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BRITISH STANDARD BS EN1114-1 : 1997
The European Standard EN 1114-1 : 1996 has the status of aBritish Standard
ICS 83.200
NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW
Rubber and plasticsmachines Ð
Extruders and extrusion lines
Part 1. Safety requirements for extruders
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BS EN 1114-1 : 1997
This British Standard, havingbeen prepared under thedirection of the EngineeringSector Board, was publishedunder the authority of theStandards Board and comes intoeffect on15 April 1997
BSI 1997
The following BSI referencesrelate to the work on thisstandard:Committee reference MCE/3/2Draft for comment 93/710604
ISBN 0 580 27068 8
Amendments issued since publication
Amd. No. Date Text affected
Committees responsible for thisBritish Standard
The preparation of this British Standard was entrusted by Technical CommitteeMCE/3, Safeguarding of machinery, to Subcommittee MCE/3/2, Rubber and plasticsmachines Ð Safety, upon which the following bodies were represented:
British Plastics Federation
British Rubber Manufacturers' Association Ltd.
Engineering Employers' Federation
Institute of Occupational Safety and Health
Plastics Machinery Distribution
Trades Union Congress
Health and Safety Executive
Co-opted members
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BS EN 1114-1 : 1997
BSI 1997 i
Contents
Page
Committees responsible Inside front cover
National foreword ii
Foreword 2
Text of EN 1114-1 3
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ii BSI 1997
BS EN 1114-1 : 1997
National foreword
This British Standard has been prepared by Technical Committee MCE/3/2, Rubber andplastics machines Ð Safety, and is the English language version of EN 1114-1 : 1996,Rubber and plastics machines Ð Extruders and extrusion machines Ð Safetyrequirements for extruders, published by the European Committee forStandardization (CEN).
EN 1114-1 was produced as a result of international discussions in which theUnited Kingdom took an active part.
Cross-references
Publication referred to Corresponding British Standard
EN 292-1 : 1991EN 292-2 : 1991
BS EN 292 Safety of machinery. Basic concepts, generalprinciples for designPart 1 : 1991 Basic terminology, methodologyPart 2 : 1991 Technical principles and specifications
EN 294 : 1992 BS EN 294 : 1992 Safety of machinery. Safety distances toprevent danger zones being reached by the upper limbs
EN 349 : 1993 BS EN 349 : 1993 Safety of machinery. Minimum gaps toavoid crushing of parts of the human body
EN 418 : 1992 BS EN 418 : 1992 Safety of machinery. Emergency stopequipment, functional aspects. Principles for design
EN 563 : 1994 BS EN 563 : 1994 Safety of machinery. Temperatures oftouchables surfaces. Ergonomics data to establishtemperature limit values for hot surfaces
EN 626-1 : 1994 BS EN 626-1 : 1995 Principles and specifications formachinery manufacturers
EN 60204-1 : 1992 BS EN 60204-1 : 1993 Safety of machinery. Electricalequipment of machines. Specification for generalrequirements
EN 60529 : 1991 BS EN 60529 : 1992 Specification for degrees of protectionprovided by enclosures (IP code)
ISO 9614-1 : 1993 BS EN ISO 9614-1 : 1995 Acoustics. Determination of soundpower levels of noise sources using sound intensity.Measurement at discrete points
Compliance with a British Standard does not of itself confer immunityfrom legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii, the ENtitle page, pages 2 to 30, an inside back cover and a back cover.
