Lifting and Load-bearing Equipment for Stages and other ... · PDF filefor Stages and other Production Areas within the Entertainment Industry ... EN 13480-3, Metallic industrial piping

CEN WS 25 – Final Version 2008 August

CEN WS 25 N 0135

CEN WS 25

Lifting and Load-bearing Equipment for Stages and other Production Areas

within the Entertainment Industry

CEN Workshop Agreement

Final Version

Date: 2008 August

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Contents Page

Foreword..............................................................................................................................................................5 Introduction .........................................................................................................................................................5 1 Scope ......................................................................................................................................................6 2 Normative references ............................................................................................................................7 3 Terms and definitions ........................................................................................................................ 10 3.1 General terms...................................................................................................................................... 10 3.2 Loads and forces ................................................................................................................................ 12 3.3 Electrical equipment........................................................................................................................... 13 3.4 Tolerances relating to movement ..................................................................................................... 15 4 Hazards ................................................................................................................................................ 15 5 Design requirements .......................................................................................................................... 16 5.1 General................................................................................................................................................. 16 5.2 Examples of machine installations showing the groups ............................................................... 16 5.3 Load assumptions for stage elevators............................................................................................. 21 5.4 Load bearing equipment .................................................................................................................... 21 5.4.1 General................................................................................................................................................. 21 5.4.2 Load bearing lines .............................................................................................................................. 22 5.4.3 Wire ropes terminations..................................................................................................................... 22 5.5 Winding devices and diverter pulleys .............................................................................................. 24 5.5.1 Winding devices for wire ropes......................................................................................................... 24 5.5.2 Diverter pulleys for round wire ropes............................................................................................... 25 5.5.3 Diverter pulleys for fibre ropes ......................................................................................................... 25 5.5.4 Drive and idler sprockets for steel chains ....................................................................................... 25 5.5.5 Drive systems...................................................................................................................................... 25 5.6 Load carrying devices........................................................................................................................ 27 5.7 Loads ................................................................................................................................................... 28 5.8 Manually operated lifting ................................................................................................................... 28 6 Safeguarding hazardous areas ......................................................................................................... 28 6.1 Protective spaces ............................................................................................................................... 28 6.2 Safeguarding at crushing, shearing and trapping points, and fall protection ............................. 28 6.3 Accessibility of maintenance areas.................................................................................................. 29 6.4 Elevator shaft walls, openings and landing doors.......................................................................... 29 6.4.1 General................................................................................................................................................. 29 6.4.2 Interlocking of doors .......................................................................................................................... 29 6.5 Counterweights................................................................................................................................... 29 7 Overhead suspension of loads ......................................................................................................... 30 7.1 General................................................................................................................................................. 30 7.2 Lifting equipment................................................................................................................................ 30 7.3 Direct Acting Force Limiters.............................................................................................................. 30 7.4 Single Components ............................................................................................................................ 30 7.5 Lifting accessories ............................................................................................................................. 30 7.6 Precautions ......................................................................................................................................... 30 7.7 Secondary suspension ...................................................................................................................... 30 8 Electrical equipment and control systems ...................................................................................... 30 8.1 General requirements......................................................................................................................... 30 8.1.1 General................................................................................................................................................. 30


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8.1.2 Selection of equipment....................................................................................................................... 31 8.1.3 Electrical supply.................................................................................................................................. 31 8.1.4 Physical environment and operation conditions............................................................................. 31 8.2 Incoming supply conductor terminations and devices for disconnecting and switching off .... 32 8.2.1 Incoming supply conductor terminations ........................................................................................ 32 8.2.2 Terminal for connection to the external protective earthing system ............................................ 32 8.2.3 Supply disconnecting (isolating) devices ........................................................................................ 32 8.2.4 Devices for switching off for prevention of unexpected start-up .................................................. 32 8.2.5 Devices for disconnecting electrical equipment ............................................................................. 32 8.2.6 Protection against unauthorised, inadvertent and/or mistaken connection ................................ 32 8.2.7 Protection against electric shock...................................................................................................... 32 8.2.8 Protection of equipment ..................................................................................................................... 33 8.2.9 Control circuits and control functions.............................................................................................. 33 8.3 Safety functions and control functions in the event of failure....................................................... 36 8.3.1 General ................................................................................................................................................. 36 8.3.2 Providing redundancy ........................................................................................................................ 37 8.3.3 Hazardous operating conditions ....................................................................................................... 37 8.3.4 Safety devices and safety functions ................................................................................................. 37 8.3.5 Devices for testing safety functions ................................................................................................. 40 8.4 Emergency stop and emergency switching-off functions.............................................................. 40 8.4.1 Emergency stop .................................................................................................................................. 40 8.4.2 Activation device................................................................................................................................. 40 8.4.3 Actuators for and design of emergency stop and switching-off functions .................................. 40 8.5 Electronic and programmable electronic systems (E/PES)............................................................ 40 8.5.1 General ................................................................................................................................................. 40 8.5.2 Programmable controllers.................................................................................................................. 40 8.5.3 Use of programmable electronic systems (E/E/PES) to implement safety functions.................. 41 8.5.4 User information for safety functions ............................................................................................... 41 8.6 Use of programmable electronic systems (E/E/PES) without safety functions............................ 41 8.7 Operator interfaces, control devices and contactors...................................................................... 42 8.7.1 General ................................................................................................................................................. 42 8.7.2 Start devices and indicators .............................................................................................................. 42 8.7.3 Devices for emergency stop and switching off ............................................................................... 42 8.7.4 Requirements for contactors ............................................................................................................. 42 8.8 Conductors and cables....................................................................................................................... 42 8.9 Wiring practice .................................................................................................................................... 42 8.10 Electric motors and associated equipment...................................................................................... 43 8.11 Accessories and lighting.................................................................................................................... 43 8.12 Marking, warning signs and reference designations ...................................................................... 43 8.13 Technical documentation................................................................................................................... 43 8.14 Testing and verification of characteristics....................................................................................... 43 8.14.1 General ................................................................................................................................................. 43 8.14.2 Scope of routine testing ..................................................................................................................... 43 9 Information for use.............................................................................................................................. 44 9.1 General ................................................................................................................................................. 44 9.2 Technical data to be included............................................................................................................ 44 9.3 Marking................................................................................................................................................. 44 9.3.1 General ................................................................................................................................................. 44 9.3.2 Safe working load................................................................................................................................ 44 9.3.3 Anchorages.......................................................................................................................................... 45 9.3.4 Loading notices................................................................................................................................... 45 9.3.5 Lifting accessories.............................................................................................................................. 46 9.3.6 Machinery............................................................................................................................................. 46 9.3.7 Remote operations.............................................................................................................................. 47 9.3.8 Personnel lifting .................................................................................................................................. 47 9.4 Documentation and information........................................................................................................ 47 9.4.1 General ................................................................................................................................................. 47 9.4.2 Operating manual................................................................................................................................ 47


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9.4.3 Installation instructions ..................................................................................................................... 49 9.4.4 Repair and maintenance instruction................................................................................................. 49 9.4.5 Inspection and examination .............................................................................................................. 50 9.4.6 Dismantling instructions.................................................................................................................... 50 9.4.7 Appendix to instructions (for additional necessary doduments).................................................. 50 9.4.8 Documentation.................................................................................................................................... 51 10 Testing prior to first use and after substantial changes ................................................................ 51 10.1 General................................................................................................................................................. 51 10.2 Test Log ............................................................................................................................................... 51 10.3 Testing Prior to First Use................................................................................................................... 51 10.3.1 Type, Extent and Performance of Tests ........................................................................................... 51 10.3.2 Acceptance Report and Test Log...................................................................................................... 54 10.3.3 Test after Changes and Modifications.............................................................................................. 54 Annex A ………………………………………………………………………………………………………………….55 Annex B ………………………………………………………………………………………………………………….77


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Foreword

This document has been prepared by CEN workshop 25 (WS 25) and is the agreement of that workshop. The members of WS 25 are trade associations, manufacturers, installers, consultants, users, public authorities and technical executives engaged within the entertainment industry. [DISCLAIMER REQUIRED CEN to advise on proposal below please] This workshop agreement does not purport to include all the necessary provisions of a contract. Users of this agree-ment are responsible for their correct application. Compliance with this workshop agreement does not of itself confer immunity from legal obligations.

Introduction

The purpose of the CEN workshop 25 is to produce European specifications for the design, manufacture and installa-tion of lifting and load bearing equipment within the entertainment industry. It is intended to provide common specifications for national and international (travelling) performances, performers, technicians and manufacturers. This document covers all machinery used in the entertainment industry including machinery that is excluded from the Machinery Directive (2006/42/EC) specifically Article 1 2j which excludes “machinery intended to move performers during artistic performances” Apart from the Machinery Directive, the Council Directive 89/655/EEC concerning the minimum safety and health requirements for the use of work equipment by workers at work states in annex II:

3.1.3 Unless required for the effective operation of the work, measures must be taken to ensure that workers are not present under suspended loads.

Loads may not be moved above unprotected workplaces usually occupied by workers.

Where that is the case, if work cannot be carried out properly any other way, appropriate proceduresmust be laid down and applied.

This workshop considers situations that give rise to danger, such as moving or holding scenery or equipment

a) over persons and/or unprotected areas b) in areas with low light conditions, limited visibility, while using stage fog and other masking effects.

These additional situations apply not only during performances, but also during rehearsals, technical set up, preparations, installations and other situ

This document covers these hazards and suggests appropriate procedures to maintain safety.


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at events.

1 Scope

This document applies to machinery and machinery installations used in places of assembly and in staging and pro-duction facilities for events and theatrical productions (stage machinery, for short). Such facilities include: theatres, multi-purpose halls, exhibition halls; film, television and radio studios; concert halls, schools, exhibition halls; bars, discotheques, open-air stages and other rooms for shows and events. The document applies to machinery and machine installations with guided or unguided load bearing and load carrying equipment. For the purposes of this document, machinery installations are all technical installations and equipment used for operations in stage and production facilities in the entertainment industry. Such installations are used to lift, lower, suspend and carry loads (e.g. scenery, traverse systems, or lighting, film/video and sound equipment). They may also be used to move persons, and persons may stand under such equipment while the loads are at rest or in motioThis machinery includes Controls, electrical and electronic control systems, electrical and electronic equipment, hydraulic and pneumatic power supplies. “Stages” include staging facilities and production areas in theatres, multipurpose halls, studios, production facilities for film, television or radio, concert halls, congress centres, schools, exhibition centres, trade-fair centres, museums, discotheques, amusement parks, sports facilities and open-air-theatre

"Events" are, for example, concerts, shows, congresses, exhibitions, presentations, demonstrations, film or television recordings, etc.

This workshop considers lifting and any movement equipment for stages and production areas within the entertainment industry, and temporary installations using trusses or truss constructions which may include ground support systems or towers Typical applications include but are not limited to the following: ⎯ acoustic doors;

⎯ auditorium elevators;

⎯ compensating elevators;

⎯ cycloramas;

⎯ fire curtains;

⎯ fly bar systems (manual, motor driven);

⎯ lighting bars;

⎯ movable lighting towers;

⎯ movable stage platforms (stage wagons);

⎯ movable proscenium arches;

⎯ orchestra elevators;

⎯ performer flying;

⎯ point hoists;

⎯ projection screens (manual or motor-driven);

⎯ revolving stages and turntables;

⎯ scenery storage elevators;

⎯ side stage and rear stage shutters;

⎯ stage elevators;


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⎯ stage wagons (stage trucks);

⎯ tiltable stage floors;

⎯ trap elevators.

The principles in this document also apply to machinery installations based on new technologies or specially designed installations which are not expressly mentioned here but which nevertheless operate in a similar manner or are meant for similar purposes to the equipment listed above.

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.

DIN EN 818-4/A1, Short link chain for lifting purposes - Safety - Part 4: Chain slings - Grade 8.

EN 294, Safety of machinery; safety distances to prevent danger zones from being reached by the upper limbs.

EN 349, Safety of machinery; minimum gaps to avoid crushing of parts of the human body.

EN 685, Resilient, textile and laminate floor coverings - Classification.

EN 795, Protection against falls from a height - Anchor devices - Requirements and testing.

EN 818-7, Short link chain for lifting purposes - Safety - Part 7: Fine tolerance hoist chain, grade T (Types T, DAT and DT).

EN 14121-1, Safety of machinery - Risk assessment - Part 1: Principles (ISO 14121-1:2007).

EN 14492-2, Cranes - Power driven winches and hoists - Part 2: Power driven hoists.

EN 1993-1-10, Eurocode 3: Design of steel structures - Part 1-10: Material toughness and through-thickness prope

EN 1999-1-2, Eurocode 9: Design of aluminium structures - Part 1- 2: Structural fire design.

EN 10204, Metallic products - Types of inspection documents.

EN 12385-1, Steel wire ropes - Safety - Part 1: General requirements.

EN 12385-2, Steel wire ropes - Safety - Part 2: Definitions, designation and classification.

