BS EN 983 1996

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BRITISH STANDARD BS EN983 : 1996

The European Standard EN 983 : 1996 has the status of a British Standard

ICS 23.100; 23.140

NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW

Safety of machinery ÐSafety requirements for fluidpower systems and theircomponents Ð

Pneumatics

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This British Standard, havingbeen prepared under thedirection of the EngineeringSector Board, was published

under the authority of theStandards Board and comes intoeffect on15 November 1996

© BSI 1996

The following BSI referencesrelate to the work on this

standard:Committee reference MCE/18Draft for comment 93/700546 DC

ISBN 0 580 26252 9

BS EN 983 : 1996

Amendments issued since publication

Amd. No. Date Text affected

Committees responsible for thisBritish Standard

The preparation of this British Standard was entrusted to Technical CommitteeMCE/18, Fluid power systems and components, upon which the following bodies

were represented:

Association of British Mining Equipment Companies

British Compressed Air Society

British Fluid Power Association

British Hydrodynamics Research Association

Department of Trade and Industry (National Engineering Laboratory)

Ministry of Defence

University of Bath

The following bodies were also represented in the drafting of the standard, through

subcommittees and panels:

British Iron and Steel Producers' Association

Engineering Equipment and Materials Users' Association

Health and Safety Executive

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BS EN 983 : 1996

i

Contents

Page

Committees responsible Inside front cover

National foreword ii

Foreword 2

Text of EN 983 3

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BS EN 983 : 1996

National foreword

This British Standard has been prepared under the direction of the TechnicalCommittee MCE/18 and is the English language version of EN 983 : 1996 Safety of

machinery ± Safety requirements for fluid power systems and their components ± Pneumatics, published by the European Committee for Standardization (CEN).

EN 983 was produced as a result of international discussion in which the UnitedKingdom took an active part.

Cross-references

Publication referred to Corresponding British Standard

EN 286-1 BS EN 286 Simple unfired pressure vessels designed tocontain air or nitrogenPart 1 : 1991 Design, manufacture and testingBS EN 292 Safety of machinery. Basic concepts, general

principles for designEN 292-1 Part 1 : 1991 Basic terminology, methodology

EN 292-2 Part 2 : 1991 Technical principles and specificationsEN 418 BS EN 418 : 1992 Safety of machinery. Emergency stop

equipment, functional aspects. Principles for designBS EN 50081 Electromagnetic compatibility. Genericemission standard

EN 50081-2 Part 2 : 1994 Industrial environmentEN 60529 BS EN 60529 Specification for degrees of protection provided

by enclosures (IP code.)ISO 1219-1 BS 2917 Graphic symbols and circuit diagrams for fluid

power systems and componentsPart 1 : 1993 Specification for graphic symbols

The Technical Committee has reviewed the provisions of prEN 954-1, prEN 1050,

ENV 1070, prEN 1127-1, prEN 50081-2, ISO/DIS 1219-2, ISO 5598 and ISO/TR 11688-1 towhich normative reference is made in the text and has decided that they areacceptable for use.

Compliance with a British Standard does not of itself confer immunity from legal obligations.

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CENEuropean Committee for Standardization

ComiteÂ EuropeÂen de Normalisation

Europa È isches Komitee fu È r Normung

Central Secretariat: rue de Stassart 36, B-1050 Brussels

© 1996 Copyright reserved to CEN membersRef. No. EN 983 : 1996 E

EUROPEAN STANDARD EN 983

NORME EUROPEÂ ENNE

EUROPA È ISCHE NORM April 1996

ICS 23.100.00; 23.140

Descriptors: Hydraulic fluid power, pneumatic fluid power, pneumatic equipment, directional control valves, fluid circuits, components,safety, accident prevention, hazards, design, equipment specifications, specifications, protection, verification, marking

English version

Safety of machinery Ð Safety requirements for fluid power systemsand their components Ð

Pneumatics

SeÂ curiteÂ des machines ± Prescriptions de seÂ curiteÂ

relatives aux systeÁmes et leurs composants de

transmissions hydrauliques et pneumatiques ±

Pneumatique

Sicherheit von Maschinen ± Sicherheitstechnische

Anforderungen an fluidtechnische Anlagen und

deren Bauteile ± Pneumatik

This European Standard was approved by CEN on 1996-03-09. CEN members arebound to comply with the CEN/CENELEC Internal Regulations which stipulate theconditions for giving this European Standard the status of a national standardwithout any alteration.