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CENEuropean Committee for Standardization
Comite EuropeÂen de Normalisation
EuropaÈisches Komitee fuÈ r Normung
Central Secretariat: rue de Stassart 36, B-1050 Brussels
1996 Copyright reserved to CEN members.Ref. No. EN 1114-1 : 1996 E
EUROPEAN STANDARD EN 1114-1
NORME EUROPEÂ ENNE
EUROPAÈ ISCHE NORM October 1996
ICS 83.200
Descriptors: Safety of machines, plastic-working machines, rubber-working machines, extruding equipment, dangerous machines, accidentprevention, hazards, hazardous areas, safety measures, information, utilization
English version
Rubber and plastics machines Ð Extruders and extrusion lines Ð
Part 1: Safety requirements for extruders
Machines pour le caoutchouc et les matieÁresplastiques Ð Extrudeuses et lignes d'extrusion ÐPartie 1: Exigences de seÂcurite pour les extrudeuses
Gummi- und Kunstsoffmaschinen Ð Extruder undExtrusionsanlagen ÐTeil 1: Sicherheitsanforderungen fuÈr Extruder
This European Standard was approved by CEN on 1996-08-11. CEN members arebound to comply with the CEN/CENELEC Internal Regulations which stipulate theconditions for giving this European Standard the status of a national standardwithout any alteration.
Up-to-date lists and bibliographical references concerning such national standardsmay be obtained on application to the Central Secretariat or to any CEN member.
This European Standard exists in three official versions (English, French, German).A version in any other language made by translation under the responsibility of aCEN member into its own language and notified to the Central Secretariat has thesame status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Denmark,Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands,Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
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Page 2EN 1114-1 : 1996
BSI 1997
Foreword
This European Standard has been prepared byTechnical Committee CEN/TC 145, Rubber and plasticsmachines Ð Safety, of which the Secretariat is held byUNI.
This European Standard shall be given the status of anational standard, either by publication of an identicaltext or by endorsement, at the latest by April 1997, andconflicting national standards shall be withdrawn atthe latest by April 1997.
This European Standard has been prepared under aMandate given to CEN by the European Commissionand the European Free Trade Association, andsupports essential requirements of EU Directives(s).
This is the first in a series of standards on the safety ofextruders and extrusion lines.
Part 2 deals with die face pelletizers.
Part 3 deals with caterpillar, roller and belt take-offs.
Further parts are under discussion.
For the relationship with EU Directive(s), seeinformative annex ZA, which is an integral part of thisstandard.
According to the CEN/CENELEC Internal Regulations,the national standards organizations of the followingcountries are bound to implement this EuropeanStandard: Austria, Belgium, Denmark, Finland, France,Germany, Greece, Iceland, Ireland, Italy, Luxembourg,Netherlands, Norway, Portugal, Spain, Sweden,Switzerland and the United Kingdom.
Contents
Page
Foreword
0 Introduction
1 Scope
2 Normative references
3 Definitions
4 Hazards and areas of danger
4.1 List of hazards
4.2 Areas of danger
5 Safety requirements and/or measures
5.1 Mechanical hazards
5.2 Electrical energy
5.3 Hot machine parts and hot plasticizedmaterial
5.4 Noise
5.5 Materials and substances processedused and/or exhausted by themachinery
5.6 Fire
5.7 Temperature control for heated areas
5.8 Emergency stop devices
5.9 Machine control systems
6 Verification of compliance with thesafety requirements and/or measures
7 Information for users
7.1 Minimum marking on the machine
7.2 Instruction manual
Annex ZA (informative) Clauses of thisEuropean Standard addressing essentialrequirements or other provisions of EUDirectives
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0 IntroductionThis European Standard is a type C Standard asdefined in EN 292.
The extent to which hazards are covered is indicatedin the scope of this standard. In addition, machineryshould conform as appropriate to EN 292 for hazardswhich are not covered by this standard.
1 ScopeIn respect of the hazards listed in 4.1 and dealt with inclause 5, this standard specifies the safety requirementsfor the design and construction of the following kindsof screw type extruders for plastics and rubber:
± single screw extruders;
± twin screw extruders;
± multi/multiple screw extruders;
± hot feed extruders;
± cold feed extruders;
± vacuum extruders;
± pin extruders.
This standard also covers the following feedingsystems:
± hoppers;
± single roller feeding systems;
± double roller feeding systems;
± crammer feeding systems:
and the following ancillary equipment which form partof or are attached to the extruder:
± screen changers;
± melt/gear pumps;
± melt ducts;
± static mixers;
± degassing equipment;
± shear head devices;
± extruder head.
This standard only applies to extruder heads that giveinitial shape to the plasticized material.
