 14122-2:2001) EN ISO 14122-3:2001, Safety of machinery — Permanent means of access to machinery — Part 3: Stairs, stepladders and guard-rails (ISO 14122-3:2001)
EN ISO 14122-4:2004, Safety of machinery — Permanent means of access to machinery — Part 4: Fixed ladders (ISO 14122-4:2004) ISO 7010 Graphical symbols — Safety colours and safety signs — Safety signs used in workplaces and public areas 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 blow moulding machine machine which expands a parison or preform to make a hollow article using fluid under pressure blown into a fixed or moving blow mould 3.2 area of movement of the moulds area in which the moulds move, close or open, also including the actuating equipment 3.3 feed area area of the extrusion head or of the injection nozzle or of the preform feeding device 3.4 cutting device apparatus which cuts the parison at the exit of the extrusion head SIST EN 422:2009
EN 422:2009 (E) 8 3.5 blowing station part of the machine in which the hollow articles are blown and stretched as appropriate and where the container aperture may be calibrated 3.6 delivery station part of the machine in which the blown parts are withdrawn from the blow mould and removed from the machine 3.7 cooling station part of the machine in which the blown parts are cooled after being withdrawn from the blow mould 3.8 finishing station part of the machine in which excess material is removed from the blown part 3.9 heating station part of the machine in which the temperature of the preform is adjusted before blowing 3.10 automatic machine machine where unloading (and/or loading) is achieved only without manual intervention 3.11 semi automatic machine machine where unloading (and/or loading) is achieved only with manual intervention or machine with a mode selector switch for selecting automatic or non automatic operation 4 List of significant hazards 4.1 General hazards Crushing, shearing or impact due to the whiplash of flexible hoses under pressure in normal operation or in case of rupture or disconnection, see 5.1.4. Injury by impact of ejected fluids or hot plastic materials, see 5.1.5.1. Injury by injection under the skin of very high pressure cooling fluids, see 5.1.4. Puncture by the blowing needles, see 5.2.1. Crushing, shearing or impact due to movements associated with hydraulic and pneumatic accumulators, see 5.1.4.
Crushing, shearing or impact due to movements of power operated guards, see 5.1.5.1 and 5.3.1. Crushing, shearing or impact due to movements of parts of the machine by gravity, see 5.1.6 and 5.1.12. Electric shock or burns due to direct or indirect contact with live conductive parts, see 5.1.7. Malfunction of the control circuits due to electromagnetic interference with the electrical equipment, see 5.1.7. Burns and/or scalds (see 5.1.8) due to very high or low temperatures of: SIST EN 422:2009
EN 422:2009 (E) 9 surfaces; the connecting hoses of the temperature control unit; fluid leakage; moulds, heating elements, plasticised material e.g. in injection blow moulding machines if the material is injected into incompletely closed moulds; extrusion head or injection nozzle, parison, ejected plastic material or gas (in the case of decomposition); cutting device; blowing gas, blowing needles or mandrels; parts accessible through the delivery aperture; hot conditioning fluid blown onto or into the preforms or parisons; cooling fluid; heating apparatus and surrounding parts;
preforms or parisons. Contact with, or inhalation of, harmful substances (see 5.1.9) that may be released from: the blowing gas;
the cooling and conditioning fluids; or
the processed plastic and the blown part when the mould is not completely closed (before blowing) or when the mould opens (after blowing). Fire due to ignition of the plastic material when a hot cutting device is used, see 5.1.10.
Impact due to bursting of the blown parts when the moulds open (applicable only when moulded parts with volume greater than 20 litres are blown with pressure greater than 10 bar), see 5.1.11.