EN 12385-4, Steel wire ropes - Safety - Part 4: Stranded ropes for general lifting applications.

EN 13411-2, Terminations for steel wire ropes - Safety - Part 2: Splicing of eyes for wire rope slings.

EN 13411-3, Terminations for steel wire ropes - Safety - Part 3: Ferrules and ferrule-securing. EN 13411-5, Terminations for steel wire ropes - Safety - Part 5: U- bolt wire grips.

EN 13411-6, Terminations for steel wire ropes - Safety - Part 6: Asymmetric wedge socket.

EN 13411-7, Terminations for steel wire ropes - Safety - Part 7: Symmetric wedge socket.

EN 13480-3, Metallic industrial piping - Part 3: Design and calculation.


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9).

99).

99).

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005).

EN 13849-2, Safety of machinery - Safety-related parts of control systems - Part 2: Validation (ISO 13849-2:2003).

EN 14492-2, Cranes - Power driven winches and hoists - Part 2: Power driven hoists.

EN 60034-1, Rotating electrical machines - Part 1: Rating and performance (IEC 60034-1:2004).

EN 60439-1, Low-voltage switchgear and controlgear assemblies. Part 1: Type-tested and partially type-tested assemblies (IEC 60439-1:1999 + A1:2004)

EN 60204-1, Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC 60204-1:2005).

EN 60204-11, Safety of machinery - Electrical equipment of machines - Part 11: Requirements for HV equipment for voltages above 1000 V a.c. or 1500 V d.c and not exceeding 36 kV (IEC 60204-11:2000).

EN 60204-32, Safety of machinery - Electrical equipment of machines - Part 32: Requirements for hoisting machines (IEC 60204-32:1998).

EN 60439-1, Low-voltage switchgear and controlgear assemblies - Part 1: Type-tested and partially type-tested assemblies (IEC 60439-1:1999 + A1:2004)

EN 60947-4-1, Low-voltage switchgear and controlgear - Part 4-1: Contactors and motor-starters - Electromechanical contactors and motor-starters (IEC 60947-4-1:2000 + Corrigendum:2001 + A1:2002 + A2:2005).

EN 60947-5-1, Low-voltage switchgear and controlgear - Part 5-1: Control circuit devices and switching elements - Electromechanical control circuit devices (IEC 60947-5-1:2003).

EN 61131-1, Programmable controllers - Part 1: General Information (IEC 61131-1:2003). EN 61131-2, Programmable controllers - Part 2: Equipment requirements and tests (IEC 65B/582/CDV:2006). EN 61346-1, Industrial systems, installations and equipment and industrial products - Structuring principles and reference designations - Part 1: Basic rules (IEC 61346-1:199

EN 61508-1, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 1: General requirements (IEC 61508-1:1998 + Corrigendum 19

EN 61508-2, Functional safety of electrical/electronic/programmable electronic safety- related systems - Part 2: Requirements for electrical/electronic/programmable electronic safety- related systems (IEC 61508-2:20 EN 61508-3, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 3: Software requirements (IEC 61508-3:1998 + Corrigendum 199

EN 61508-4, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 4: Definitions and abbreviations (IEC 61508-4:1998 + Corrigendum 19

EN 61508-5, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 5: Examples of methods for the determination of safety integrity levels (IEC 61508-5:1998 + Corrigendum 19 EN 61508-6, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 6: Guidelines on the application of IEC 61508-2 and IEC 61508-3 (IEC 61508-6:20

EN 61508-7, Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 7: Overview of techniques and measures (IEC 61508-7:200

EN 61000-6-2, Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments (IEC 61000-6-2:2


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05).

EN 61000-6-4, Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments (IEC/CISPR/H/99/CDV:2005).

EN 62061, Safety of machinery - Functional safety of safety- related electrical, electronic and programmable electronic control systems (IEC 62061:2005).

EN 62079, Preparation of instructions - Structuring, content and presentation (IEC 62079:2001). EN ISO 12100-1, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology (ISO 12100-1:2003

EN ISO 12100-2, Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles (ISO 12100-2:2003).

EN ISO 13849–2, Safety of machinery - Safety-related parts of control systems - Part 2: Validation (ISO 13849-2:2003).

IEC 60050-191, International Electrotechnical Vocabulary - Chapter 191: Dependability and quality of service.

IEC 60050-441, International Electrotechnical Vocabulary - Chapter 441: Switchgear, controlgear and fuses.

IEC 60204-32:1998, Safety of machinery - Electrical equipment of machines - Part 32: Requirements for hoisting machines (IEC 44/507/CD:2005

IEC 61508-4:1998, Functional safety of electrical/electronic/programmable electronic safety- related systems - Part 4: Definitions and abbreviations (IEC 65A/470/CD:2005).

IEC 62079, Preparation of instructions. Structuring, content and presentation.

IEV 191, International Electrotechnical Vocabulary - Chapter 191: Dependability and quality of service (Consolidated version included Amendment 1 and Amendment 2); Identical with IEC 60050-191:1990- 12 (Consolidated with IEC 60050-191/A1:1993-03 and IEC 60050-191/A2:2002-01).

ISO 3834, Quality requirements for fusion welding of metallic materials - Part 1: Criteria for the selection of the appropriate level of quality requirements (ISO 3834- 1:20

ISO 4301-2, Lifting appliances - Classification - Part 2: mobile cranes.

ISO 13849-1, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design.

Council Directive 89/655/EEC

Machinery Directive 2006/42 EC Minimum safety and health requirements for the use of work equipment by workers at work 95/63/EC. Pressure Equipment Directive (97/23/EC 1977)


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3 Terms and definitions

For the purposes of this document, the following terms and definitions apply.

3.1 General terms

3.1.1 Competent Person person with sufficient practical and theoretical knowledge and experience to carry out the person's duties, and who is aware of the limits of the person's competency, expertise and knowledge

3.1.2 Drive System part of a load bearing machine that executes movement and holding of the load; Part of the machine that converts energy into movement

3.1.3 Emergency Stop device that causes a controlled stop as quickly and as safely as possible and which overrides all other controls

3.1.4 Factor of Safety (FOS) Safety Factor the quotient of the minimum breaking load and the partial tensile force acting at characteristic loading

3.1.5 Fly bar system fly bar (e.g. bar hoist or truss) having several load bearing lines for lifting, lowering, and suspending loads, with the load being either uniformly distributed or concentrated (point load)

NOTE A distinction is made between manually operated flying systems (e.g. manual counterweight systems) and motor-driven systems (e.g. with electric or hydraulic drive).

3.1.6 Lifting accessories lifting accessory’ means a component or equipment not attached to the lifting machinery, allowing the load to be held, which is placed between the lifting machinery and the load or on the load itself, or which is intended to constitute an integral part of the load and which is independently placed on the market. Slings and their components are also regarded as lifting accessories

3.1.7 Load bearing equipment lifting equipment, including the drive mechanism, which bears loads

3.1.8 Load carrying device part of stage machinery which directly carries the intended load

EXAMPLE Fly bar of a bar hoist, platform of an elevator, truss.

3.1.9 Locking device mechanical device being an intrinsic part of the machinery which prohibits unintentional movement

EXAMPLE Brake, shut-off valve, rope lock.

3.1.10 Machinery installation all elements between the load and the point of attachment to the building or the ground


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3.1.11 Manual flying system flying system (e.g. bar hoist) operated by a manual, not machine powered drive system

3.1.12 Manual counterweight system manually operated flying bar moved by means of an operating rope, where the load is fully or partially balanced by counterweights carried in a guided frame connected to the flying bar

3.1.13 Point hoist lifting equipment having one load bearing line for lifting, lowering, and suspending loads

3.1.14 Risk combination of the probability of occurrence of harm and the severity of that harm

[EN ISO 12100-1:2004] 3.1.15 Stage elevator Stage lift part of a horizontal or inclined (tilted) stage, performance area, studio or auditorium floor which can be moved vertically up and/or down, including all necessary drive elemen

EXAMPLE 1: Elevator which is a permanent part of the stage, performance area, studio or auditorium floor (e.g. orchestra elevator, single- or double-deck stage elevator, stage compensating elevator, scenery storage elevator or auditorium elevator

EXAMPLE 2: Elevator which is not a permanent part of the stage, performance area, studio or auditorium floor, which is used primarily for scenic purposes and which normally rests below stage (e.g. stage trap elevator).

NOTE A stage elevator at rest can be part of that stage.

3.1.16 Stage elevator platform part of a stage elevator which supports the load

3.1.17 Load bearing element element between the load and the point of attachment, within the machinery installation


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3.2 Loads and forces

Table 1 — Loads and Forces

Loads and forces in normal use

SAFE WORKING LOAD (SWL) This is the load that can be applied by the user.

+ WEIGHT OF LOAD CARRYING DEVICE This is the bar or the truss or the elevator-platform

= SYSTEM LOAD This is the static load

+ DYNAMIC FORCES

= CHARACTERISTIC LOAD Load to be considered by the manufacturer when designing the machine for normal use.

Loads and forces occurring at failure

SAFE WORKING LOAD (SWL) This is the load that can be applied by the user.

+ WEIGHT OF LOAD CARRYING DEVICE This is the bar or the truss or the elevator-platform

= SYSTEM LOAD This is the static load

+ DYNAMIC FORCES AT FAILURE

= LOAD AT FAILURE Load to be considered by the manufacturer when designing the machine in case of failure.

3.2.1 Characteristic load characteristic load is the sum of the system load and the dynamic forces occurring during operation

3.2.2 Load at failure sum of the system load and the dynamic forces occurring by uncontrolled stops in case of failure. Uncontrolled stops may occur e.g. due to:

Failure in electric power supply; Pressure failure in hydraulic system; Activation of a safety device. 3.2.3 Load pressure in a hydraulic system, the pressure generated by the external load


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3.2.4 Safe working load (SWL) useful load which is borne by the load carrying or securing device, or directly by the load bearing equipment

NOTE The safe working load is equal to the system load minus the weight of the load securing and carrying devices and, in the case of stage elevators, minus the self-weight of the parts being moved with the load.

3.2.5 System Load sum of safe working load and the weight of the load carrying device

3.2.6 Test load load used when testing a lifting device, load bearing equipment, or load carrying or securing devices

NOTE The test load is equal to the safe working load multiplied by the test load factor.

3.3 Electrical equipment

3.3.1 Control circuit used for the operational control of stage machinery and for protection of the power circuits

3.3.2 Control device for the activation of a movement, e.g. lever, push button, wheel

3.3.3 Controlled stop the stopping of machine movement by, for example, reducing the electrical command signal to zero once the stop signal has been recognised by the control but retaining electrical power to the machine during the stopping process

[IEC 60204-1:1997] 3.3.4 Electrical/electronic/programmable electronic (E/E/PE) based on electrical (E) and /or electronic (E) and/or programmable electronic (PE) technology

NOTE The term is intended to cover any and all devices or systems operating on electrical principles.

EXAMPLE Electrical/electronic/programmable electronic devices include:

⎯ electro-mechanical devices (electrical);

⎯ solid-state non-programmable electronic devices (electronic);

⎯ electronic devices based on computer technology (programmable electronic).

[IEC 61508-4:1998] 3.3.5 Equipotential bonding electrical connection putting various exposed conductive parts and extraneous conductive parts at a substantially equal potential

[IEC 60204-32:1998]


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3.3.6 Failure the termination of the ability of an item to perform a required function

NOTE 1 After failure the item has a fault.

NOTE 2 “Failure” is an event, as distinguished from “fault”, which is a state.

NOTE 3 This concept as defined does not apply to items consisting of software only.

NOTE 4 In practice the terms “failure” and “fault” are often used synonymously.

[IEC 60050-191:2002] 3.3.7 Fault the state of an item characterised by inability to perform a required function, excluding the inability during preventive maintenance or other planned actions, or due to lack of external resources

NOTE 1 A fault is often the result of a failure of the item itself, but may exist without prior failure.

NOTE 2 In the field of machinery, the English term “fault” is commonly used in accordance with the definition in IEV 191-05-01, whereas the French term “défaut” and the German term “Fehler” are used rather than the terms “Panne” and “Fehlzustand” that appear in the IEV with this definition.

NOTE 3 In practice, the terms “fault” and “failure” are often used synonymously.

[EN ISO 12100-1:2004] 3.3.8 Hazard something with the potential to cause harm. This can be a task, machine, process, substance or premises

[EN ISO 12100-1:2004] 3.3.9 Protective bonding circuit / Equipotential bonding the whole of the protective conductors and conductive parts used for protection against electric shock in the event of an insulation failure

[EN 60204-11:2001] 3.3.10 Protective conductor (PE) a conductor required by some measures for protection against electric shock for electrically connecting any of the following parts

a) exposed conductive parts;

b) extraneous conductive parts;

c) main earthing terminal;

d) earth electrode;

e) earthed point of the source or artificial neutral.