This standard does not apply to extruders withoutscrews, e.g.:
± piston extruders;
± disc extruders;
± roller extruders.
This standard applies primarily to machines which aremanufactured after the date of approval of thisEuropean Standard.
2 Normative referencesThis European Standard incorporates by datedreference, provisions from other publications. Thesenormative references are cited at the appropriateplaces in the text and the publications are listedhereafter. For dated references, subsequentamendments to or revisions of any of thesepublications apply to this European Standard onlywhen incorporated in it by amendment or revision. Forundated references the latest edition of the publicationreferred to applies.
EN 292-1 : 1991 Safety of machinery Ð Basicconcepts, general principles fordesign ÐPart 1: Basic terminology,methodology
EN 292-2 : 1991+A1: 1995
Safety of machinery Ð Basicconcepts, general principles fordesign ÐPart 2: Technical principles andspecifications
EN 294 : 1992 Safety of machinery Ð Safetydistances to prevent danger zonesbeing reached by the upper limbs
EN 349 : 1993 Safety of machinery Ð Minimumgaps to avoid crushing to parts ofthe human body
EN 418 : 1992 Safety of machinery Ð Emergencystop equipment, functionalaspects Ð Principles for design
EN 563 : 1994 Safety of machinery ÐTemperatures of touchablesurfaces Ð Ergonomics data toestablish temperature limit valuesfor hot surfaces
prEN 574 : 1991 Safety of machinery Ð Two-handcontrol devices
EN 626-1 : 1994 Safety of machinery Ð Reduction ofrisks to health from hazardoussubstances emitted by machinery ÐPart 1: Principles and specificationsfor machine manufacturers
prEN 811 : 1992 Safety of machinery Ð Safetydistances to prevent danger zonesbeing reached by the lower limbs
prEN 953 : 1992 Safety of machinery Ð Generalrequirements for the design andconstruction of guards (fixed,movable)
prEN 954-1 : 1994 Safety of machinery Ð Safetyrelated parts of control systems ÐPart 1: General principles for design
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EN 1037 : 1995 Safety of machinery Ð Preventionof unexpected start-up
EN 1088 : 1995 Safety of machinery Ð Interlockingdevices associated with guards ÐPrinciples for design and selection
EN ISO 11201 :1995
Acoustics Ð Noise emitted bymachinery and equipment ÐMeasurement of emission soundpressure levels at a work stationand at other specified positions ÐEngineering method in anessentially free field over areflecting plane
EN ISO 11204 :1993
Acoustics Ð Noise emitted bymachinery and equipment ÐMeasurement of emission soundpressure levels at a work stationand at other specified positions ÐMethod requiring environmentalcorrections
EN 60204-1 : 1992 Safety of machinery Ð Electricalequipment of machines ÐPart 1: General requirements
EN 60529 : 1991 Degrees of protection provided byenclosures
EN ISO 3744 :1995
Acoustics Ð Determination ofsound power levels of noise sourcesusing sound pressure ÐEngineering method in anessentially free field over areflecting plane
prEN ISO/DIS :4871 : 1995
Acoustics Ð Declaration andverification of noise emissionvalues of machinery and equipment
EN ISO 9614-1 :1995
Acoustics Ð Determination ofsound power levels of noise sourcesusing sound intensity ÐPart 1: measurement at discretepoints
3 DefinitionsFor the purposes of this standard the followingdefinitions apply.
3.1 extruder
The extruder is a machine which conveys solid orliquid material by means of one or more screwsrotating within a barrel and discharges it continuouslythrough the extrusion head. In doing so the materialcan be heated, cooled, consolidated, mixed, plasticized,can undergo chemical reactions, and may be degassedor gas injected. Viewed in the direction of flow of thematerial the extruder itself ends with the tip of thescrew or screws.
Screen changers, melt pumps, shear head devices,static mixers and degassing equipment, etc., may bearranged between the extruder and the extruder heador along the barrel.
3.2 plasticized material
A liquid, paste or solid product which is ready to beprocessed into semi-finished products or finishedproducts.