Up-to-date lists and bibliographical references concerning such national standardsmay be obtained on application to the Central Secretariat 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 Central Secretariat has thesame status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Denmark,Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands,Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

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EN 983 : 1996

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Foreword

This European Standard has been prepared by CEN/TC114, Safety of machinery, the Secretariat of which isheld by DIN.

This European Standard shall be given the status of a national standard, either by publication of an identicaltext or by endorsement, at the latest by October 1996,and conflicting standards shall be withdrawn at thelatest by October 1996.

This European Standard has been prepared under a mandate given to CEN by the European Commissionand the European Free Trade Association and supportsessential requirements of EC Directive(s).

According to the CEN/CENELEC Internal Regulations,the national standards organizations of the followingcountries are bound to implement this EuropeanStandard: Austria, Belgium, Denmark, Finland, France,Germany, Greece, Iceland, Ireland, Italy, Luxembourg,Netherlands, Norway, Portugal, Spain, Sweden,Switzerland and the United Kingdom.

It was developed to contribute towards unification of safety regulations and procedures in the variousmember countries for each aspect within the field of

pneumatics for fluid power systems and their components. This standard utilizes the most recently

validated technical information from established

technical sources (e.g. CEN, ISO, national standardsand European documents).

Contents

Page

Foreword 2

0 Introduction 3

1 Scope 3

2 Normative references 3

3 Definitions 4

4 List of hazards 4

5 Safety requirements and/or measures 4

5.1 Basic requirements for the design and

specification of pneumatic systems 45.2 Additional requirements 7

5.2.1 Site conditions 7

5.2.2 Component removal 7

5.2.3 Preparation for transportation 7

5.3 Specific requirements for componentsand controls 8

5.3.1 Motors and rotary actuators 8

5.3.2 Cylinders 8

5.3.3 Valves 8

5.3.4 Energy transmission and conditioning 9

5.3.5 System protection 10

5.3.6 Sequence control 10

5.3.7 Control systems with servo or proportional valves 10

5.3.8 Silencers 10

6 Verification of safety requirementsand/or measures 10

6.1 Inspection 10

6.2 Testing 10

7 Information for use 11

7.1 Final data 11

7.2 Maintenance data 11

7.3 Marking 11

7.3.1 Components 11

7.3.2 Components within a system 11

7.3.3 Ports 11

7.3.4 Valve control mechanisms 11

7.3.5 Internal devices 11

Annex A (informative) Bibliography 12

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0 Introduction

This standard is a type B2 standard (according to

EN 292-1) and contains the general requirements for pneumatic systems and their components onmachinery. For type C standard makers, it is a basis for the development of specific requirements on dedicatedmachines. If no type C-standards are available, it is a basis for the manufacturers when constructingmachines that include pneumatic systems and their components.

In developing this standard, safety related requirementsout of ISO 4414 were selected as well as additionalsafety related requirements.

Equivalent safety requirements for hydraulic systemsare defined in EN 982 Safety of machinery Ð Safety

requirements for fluid power systems and their components Ð Hydraulics.

1 Scope

This standard applies to pneumatic systems and their components on machinery. It identifies hazards andfactors which affect the safety of systems and their components when they are put to their intended use.

Gas bottles and receivers are excluded from the scopeof this standard. For receivers see EN 286-1.

The principles specified apply to the design,construction and modification of new systems and

their components and aspects of use including:

± assembly;

± installation;

± adjustment;

± operation;

± cleaning;

± maintenance.

Components are covered in the standard, but only tothe extent that safety requirements are given to allowthe components to be safely integrated into a system'sdesign.

The standard applies to systems and their componentson machinery that are manufactured after the date of the adoption of this standard.

2 Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications.These normative references are cited at theappropriate places in the text and the publications arelisted hereafter. For dated references, subsequentamendments to or revisions of any of these

publications apply to this European Standard onlywhen incorporated in it by amendment or revision. For undated references, the latest edition of the publicationreferred to applies.