[IEC 60439-1:1999]


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ailure

3.3.11 Redundancy the application of more than one device or system, or part of a device or system, with the objective of ensuring that in the event of one failing to perform its function another is available to perform that function

[IEC 60204-32:1998] 3.3.12 Safeguard guard or protective device

[EN ISO 12100-1:2004] 3.3.13 Safety integrity level (SIL) discrete level (one out of a possible four) for specifying the safety integrity requirements of the safety functions to be allocated to the E/E/PE safety-related systems, where safety integrity level 4 has the highest level of safety integrity and safety integrity level 1 has the lowest

[IEC 61508-4:1998] 3.3.14 Uncontrolled stop the stopping of machine movement by removing power to the machine

3.4 Tolerances relating to movement

3.4.1 Group synchronisation tolerance permissible deviation in the position in relation to one another of the machinery installations within a group, or permissible deviation from the travel curve calculated for the instal

3.4.2 Group synchronisation tolerance in the event of failure permissible deviation in the position in relation to one another of the machinery installations within a group, or permissible deviation from the travel curve calculated for the installation in the event of f

4 Hazards

When designing and using lifting and load-bearing equipment as in this standard, all foreseeable hazards, shall be identified. Only competent persons can be responsible for a) describing the intended use;

b) risk assessment.

After risk assessment has been carried out, the appropriate measures to be taken shall be established for specific hazards.

a) The risk assessment can be carried out on the basis of EN ISO 14121-1 or according to the significant hazards listed in Annex A;

b) Suitable facilities and provisions to enable the recovery of performers and other persons shall be provided in the event of any of the identified hazards occurring.

The following steps shall be taken when selecting protective measures:


a) specify the limits of the product (intended use, reasonably foreseeable misuse, space limits, the foreseeable life

limit, and wear factors);

a) identify hazards and estimate risks;

a) avoid hazards by means of inherently safe design measures and reduce risks as much as possible;

a) inform users of any residual risks (information for use).

A list of hazards is at Annex A

5 Design requirements

5.1 General

Stage Machinery can be grouped into three parts: a) Load bearing equipment;

a) Drive system;

a) Load Carrying device.

5.2 Examples of machine installations showing the groups

Figure 1.1 — Machinery Installation

Figure 1.2 — Load bearing equipment

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Figure 1.3 — Drive System

Figure 1.4 — Load carrying device

Figure 1.5 — Scenery or equipment on the Bar or Truss or Elevator

Figure 1 — Schematic representation of a bar hoist winch system

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Figure 2.5 — Scenery or equipment on the Bar of Truss or Elevator

Figure 2 — Schematic representation of a stage elevator



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Figure 3.5 — Scenery or equipment on the Bar or Truss or Elevator

Figure 3 — Schematic representation of a truss system

Load bearing elements of stage machinery shall be designed such that twice the characteristic load shall not give rise to permanent deformation or failure of the component.

To account for failure conditions (e.g. due to a power failure, failure of the drive control system, or bursting of pipes), elements shall be designed such that 1.2 times the load at failure shall not give rise to permanent deformation or failure of the component. See figure 4.

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Figure 4 Design requirements

Load bearing elements shall be designed according to EN 1993 1 - 10 (EUROCODE 3 ) for steel constructions and EN 1999 1 – 2 (EUROCODE 9) for aluminium constructions. All welding of fabrications shall be constructed and manufactured according to ISO 3834. Natural frequency and lateral torsion or buckling of the structures shall be considered. 5.3 Load assumptions for stage elevators

The following minimum loads shall be assumed when making calculations: a) safe working load with elevator at rest as part of the stage floor shall be at least the same as the surrounding

stage floor;

b) safe working load in motion must be specified by the designer.

An exception to item a) are stage elevators used solely for artistic purposes and which are not a permanent part of the stage floor construction. To obtain sufficient longitudinal and lateral stiffness the elevator should be capable of withstanding a horizontal force of at least 1/20th of the safe working load. 5.4 Load bearing equipment

5.4.1 General

It is permitted to use a single load bearing line. When a load is suspended by more than one line, the load on each line shall be distributed proportionally. All elements shall be secured against unintentional loosening. All structural elements of load bearing equipment shall be made of non-flammable materials. This requirement does not apply to platform floor coverings. Inflammable elements are permitted only where design measures ensure that their destruction does not lead to the load carrying device and its load falling.

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5.4.2 Load bearing lines

5.4.2.1 Wire ropes

Wire rope which complies with EN 12385-1, EN 12385-2 and EN 12385-4 may be used as load bearing lines. All wire ropes in fly bar systems shall be provided with a device for length compensation. Wire rope used as load bearing lines shall normally meet the requirements for a safety factor of at least 10 at characteristic loading, where the safety factor is the quotient of the minimum breaking load and the partial tensile force acting at characteristic loa When wire-ropes do not travel over pulleys or drums, a lesser safety-factor may be used following a risk assessment. A type 3.1 inspection document specified in EN 10204 confirming testing as specified in EN 12385-4 shall be provided for the wire rope. If a wire rope is replaced it must be ascertained that it is of an equivalent construction to the rope which is replaced. If a cover (plastic or textile) is used it must be possible to inspect the entire length of the wire rope. Covered wire ropes shall not be used as part of the machinery unless used as a lifting accessory. 5.4.2.2 Chains

In stage machinery as in this document, the chains used to carry loads are primarily of the round steel type. These are to be calibrated, and tested as in EN 818-7. Round steel chains used to carry loads shall meet the requirements for a safety factor of at least 8 at characteristic loading, in relation to the breaking force as specified in EN 818-7. A type 3 1 inspection document as in EN 10204 confirming testing as in EN 818-7 shall be provided for the chain Other types of chain (e.g. roller chains) shall meet the above requirements by analogy. Type-specific characteristics are to be taken into consideration. 5.4.3 Wire ropes terminations

5.4.3.1 General

Terminations shall be such that at least 80 % of the rope’s minimum breaking force is maintained. Wire rope terminations shall be such that their condition can be visually checked. 5.4.3.2 Detachable terminations

Detachable wire rope terminations may be: a) asymmetric wedge socket as in EN 13411-6;

b) symmetric wedge socket in EN 13411-7.

Detachable terminations shall be secured against self-detachment, for instance by using grips as in EN 13411-5, which may only be attached to the free end of the rope termination (see figures 6 and 7 for examples). the connection to the fly bar must allow free movement in all horizontal directions. See Fig 5.


Key 1 Rope deflection D:d ratio of not less than 10 2 Fly bar 3 sliding clip

Figure 5 — Sliding pipe clip as an example of a device for compensating the length of a wire rope

Key 1 Protective Sleeve 2 Grip as in EN 13411-5 3 symmetric wedge socket in EN 13411-7 4 Quick link with screw caps 5 Fly bar with welded lug

Figure 6 — Example of a means of suspending a fly bar

5.4.3.3 Fixed or Non-detachable terminations

Examples of non-detachable terminations for wire rope are: a) splices as in EN 13411-2;

b) ferrules as in EN 13411-3;

c) swage terminals, where proof of their load capacity is provided, e.g. in the manufacturer's documentation.

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5.4.3.4 End connections for steel chains

Chain end terminations shall be designed and manufactured in such a way that they shall withstand at least 80% of the chain’s minimum breaking force before failure occurs. Roller chain terminations shall be designed and calculated with clear indications of the limits of bending in the unfavourable plane. The manufacturer shall take these limits into account when installing roller chains in entertainment lifting machinery. A pivoting or hinging attachment shall prevent unintended side loading.

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2-2

Chain anchorage devices shall withstand four times the static chain tensile force at a rated capacity of the hoist without ruptureThreaded connections on chain anchorage devices shall be locked to prevent self loosening. The state of the fastening shall be verifiable. See also EN1449 5.5 Winding devices and diverter pulleys

5.5.1 Winding devices for wire ropes

Where round ropes are used, a wire rope drum with a helical groove shall be used to take up the rope. Other lifting devices that do not use a drum are permitted. Round wire rope may only be wound in one layer, except when using bobbins or pile wind drums, in which case each rope shall have its own winding chamber and it shall be ensured that the rope is layered in such a manner that the rope centrelines line up.

Key A drum core diameter B minimum pitch circle diameter C maximum pitch circle D wire rope slot width

Figure 7 — Pile wind drum

The attachment of the rope to the drum shall be designed to take 80 % of the ropes minimum breaking force either by friction by the remaining turns on the drum or by end termination or a combination of both.


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ter.

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d.

When Clamps are used to attach the rope, it shall be ensured that the failure of a screw does not lead to the attachment becoming ineffec Design measures shall ensure that the fleet angle of the rope from the groove of the drum or pulley when it is being pulled up or down, even when it is under loaded or slack. This fleet angle of the rope from the groove shall never ex-ceed 4 degrees on either side, but it is preferred, that the maximum should not be more than 1.5 degrees. The rope drum diameter, measured from the rope centreline to centreline, should be not less than 18 times, but preferably equal to at least 20 times the rope diame 5.5.2 Diverter pulleys for round wire ropes

The diverter pulley diameter, measured from the rope centreline to centreline, shall be equal to at least 20 times the rope diameter. The bottom of the rope groove shall be a circular arc. The radius of the rope groove shall be between 0.52d and 0.56d 5.5.3 Diverter pulleys for fibre ropes

The bottom of the rope groove shall be in general a circular arc over an angle of 180 degrees. The groove radius shall be nominally 20 % larger than the nominal rope radius. Grooves shall be smooth with radiused/chamfered edg Pulley pitch circle diameter for fibre rope should be a minimum of 8 times the rope diameter. Fibre ropes should not be used as load carrying devices for loads over 20 kg. 5.5.4 Drive and idler sprockets for steel chains

The pitch circle of idler sprocket wheels shall be not less than 10 times the chain pitch. When lifting and lowering in all operating modes, at least 3 chain links shall be form-locked in the sprocket.

The chain is to be fed onto the sprocket in such a manner that it does not twist and that feeding and run-out is controlle

5.5.5 Drive systems

5.5.5.1 General

Drive systems shall be designed so as to preclude unintentional hazardous movements. This can be achieved by means of: a) movement-operated self-locking (dynamic self-locking);

b) at least two independently functioning securing devices.

An example of movement-operated self-locking device may be a self sustaining gear box; an independent functioning securing device may be brakes which function independently in all operating modes, for some cases there may be a delayed engagement of a second brake.


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If brakes are used, the braking and clamping forces may only be generated by means of weight forces or guided com-pression springs. In the event of a compression spring breaking, coils of springs shall not become twisted within each other, leading to a shortening of the spring. Each of these securing devices shall be capable of bringing the test load to rest. It shall be possible to check the effectiveness of each securing device separately Where brakes are used for emergency stops, (including hydraulic drive systems, valves or clamps) these shall be engaged by means of two independent devices. These can be the same as the devices used to shut-off the system The risk assessment may demonstrate that one securing device is sufficient. Stage elevators at rest may be held by means of an interlocking mechanism. Between the load carrying and the securing device all components of drive systems: a) shall be designed such that twice the characteristic load shall not give rise to permanent deformation or failure of

the component, taking 400 operating hours as the basis for calculations unless a longer operating time is appro-priate; (see ISO 4301)

b) for stage elevators, shall be designed for loads 1.5 times the system load. This shall not give rise to permanent deformation or failure of the component;

To account for failure conditions, all drive system components between the load carrying device and securing devices shall be designed such that 1.2 times the load at failure shall not give rise to permanent deformation or failure of the component. All guided power driven suspended load carrying devices shall have a component which interrupts their movement when the suspension system becomes slack. 5.5.5.2 Screw Jack systems (spindle drives)

Screw Jacks shall have a greater wear resistance than the supporting nut.

In Screw Jack drives, the supporting nut shall be designed to accommodate a load twice the characteristic load. The wear of the supporting nut shall be monitored by means of a wear measuring device, e.g. a backup safety nut.- a non-load bearing rotary nut used to track the wear of the supporting nut. In the case of stage elevator platforms with a maximum lifting height of 400 mm, the wear measuring device may be dispensed with if the permissible wear can be established visually, although in this case, the supporting nut shall still be designed to accommodate a load twice the characteristic load. Screw Jacks with ball screw nuts do not need a wear measuring device. A residual load capacity of at least 1.6 times the characteristic load shall be maintained. 5.5.5.3 Hydraulic systems

Components of hydraulic systems shall be designed using twice the load pressure for calculations. Cylinder and pressure pipelines shall be designed for predominantly non-cyclic loads as in EN 13480-3; The design shall comply with the minimum requirements of the Pressure Equipment directive (97/23/EC 1997) Compression or flared joints, joints using a conical ring fitting, and other similar joints, as well as hose assemblies, may not be used between a hydraulic drive system and security device. In the case of commercially available components, e.g. pipe connections or valves, which are placed between the cylinder and the securing device, the nominal pressure as stated by the manufacturer shall be at least twice the value of the load pressure


For the rest of the hydraulic system, calculations shall be based on the unfactored operating pressure when designing components between the securing device and the pressure generating equipment. The operating pressure shall be limited by means of a pressure limiting device. It shall be possible to measure the system pressure. Hydraulic drives shall in general be provided with local manual isolating valves with which the drive can be cut off from the rest of the system. If the pressure is generated by means of a gaseous cushion which has a direct influence on the hydraulic fluid, all drive systems shall automatically switch off once the fluid reserve goes below the minimum level. 5.5.5.4 Auxiliary drive systems

When a hand crank or auxiliary drive equipment is engaged, the power drive shall be automatically interrupted. The direction of travel (upwards or downwards) of the machinery installation shall be clearly indicated. 5.5.5.5 Manual systems

Manual drive systems, e.g. manual winches shall apply all the requirements described in chapter 5.