3.3 feeding system
Any equipment which feeds the material into thescrew(s).
3.4 crammer feeding system
A system which has a dedicated drive which assiststhe flow of materials from the hopper feed into theextruder by means of screws or other devices. It isalso used to densify bulk low density materials.
3.5 double roller feeding device
A device used for constant feeding of the extruderwith rubber, e.g. rubber strips. The feeding deviceconsists of two rolls arranged in parallel positioned atthe feed opening of the extruder above the open screw.The rolls are driven in contra-rotating direction underconstant power so that the material is transported intothe extruder under constant pressure. The rolls arewater cooled to prevent heating and vulcanizing of theproduct.
3.6 single roller feeding device
A roller, which has an axis parallel to that of the screw.The screw and the roller counter-rotate and form anin-running nip and thereby improve the regularity offeeding. It may be driven by the screw or by anindependent device.
3.7 main feed opening
An opening in the barrel through which, for example,the granulate, sheets, strips, powder or plasticizedmaterial passes.
3.8 secondary feed opening
A subsidiary opening in the barrel through which, forexample, granulate, powder, liquid or paste (e.g. colour,stabilizers, plasticizers) passes.
3.9 barrel
A housing which surrounds one or more screws.
3.10 degassing equipment
A device which is arranged in certain sections of thescrew barrel and is intended to remove volatilecomponents of the plasticized material duringpreparation of plastic material and rubber.
3.11 pins
These are components fixed into the extruder barreland which protrude into the inside of the barrel toallow a better mix of the material.
3.12 accessories attached to openings in theextruder barrel
Accessories are parts of measuring devices; forexample, temperature or pressure gauges with amaximum connection diameter of 30 mm.Li
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3.13 melt/gear pump
A pump which has a dedicated drive conveyingcontinuously plasticized material. Its purpose is toensure equalization of pressure; in particular, toincrease it downstream of the screw leading to animprovement in the regularity of delivery.
3.14 melt ducts
Melt ducts are heated pipes connecting accessories(for example, screen changers, melt pumps and staticmixers), and carry plasticized material.
3.15 static mixer
A device positioned at the outlet of the screw of anextruder which contains fixed obstacles. When thescrew pushes the material it cuts and kneads it toimprove homogeneity.
3.16 screen changer
A device containing one or more screens throughwhich plasticized material flows to remove foreignparticles. The screen or screens are fixed on a carrierand can be moved from an on-line operating positionto an off-line or non-operating position and vice versa.
3.17 shear head device
An item of ancillary equipment which has its ownmotive power and temperature control system, fittedbetween the screw of the extruder and the extrusionhead. It serves to raise the plasticized materialdischarged from the extrusion head to the correcttemperature for continuous vulcanization.
3.18 extruder head
A device that gives shape to the plasticized material.
3.19 extrudate
The plasticized material which comes out of theextrusion head during extrusion. If there is noextrusion head, the extruded product is the plasticizedmaterial which leaves the extruder.
4 Hazards and areas of danger
4.1 List of hazards
4.1.1 Mechanical hazards
± crushing;
± shearing;
± cutting and severing;
± drawing in or trapping;
± ejection of parts of machinery;
± discharge of plasticized material under pressure orby other causes.
These hazards are principally due to:
± the rotating parts of the drive and powertransmission machinery;
± the moving parts in the extrusion barrel;
± the rotating screw or screws of the extruder at anyopening;
± the moving parts of the feeding systems;
± the accessible moving parts during purging,cleaning and pre-heating;
± the accessible moving parts of the cooling air fans;
± over pressure in the barrel;
± over pressure in melt ducts;
± the accessible moving parts of the screen changer;
± the extruder itself when moved;
± any dangerous movement of the extruder headand/or its parts;
± gravity fall of any parts.
4.1.2 Hazards from electrical energy
4.1.2.1 Electrical shock or burns due, for example, todirect or indirect contact with live parts.
4.1.2.2 Electrical shock due to electrostaticphenomena.
4.1.3 Thermal hazards
± burns;
± scalds;
due to contact with hot machine parts or hot extrudedproduct.