EN 286-1 Simple unfired pressure vesselsdesigned to contain air or nitrogen ±

Part 1: Design, manufacture andtesting

EN 292-1 : 1991 Safety of machinery ± Basicconcepts, general principles for design ± Part 1: Basic terminology,

methodology

EN 292-2 : 1991 Safety of machinery ± Basicconcepts, general principles for design ± Part 2: Technical principlesand specifications

EN 418 Safety of machinery ± Emergencystop equipment, functional aspects ±

Principles for design

prEN 954-1 : 1992 Safety of machinery ± Safety related parts of control systems ± Part 1:General principles for design

prEN 1050 : 1992 Safety of machinery ± Riskassessment

ENV 1070 Safety of machinery ± Terminology

prEN 1127-1 :1993

Safety of machinery ± Fire andexplosions Part 1: Explosion

prevention and protection

EN 50081-2 Electromagnetic compatibility ±Generic emission standard ± Part 2:

Industrial environment prEN 50082-2 Electromagnetic compatibility ±

Generic immunity standard ± Part 2: Industrial environment

EN 60204-1 :1992

Safety of machinery ± Electricalequipment of machines ± Part 1:General requirements (IEC 204-1 :1992, modified)

EN 60529 Degrees of protection provided byenclosures (IP code) (IEC 529 :1989)

ISO 1219-1 Fluid power systems and

components ± Graphic symbols andcircuit diagrams ± Part 1: Graphicsymbols

ISO/DIS 1219-2 :1993

Fluid power systems andcomponents ± Graphic symbols andcircuit diagrams ± Part 2: Circuitdiagrams

ISO 5598 Fluid power systems andcomponents ± Vocabulary

ISO/TR 11688-1 Acoustics ± Recommended practice for the design of low-noise machinery and equipment ± Part 1: Planning

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3 Definitions

For the purpose of this standard, the definitions of ENV 1070 and the following apply. Other definitionsnot included are given in ISO 5598.

3.1 fluid power

The means whereby signals and energy can betransmitted, controlled and distributed using a

pressurized fluid as the medium.

3.2 system

Arrangement of interconnected components whichtransmits and controls fluid power energy.

3.3 component

An individual unit (e.g. cylinder, motor, valve, filter)comprising one or more parts designed to be a functional part of a fluid power system.

3.4 pneumatics

Science and technology which deals with the use of air or neutral gases as the fluid power medium.

3.5 maximum working pressure

The highest pressure at which the system or part of the system is intended to operate in steady-stateconditions.

3.6 rated pressure

The highest pressure at which the component isintended to operate for a number of repetitionssufficient to assure adequate service life.

3.7 operating device

Device that provides an input signal to a controlmechanism (e.g. cam, switch).

3.8 control mechanism

A device that provides an input signal to a component(e.g. lever, solenoid).

3.9 actuator

Component that transforms fluid energy intomechanical energy (e.g. motor, cylinder).

3.10 piping Any combination of fittings, couplings or connectorswith pipes, hoses or tubes which allows fluid flowbetween components.

3.11 neutral gas

A gas which has properties similar to air and does notreact to the effects of pressure and/or temperature in a manner different to air.

4 List of hazards

The possible hazards associated with the use of pneumatic power in a machine are given in table 1.

5 Safety requirements and/or measures

When designing pneumatic systems for machinery, allintended operations and use of systems shall beconsidered. Risk assessment in accordance with

prEN 1050 shall be carried out to determine theforeseeable risks associated with systems when theyare used as intended by their design. So far as it is

practicable, the risks identified shall be eliminated bydesign and, where this is not practicable, the designshall incorporate safeguards against such risks. SeeEN 292-2.

Where systems or parts of systems have safety relatedcontrol functions, they should be designed andconstructed to meet specified categories of

performance, as given in prEN 954-1.

5.1 Basic requirements for the design andspecification of pneumatic systems

5.1.1 All components in the system shall be selectedor specified to provide for safety in use, and they shalloperate within the design limits when the system is putto its intended use. Components shall be selected or specified so that they have adequate characteristics toallow them to operate reliably under all intended usesof the system. Particular attention shall be paid to thereliability of components that could create a hazard, inthe event of their failure or malfunction.

The components shall be selected, applied andinstalled in accordance with the manufacturer's

recommendations.NOTE. It is recommended that wherever practicable componentsshould be made in conformance with recognized international or national standards.

5.1.2 All parts of the system shall be designed or otherwise protected against pressures exceeding themaximum working pressure of a system or any part of the system or the rated pressure of any specificcomponent.

The preferred means of protection against excessive pressure are one or more pressure relief valves locatedto limit the pressure in all parts of the system.

Alternative means, such as pressure regulators, may be

used, provided those means satisfy the applicationrequirements.

Systems shall be designed, constructed and adjusted tominimize surge pressures and intensification pressures.Surge pressure and intensified pressure shall not causehazards.

Loss of pressure or critical drops in pressure shall notexpose persons to a hazard.