Crushing, shearing or impact during setting (see 5.1.12) due to movement of: the blowing mould and its parts; the blowing needles or mandrels; the stretch rods; the individual blowing stations (multistation machines); the rotary table; the injection unit; the insert loading system. SIST EN 422:2009
EN 422:2009 (E) 10 4.2 Mechanical hazards related to power operated movements during production NOTE In subclauses 4.2 to 4.4, the sequence of hazards corresponds with the sequence of the safety requirements and/or protective measures specified in subclauses 5.2 to 5.4. Injuries due to dangerous movements or parts as listed in Table 1 (see 5.2.1). 4.3 Additional hazards associated with machines of specific design 4.3.1 Machines allowing whole body access Crushing, shearing, impact and entanglement by moving parts when operators have whole body access: in the area of movement of the moulds; between the guard or safety device and dangerous moving parts; through the discharge aperture. 4.3.2 Rotary machines Crushing, shearing, drawing-in or impact due to movements of the rotating table. Crushing, shearing, drawing-in or impact due to movements of the rotating table because of imbalance during mould changing (only in the case of a horizontal axis of rotation). 4.4 Additional hazards when using ancillary equipment Hazards are dependent on the type of ancillary equipment. 5 Safety requirements and/or protective measures 5.1 General 5.1.1 Basic requirements Blow moulding machines shall comply with the safety requirements and/or protective measures of this clause. In addition, the machine shall be designed in accordance with the principles of EN ISO 12100 for relevant but not significant hazards which are not dealt with in this document. The safety related parts of the control system shall be designed in accordance with EN ISO 13849-1:2006. The required performance level (PLr) for each safety function is specified below. See also 7.1.2. Adjustment elements which must be adjusted during production shall be accessible from outside the danger zone. When these adjustment elements are higher than 2 m above floor level, permanent means of access according to EN ISO 14122 series shall be provided. Where a special tool is necessary for adjustment such a tool shall be supplied by the machine manufacturer. 5.1.2 Safety distances For fixed guards or machine parts preventing access to the moving moulds (closing and transfer movements), EN ISO 13857:2008 Tables 2 and 4 shall be used. Tables 1 and 4 shall be used in all other cases. Electro-sensitive protective equipment (ESPE) shall be positioned in accordance with EN 999:1998. SIST EN 422:2009
EN 422:2009 (E) 11 5.1.3 Emergency stop The emergency stop shall stop all movement but not necessarily the heating. The stop category shall be 0 or 1 according to EN 60204-1:2006 whichever provides the shorter rundown time. See 7.1.3. 5.1.4 Fluid systems Hydraulic and pneumatic systems shall be designed in accordance with respectively EN 982:1996 and
EN 983:1996. The flexible hoses for hydraulic fluids under a pressure of more than 50 bar and for pneumatic fluids of more than 10 bar shall be secured to the machine by additional fastenings (for example chains) limiting the whiplash. On machines equipped with guards, this requirement does not apply to flexible hoses situated inside the guards.
However, additional fastenings for flexible hoses for blowing fluids are also required inside the machine, except if the machine is safeguarded by interlocking guards with guard locking and the pressure in the pneumatic hoses is reduced to under 10 bar before the guard lock can be released. The PLr for this safety function shall be c. To avoid injury by ejected fluids accessible hoses and connections shall be covered by guards. For hydraulic or pneumatic accumulators the following shall apply. The operation of a protective device shall interrupt all power from accumulators for the blowing fluid or which are associated with dangerous movements.