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Manual counterweight hoists shall have a locking device which can withstand the manual force (force applied by a person, either as a tensile or compressive force (pulling or pushing)) of at least two persons (2 x 200 N) in both directions. This device may be located on the line being handled by the opera

Key 1 pulley 2 Fly bar 3 pulley and head block 4 loading galleries 5 operator's line 6 counterweight 7 rope lock 8 line collector 9 winch

Figure 8 — Examples of manual systems 5.6 Load carrying devices

Load carrying devices shall be calculated as part of the load bearing elements.


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rtains.

For trusses intended for use as load carrying devices see parts A Specification for design and manufacture of aluminium and steel trusses and towers & part B Use of aluminium and steel trusses and tow When designing stage elevator platforms, the characteristic load shall be assumed for calculations and the deflection or excitation of the floor shall be taken into account. The maximum deflection shall be defined. Hoist bars or lifting beams shall be dimensioned so that the calculated deflection between two suspension points due to the safe working load is not greater than 1/200. 5.7 Loads

Loads may consist of many varied items such as scenery elements, speaker cabinets, lighting fixtures etc and when constructing the load the hanging points shall be designed as load bearing points and the maximum allowable stress values of the materials used shall be taken into account, as well as the forces on the lifting points. 5.8 Manually operated lifting

This document does not apply to manually operated lifting with a system load of less than 20 kg.

6 Safeguarding hazardous areas

6.1 Protective spaces

Protective spaces shall be provided for persons carrying out inspection and maintenance work in spaces underneath the machinery installation (e.g. underneath a stage elevator). It shall be possible to lower stage elevators only so far so as to allow for the protective space to be formed underneath the entire platform area. The vertical distance from the lowest point of the elevator platform shall be at least: a) 0.8m to the bottom of the protective space;

b) 0.5m to any permanent constructions, disregarding limit stops, above or below the space;

c) 0.12m between the elevator apron and the bottom of the protective space.

The protective space may be be temporarily formed during maintenance by means of hinged supports, for example. Guides, including permanent constructions, are to be disregarded, as long as the protective space has a floor area of at least 0.8m x 1.5m. Hinged supports shall have securing devices to prevent them from being unintentionally moved. The use of hinged supports during inspection and maintenance work shall be indicated by means of signs. Access openings to protective spaces shall have a be at least 0.6m x 0.8m. Permanent lighting shall be provided in maintenance areas under stage elevator platforms. 6.2 Safeguarding at crushing, shearing and trapping points, and fall protection Crushing, shearing and trapping points are to be avoided. Where such points are unavoidable, they are to be safeguarded by means of effective devices or other safety measures. Such devices include (pressure) sensitive edges, light beams and light cu


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Gaps in the stage floor due to moving elements such as stage elevators may not be wider than 20mm. If operating conditions make wider gaps necessary, it must be possible to cover them. If heights from which a person can fall are unavoidable within the travel range of stage machinery (e.g. a stage elevator), then protective measures shall be provided wherever possIt is however recognised within the entertainment industry that it may not be possible to provide guarding or other physical measures to prevent falls. In this case the risk of falling shall be addressed by operational procedures 6.3 Accessibility of maintenance areas Walkways between drive systems and control gear/switchgear which are used during maintenance work or when monitoring machinery operations should be at least 0.7m wide and have a clearance height of at least 2m Where the distance between the bottom of a protective space and the highest operating position of a stage elevator platform is no greater than 3m, the space may be entered through the elevator platform. Access flaps in the stage floor at positions of drive systems or controlgear/switchgear shall have a clearance of at least 0.6m x 0.8m and open upwards or be removable. It shall be possible to open the flaps into a stable position, or they shall be provided with an automatic hold-open device. Guards against falls and access aids shall be provided. Floor flaps shall be secured against unintentional lifting. Maintenance walkways shall be clearly and permanently identified by means of a sign saying "Maintenance access - Authorised personnel only". 6.4 Elevator shaft walls, openings and landing doors

6.4.1 General

If stage machinery (e.g. a stage elevator) moves against a wall, any openings in such walls shall have suitable eleva-tor landing doors, the clearance height of which shall be at least 2.0m. Elevator shaft walls and doors shall be even and smooth on the inside of the shaft. The distance to the elevator platform installation shall be no greater than 20mm unless this gap is protected by some other mean On the shaft side, doors shall be flush when closed. Crushing or shearing points at projections or recesses near sliding doors shall be avoided or safeguarded. Doors along escape routes shall open in the direction of escape and shall not project into the shaft. 6.4.2 Interlocking of doors

It shall not be possible for the machinery (e.g. stage elevator) to start until all elevator shaft doors are closed and loc-ked. Door closers shall be provided with an electrical safety device. It shall only be possible to open elevator shaft doors when the elevator is stationary and the vertical distance between the platform and the access landing is no greater than 0.15 m. Door closures shall be designed so that the interlock cannot engage when the door is not closed. 6.5 Counterweights

Counterweight cradles shall be designed to prevent weights from falling out. The use of mechanical springs instead of counterweights is not permitted.


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.

Where counterweights travel in work areas and traffic areas, safety distances as in EN 294 and EN 349 shall be maintained, or suitable guarding shall be provided to ensure that any falling counterweight is contain

7 Overhead suspension of loads

7.1 General

Where standard lifting machinery and accessories compliant to Machinery Directive 2006/42 EC are used to provide overhead suspension of loads and where it is not required to move these loads above people, the following applies after a satisfactory risk assessment has been carried out: 7.2 Lifting equipment

Standard lifting equipment designed according to the requirements as set in the Machinery Directive 2006/42 EC and EN 14492-1/2 shall be loaded to no more than 0.5 times the safe working load as given by the manufacturer. Examples of lifting equipment are, but not limited to, manual or power driven chain hoists and winches.

7.3 Direct Acting Force Limiters

Direct acting lifting force limiters lying in the kinetic chain between the load and the securing devices are admissible.

7.4 Single Components

Single components in the kinetic chain (e.g. a single brake) are admissible provided they are rated for a minimum of 200% of the applied load. 7.5 Lifting accessories

Standard lifting accessories designed according to the requirements as set in the Machinery Directive 2006/42 EC shall be loaded to no more than 0.5 times the safe working load as given by the manufacturer. Examples of lifting accessories are shackles, round slings, wire rope slings, O-rings, beam clamps, clutch chains, lifting beams etc

7.6 Precautions

During the lifting and lowering operation, arrangements shall be made to secure the working area and appropriate measures shall prevent unauthorised starting.

7.7 Secondary suspension

When an equivalent secondary suspension is used, lifting equipment and accessories designed according to the requirements as set out in the Machinery Directive 2006/42 EC and EN14492-1/2 can be loaded to the safe working load as given by the manufacturer.

8 Electrical equipment and control systems

8.1 General requirements

8.1.1 General

The fundamental health and safety requirements laid down in Annex I of the Machinery Directive 2006/42 EC are to be observed when designing and installing electrical and electronic systems, including any safety components, of ma-chinery installations as in this document. The following standards are also to be used:


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a) EN 60204-1;

b) EN 60204-32;

c) EN 61508-1to 7;

d) EN 62061;

e) EN ISO 13849-1 and 2.

This clause specifies additional requirements for particular equipment to supplement the requirements of the above-mentioned standards. NOTE In this document the term “electrical” includes both electrical and electronic matters (i.e. “electrical equipment” means both the electrical and the electronic equipment).

The equipment covered by this document commences at the point of connection of the power supply to the machine. When installing the power supply system, including the electrical control system, and when selecting electrical equipment, steps shall be taken to ensure that hazardous operating conditions are prevented in the event of fail Risks due to hazards associated with the electrical equipment shall be considered when carrying out risk assessment of the machinery installation. Where electronic, and/or software systems are used in safety functions, the necessary safety integrity level (SIL) (as in the EN 61508 series) shall be determined for each safety function on the basis of hazard identification and risk assessment, and the resulting safety requirements are to be specified in accordance with the EN 62061 Annex A By selecting suitable safety measures for the relevant SIL when designing electrical equipment, the necessary protective measures and acceptable level of risk for persons exposed to the relevant hazards can be determ Safety measures are a combination of the measures incorporated at the design stage and the measures to be implemented by the u 8.1.2 Selection of equipment

Electrical components and devices shall be suitable for their intended use and shall conform to the relevant standards. 8.1.3 Electrical supply

The electrical equipment shall be designed to operate correctly under the conditions of supply specified in EN 60204-1. 8.1.4 Physical environment and operation conditions

8.1.4.1 General

The electrical equipment shall be suitable for use in the physical environment and operating conditions specified in EN 60204-1.

8.1.4.2 Electromagnetic compatibility (EMC)

The electrical/electronic equipment shall not exceed the limits for EMC emission specified in EN 61000-6-4, and shall meet the requirements for EMC immunity specified in EN 61000-6-2. Requirements for electromagnetic emission and immunity apply within the frequency range of 0 Hz to 400 GHz: a) Methods of measurement and limits are specified in EN 61000-6-4 for EMC emissions and in EN 61000-6-2 for

EMC immunity;


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b) The user is to be informed of any special measures needed to fulfil the above-mentioned requirements (e.g. use of shielded or special cables).

8.1.4.3 Ambient air temperature and humidity

All electrical equipment shall be designed and chosen to operate correctly in the expected environmental conditions Harmful effects (e.g. of condensation in control cabinets) shall be avoided by the provision of built-in heaters and air conditioners. 8.2 Incoming supply conductor terminations and devices for disconnecting and switching off

8.2.1 Incoming supply conductor terminations

As in EN 60204-32. 8.2.2 Terminal for connection to the external protective earthing system

As in EN 60204-32. 8.2.3 Supply disconnecting (isolating) devices

As in EN 60204-32. 8.2.4 Devices for switching off for prevention of unexpected start-up

As in EN 60204-32. Each machine shall be provided with a device to disconnect the machine from power for the prevention of unexpected start-up. 8.2.5 Devices for disconnecting electrical equipment

As in EN 60204-32. 8.2.6 Protection against unauthorised, inadvertent and/or mistaken connection

As in EN 60204-32. 8.2.7 Protection against electric shock

Persons shall be protected against electric shock: a) under normal conditions (basic protection);

b) under single-fault conditions (fault protection);

c) additional protection may be specified as part of the measures taken under specific conditions as protection against external influences and in special areas of application.

EN 60204-32 describes recommended protective measures.


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8.2.8 Protection of equipment

8.2.8.1 General

Recommended design criteria for safety devices are described in EN 60204-32. According to EN 60204-32, the equipment is to be protected against the effects of: a) overcurrent arising from a short circuit;

b) overload current;

c) abnormal temperature;

d) loss of or reduction in the supply voltage;

e) earth fault;

f) incorrect phase sequence;

g) overvoltage due to lightning and switching surges.

If one of these malfunctions causes the operation of a protective device resulting in the stopping of a machine, an au-tomatic restart shall be prevented. 8.2.8.2 Protection under fault conditions

A fault in the electrical equipment must not lead to a hazardous condition. Suitable measures shall be taken to prevent such hazards, by e.g. providing: a) additional safety-related control circuits;

b) redundancy (with monitoring).

When a fault occurs, safety-related control circuits shall restore safe conditions. 8.2.8.3 Equipotential bonding

As in EN 60204-32. 8.2.9 Control circuits and control functions

8.2.9.1 General

As a rule, control circuits for machinery installations as in this document shall be designed in accordance with EN 60204-32 (see figures 9 and 10). 8.2.9.2 Control functions

8.2.9.2.1 General

In general, control functions for machinery installations as in this document shall be selected in accordance with EN 60204-32 (see figures 9 and 10).


Figure 9 — Sample Block diagram of a variable speed drive system

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Figure 10 — Sample Block diagram of a Reversible Fixed speed drive system

8.2.9.3 Control devices

All movements shall be initiated and ended by means of a control device, with the direction of movement being clearly indicated to the operator. If it is possible to initiate contrary movements concurrently, this function shall be clearly indi-cated. The movement shall continue only as long as the operator is actively involved. with the control device. Control devices shall be protected against unintentional actuation (e.g. by means of protective shrouds or blocking devices) and unauthorised actuation (e.g. by means of key-operated switches).