5.1.3 Leakage (internal or external) shall not cause a hazard.

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Table 1. List of hazards

Hazard type Relevant clauses

EN 292-1 : 1991 EN 292-2 : 1991 Annex A of EN 292-2 : 1991

Relevant type Bstandard or clause inthis standard

4.1 Mechanical hazards 4.2 1.3,1.4,

5.1.1,5.1.2,

± shape 1.3.7 5.1.3,5.1.5,

± relative location 5.1.7,5.2.1,

± mass and stability (potentialenergy of elements)

5.2.2,5.2.3,

± mass and velocity (kineticenergy of elements)

5.3.1,5.3.2,

± inadequacy of the mechanicalstrength

5.3.3,5.3.4.2,

± accumulation of potentialenergy by:

5.3.4.3,5.3.4.4,

± elastic elements (springs), or 5.3.5.1,7.2,

± liquids or gases under pressure, or

7.3.1

± vacuum

± leakage

4.2 Electrical hazards 5.1.6,5.2.1,5.3.3.3.2a,EN 60204-1

4.3 Thermal hazards resultingin burns and scalds, by a

possible contact of persons, byflames or explosions and alsoby the radiation of heat sources

5.1.8,5.2.1

4.4 Hazards generated by noise 5.1.8,5.2.1,

5.3.84.5 Hazards, especiallyunintended movements causedby electromagnetic fields

3.7.11 1.5.10,1.5.11

EN 50081-2, prEN 50082-2

4.6 Hazards generated bymaterials and substances

processed, used and exhaustedby machinery

1.5.13

4.6.1 Hazards resulting fromcontact with or inhalation of harmful fluids, gases, mists,fumes and dusts

5.1.9,5.3.2.6,7.1

4.6.2 Fire or explosion hazards 5.2.1

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Table 1. List of hazards (continued)


EN 292-1 : 1991 EN 292-2 : 1991 Annex A o f EN 292-2 : 1991 Relevant type Bstandard or clause inthis standard

4.7 Hazards caused by failureof energy supply, breakingdown of machinery parts andother functional disorders

5.2.2 3 1.2

4.7.1 Failure of energy supply(of energy and/or controlcircuits)

3.16 3.7 1.2.6 5.1.4, 5.1.6, 5.2.1,5.3.3.3.2c,

± variation of energy 5.3.3.3.2d

± unexpected start

± prevention from stopping if the command has already beengiven

± falling or ejecting of moving parts or pieces held by themachinery

± impeded automatic or manualstopping

± protection device remains notfully effective

4.7.2 Unexpected ejection of

machine parts or fluids

4.2.1 3.8, 4 1.3.2,

1.3.3

5.2.1,

5.3.4.3.24.7.3 Failure, malfunction of control system (unexpectedstart up, unexpected overrun)

3.1.5,3.1.6,3.1.7

3.7 1.2.7,1.6.3

prEN 954-1,5.1.4,5.1.6,5.3.3.2,5.3.5,5.3.6,5.3.7

4.7.4 Errors of fitting 1.5.4 5.2.1,5.2.3,5.3.3.1,5.3.4.2,5.3.4.3,

7.3

4.8 Hazards caused bytemporarily missing and/or incorrectly positioned safetyrelated measures/means, for example

4

4.8.1 Starting and stoppingdevices

3.7 1.2.3,1.2.4

5.1.4

4.8.2 Safety signs and signals 3.6.7,5.2,5.3,5.4

1.7.2,1.7.3

7.2

4.8.3 All kinds of informationor warning devices

5.4 1.7.0,1.7.1

5.3.4.1.1c,5.3.5.8,7.3

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Table 1. List of hazards (continued)


EN 292-1 : 1991 EN 292-2 : 1991 Annex A of EN 292-2 : 1991

Relevant type Bstandard or clause inthis standard

4.8.4 Energy supplydisconnecting devices

6.2.2 1.6.3 5.1.6,7.2

4.8.5 Emergency devices 6.1 1.2.4 EN 418

4.8.6 Essential equipment andaccessories for safe adjustingand/or maintaining

3.3,3.11

3.12,6.2.1,6.2.3,6.2.6

1.1.2f,1.1.5

5.1.5,5.3.1,5.3.2.3,5.3.4.3.2,5.3.4.4,5.3.5.2,

5.3.5.3

5.1.4 Whatever the type of control or power supplyused (e.g. electrical, pneumatic, etc.), the followingactions or occurrences (unexpected or by intention)shall not create a hazard:

± switching the supply on or off;

± supply reduction;

± supply cut-off or re-establishment.

5.1.5 The system shall be designed and constructedso that components are located where they areaccessible and can be safely adjusted and serviced.

