SIST EN 869:2007+A1:2009

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.RYLQSicherheit von Maschinen - Sicherheitsanforderungen an Metall-DruckgießanlagenSécurité des machines - Prescriptions de sécurité pour les chantiers de moulage des métaux sous pressionSafety of machinery - Safety requirements for pressure metal diecasting units25.120.30Livarska opremaMoulding equipmentICS:Ta slovenski standard je istoveten z:EN 869:2006+A1:2009SIST EN 869:2007+A1:2009en,fr01-junij-2009SIST EN 869:2007+A1:2009SLOVENSKI
STANDARD



SIST EN 869:2007+A1:2009



EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 869:2006+A1
April 2009 ICS 25.120.30 Supersedes EN 869:2006English Version
Safety of machinery - Safety requirements for pressure metal diecasting units
Sécurité des machines - Prescriptions de sécurité pour les chantiers de moulage des métaux sous pression
Sicherheit von Maschinen - Sicherheitsanforderungen an Metall-Druckgießanlagen This European Standard was approved by CEN on 6 August 2006 and includes Amendment 1 approved by CEN on 1 March 2009.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards 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 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
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2009 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 869:2006+A1:2009: ESIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 2 Contents Page Foreword .5Introduction .61 Scope .62 Normative references .73 Terms and definitions .84 List of significant hazards . 124.1 General . 124.2 Mechanical hazards . 124.3 Electrical hazards/control system . 124.4 Thermal hazards . 134.5 Fire hazards . 134.6 Noise hazards . 134.7 Hazards caused by gases, vapours, fumes and dusts . 134.8 Hazards generated by neglecting ergonomic principles in machinery design . 144.9 Setting-up the diecasting machine . 144.10 Falls from heights . 144.11 Particular hazards with regard to cold-chamber diecasting machines . 144.11.1 Bursting of slugs . 144.11.2 Injection drive area . 144.12 Particular hazards of diecasting machines with vertical closing movement . 144.13 Particular hazards with regard to hot-chamber diecasting machines . 154.13.1 Nozzle . 154.13.2 Initiation of the casting process due to a fault in the control system . 154.14 Hydraulics and pneumatics . 155 Safety requirements and/or protective measures . 155.1 General . 155.2 Mechanical . 155.2.1 General . 155.2.2 Guards and protective devices for die area (see also 5.4.1) . 165.2.3 Guards for the die closing mechanism area . 175.2.4 Additional requirements for movable guards and access doors . 185.2.5 Diecasting units . 195.3 Electric equipment and control systems . 195.3.1 Electric equipment . 195.3.2 Safety related parts of the control system: General . 195.3.3 Emergency stop functions . 195.3.4 Safety related control system of the dangerous movements of the die . 195.3.5 Safety related control system of the dangerous movements with closing safety device . 195.3.6 Control of ancillary equipment . 205.4 Measures against thermal hazards . 215.4.1 Spurting of molten metal . 215.4.2 Contact with hot surfaces . 215.5 Hydraulics, pneumatics, combustible fluids . 215.5.1 Hydraulics, pneumatics . 215.5.2 Pressure fluids . 215.5.3 Spray systems for release agents. 215.5.4 Heat exchanger media . 215.6 Noise . 215.6.1 Noise sources . 21SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 3 5.6.2 Noise reduction as a safety requirement . 225.6.3 Noise emission measurement and declaration . 225.7 Gases, vapours, fumes and dusts . 225.8 Ergonomic aspects . 225.9 Protective measures when setting-up diecasting machines, inserting and removal appliances, tie bar pulling devices, and other ancillary equipment . 235.9.1 Setting-up without protective devices for the die area . 235.9.2 Movement of core pullers and ejectors . 235.9.3 Movement of tie bar pulling devices . 235.9.4 Movement of the plunger of cold chamber machines . 235.10 Elevated working places . 235.11 Additional protective measures for cold-chamber diecasting machines . 235.11.1 Bursting and removal of slugs . 235.11.2 Guards for the plunger area with vertical shot sleeve . 245.11.3 Guards for the plunger area with horizontal shot sleeve . 245.12 Additional protective measures for diecasting machines with vertical closing movement . 245.13 Additional protective measures for hot-chamber diecasting machines . 245.13.1 Metal spraying between nozzle and die . 245.13.2 Movement of the injection piston . 246 Verification of the safety requirements and/or protective measures . 247 Information for use . 267.1 General . 267.2 !Warning devices and safety signs . 267.3 Accompanying documents. 277.3.1 Instruction handbook . 277.4 Marking . 29Annex A (informative)
Examples . 31Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC . 43Annex ZB (informative)
!Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC" . 44Bibliography . 45 Figures Figure A.1 — Example of a hot chamber diecasting machine (can be manufactured with a
horizontal or a vertical die closing system) . 31Figure A.2 — Example of a horizontal cold-chamber diecasting machine (can be manufactured with a horizontal or a vertical die closing system) . 31Figure A.3 — Example of a vertical cold-chamber diecasting machine with vertical shot-end (can be manufactured with a horizontal or a vertical die closing system) . 32Figure A.4 — Examples of mechanical hazards and danger zones . 32Figure A.5 — Examples of danger zones for metal spraying at horizontal cold-chamber machines . 33Figure A.6 — Examples of danger zones for metal spraying at vertical cold-chamber machines with vertical shot-end. 33Figure A.7 — Examples of danger zones for metal spraying at hot-chamber machines . 34Figure A.8 — Distance between the guard and machine frame according to 5.2.2.1 . 34SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 4 Figure A.9 — Example of guarding the hazardous area of a diecasting cell . 35Figure A.10 — Example for a closing safety device with positively actuated hydraulic valve, see 5.3.5.1 a) . 36Figure A.11 — Example for a closing safety device with positively actuated pilot valve, see 5.3.5.1 b) . 37Figure A.12 — Example for a closing safety device with positively actuated limit switch which drives the shut-off valve, see 5.3.5.1 c) . 38Figure A.13 — Example for a closing safety device with positively actuated limit switch which drives a pilot valve, see 5.3.5.1 c) . 39Figure A.14 — Example of safety related control system with closing safety device for closing units, see 5.3.5.1 d) . 40Figure A.15 — Example of safety related control system with closing safety device for closing units, see 5.3.5.1 d) . 41Figure A.16 — Example of additional requirements on the hydraulic control of machines with vertical closing movement against pressure peaks and gravity (for electrical interlocking and monitoring, see Figures A.10 to A.15 . 42 Tables Table 1 — Methods of verification . 25 Table 1 (continued) . 26
SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 5 Foreword This document (EN 869:2006+A1:2009) has been prepared by Technical Committee CEN/TC 202 “Foundry machinery”, the secretariat of which is held by DIN. 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 October 2009, and conflicting national standards shall be withdrawn at the latest by December 2009. This document includes Amendment 1, approved by CEN on 2009-03-01. This document supersedes !EN 869:2006". The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ". 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." An assessment of the foreseeable risks arising from the use of the machinery was carried out when this standard was drafted by CEN/TC 202/WG 1, comprising experts from the following countries: Germany, Italy, Spain, Sweden and Switzerland. 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.
SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 6 Introduction This document is a type C standard as stated in EN ISO 12100. The machinery concerned and the extent to which hazards, hazardous situations and hazardous events are covered are indicated in the scope of this document. 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. !Where for clarity an example of a preventative measure is given in the text, this should not be considered as the only possible solution. Other solutions can be used as far as they fulfil correctly the criteria expressed in the requirement. This European Standard assumes, that the equipment is operated and maintained by trained personnel." 1 Scope This European Standard specifies the safety requirements for pressure metal diecasting units. It applies to pressure diecasting machines and to the interfaces with the following ancillary equipment:  die,  melting, holding and dosing furnaces (see EN 746-1),  metal feeding equipment,  inserting and removal devices,  spraying appliances,  heat exchanger for the die. This ancillary equipment itself is not covered. Additional risks arising from the material being cast are not covered. This standard does not apply to low pressure diecasting machines and/or gravity diecasting machines. This standard deals with all significant hazards, hazardous situations and events relevant to pressure diecasting machines when used as intended and under conditions of misuse which are reasonably foreseeable by the manufacturer (see Clause 4). It provides the requirements to be met by the manufacturer to ensure the safety of persons and property during transport, commissioning, use, de-commissioning and maintenance periods, as well as in the event of foreseeable failures or malfunctions that can occur in the equipment.