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Control devices shall be located so that the operator or operators can safely monitor the operating zones from the operating position(s). Alternatively an enabling device shall be included to ensure safe monitoring. Where a system has multiple control stations, interlocks (hardware or software) shall prevent the simultaneous control of an axis or group of axes by more than one control device. The control system shall be so designed that no sequence of operations shall cause unintended motion. It shall be possible to reset the control system after an incorrect sequence of controls has been selected. 8.2.9.4 Enabling devices

An enabling device may be necessary, for instance, when it is not possible to monitor the machine’s movements from the operator’s position. Design features of enabling devices are specified in detail in EN 60204-32. 8.2.9.5 Cable-less control devices

Cable-less controls may be used if they meet the same safety requirements as the rest of the installation. They shall also meet the relevant requirements specified in EN 60204-32. 8.3 Safety functions and control functions in the event of failure

8.3.1 General

Safety functions for an E/E/PES shall be selected on the basis of hazard analysis. NOTE Where the supplier of the E/E/PES is not responsible for designing the entire system (E/E/PES and drive equipment), the system developer shall specify the functional safety requirements for the E/E/PES based on hazard analysis carried out in accordance with the EN 62061 or EN 61508 series of standards

Functions integrated into the E/E/PES may also serve as safety functions. The Safety Functions performed by the E/E/PES shall be determined to mitigate the hazards identified in the risk assessment process and may include the following and or other functions for example: a) stop functions;

b) emergency stop functions;

c) start functions;

d) speed limits;

e) overloading and underloading;

f) position limits;

g) deviations in speed;

h) exceeding specified travel limits in the case of synchronous travel;

i) deviations from specified trajectories;

j) overtravel;

k) acoustic signals;

l) override functions and

m) group synchronisation and monitoring functions.

General requirements for control functions in the event of failure are described in detail in EN 60204-32. Where faults or disturbances in the electrical equipment can result in a hazardous condition or damage to the machi-nery, suitable measures shall be taken to minimise the probability of such hazards occurring. The required measures


37

nel.

and the extent to which they are to be implemented, either individually or in combination, will depend on the level of risk associated with the respective application. Measures to minimise risk and risk reduction in the event of failure are also described in EN 60204-32. 8.3.2 Providing redundancy

By providing partial or complete redundancy, it is possible to minimise the probability that a single fault in the electrical circuit can result in a hazardous condition. As a rule, redundancy is to be designed-in for switching devices (e.g. contactors, relays, valves) in safety devices, and such devices are to be monitored separately. Redundancy is also to be provided for any contactor relays (intermediate relays) in safety circuits (that is, if a fault in such a relay could disable a safety function). 8.3.3 Hazardous operating conditions

Faults in the installation shall not lead to hazardous operating conditions. Such conditions exist, for example, when: a) the prescribed speed is exceeded;

b) the barriers or door closures on stage elevator doors are not engaged;

c) load bearing lines become overloaded or slacken;

d) the wear limit of spindle drives is reached;

e) the floor of a stage elevator exceeds travel limits;

f) the permissible group synchronisation tolerance is exceeded;

g) the prescribed trajectories are not maintained.

Faults in the control or regulating system must not hinder stopping. 8.3.4 Safety devices and safety functions

The technical measures needed to perform these functions will depend on their functioning under failure conditions within the E/E/PES, and are to be selected on the basis of risk assessment. If a safety device is activated, the machine shall stop at least in the direction of movement. Where a safety device at crushing or shearing points is activated, movement in the direction contrary to that of the hazardous movement shall be possible. It shall be possible to check the functioning of all safety devices. The activation of a safety device shall be indicated as long as the activation is in effect. Overtravel limit switches shall be designed as in EN 60947-5-1. It is possible to replace overtravel limit switches with encoder sensing of overtravel, provided that the system is designed in such a manner that the required SIL level, determined by risk assessment, is achieved. The minimum expected SIL level in such circumstances is SIL 3, unless the overtravel will result in no mechanical damage or injury to person Safety circuits shall be configured in such a manner that the required SIL determined by means of risk assessment can be achieved even without position switches. Safety circuits which register the exceeding of specified travel paths, speeds, or loads, or unacceptable deviations from specified trajectories, which could cause a hazardous condition or damage the machinery installation shall initiate a secure emergency stop when activated. The stop category shall be established on the basis of risk assessment for the machinery installation in question.


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08.

8.3.4.1 Overtravel limits (limit switches)

Where overtravel will result in mechanical damage or failure then 2 sets of limit switches should be fitted, an ‘initial’ and an ‘ultimate’ limit switch. (This does not apply where the overtravel of a hydraulic cylinder is limited by means of fixed, damped limit stops, and a shut-off is ensured by additional means, such as a pressure switch.) The ‘initial’ limit switch shall be a mechanical limit switch connected to the electrical system in such a manner as to prevent further movement in the overtravel direction. It shall allow the user to operate the system in the opposite direct The ‘Ultimate’ emergency limit switch should be a positive break mechanical limit switch, which immediately removes power to the motor, and brake. Optionally the ultimate stop function of an emergency limit switch can implement a category 1 stop. In this case special note should be taken of the following paragraph. Ultimate limit switches shall be located in such a manner that should the initial limit fail to operate, and the machinery strikes the ultimate limit at maximum speed and taking the expected system delay time into consideration - the machinery installation can come to a stop safely before the overtravel results in mechanical dam Where the machine can be re-configured after the initial installation, it shall be possible to set ‘initial’ and ‘ultimate’ limit switches and end-of-travel switches for the relevant travel range. The modification of machinery installations as in this document, including the resetting of initial and ultimate limit switches, may only be carried out by trained, authorised persons. As an alternative to limit switches the control system may use a suitable position sensor(s) and control/software system to implement the initial and or ultimate travel limits of the system. If this method is chosen then the overall overtravel limit system must meet the requirements of SIL 3 as specified in EN 615 8.3.4.2 Providing protection when characteristic loads are exceeded (Overload Protection)

The machinery movement shall be stopped when the load exceeds 1.2 times the characteristic load. The machinery movement shall be stopped when the load is exceeded, the system shall allow the operator to move the machinery in a direction so as to lower or reduce the load. 8.3.4.3 Providing protection in underload and slack-wire situations

In machinery installations where underload situations can lead to mechanical damage or a hazardous situation, (e.g. due to slackening of lines) the machine shall be stopped in the direction of travel, although movement in the contrary direction may be possible. 8.3.4.4 Providing protection when wear limits of screw jacks are reached

The machinery installation shall stop when the wear limit is reached. See 5.5.5: Drive Systems 8.3.4.5 Providing protection when speed regulators fail

Speed regulators in drive systems of machinery installations shall be capable of automatically identifying unallowable deviations in speed which could cause a hazardous condition in which case the system should be brought to a full stop. 8.3.4.6 Providing protection when nominal speeds are exceeded

When the speed of the drive system in variable speed drive systems is greater than the maximum speed, the machi-nery installation shall stop no later than when a speed 1.25 times the nominal speed is reached.


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8.3.4.7 Travel of groups of machines

Machines may be controlled together to form a group of machines by an operator. In this case the action of the group upon an error condition will depend upon the type of group operation. There are 3 types of group operation possible. 8.3.4.7.1 Asynchronous travel without group deactivation

In the case of asynchronous travel without group deactivation, only the relevant machine shall come to a stop when the work limit is reached or when a relevant safety device is activated. 8.3.4.7.2 Asynchronous travel with group deactivation

In the case of asynchronous travel with group deactivation, it shall be ensured that the entire group comes to a stop when the overtravel limit is reached or when a relevant safety device is activated. The system shall easily identify which machine has caused the error condition. 8.3.4.7.3 Synchronous travel of a group of machines

Synchronous travel (that is, when all of the machines in a group travel interdependently (route- or time-synchronised travel)) shall be monitored. The permissible group synchronisation tolerances may not be exceeded in any operating mode. The group shall be stopped when a safety device is activated, limits are exceeded (e.g. when monitoring travel curves), or in the event of failure. The specified group synchronisation tolerances in the event of failure may not be exceeded If a machinery installation is driven by several drive systems, or where several installations are used to lift the same load, synchronism is to be ensured. The permissible group synchronisation tolerances may not be exceeded in any operating mode. When a safety device is activated, the permissible group synchronisation tolerance in the event of failure may not be exceeded. The system shall easily identify which machine has caused the error condition. 8.3.4.7.4 Travel of several groups

Where several groups and/or single installations travel simultaneously and are controlled by a single control device, the travel modes of the various groups/installations shall be maintained. 8.3.4.8 Interlocking devices

Safeguards for danger zones shall be interlocking and shall prevent the hazardous movement or bring it to a stop. 8.3.4.9 Cutting off power

When necessary to cease torque at the drive system the power to the drive system shall be cut off safely Suitable measures for power cut-off include combinations of the following measures: a) providing contactors between the power supply and drive system (mains isolation);

b) providing contactors between the drive system and the drive motor (motor isolation);

c) safely blocking the control pulse of the semiconductor device within the drive system.

NOTE This is not the same as isolating the electrical supply.


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8.3.5 Devices for testing safety functions

Each machinery installation shall be provided with the means for the functional testing of safety devices and securing devices: a) Means for releasing the brake(s) individually so that it is possible to check the effectiveness of each brake;

b) Devices for checking safety limits;

c) Means for bypassing individual overtravel limits;

d) Means for bypassing activated safety switches and interlocking movement out of the range of the ultimate limit stop to enable movement in the opposite direction.

It shall be possible to check the effectiveness of each safety switch individually. 8.4 Emergency stop and emergency switching-off functions

8.4.1 Emergency stop

Machinery installations shall have an emergency stop function which stops the drive system. The emergency stop system may either implement a Category 0, or a Category 1 stop for the equipment. The choice of category shall be on the basis of a risk assessment and the functional needs of the machine. Category 0: Stopping by immediate removal of power to the drive elements of the machine (uncontrolled stop); Category 1: A controlled stop with power available to the drive elements of the machine to achieve the stop and then a guaranteed removal of power. 8.4.2 Activation device

8.4.3 Actuators for and design of emergency stop and switching-off functions

This section applies to Emergency Stop switches only. Emergency switching off and stop devices are to be interlocking push button switches designed in accordance with EN 60204-32. Where there are several operator control stations for the same machinery installation, each station shall be equipped with an emergency switching-off device. Stations from which several different installations can be operated may only be equipped with one emergency switching-off device which has an effect on all installations in question. Emergency switching off devices shall have a positive break operation. 8.5 Electronic and programmable electronic systems (E/PES)

8.5.1 General

General requirements which apply to all types of electronic control devices are described in EN 60204-32. 8.5.2 Programmable controllers

Programmable controllers shall fulfill the relevant ergonomic and general safety requirements specified in EN 61131-1 and EN 61131-2. They shall be designed to prevent unauthorised persons from making changes to the program memory.


8.5.3 Use of programmable electronic systems (E/E/PES) to implement safety functions

Where E/E/PES systems are used to implement safety functions within the control system (or functions that could in the future potentially affect safety), then the SIL level according to EN 62061 and EN 61508 should be determined for each safety function. To determine the safety level in simple systems, EN 13849 1 & 2 can also be considered. 8.5.4 User information for safety functions

In order that the user can determine the appropriateness of the control system in specific applications the manufactu-rer shall supply the SIL Level for each safety function, and indicate the response of the control system to error condi-tions. This response should be the combined response of the electrical and mechanical system. The information should be displayed prominently on the equipment, or in the associated manuals for the equipment. The information, should, as a minimum include the information laid out in the table below. Additional information that is required for particular installations should be identified by risk assessment.

Table 2 — Minimum/Sample E/E/PES Safety Functions - informative

8.6 Use of programmable electronic systems (E/E/PES) without safety functions

There are no particular requirements for programmable control systems (e.g. for selection functions such as group formation), if they do not perform safety-relevant tasks. If the programmable control system performs selection functions, the successful selection of a function shall be indicated by means of a feedback signal. The computer shall not have any influence on the effectiveness of the safety device. Speed and position values may be processed by the computer if they are not used to reach an arrival point specified for safety reasons.

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8.7 Operator interfaces, control devices and contactors

8.7.1 General

General requirements regarding the location and mounting of control devices, as well as their protection against out-side influences are given in EN 60204-32. 8.7.2 Start devices and indicators

Design criteria for start devices, and indicator lights and displays are described in detail in EN 60204-32. 8.7.3 Devices for emergency stop and switching off

The location, type, function and activation of devices for emergency stop and switching off are described in detail in EN 60204-32. 8.7.4 Requirements for contactors

The co-ordination of the contactors with the associated short-circuit protective devices shall be a "type 2" coordination as in 7.2.5.1 of EN 60947-4-1:2001-10. Contactors which fulfil the stop function of drive systems and which are controlled by control devices with a safety function shall be selected and combined with other equipment in such a manner that contact welding is either avoided or does not affect the emergency stop function. 8.8 Conductors and cables

Conductors and cables shall be selected so as to be suitable for the operating conditions (e.g. in terms of voltage le-vels, currents, protection against electric shock, grouping of cables and conductors) and any external influences (e.g. ambient temperature, presence of water or corrosive substances, mechanical stresses, fire hazards) that can exist. The minimum requirements regarding a) insulation,

b) current-carrying capacity,

c) voltage drops, and

d) minimum cross-sectional areas

are specified in EN 60204-32. 8.9 Wiring practice

The minimum requirements regarding a) connections and routing,

b) identification of conductors,

c) wiring inside and outside enclosures, and

d) ducts, connection boxes and other boxes

are specified in EN 60204-32. 8.10 Electric motors and associated equipment Electric motors shall meet the requirements of EN 60034-1:2003.