5.1.6 The system shall be designed to facilitate positive isolation from energy sources and also tofacilitate dissipation of the fluid pressure in the systemin order to prevent unexpected start-up. In pneumaticsystems this can be done by, e.g.:

± isolation of the supply by a suitable shut-off device, which may need to be lockable; or

± isolation and dissipation of pressure from thesystem with a suitable shut-off device(s) having a

pressure release feature, which may need to belockable;

± release or support of mechanical loads when the

system is depressurized;± isolation of the electrical supply (see 5.3 of EN 60204-1 : 1992).

Precautions should be taken when the supply isreinstated after isolation or depressurization.

5.1.7 Mechanical movements, whether intended or unintended (including effects from e.g. acceleration,deceleration or lifting/holding of masses), shall notresult in a situation hazardous to persons.

5.1.8 For the design of low noise machinery andsystems, see ISO /TR 11688-1.

5.1.9 Systems shall be so designed, constructed

and/or equipped that hazards due to airbornehazardous substances included in the exhausting air can be minimized.

5.2 Additional requirements

5.2.1 Site conditions

When designing systems, it shall be ensured that thefollowing influences that can lead to a hazard areconsidered:

± vibration, contamination, humidity, range of ambient temperatures;

± fire or explosion hazard (see prEN 1127-1);

± electrical network (voltage and its tolerances,frequency, available power);

± protection for electrical devices;

± requirements for guarding;

± legal and other environmental limiting factors (e.g.noise emission level);

± space required for access, use and maintenance aswell as the location and mounting of componentsand systems to ensure their stability and security inuse;

± specification of pneumatic supply available;

± other safety requirements.

5.2.2 Component removal

Components should be located such that their removalfor maintenance should not necessitate extensivedisassembly of adjacent parts.

5.2.3 Preparation for transportation

5.2.3.1 Identification of piping

Whenever systems have to be dismantled for transportation, the piping and connections shall beclearly identified. The identification shall correspondand not conflict with the data on any appropriatedrawings.

5.2.3.2 Packaging

All systems/components shall be packaged in a manner that protects them from damage and distortion and preserves their identification during transportation.

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5.2.3.3 Protection of openings

Exposed openings in components shall be covered,and male threads shall be protected during

transportation. These covers shall only be removedimmediately before reassembly. Only covers thatrequire their removal before reassembly can take placeshall be used.

5.3 Specific requirements for components andcontrols

5.3.1 Motors and rotary actuators

Rotating shafts and couplings shall be guarded to prevent hazard to personnel.

5.3.2 Cylinders

5.3.2.1 Resistance to buckling

Attention shall be given to stroke length, loading, andcylinder mountings in order to avoid bending or buckling of the cylinder piston rod in any position.

5.3.2.2 Resistance to shocks and vibrations

Any components mounted on or connected to a cylinder shall be attached in a way that resistsloosening caused by shocks, vibrations, etc.

5.3.2.3 Stroke end stops

If stroke length is determined by external stroke endstops, means shall be provided for locking adjustableend stops.

5.3.2.4 Alignment

Mounting surfaces shall be designed to preventdistortion of the cylinder when installed. The cylinder shall be mounted in a way that avoids unintended sideloads during operation.

5.3.2.5 Mounting fasteners

Mounting fasteners for cylinders and attachments shallbe designed and installed to accommodate all

predictable forces. As far as possible the fastenersshould be free from shear forces. Foot-mountedcylinders should have means to absorb shear loads,rather than depending on mounting fasteners. Themounting fasteners shall be adequate to absorb

overturning moments.5.3.2.6 Air vent

A single acting piston type cylinder shall have its air vent port designed and/or positioned to avoid hazardsto persons when displaced air is exhausted.

5.3.2.7 Rod protection

Piston rods should be protected against foreseeabledamage from dents, scratches, corrosive fluids etc.

5.3.3 Valves

5.3.3.1 Mounting

5.3.3.1.1 Method

Valve type and method of mounting shall be selected toensure correct function, adequate leak tightness andresistance against foreseeable mechanical and/or environmental influence.

5.3.3.1.2 Orientation

There shall be means to avoid incorrect mounting of valves.

5.3.3.1.3 Attitude

The effects of gravity, impact or vibration on the mainelements of a valve shall be considered when mountingany valve.

5.3.3.1.4 Back pressure

When stacked or manifold valves or common exhaustlines are used, then special consideration needs to begiven to the design of the system to avoid the influenceof back pressure which could affect safe use.