This document is not applicable to pressure metal diecasting units/machinery which are manufactured before the date of its publication as EN. SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 7 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. !deleted text" EN 349, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body !deleted text" EN 574:1996, Safety of machinery — Two-hand control devices — Functional aspects — Principles for design EN 614-1, Safety of machinery — Ergonomic design principles — Part 1: Terminology and general principles EN 614-2, Safety of machinery — Ergonomic design principles — Part 2: Interactions between the design of machinery and work tasks !EN 842, Safety of machinery — Visual danger signals — General requirements, design and testing" EN 894-1, Safety of machinery — Ergonomic requirements for the design of displays and control actuators — Part 1: General principles for human interactions with displays and control actuators EN 894-2, Safety of machinery — Ergonomics requirements for the design of displays and control actuators — Part 2: Displays EN 894-3, Safety of machinery — Ergonomics requirements for the design of displays and control actuators — Part 3: Control actuators EN 953:1997, Safety of machinery — Guards — General requirements for the design and construction of fixed and movable guards !deleted text" !EN 981, Safety of machinery — System of auditory and visual danger and information signals" EN 982, Safety of machinery — Safety requirements for fluid power systems and their components — Hydraulics EN 983, Safety of machinery — Safety requirements for fluid power systems and their components — Pneumatics EN 999, Safety of machinery — The positioning of protective equipment in respect of approach speeds of parts of the human body EN 1088:1995, Safety of machinery — Interlocking devices associated with guards — Principles for design and selection EN 1265, Noise test code for foundry machines and equipment EN 13861, Safety of machinery — Guidance for the application of ergonomics standards in the design of machinery EN 1760-2, Safety of machinery — Pressure sensitive protective devices — Part 2: General principles for the design and testing of pressure sensitive edges and pressure sensitive bars SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 8 !EN 60204-1:2006, Safety of machinery — Electrical equipment of machines — Part 1: General requirements (IEC 60204-1:2006)" EN 61310-1, Safety of machinery — Indication, marking and actuation — Part 1: Requirements for visual, auditory and tactile signals !(IEC 61310-1:2007)" EN 61310-2, Safety of machinery — Indication, marking and actuation — Part 2: Requirements for marking !(IEC 61310-2:2007)" !EN ISO 7731, Ergonomics — Danger signals for public and work areas — Auditory danger signals
(ISO 7731:2003)" EN ISO 11688-1, Acoustics — Recommended practice for the design of low-noise machinery and equipment — Part 1: Planning (ISO/TR 11688-1:1995) 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, 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 13849-1:2008, Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design (ISO 13849-1:2006)" !EN ISO 13850:2006, Safety of machinery — Emergency stop — Principles for design
(ISO 13850:2006)" !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, 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, 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" ISO 7000, Graphical symbols for use on equipment — Index and synopsis 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN ISO 12100-1:2003 and the following apply. NOTE Definitions used in EN and ISO standards referred to in this document are also valid for this document. 3.1 casting to cast a component/product by the use of pressure diecasting SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 9 3.2 diecasting a process in which molten metal is injected into a die and held under pressure until complete solidification 3.3 diecasting machine a machine that injects molten metal under high pressure into a parted die which is connected to the platens of the machine 3.4 diecasting unit a diecasting machine, together with ancillary equipment, which form a complete production unit 3.5 ancillary equipment devices which automatically carry out process functions additional to those of the diecasting machine itself, e. g., feeding the metal, removing the castings, spraying the die 3.6 metal the material being cast 3.7 hot-chamber diecasting machine diecasting machine having the shot sleeve and plunger submerged in the molten metal of the furnace (see Figure A.1) 3.8 cold-chamber diecasting machine diecasting machine where molten metal is delivered to the shot sleeve in measured amounts from a separate furnace 3.9 horizontal cold-chamber diecasting machine cold-chamber diecasting machine with the shot sleeve mounted horizontally (see Figure A.2) 3.10 vertical cold-chamber diecasting machine cold-chamber diecasting machine with the shot sleeve mounted vertically (see Figure A.3) 3.11 die closing system assembly which opens and closes the die and holds the die against the force exerted on the metal during injection and solidification 3.12 injection system assembly which forces metal from the shot sleeve into the die and applies pressure to the metal during solidification 3.13 ejector system assembly which ejects castings from the die cavity 3.14 core puller assembly which controls movements of cores SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 10 3.15 automatic tie bar puller device for automatically pulling tie bars in order to facilitate die set-up procedure 3.16 automatic ejector coupler device for automatically coupling the ejector plate of the machine with the ejector device of the die 3.17 automatic die clamper device for automatically clamping the die to the platens of the machine 3.18 fixed platen platen to which the fixed die-half and the metal injection system are connected 3.19 moving platen platen to which the moving die-half is connected 3.20 cylinder platen (also known as thrust platen, reaction platen, rear platen) platen to which the die closing mechanism and the closing cylinder are connected 3.21 tie bar bars which carry the locking load and guide the moving platen 3.22 injection drive system, e. g., hydraulic, which moves the plunger and applies force to it 3.23 shot sleeve cylindrical container of a cold-chamber diecasting machine in which pressure is applied to molten metal 3.24 plunger piston which forces metal from the shot sleeve into the die and applies pressure to the metal during solidification 3.25 plunger rod rod which joins the plunger to the injection drive 3.26 gooseneck (hot-chamber diecasting machine) that part of an injection system (containing the shot sleeve and metal flow channel) which is submerged in molten metal 3.27 nozzle connection between the gooseneck and the fixed die-half 3.28 slug metal surplus which solidifies in the cold-chamber shot sleeve and is ejected with the casting SIST EN 869:2007+A1:2009



EN 869:2006+A1:2009 (E) 11 3.29 ejector plate part which transmits movement to the ejector device of the die 3.30 ejector rod part which joins the ejector plate of the machine to the ejector device of the die 3.31 die area area between fixed platen and moving platen 3.32 die closing mechanism area area between moving platen and cylinder platen 3.33 injection drive area area between fixed platen and shot cylinder 3.34 closing safety device device, actuated by the movable guard, which prevents the die from closing if a f
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