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The characteristics of motors and associated equipment shall be selected in accordance with the anticipated service and physical environmental conditions (see also EN 60204-32). 8.11 Accessories and lighting The minimum requirements for accessories and lighting are specified in EN 60204-32. 8.12 Marking, warning signs and reference designations Electrical equipment shall be marked with the supplier’s name and the reference designation in accordance with EN 61346-1. Design features of markings, warning signs and reference designations are specified in EN 60204-32. 8.13 Technical documentation

The information to be included in technical documentation for electrical equipment, and the presentation of that infor-mation are specified in EN 60204-32. 8.14 Testing and verification of characteristics

8.14.1 General

Tests to verify the characteristics of equipment shall be carried out on all switchgear/controlgear assemblies in accor-dance with EN 60439-1 and the results documented. Such tests include: a) type tests, and

b) routine tests.

Type tests are carried out to establish whether the requirements of EN 60439-1 have been met, and shall be perfor-med by the switchgear/control gear assembly manufacturer. Routine tests are intended to detect any faults in materials and workmanship. They are to be carried out on every new switchgear/control gear assembly after it has been assembled or on each transport unit, by the manufacturer of the assembly The performance of the routine tests at the manufacturer’s works does not relieve the installer of the assembly from the duty of checking it after transport and installation. 8.14.2 Scope of routine testing

Continuity of the equipotential bonding circuit should always be verified. In addition, the following tests are to be carried out in the order shown: a) verification that the electrical equipment agrees with the technical documentation;

b) inspection of the assembly, including inspection of wiring and, if necessary, electrical operation testing;

c) insulation resistance tests;

d) continuity of the earth equipotential bonding protective circuits.

General requirements for testing are described in detail in EN 60204-32 and EN 60439-1.


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079).

9 Information for use

9.1 General

Instructions for use shall be prepared in accordance with the machine directive and EN 62079 - Preparation of instructions - Structuring, content and presentation (IEC 62

9.2 Technical data to be included

Data from the following technical list shall be included in the specification of the machinery installation as far as is ap-plicable in this document: a) Intended use;

b) operating conditions;

c) duty type of drive system, as in EN 60034-1 - Rotating electrical machines - Part 1: Rating and performance;

d) (IEC 60034-1:2004);

e) Safe Working Load at rest and in motion;

f) maximum concentrated and area loads;

g) travel speeds;

h) acceleration and deceleration values under normal operating conditions and under failure conditions;

i) travel path;

j) operating mode (synchronisation tolerances and overtravel limits);

k) tolerances in the event of failure;

l) type of group travel;

m) type of control system;

n) independent third party certification of safety functions and their SIL levels;

o) Operating and ambient temperature limits;

p) Maximum allowable deflection of elevators.

This information is to be included in the user's instructions and recorded in a test log.

9.3 Marking

9.3.1 General

All marking shall be clear, legible and located in a place where it can be easily seen. Markings shall not significantly reduce the safety or strength of a component. Markings shall not easily disappear as a result of wear and tear. 9.3.2 Safe working load

Lifting machines and lifting accessories shall be marked with their safe working load (SWL).

When the SWL is reduced to a lower level than the calculated SWL for operational reasons, the completed installation shall be labelled accordingly.

Machinery that is installed shall be marked with the SWL near to where the load is attached.


Where the load is applied as other than a single vertical point load, a loading notice shall be provided to indicate the SWL under the different permitted distribution conditions.

Key A max. concentrated load under one wire rope, depending on rope dimensions B max. concentrated load between two wire ropes, at mid-span, depending on bar dimensions and max. load A C max. uniformly distributed load between two wire ropes, depending on bar dimensions and max. load A D max. concentrated load at bar end, depending on bar dimensions and max. load A

Figure 11 — Loading Notice giving maximum allowable loads (example) 9.3.3 Anchorages

All anchorages shall be clearly marked with their SWL and the direction in which the load may be applied. NOTE For the marking of anchorages for use with personal protective equipment see EN 795.

9.3.4 Loading notices

Loading notices shall be displayed prominently.

NOTE 1 Typically notices should be provided on the stage/studio floor, on any galleries/gantries, on the grid, adjacent to ancho-rages and at any load control point.

The loading notice shall detail the loading limitations. Detailed design information shall be obtained from the structural engineer responsible for the building and a competent mechanical engineer or the suppliers of the lifting equipment. The loading notice shall also reflect any controls or limitations that may have been applied to the system by indepen-dent testers and or local authorities.

NOTE 2 Ideally the information should be detailed in both written form and via pictorial representation which should include any terminology specific to the area. For example if there is a maximum load in any one bay (or section) of the grid, then the pictorial representation should show what a bay is.

The loading notice shall include the following information: q) where counterweights are stored, the floor loading including the distribution of weights. This shall state the safe

point loading in kg and safe distributed loading in kg/m2;

r) the maximum SWL for each different type of hoist or counterweight set;

s) details as to whether the load on the bar is allowable as a point load or a uniformly distributed load;

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46

ation.

t) the parts of the structure upon which the load may be applied;

NOTE For example, it may be appropriate to paint certain parts of the structure a different colour if loads are permitted. In the converse case if it is not permitted to suspend loads on any general parts of the structure this should be clearly indicated on the loading notice with a suitable disclaimer e.g. loads may not be applied to any part of the building structure unless painted yellow.

u) where the load is permanently installed, and no additional loading is allowed, the total load suspended shall be prominently marked on the load with a notice forbidding any additional loading.

9.3.5 Lifting accessories

Lifting accessories shall be marked in accordance with the requirements of their relevant standards, e.g. CE mark.

NOTE 1 These markings usually include the SWL, classification mark, manufacturer and a distinguishing mark to allow identifi-cation with the manufacturer’s certificate of test and examination. Markings shall consider requirements set out in clause 7.5.

For lifting accessories with one SWL, this value shall be marked on the accessory.

NOTE 2 Where this is not possible, a coding system should be used which allows the user to determine the SWL, examples of such systems include colour coding or attaching some form of label. Care should be exercised to avoid confusion with other colour coding systems.

Where the configuration of an accessory affects the SWL it shall be clearly marked by a tag or a plate, or a notice shall be readily available providing the user with information on the SWL for each configuration. Lifting accessories shall be marked in such a way that it is possible to identify the characteristics necessary for their safe use.

Where a number of lifting accessories are assembled to form one lifting assembly or part of a lifting system which is not dismantled after use, the assembly shall be marked to indicate its safety characteristics to users.

Where the weight of a lifting accessory is significant in relation to the SWL of the machine with which it is to be used, the accessory shall be clearly marked with its weight. Where there are other characteristics that make the use of a lifting accessory unsuitable in a particular application, then this information shall be marked or otherwise be available to the user. A unique number or a batch number shall identify wire rope and termination assemblies and be quoted on the accompanying certific

All chain slings and bridle chains shall be marked in accordance with EN 818-4.

9.3.6 Machinery

Every machine, whether manually or power operated, shall carry a “rating label” as set in 3.2 legibly marked with the following minimum particulars:

v) name and address of manufacturer or importer where relevant;

w) CE mark (where relevant);

x) designation of series or type;

y) serial number;

z) year of construction or manufacture;

aa) SWL;

bb) correct power supplies;

cc) And where relevant:


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dd) self weight;

ee) maximum permitted speed;

ff) travel range.

9.3.7 Remote operations

All areas where remotely operated machines may start without warning shall have signage to warn of the hazard.

9.3.8 Personnel lifting

Lifting equipment specifically designed for lifting or carrying people shall be clearly marked as such. Other equipment, not so marked, shall NOT be used for lifting or carrying people.

9.4 Documentation and information

9.4.1 General

The manufacturer shall supply operating instructions upon commissioning, drawing attention to any significant tasks and the corresponding safety measures that are necessary. A separate set of technical instructions shall also be pro-vided giving details of specification, installation, testing, inspections, maintenance, spare parts and dismantling. The manufacturer shall maintain a technical file for ten years from the date of commissioning. Any booklet of more than ten pages shall include a list of contents with page numbers.

9.4.2 Operating manual

9.4.2.1 General

The operating instructions shall contain the following information as a minimum: a) description of the machinery;

b) an instruction book reference;

c) the intended use of the machinery;

d) the competency required of the operator;

e) how to operate the controls;

f) how to monitor the operation;

g) any special requirements.

9.4.2.2 Description

The description of the machinery shall include: h) the make and model, in order to link the instructions effectively to the machinery;

i) the address of manufacturer or agents for technical support purposes;

j) a repeat of the information with which the machinery is marked, except date of construction, serial number or batch number.


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9.4.2.3 Instruction book reference

The instruction book reference shall contain the manufacturer’s address, identification reference and date of compila-tion of the instructions.

9.4.2.4 Use

The operating instructions shall contain:

k) details of the intended use of the machinery including normal and other uses that can be foreseen; and

l) details of uses which are forbidden.

The manufacturer, importer or distributor shall supply an operator or user instruction manual as in EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles (ISO 12100-2:2003) in national language as part of the information for use as required by the Machinery Directive.

The instruction manual shall include the following information: m) range of applications;

n) information relating to the commissioning of the machine;

o) detailed instructions relating to the use of the machine;

p) circuit diagrams;

q) information relating to the monitoring of safeguards;

r) information relating to maintenance;

s) information as to what to do in emergency situations (i.e. in the event of failure);

t) information as to the acquisition of replacement parts; The following information may also be included: a) information as to the intended use of the machine;

b) description of safeguards and other safety devices, e.g. protection against unintentional movement;

c) information on the performance of tests and inspections.

9.4.2.5 Operator qualification

Guidance shall be included concerning necessary competence of operators.

9.4.2.6 Control

A diagram shall be provided showing any control panel with descriptions of functions of all controls. Where controls require sequential operation, this shall be explained.

9.4.2.7 Vigilance

Instructions shall advise operators to cease operation if there is cause to suspect hazard or malfunction, with gui-dance concerning the particular machinery and advice to report to maintenance personnel.

9.4.2.8 Special requirements

Special requirements shall be explained in full, e.g. for high acceleration machinery the dynamic loading effect shall be fully explained.


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9.4.3 Installation instructions

9.4.3.1 General

The installation instructions shall include details of the following as a minimum: a) handling;

b) mounting details;

c) installation;

d) commissioning;

e) installation load testing.

9.4.3.2 Handling

The instructions shall include the handling procedure for installation, giving the mass of each separate part of the ma-chinery with details of lifting points if critical.

9.4.3.3 Mounting details

The mounting details shall include: a) the loading imposed at all the mounting points;

b) the dimensional layout of mountings and clearances;

c) the environmental conditions for which the machinery has been designed.

9.4.3.4 Installation

The installation procedure shall include warnings of hazards and recommend a sequence of operations to ensure effi-cient installation. Corrosion avoidance shall be addressed.

9.4.3.5 Commissioning

The commissioning procedure shall include warnings of hazards and explain a sequence of operations to check that all functions and features operate correctly. Where items have to be adjusted during the commissioning procedure, precise instructions shall be listed in the correct sequence.

9.4.3.6 Installation load testing

The instructions shall set out recommendations for proof load testing of all systems after commissioning and shall draw attention to the fact that all machinery should conform to the relevant regulations before it can be handed over to operators for normal use (as clause 10.3.16 and EN14492-2).

9.4.4 Repair and maintenance instruction

9.4.4.1 General

Maintenance work should only be carried out by those who are adequately trained and competent.

Routine maintenance shall be required to ensure the continued safe condition of lifting equipment.


50

The manufacturer shall supply details of the extent of maintenance and its frequency. The manufacturer’s instructions shall take into account that some equipment is used infrequently.

A maintenance log shall be provided.

9.4.4.2 Repairs, adjustment, lubrication and replacements

Repair procedures shall be sufficiently detailed to determine the permissible extent of repairs and to identify when specialist skills are required.

The limitations for adjustments to wearing parts shall be detailed.

The quantity and quality of lubricants and their means of application shall be specified.

Replacement components or modular assemblies shall be supported by detailed installation instructions and a full description of all testing procedures necessary, before repaired machinery may be declared fit for service.

Details shall be included to enable any component to be identified so that spare parts can be requested.

NOTE This does not preclude the use of non-repairable items.

Consumable spares required for routine maintenance shall be listed as such.

9.4.5 Inspection and examination

Documentation shall be provided to cover thorough examination after installation, including installation at a new site or location, and before being put into service for the first time and shall provide guidance for further inspection.

9.4.6 Dismantling instructions

Dismantling procedures shall be described to enable machinery to be removed from site efficiently, and warnings shall be included to guard against foreseeable hazards.