Actuation of the emergency stopping devices or disconnection of power to the machine shall isolate all power from accumulators for the blowing fluid or which are associated with dangerous movements. Where accumulators are integrated parts of the machine, unloading shall be initiated automatically. Visual indication of accumulator pressure shall be provided. Where hydraulic accumulators are integrated parts of the machine, the isolating valve or valves shall be position monitored. When the position monitoring system detects the valve or valves failing to isolate the accumulators, then: an optical or audible signal shall be given; and all accumulators connected with the failed valve or valves shall be automatically unloaded. Machines with hydraulic or pneumatic supply from an external source shall be provided with a manual isolation valve lockable by key. 5.1.5 Safeguards 5.1.5.1 Guards Guards shall be in accordance with EN 953. Guards located in areas where ejection of hot plastic can take place shall also contain the ejected material. If the movement of power operated guards can cause injury (force > 150 N or pressure > 50 N/cm2), pressure sensitive edges in accordance with EN 1760-2:2001 shall be provided in order to either arrest or reverse the closing movement of the guard. Actuation of the sensitive edge shall arrest or reverse the closing movement of the guard in accordance with EN ISO 13849-1:2006 PLr = c. Reversing the movement shall not create further hazards. SIST EN 422:2009
EN 422:2009 (E) 12 5.1.5.2 Electro-sensitive protecting equipment (ESPE) ESPE may be used if the ejection of hot plastics is prevented by design of the machine. The ESPE shall be in accordance with EN 61496-1:1997 or EN 61496-3:2001 and be positioned according to EN 999:1998. The ESPE shall become effective as soon as the blow moulding machine is switched on. It shall not be possible to reach the danger area around, above or beneath the ESPE. The end of an interruption of the ESPE shall not automatically initiate any further movement. A new start command shall be required. 5.1.6 Movements caused by gravity Machine parts which can have a dangerous movement under gravity shall be provided with an automatic blocking device which operates as soon as the corresponding movable guard is opened or ESPE is interrupted. The blocking shall remain active until a new start command is given. The required performance level for this safety function shall be PLr c. 5.1.7 Electrical hazards and hazards due to electromagnetic interference The electrical equipment shall be in accordance with EN 60204-1:2006. Protection against direct contact shall be in accordance with 6.2 of EN 60204-1:2006, with minimum degrees of protection in accordance with EN 60529:1991. Protection against indirect contact shall be in accordance with 6.3 of EN 60204-1:2006. Electronic control systems shall be designed and installed so as to be protected from electromagnetic interference and be stable when exposed to electrical system operation or failure in accordance with
EN 61000-6-2:2001. Electrical/electronic design shall apply technical information and physical measures to limit electromagnetic emissions in accordance with EN 61000-6-4:2001. During installation of electrical and electronic components, the machine manufacturer shall follow the information for use provided by the manufacturer of those components. 5.1.8 Thermal hazards To prevent burns through unintentional contact with hot machine parts, products or conditioning fluids, fixed guards or insulation shall be provided at accessible parts outside of the guarded area where the maximum operating temperature can exceed the limit values given in EN ISO 13732-1:2008. The same requirements apply for very cold parts (EN ISO 13732-3:2008). Warning signs in accordance with ISO 7010, W017/W010 shall be affixed in the immediate vicinity of the moulds and the heating elements, the feed area, the cutting device, the blowing station, the delivery aperture, the conditioning station and/or on the relevant guards. See 7.1.4. 5.1.9 Hazards due to harmful substances The blow moulding machine shall be so designed that an exhaust system can be fitted or positioned without modification of the machine for the extraction of harmful substances from the blowing gas, the cooling and conditioning fluids or the blown article. SIST EN 422:2009
EN 422:2009 (E) 13 See 7.1.5. This European Standard does not cover the requirements for the design of the exhaust system (see Clause 1). 5.1.10 Fire hazards When a hot cutting device is used:
ignition of the plastic material shall be detected automatically; and an acoustic or a visible signal shall be given; and feeding the parison or preforms shall stop if this does not create further hazards. The required performance level of this safety function shall be PLr a. See 7.1.6. 5.1.11 Hazards due to overpressure When the burst of a blown part can result in a hazard, the blowing pressure shall be monitored.
Opening the mould shall only be possible when the inside pressure is so reduced that the blown part cannot burst, or a combination of fixed guards and interlocking guards with guard locking may be used provided that these guards have sufficient strength to withstand ejected parts. The required performance level PLr of that safety function shall be: PLr b where guards are used;
PLr c where ESPE is used.
5.1.12 Mechanical hazards during setting Blow moulding machines shall preferably be designed to enable setting when the machine is at rest or from outside the safeguards whilst the mac
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