5.3.3.2 Spring biased or detent located valves

Any actuator required to maintain its position or to

adopt a specific position for safety, in the event of a control system failure, shall be controlled by a valvewhich is either spring biased or detent located to a safe position.

5.3.3.3 Valve operating devices

5.3.3.3.1 Mechanically operated valves

Mechanically operated valves shall be installed so thatthey cannot be damaged by the operating device.

5.3.3.3.2 Electrically operated valves

a) Electrical connections

Electrical connections to a supply shall be inaccordance with appropriate standards, e.g.EN 60204-1. For hazardous operating conditions, theappropriate degree of protection (e.g. explosion

proofing, water proofing) shall be employed.

b) Terminal block housing

Where terminal blocks and housings are specified inthe valves, the terminal block housing shall beconstructed as follows:

± the appropriate degree of protection in accordancewith EN 60529;

± adequate space for permanently located terminalsand for the terminal cable including an additionallength of cable;

± captive fasteners for the electrical access cover to prevent loss, e.g. screws with retaining washer;

± suitable securing device for the electrical accesscover, e.g. a chain;

± cable connections with strain relief.

c) Solenoids

Solenoids shall be sized so that they are capable of operating the valves reliably at the nominal voltage10 %.

d) Manual override

If an electrically operated valve needs to be operatedfor safety reasons when electrical control is notavailable, then it should be fitted with manual

override means. These shall be designed so that theycannot be operated inadvertently, and they shouldreset when the manual control is removed unlessotherwise specified.

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5.3.4 Energy transmission and conditioning

5.3.4.1 Fluids

5.3.4.1.1 Filtration

a) Filters, drains and dryers

Means shall be provided to remove detrimental solid,liquid and gaseous materials from the compressedair or neutral gas.

b) Degree of filtration

The degree of filtration shall be consistent with therequirements for the components and environmentalconditions.

c) Filter condition monitoring

If deterioration of filter performance could lead to a

hazardous situation, clear indication of suchdeterioration shall be given.

5.3.4.1.2 Compatibility of lubricating fluids

Where necessary, appropriate lubricating fluids shouldbe recommended for use in systems. The fluids shouldbe compatible with all components, elastomers, plastictubing and flexible hoses in the system.

5.3.4.2 Pipes, fittings and fluid passages

5.3.4.2.1 Design of layout

Piping should be designed to discourage its use as a step or ladder. External loads should not be imposed

upon piping.5.3.4.2.2 Piping location

To avoid incorrect connections which might cause a hazard, pipes should be identified and locatedaccordingly.

Piping, both rigid and flexible, shall be located to protect against foreseeable damage and not restrictaccess for adjustment, repairs, replacement of components or work in process.

5.3.4.2.3 Foreign matter

Pipes, fittings, and fluid passages, including cored anddrilled holes, shall be free of detrimental foreign matter

such as scale, burrs, swarf, etc., that may restrict flowor be dislodged and cause malfunction of and/or damage to any component including seals and

packings.

5.3.4.2.4 Supports

If necessary, piping shall be securely supported both atits ends and at intervals along its length by correctlydesigned supports.

Pipe supports shall not damage the piping or reducethe flow.

Piping shall not be used to support components wherethey would impose undue loads on the piping.

Undue loads may arise from component mass, shock, vibration and surge pressure.

5.3.4.2.5 Piping runs across access ways

Piping runs across access ways shall not interfere with

the normal use of the access way. They should belocated either below or well above the floor level, andin accordance with site conditions. These piping runsshall be readily accessible, rigidly supported, andwhere necessary, protected from external damage.

5.3.4.2.6 Characteristics of piping

The safe use of piping within a system shall take intoaccount site conditions. Where plastic piping isselected, it shall not be adversely affected by any fluidsassociated with the system.

5.3.4.2.7 Quick action (release) couplings

Quick action (release) couplings shall be selected so

that when they are coupled or uncoupled:

± the coupling shall not be forced apart in a hazardous manner;

± compressed air or particles shall not be expelled ina hazardous manner;

± a controlled pressure release system shall be provided where a hazard may exist.

5.3.4.3 Flexible hose assemblies

Flexible hose assemblies shall not be constructed fromhoses which have been previously used as part of a hose assembly. Flexible hose assemblies shall fulfill all

performance requirements specified in the appropriate

European and/or international standard(s).

Recommendations on storage time for the flexible hoseassemblies given by the hose manufacturers shall beconsidered.

Consideration should be given to recommending a service life for hose assemblies.