9.4.6.1 Access

Where specialist access techniques are advisable these shall be described.

9.4.6.2 Sequence of operations

An efficient sequence of operations shall be recommended.

9.4.6.3 Protection

Information shall be listed to ensure protection from hazards, damage and deterioration of machinery during handling and storage.

9.4.7 Appendix to instructions (for additional necessary doduments)

9.4.7.1 General

Wiring diagrams and the like shall be listed and included within an appendix.


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9.4.7.2 Wiring diagrams

All wiring diagrams relevant to the machinery shall be included with sufficient detail to enable installation putting into service and fault finding.

9.4.7.3 Drawings and diagrams

All drawings and diagrams relevant to the instructions that have not been included within the main part of the instruc-tions shall be listed and included.

9.4.7.4 Optional items

Where optional items have been incorporated with the machinery, and instructions do not cover such items, the rele-vant instructions shall be included within this appendix.

9.4.8 Documentation

9.4.8.1 General

The documentation described in 9.4.8.2 to 9.4.8.3 shall be provided with machinery.

9.4.8.2 Declaration of conformity

Where relevant a declaration of conformity shall be provided in accordance with The Machinery Directive.

9.4.8.3 Test certificates

Copies of all relevant test certificates shall be provided in duplicate.

10 Testing prior to first use and after substantial changes

10.1 General

Prior to first use or after substantial changes, the machinery shall be subjected to testing in accordance with any spe-cific national safety legislation and meet the standards as set out in clause 10.

If there is any cause for concern with the equipment or any test fails, corrective measures should be taken and the inspection and testing process repeated. This process should be fully documented and copies provided to all parties concerned.

10.2 Test Log

A test log shall be compiled, comprising the manufacturer’s documentation for the machinery installation and test re-ports.

10.3 Testing Prior to First Use

10.3.1 Type, Extent and Performance of Tests

The test prior to first use comprises the following parts: a) Preliminary test;


52

b) structural (construction) test;

c) Acceptance test;

d) re-verification test (if necessary).

10.3.1.1 Preliminary Test

The preliminary test includes the examination of technical documentation. In general, the following documentation must be submitted for examination:

a) Design documentation presenting the suspension mechanisms in their entirety as well as their individual parts and containing information on suspension elements, hoisting accessories, drive mechanisms, counterweights, travel ranges, safety equipment;

b) Calculations proving the strength of supporting structural elements, supporting drive, components, suspension elements, safety equipment and connections;

c) Information on materials, standardised parts and any special manufacturing processes;

d) Layout plans, wiring and circuit diagrams as well as program flowcharts for hydraulic, pneumatic, electrical and electronic systems including lists of items, legends and functional descriptions;

e) The examiner may request the submission of further documentation if this is necessary for reasons of safety as-sessment.

10.3.1.2 Structural (construction) Test

The construction test shall include the following steps:

⎯ determining whether the equipment is in conformity with the design and manufacturing documentation, for ins-tance with regard to the compliance with material requirements and crucial measurements, the electrical, hydrau-lic and pneumatic materials employed, the position and arrangement of suspension elements and safety equip-ment;

⎯ in addition, the required material certificates and those for components such as ropes, chains, pressure hoses and gears shall be provided. For welding operations the necessary documents proving the welders' qualifications and skills shall be submitted;

⎯ if proof of a quality management system of the manufacturing company is furnished, the structural test procedure may be restricted.

10.3.1.3 Acceptance Test

10.3.1.4 General Comments

The acceptance test shall be performed on equipment ready to operate. Operating instructions shall be made availa-ble. The acceptance test shall assess: a) proper assembly;

b) functional sequences by test runs according to the specification;

c) safety equipment;

d) results of test loads;

e) completeness of information on necessary characteristics, remarks, safety markings.


53

10.3.1.5 Acceptance Test for Safety Equipment

Safety equipment shall be particularly tested for: a) execution and setting of travel and emergency limit switches;

b) locking of stage lifts;

c) safety catches, pipe fracture safety devices, back up safety nuts for spindle drives;

d) speed limiters;

e) load-limiting devices;

f) pressure-limiting valves;

g) equipment preventing slackening of suspension elements;

h) synchronicity-monitoring equipment;

i) emergency control elements;

j) safety circuits;

k) continuous connection of the main protective bonding conductor;

l) insulation resistance examination;

m) interlocking of command elements in case of various control points;

n) control-release equipment;

o) signalling equipment.

10.3.1.6 Load Test of Lifting Equipment

Load tests shall be carried out with the SWL for motion, multiplied with a test load factor of at least 1.25 for static loads and 1.1 for dynamic loads, (EN14492-2) ensuring the lifting capacity for the test load and the efficient operation of: a) brakes;

b) engaging and disengaging clutches;

c) components in hydraulic, pneumatic and electrical systems;

d) locks.

The emergency stop function shall be tested with SWL and at rated speed.

If hoisting equipment is exposed to higher forces during standstill than during movement the following shall be taken into account:

For installations with friction based holding devices for example: braked motor and/or secondary brake on output shaft of primary gearbox and having no self-sustaining mechanism, static load tests shall be performed with the highest admissible static load for standstill. These load tests may be carried out by applying test loads or in a different manner (e.g. torque wrench on the drive, etc.).

For positive holding devices e.g., for hydraulic cylinders resting on seat valves and friction based holding devices ha-ving a locking mechanism, static load tests or equivalent tests with the highest admissible load for standstill are not necessary.

For lifting equipment (except hoisting equipment with drive sheave and clamping sheave) with permanent counter-weights the test load amounts to at least 1.25 times the differential load between the total load and the load of the counterweight piece.


54

For drive sheave powered lifting equipment the test has to be carried out during travel with at least 1.3 times the rated load and the counterweight provided for operation with rated load.

For jaw operated winch drives the test has to be carried out with at least 1.3 times the rated load during travel and with twice the rated load during standstill.

Load tests of hoisting equipment are carried out in order to test the hoisting, coupling, braking and holding equipment. The steel structure (e.g. of the stage platform) does not require any load test, a calculated proof is sufficient.

10.3.1.7 Load test of travelling and turning equipment (particularly stage wagons and revolving stages)

For this equipment load tests are used for testing the drives and brakes. The steel structure does not require any load test, a calculated proof is sufficient. Load tests have to be carried out with payload during travel. For equipment mo-ved by direct manual manipulation (e.g. auxiliary stage trucks) this load test is omitted.

10.3.1.8 Testing of Electrical Protection measures

The proper execution of electrical protection measures shall be examined.

10.3.2 Acceptance Report and Test Log

The test result shall be entered into an acceptance report which shall also include figures of the highest test load for each hoisting mechanism. Essential data concerning the installation shall be entered into a test Log, to which shall be attached a copy of the acceptance report.

10.3.3 Test after Changes and Modifications

10.3.3.1 Substantial changes such as major modifications and large scale repairs

This shall include:

a) modifications in the system of travel ranges and their access points;

b) modifications in the system of control equipment;

c) increase in lifting capacity;

d) modifications of drives and brakes;

e) design modifications in supporting parts and suspension elements.

The replacement by parts of the same type (such as ropes, hydraulic cylinders, gears, motors, brakes) shall not be regarded as a large-scale repair.

In the case of large scale changes, tests shall be performed in accordance with 10.3.1 before operation resumes. The type and extent of the test shall be determined by the examiner.

10.3.3.2 Any other changes

Tests shall be performed in accordance with 10.3.1 before operation resumes. The type and extent of the test shall be determined by the examiner. In this case it is acceptable to test individual components only.

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1.0.

4 d)

m

ass

and

velo

city

(k

inet

ic

ener

gy

of

elem

ents

in

co

ntro

lled

or u

ncon

trolle

d m

otio

n);

1.0.

5 e)

inad

equa

cy o

f mec

hani

cal s

treng

th; s

ee n

o. 2

7.4

- acc

umul

atio

n of

ene

rgy

insi

de th

e m

achi

nery

, e.g

.

1.0.

6 f)

elas

tic e

lem

ents

(spr

ings

);

1.0.

7 g)

liqu

ids

and

gase

s un

der p

ress

ure;

1.0.

7 h)

the

effe

ct o

f vac

uum

1.1

Cru

shin

g ha

zard

due

to:

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

57

1.2

Shea

ring

haza

rd d

ue to

:

1.3

Cut

ting

or s

ever

ing

haza

rd d

ue to

:

1.4

Enta

ngle

men

t haz

ard:

1.5

Dra

win

g-in

or t

rapp

ing

haza

rd d

ue to

:

1.6

Impa

ct h

azar

d du

e to

:

1.7

Stab

bing

or p

unct

ure

haza

rd d

ue to

:

1.8

Fric

tion

or a

bras

ion

haza

rd d

ue to

:

1.9

Hig

h pr

essu

re fl

uid

inje

ctio

n or

eje

ctio

n ha

zard

due

to:

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

58

2.

Elec

tric

al h

azar

ds d

ue to

:

2.1

Con

tact

of p

erso

ns w

ith li

ve p

arts

(dire

ct c

onta

ct)

2.2

Con

tact

of p

erso

ns w

ith p

arts

whi

ch h

ave

beco

me

live

un-

der f

aulty

con

ditio

ns (i

ndire

ct c

onta

ct)

2.3

App

roac

h to

live

par

ts u

nder

hig

h vo

ltage

2.4

Ele

ctro

stat

ic p

heno

men

a

2.5

Ther

mal

radi

atio

n or

oth

er p

heno

men

a su

ch a

s th

e pr

ojec

-tio

n of

mol

ten

parti

cles

and

che

mic

al e

ffect

s fro

m s

hort

circ

uits

, ove

rload

s et

c

3.

Ther

mal

haz

ards

due

to:

3.1

Bur

ns,

scal

ds a

nd o

ther

inju

ries

by a

pos

sibl

e co

ntac

t of

pe

rson

s w

ith o

bjec

ts o

r m

ater

ials

with

an

extre

me

high

or

low

tem

pera

ture

, by

flam

es o

r ex

plos

ions

and

als

o by

the

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

59

radi

atio

n of

hea

t sou

rces

3.2

Dam

age

to h

ealth

by

hot o

r col

d w

orki

ng e

nviro

nmen

t

4.

Noi

se h

azar

ds d

ue to

:

4.1

Hea

ring

loss

(d

eafn

ess)

, ot

her

phys

iolo

gica

l di

sord

ers

(e.g

. los

s

of b

alan

ce, l

oss

of a

war

enes

s)

4.2

Inte

rfere

nce

with

spe

ech

com

mun

icat

ion,

aco

ustic

sig

nals

, e

5.

Vibr

atio

n ha

zard

s du

e to

:

5.1

Use

of h

and-

held

mac

hine

s re

sulti

ng in

a v

arie

ty o

f neu

ro-

logi

cal a

nd v

ascu

lar d

isor

ders

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

60

5.2

Who

le b

ody

vibr

atio

n, p

artic

ular

ly w

hen

com

bine

d w

ith

poor

pos

ture

s

6.

Rad

iatio

n ha

zard

s du

e to

:

6.1

Low

freq

uenc

y, ra

dio

frequ

ency

radi

atio

n, m

icro

wav

es

6.2

Infra

red,

vis

ible

and

ultr

avio

let l

ight

6.3

X a

nd g

amm

a ra

ys

6.4

Alp

ha, b

eta

rays

, ele

ctro

n or

ion

beam

s, n

eutro

ns

6.5

Lase

rs

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

61

7.

Haz

ards

gen

erat

ed b

y m

ater

ials

an

d su

bsta

nces

:

7.1

Haz

ards

fro

m c

onta

ct w

ith o

r in

hala

tion

of h

arm

ful f

luid

s,

gase

s, m

ists

, fum

es, a

nd d

usts

7.2

Fire

or e

xplo

sion

7.3

Bio

logi

cal o

r mic

robi

olog

ical

(vira

l or b

acte

rial)

haza

rds

8.

Haz

ards

gen

erat

ed d

ue to

ba

d er

gono

mic

:

negl

ectin

g er

gono

mic

prin

cipl

es in

mac

hine

ry d

esig

n as

, e.g

. ha

zard

s fro

m

8.1

Unh

ealth

y po

stur

es o

r exc

essi

ve e

ffort

8.2

Inad

equa

te c

onsi

dera

tion

of h

and-

arm

or f

oot-l

eg a

nato

my

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

62

8.3

Neg

lect

ed u

se o

f per

sona

l pro

tect

ion

equi

pmen

t

8.4

Inad

equa

te lo

cal l

ight

ing

8.5

Men

tal o

verlo

ad a

nd u

nder

load

, stre

ss

8.6

Hum

an e

rror

, hum

an b

ehav

iour

8.7

Inad

equa

te d

esig

n, lo

catio

n or

iden

tific

atio

n of

man

ual c

ontro

ls

8.8

Inad

equa

te d

esig

n or

loca

tion

of v

isua

l dis

play

uni

ts

9.

Haz

ards

gen

erat

ed b

y

com

bina

tion

of h

azar

ds:

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

63

9.