4.1.4 Hazards generated by noise
± hearing loss;
± interference with speech communication;
± interference with the perception of acousticsignals, due to high noise levels.
4.1.5 Hazards resulting from materials andsubstances processed, used and/or exhausted bythe machinery
Health effects due, for example, to contact with, orinhalation of, harmful fluids, gases, mists, fumes anddusts.
4.1.6 Fire hazards
Ignition due to:
± contact with flammable materials and hot surfaces;
± faulty electrical equipment;
± leaks from hydraulic lines on to hot surfaces.
4.1.7 Hazards of falling from height
Injury due to falling from high level working places.
4.2 Areas of danger
The areas of danger described below are examples.
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4.2.1 Principal areas of danger of an extruder
I Drive and power transmission to the screw
II Feed opening
III Barrel heaters
IV Barrel cooling
V Hot surfaces
VI Degassing
VII Wheels for horizontal movement
VIII Electrical junction box
Figure 1. Example of a plastic extruder
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I Drive and power transmission to the screw
II Feed opening
III Barrel heaters
IV Barrel cooling
V Extruder head
VI Degassing
VII Wheels for horizontal movement
VIII Electrical junction box
Figure 2. Example of a rubber extruder
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4.2.2 Principal areas of danger of crammer feed systems
I Feed opening
II Drive and power transmission
III Rotating area
IV Cutting/shearing area
V Access
VI Extruder
Figure 3. Example of a vertical crammer feed system
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I Feed opening
II Drive
III Crushing area
IV Rotating area
Figure 4. Example of a vertical crammer feed system for rubber
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4.2.4 Principal areas of danger of a melt pump/gear pump
I Rotating transmission area
II Machine parts under pressure
III Hot surfaces
Figure 6. Example of a melt pump/gear pump
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4.2.5 Principal areas of danger of the shear head device
I Drive and power transmission to the mandrel
II Electrically controlled heating and cooling system
III Shear head
IV Hot surfaces
Figure 7. Example of a shear head device
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4.2.6 Principal areas of danger of a static mixer
I Machine parts under pressure
II Hot surfaces
Figure 8. Example of a static mixer
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4.2.7 Principal areas of danger of degassing equipment
I Return pipes which may contain
Ð hot gases harmful to health
Ð hot condensate harmful to health
Ð hot plasticized material
II Hot surfaces
Figure 9. Example of degassing equipment
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4.2
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4.2
.9P
rin
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al
are
as
of
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er
of
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roll
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4.2.10 Principal areas of danger of extrusion heads
I Outlet of hot extrudate
II Hot surfaces
Figure 12. Example of extrusion head with flat die for plastic film
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I Outlet of hot extrudate
II Hot surfaces
III Wheels for horizontal movement
Figure 13. Example of extrusion head for blown film
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I Hot surfaces
II Crushing area
Figure 14. Example of a single head for rubber
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IH
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IIC
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5 Safety requirements and/or measuresGuards shall be designed and constructed inaccordance with 4.2 of EN 292-2 : 1991, with prEN 953,and prEN 1088.
5.1 Mechanical hazards
5.1.1 Drive and power transmission
The drive shafts and couplings between the motor andreduction gear and transmission belts shall beprotected by fixed guards conforming to 4.2.2.2 ofEN 292-2 : 1991. The safety distances given in EN 294shall apply; for reaching over protective structures,table 2 shall apply.
5.1.2 Screw shaft
If the end of the screw shaft is not enclosed by ahousing, it shall be protected by fixed guardsconforming to 4.2.2.2 of EN 292-2 : 1991. The safetydistances given in EN 294 shall apply; for reaching overprotective structures, table 1 shall apply.
5.1.3 Openings in the barrel
5.1.3.1 Main feed opening - with or without a feedingsystem
The main feed opening shall be protected:
± by design, taking into account the safety distancesin EN 294 (for reaching over protective structurestable 2 applies); or
± by the presence of a fixed or movable feedingsystem (for example, hoppers or crammer feedsystems).