5.3.4.3.1 Installation

Installation of flexible hose assemblies shall:

± have the minimum length necessary to avoid sharpflexing and straining of the hose during thecomponent operation. Flexible hoses should not bebent with a radius smaller than the recommendedminimum bending radius;

± minimize torsional deflection of the hose duringthe installation and use, e.g. as the result of a rotating connector jamming;

± be located or protected to minimize abrasiverubbing of the hose cover;

± be supported, if the weight of the hose assemblycould cause undue strain.

5.3.4.3.2 Failure of flexible hose assemblies and plastic piping

If the failure of a flexible hose assembly or plastic

piping constitutes a whiplash hazard, it shall berestrained or shielded.

If the failure of a flexible hose assembly or plastic piping constitutes a fluid ejection hazard, it shall beshielded.

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5.3.4.4 Non-metallic bowls on fluid conditioningunits

To protect personnel from the hazard of a non-metallic

bowl failure on filters, separators, filter-regulators andlubricators when the product of the pressure in bar and the volume in litres of the bowl is greater than 1bar litre the bowl should be capable of being shielded.

5.3.5 System protection

5.3.5.1 Pressure regulation

Control shall be provided to maintain the system pressure within safe limits, e.g. where pressureregulators are used in pneumatic circuits for safety,they should be of the self-relieving type.

NOTE. Relieving type regulators are not safety relief devices andshall not be the sole device to prevent excess pressure where

their relief capability is inadequate.

5.3.5.2 Tamper-resistant protection

Pressure and flow control devices on their enclosuresshall be fitted with tamper-resistant devices where anunauthorized alteration to pressure or flow can cause a hazard.

5.3.5.3 Adjustable control mechanisms

Pressure and flow control devices shall be constructedto permit adjustment within their ratings. Adjustmentbeyond these ratings may be possible; the ratings arenot maximum adjustable limits.

Adjustable control mechanisms shall hold their settings

within specified limits until reset.

5.3.5.4 Control of multiple devices

Where there is more than one interrelatedautomatically and/or manually controlled device on theequipment, and where failure of any of these devicescould cause a hazard, protective interlocks or other safety means shall be provided. Where practical, theseinterlocks should interrupt all operations, provided thatsuch interruption does not of itself cause a hazard.

5.3.5.5 Protection under external loads

Means shall be provided to prevent unacceptable pressure build-up where high external loads arereflected on actuators.

5.3.5.6 Unintended movement

Control systems shall be designed to preventunintended hazardous movement and improper sequencing of actuators. This applies to all phases of the operation.

5.3.5.7 Control system stability

Pressure and flow control valves shall be selected sothat changes in working pressure, working temperatureand load do not influence the operation in a hazardousway.

5.3.5.8 Monitoring of system parameters

Where changes in system operating parameters couldconstitute a hazard, clear indication shall be provided.

5.3.6 Sequence control

Sequencing by position sensing shall be used wherever practicable and shall always be used when a sequencing malfunction of a pressure or time lapsecontrol, on its own, could cause a hazard.

5.3.7 Control systems with servo or proportionalvalves

Where actuators are controlled by servo or proportional valves and malfunction of the controlsystem may result in the actuators causing a hazardthen means shall be provided to maintain or recover control of these actuators. Actuators, speed controlledby servo or proportional valves, shall have means tohold or move the actuator to a safe position if unintended movement may cause a hazard.

5.3.8 Silencers

Silencers shall be used where the sound pressure levelcaused by exhausting air is above that permitted byapplicable codes and standards.

The use of exhaust port silencers in themselves shallnot constitute a hazard.

6 Verification of safety requirements

and/or measuresSince a pneumatic system may not be a completemachine, many verification procedures cannot becarried out until the pneumatic system is incorporatedinto the machine. Appropriate instructions shall begiven to the machine manufacturer by the pneumaticsystem designer/manufacturer.

6.1 Inspection

The systems and their components shall be verified byinspecting their identification in comparison to thesystem specifications.

In addition the connection of components on the

pneumatic system shall be inspected to verify itscompliance with the circuit diagram.

6.2 Testing

The following tests shall be conducted to determinecompliance with the applicable safety requirements:

± operational tests to prove the correct operation of the system and all safety devices;

± pressure test to test each part of the system at themaximum working pressure which may be sustainedunder all conditions of intended use.

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7 Information for use

Information for use shall be in accordance with clause

5 of EN 292-2 : 1991.

7.1 Final data

A circuit diagram shall be provided. This diagramshould be in accordance with ISO/DIS 1219-2.