1 M

ultip

le s

imul

tane

ous

lifts

10.

Une

xpec

ted

star

t-up,

unex

pect

ed o

verr

un/o

vers

peed

:

10.1

Fa

ilure

/dis

orde

r of t

he c

ontro

l sys

tem

10.2

R

esto

ratio

n of

ene

rgy

supp

ly a

fter a

n in

terr

uptio

n

10.3

E

xter

nal i

nflu

ence

s on

ele

ctric

al e

quip

men

t

10.4

O

ther

ext

erna

l inf

luen

ces

(gra

vity

, win

d, e

tc

10.5

E

rror

s in

the

softw

are

10.6

E

rror

s m

ade

by th

e op

erat

or (d

ue to

mis

mat

ch o

f mac

hine

ry

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

64 w

ith h

uman

cha

ract

eris

tics

and

abili

ties

11.

Impo

ssib

ility

of s

topp

ing

the

mac

hine

in

the

best

pos

sibl

e co

nditi

ons:

12.

Varia

tions

in th

e ro

tatio

nal s

peed

of

tool

s:

13.

Failu

re o

f the

pow

er s

uppl

y:

14.

Failu

re o

f the

con

trol

circ

uit

15.

Erro

rs o

f fitt

ing

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

65

16.

Bre

ak-u

p du

ring

oper

atio

n

17.

Falli

ng o

r eje

cted

obj

ects

or f

luid

s

18.

Loss

of s

tabi

lity

/ ove

rtur

ning

of

mac

hine

ry

19.

Slip

, trip

and

fall

of p

erso

ns

(rel

ated

to m

achi

nery

)

Add

ition

al h

azar

ds, h

azar

dous

situ

atio

ns a

nd h

azar

dous

eve

nts

due

to m

obili

ty

20.

Haz

ards

rela

ting

to tr

avel

ling

20.1

M

ovem

ent w

hen

star

ting

the

engi

ne

20.2

M

ovem

ent w

ithou

t a d

river

at t

he d

rivin

g po

sitio

n

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

66

20.3

M

ovem

ent w

ithou

t all

parts

in a

saf

e po

sitio

n

20.4

E

xces

sive

spe

ed o

f ped

estri

an c

ontro

lled

mac

hine

ry

20.5

Exc

essi

ve o

scilla

tions

whe

n m

ovin

g

20.6

In

suffi

cien

t abi

lity

of m

achi

nery

to b

e sl

owed

dow

n, s

topp

ed

and

imm

obili

sed

21.

Haz

ards

link

ed to

the

wor

k po

sitio

n

21.1

Fa

ll of

per

sons

dur

ing

acce

ss to

(or a

t/fro

m) t

he w

ork

posi

tion

21.2

E

xhau

st g

ases

/lack

of o

xyge

n at

the

wor

k po

sitio

n

21.3

Fi

re (f

lam

mab

ility

of th

e ca

b, la

ck o

f ext

ingu

ishi

ng m

eans

)

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

67

21.4

M

echa

nica

l haz

ards

at t

he w

ork

posi

tion

21.4

.1

a) C

onta

ct w

ith th

e w

heel

s

21.4

.2

b) R

ollo

ver

21.4

.3

c) F

all o

f obj

ects

, pen

etra

tion

by o

bjec

ts

21.4

.4

d) B

reak

-up

of p

arts

rota

ting

at h

igh

spee

d

21.4

.5

e) C

onta

ct o

f per

sons

with

mac

hine

par

ts o

r too

ls

21.5

In

suffi

cien

t vis

ibilit

y fro

m th

e w

ork

posi

tions

21.6

Inad

equa

te li

ghtin

g

21.7

Inad

equa

te s

eatin

g

21.8

N

oise

at t

he w

ork

posi

tion

21.9

V

ibra

tion

at th

e w

ork

posi

tion

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

68

21

.10

Insu

ffici

ent m

eans

for e

vacu

atio

n / e

mer

genc

y ex

it

22.

Haz

ards

due

to th

e co

ntro

l sys

tem

22.1

In

adeq

uate

loca

tion

of m

anua

l con

trols

22.2

In

adeq

uate

des

ign

of m

anua

l con

trols

and

thei

r mod

e of

oper

atio

n

23.

Haz

ards

from

han

dlin

g th

e m

achi

ne

23.1

Fr

om h

andl

ing

the

mac

hine

(lac

k of

sta

bilit

y

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

69

24.

Haz

ards

du

e to

th

e po

wer

so

urce

to

the

tran

smis

sion

of p

ower

24.1

H

azar

ds fr

om th

e en

gine

and

the

batte

ries

24.2

H

azar

ds fr

om tr

ansm

issi

on o

f pow

er b

etw

een

mac

hine

s

24.3

H

azar

ds fr

om c

oupi

ng a

nd to

win

g

No.

H

azar

ds

Req

uire

men

t

docu

men

t

Prob

a

bilit

y

Seve

r

ity

Freq

uenc

of E

xpos

Σ P*S

*F

Mea

sure

men

t

25.

Haz

ards

from

/to th

ird p

erso

ns

25.1

Una

utho

rised

sta

rt-up

/use

25.2

D

rift o

f a p

art a

way

from

its

stop

ping

pos

ition

25.3

La

ck o

r ina

dequ

acy

of v

isua

l or a

cous

tic w

arni

ng m

eans

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

70

26.

Haz

ards

due

to In

suffi

cien

t ins

truc

tions

fo

r the

driv

er/o

pera

tor

Add

ition

al h

azar

ds, h

azar

dous

situ

atio

ns a

nd h

azar

dous

eve

nts

due

to li

fting

No.

H

azar

ds

Req

uire

men

t

docu

men

t

Prob

a

bilit

y

Seve

r

ity

Freq

uenc

of E

xpos

Σ P*S

*F

Mea

sure

men

t

27.

Mec

hani

cal h

azar

ds a

nd h

azar

dous

ev

ents

:

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

71

27.1

Lo

ad fa

lls, c

ollis

ions

, mac

hine

tipp

ing

27.1

.1

Lack

of s

tabi

lity

27.1

.2

Unc

ontro

lled

load

ing,

ove

rload

ing,

ove

rturn

ing

mom

ents

exce

eded

27.1

.3

Unc

ontro

lled

ampl

itude

of m

ovem

ents

27.1

.4

Une

xpec

ted

/ uni

nten

ded

mov

emen

t of l

oads

27.1

.5

Inad

equa

te h

oldi

ng d

evic

es/a

cces

sorie

s

27.1

.6

Col

lisio

n of

mor

e th

an o

ne m

achi

ne

27.2

A

cces

s of

per

sons

to lo

ad s

uppo

rt

27.3

Der

ailm

ent

27.4

In

suffi

cien

t mec

hani

cal s

treng

th o

f par

ts

27.5

In

adeq

uate

des

ign

of p

ulle

ys, d

rum

s

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

72

27.6

In

adeq

uate

sel

ectio

n of

cha

ins,

rop

es,

liftin

g an

d ac

cess

o-rie

s an

d th

eir i

nade

quat

e in

tegr

atio

n in

to th

e m

achi

ne

27.7

Lo

wer

ing

of th

e lo

ad u

nder

the

cont

rol o

f fric

tion

brak

e

27.8

A

bnor

mal

con

ditio

ns o

f ass

embl

y/te

stin

g/us

e/m

aint

enan

ce

27.9

Lo

ad o

n pe

rson

s (im

pact

by

load

or

coun

terw

eigh

t)

28.

Elec

tric

al h

azar

ds:

28.1

Ligh

ting

29.

Ergo

nom

ic p

rinci

ples

, des

ign:

29.1

In

suffi

cien

t vis

ibilit

y fro

m th

e dr

ivin

g po

sitio

n

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

73

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

74

Add

ition

al h

azar

ds, h

azar

dous

situ

atio

ns a

nd h

azar

dous

eve

nts

due

to u

nder

grou

nd w

ork

No.

H

azar

ds

Req

uire

men

t

docu

men

t

Prob

a

bilit

y

Seve

r

ity

Freq

uenc

of E

xpos

Σ P*S

*F

Mea

sure

men

t

30.

Mec

hani

cal h

azar

ds a

nd h

azar

dous

eve

nts:

30.1

La

ck o

f sta

bilit

y of

pow

ered

roof

sup

ports

30.2

Fa

iling

acc

eler

ator

or b

rake

con

trol o

f mac

hine

ry ru

nnin

g on

ra

30.3

Fa

iling

or

lack

of

dead

man

´s c

ontro

l of

mac

hine

ry r

unni

ng

on ra

ils

31.

R

estr

icte

d m

ovem

ent o

f per

sons

32.

Fi

re a

nd e

xplo

sion

33.

Emis

sion

of d

ust,

gase

set

c

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

75

Add

ition

al h

azar

ds, h

azar

dous

situ

atio

ns a

nd h

azar

dous

eve

nts

due

to li

fting

or m

ovin

g of

per

sons

No.

H

azar

ds

Req

uire

men

t

docu

men

t

Prob

a

bilit

y

Seve

r

ity

Freq

uenc

ofE

xpos

Σ P*S

*F

Mea

sure

men

t

34.

Mec

hani

cal h

azar

ds a

nd h

azar

dous

eve

nts

due

to:

34.1

In

adeq

uate

mec

hani

cal s

treng

th –

inad

equa

te w

orki

ng

coef

ficie

nts

34.2

Failin

g of

load

ing

cont

rol

34.3

Fa

iling

of c

ontro

ls in

per

son

carr

ier (

func

tion,

prio

rity)

34.4

Ove

rspe

ed o

f per

son

carr

ier

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

76

35.

Falli

ng o

f per

son

from

per

son

carr

ier d

oes:

36.

Falli

ng o

r ove

rtur

ning

of p

erso

n ca

rrie

r

37.

H

uman

err

or, h

uman

beh

avio

ur

CEN

WS

25 –

Fin

al V

ersi

on 2

008

Aug

ust

77

Ann

ex B

Le

gend

Sco

res

Ris

k A

sses

smen

t / C

lass

ifica

tion

of ri

sks

The

rank

ing

list c

an b

e us

ed to

eva

luat

ing

Pro

babi

lity

(P),

Sev

erity

(S) a

nd F

requ

ency

(F),w

hen

risk

asse

smen

t is

carr

ied

out a

ccor

ding

to th

e ha

zard

list

in

Ann

ex A

. The

risk

sco

re fo

r eac

h pa

ram

eter

is c

alcu

late

d by

mul

tiply

ing

the

scor

es in

the

haza

rd li

st.

Rel

ativ

e-ra

nkin

g (P

riorit

y)

R

isk

(R) =

Pro

babi

lity

(P) *

Sev

erity

(S) *

Fre

quen

cy o

f exp

osur

e (F

)

Prob

abili

ty o

f the

inci

dent

Se

verit

y, if

the

inci

dent

occ

urs

Freq

uenc

y of

exp

osur

e

0,2

- Pra

ctic

ally

impo

ssib

le

1

- lo

w; f

irst a

id /

inco

nven

ienc

e 0,

5 - v

ery

rare

ly (o

nce

a ye

ar)

0,5

- Im

agin

able

but

unl

ikel

y 3

-

impo

rtant

; no

perm

anen

t inj

ury

1

- rar

ely

(yea

rly)

1

- Unl

ikel

y bu

t pos

sibl

e a

bord

erlin

e ca

se

5

- ve

ry im

porta

nt; p

erm

anen

t inj

ury

2

- som

etim

es (m

onth

ly)

3

- Unl

ikel

y bu

t pos

sibl

e 7

-

serio

us; i

rrev

ersi

bel e

ffect

/ di

sabi

lity

3

- now

and

then

(wee

kly)

6

- P

ossi

ble

15

- ver

y se

rious

; dea

d (a

cute

or o

ver p

erio

d)

6

- fre

quen

tly (d

aily

) 7

- E

xpec

tabl

e 40

- d

isas

ter;

till 5

dea

d (a

cute

or o

ver p

erio

d)

10 -

con

tinuo

usly

100

- cat

astro

phe;

mor

e th

en 5

dea

d

The

crite

ria to

eva

luat

e if

mea

sure

s m

ust b

e ta

ken

are

stat

ed in

the

list o

f Cla

ssifi

catio

n of

risk

s.

Whe

n m

easu

res

have

bee

n ex

ecut

ed a

new

risk

ass

essm

ent m

ust b

e ca

rrie

d ou

t.

Cla

ssifi

catio

n of

risk

s

Prio

rity

Ris

k sc

ore

Des

crip

tion

Act

ion

/ Adv

ise

1 R

> 2

00

Hig

h R

isk

Imm

edia

te a

ctio

n ne

cess

ary

2 50

< R

< 2

00

Gen

eral

Ris

k A

ctio

n re

quire

d 3

R <

50

Low

Ris

k O

pen

to im

prov

emen

t

Documents

Lifting and Load-bearing Equipment for Stages and other ... · PDF filefor Stages and other Production Areas within the Entertainment Industry ... EN 13480-3, Metallic industrial piping