Details of any hazards associated with the specifiedlubrication fluids should be given. Information suppliedshould include:

± hygiene requirements;

± toxicity;

± asphyxiating hazards in the event of fire;

± biological resistance;

± method of disposal.

7.2 Maintenance data

All systems shall be provided with the necessarymaintenance data which shall clearly:

± indicate external lubrication points, the type andlevels of lubricant required and whether or not thelubricator(s) can be filled under pressure;

± locate drains, filters, test points, strainers, magnets,etc., that require scheduled maintenance;

± identify those parts of a system that are notdepressurized by the normal venting device;

± give any required depressurizing instructions.7.3 Marking

7.3.1 Components

The following particulars shall be shown, if practicable,in a permanent and readily visible form on allcomponents:

± the manufacturer's/supplier's name and brief address;

± the manufacturer's/supplier's productidentification;

± the rated pressure;

± symbols according to ISO 1219-1, and all portscorrectly identified;

± for hose assemblies: date of manufacture;

± for stacking modules: their order shall be clearlyindicated adjacent to, but not on, the stack.

7.3.2 Components within a system

Each pneumatic component shall be allocated an item

number and/or letter. This item number and/or letter shall be used to identify the component on alldiagrams, lists and layouts. It should be clearly and

permanently marked on the installation adjacent to thecomponent.

7.3.3 Ports

Component ports and power take-off points (test portsand bleed points) shall be clearly and distinctlyidentified. The identification shall correspond to thedata on the circuit diagram.

7.3.4 Valve control mechanisms

7.3.4.1 Non-electrical control mechanisms

Valve control mechanisms and their functions shall be plainly and permanently identified with the sameidentification used on the circuit diagram.

7.3.4.2 Electrical control mechanisms

Electrical control mechanisms (solenoids and their attaching plugs or cables) shall be identified on theelectrical and pneumatic circuit diagrams with thesame identification.

7.3.5 Internal devices

Valves and other functional devices (orifice plugs, passages, shuttle valves, check valves, etc.) located

within a manifold, mounting plate, pad, or fitting, shallbe identified adjacent to their access openings. Whereaccess openings are located under a component or components, identification shall, if practicable, be

provided adjacent to the component and marked`CONCEALED'.

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prEN 574 : 1991 Safety of machinery ± Two-hand control device

EN 982 Safety of machinery ± Safety requirements for fluid power systems and their components ± Hydraulics

prEN 1037 : 1993 Safety of machinery ± Isolation and energy dissipation Ð Prevention of unexpectedstart-up

EN 50081-1 Electromagnetic compatibility (EMC) ± Generic emission standard ± Part 1: Residential,commercial and light industry

prEN 50082-1 : 1994 Electromagnetic compatibility (EMC), Generic immunity standard ± Part 1: Residential,commercial and light industry

International StandardsISO 2230 Vulcanized rubber ± Guide to storage

ISO 2398 Industrial rubber hose for compressed air (up to 2,5 MPa)

ISO 2944 Fluid power systems and components ± Nominal pressures

ISO 4400 Fluid power systems and components ± Three-pin electrical plug connector ±Characteristics and requirements

ISO 4414 Pneumatic fluid power ± Recommendations for the application of equipment totransmission and control systems

ISO 5774 Plastics hoses ± Textile-reinforced thermoplastics type for compressed air ± Specification

ISO 6150 Pneumatic fluid power ± Cylindrical quick-action couplings for maximum working pressures of 10 bar, 16 bar and 25 bar (1 MPa, 1,6 MPa and 2,5 MPa) ± Plug connecting

dimensions, specifications, application guidelines and testingISO 6952 Fluid power systems and components ± Two-pin electrical plug connector with earth

contact ± Characteristics and requirements

ISO 7751 Rubber and plastics hoses and hose assemblies ± Ratios of proof and burst pressure todesign working pressure

ISO 8331 Rubber and plastics hoses and hose assemblies ± Guide to selection, storage, use and maintenance

ISO 8573-1 Compressed air for general use ± Part 1: Contaminants and quality classes

ISO 10099 Pneumatic fluid power ± Cylinders Acceptance test

CETOP 1) Recommendations

RP 5 P Specification for pneumatic cylinders

RP 68 P Identification code for ports and operators of pneumatic control valves and other components

1)CETOP: EUROPEAN OIL HYDRAULIC AND PNEUMATIC COMMITTEE.

Annex A (informative)

Bibliography

European Standards

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BS EN 983 1996