If access is necessary to the feed opening, protectionshall be given by a movable feeding system which isinterlocked to the screw drive. The interlocking systemshall conform to 4.2.2.3b of EN 292-2 : 1991, 3.22.4 ofEN 292-1 : 1991 and category 1 of prEN 954-1 : 1994.
Alternatively, when the movable feeding system isremoved, the main feed opening may be protected by ascreen conforming to the safety distances of EN 294,table 4, and which shall be inserted automatically insuch a way that the feed opening can in nocircumstance stay open during the movement.
Where for exceptional reasons, for example in therubber industry, it is necessary for the screw(s) torotate in the absence of the feeding system, thescrew(s) shall, if they are not protected by design, onlycontinue to be operated by actuating a two-handcontrol device conforming to type II of prEN 574. Thistwo-hand control device shall be located in theimmediate vicinity of the feed opening. Fixed guards orequivalent protective devices shall be fitted where thisis necessary to prevent the access of a second personto the danger area.
5.1.3.2 Secondary feed openings
Secondary feed openings not under pressure shall beprotected in accordance with 5.1.3.1.
Secondary feed openings which are pressurized shallbe protected in accordance with 5.1.3.3.
5.1.3.3 Openings for the attachment of accessories
These openings shall be protected:
± by design, taking into account the safety distancesin table 4 of EN 294; or
± by the presence of the accessories.
Suitable fixed guards conforming to 4.2.2.2 ofEN 292-2 : 1991 shall be provided for openings whenaccessories are not in place.
5.1.3.4 Degassing opening
The degassing openings shall be protected bydegassing equipment which acts as a fixed guardconforming to 3.22.1 of EN 292-1 : 1991. When there isaccess through the degassing equipment to the screw,the danger areas shall be protected:
± by design, taking into consideration the safetydistances in table 4 of EN 294; or
± by halting the movement of the screw(s) by amovable interlocking guard conforming to 4.2.2.3bof EN 292-2 : 1991, 3.22.4 of EN 292-1 : 1991 andcategory 1 of prEN 954-1 : 1994; or
± by inserting an obstructer automatically.
5.1.4 Feed systems
5.1.4.1 Hopper feed system
Access to dangerous movement shall be prevented:
± by design, taking into consideration the safetydistances in tables 2 and 4 of EN 294 : 1992; or
± by a movable interlocking guard conformingto 4.2.2.3b of EN 292-2 : 1991, 3.22.4 ofEN 292-1 : 1991 and category 1 of prEN 954-1 : 1994.
5.1.4.2 Single roller feeding system
The intake area of the single roller feeding system shallbe protected against reaching in:
± by design, taking into account the safety distancesin EN 294 (for reaching over protective structurestable 2 applies); or
± by a fixed hopper or other fixed guard conformingto 3.22.1 of EN 292-1 : 1991.
If the single roller feeding system is opened, themovement of the screw(s) and the roller shall bestopped by an interlocking system conformingto 4.2.2.3b of EN 292-2 : 1991, 3.22.4 of EN 292-1 : 1991and category 1 of prEN 954-1 : 1994.
If the opening and closing of the feed roller ismotorized, the danger points shall be protected:
± by an interlocking guard conforming to 3.22.4of EN 292-1 : 1991 and category 3 ofprEN 954-1 : 1994; or
± by a hold-to-run control device conformingto 3.23.3 of EN 292-1 and category 1 ofprEN 954-1 : 1994, which is positioned so that thedanger area is visible to the operator and at asufficient distance to prevent the operator beingendangered by the opening and closing of the rollerhousing.
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If there is no protection device the roller housing shallmove at an angular velocity of less than 0,4 rad/s whenopening and closing.
If it is necessary, for certain operations, to rotate thescrew(s) or the feed roller with the feed system open,then if they are not protected by design, a two-handcontrol device conforming to type II of prEN 574 shallbe provided. This two-hand control device shall belocated in the immediate vicinity of the feed roller.Fixed guards or equivalent protective devices shall befitted where this is necessary to prevent the access ofa second person to the danger area.
The single roller feeding device shall be provided witha stopping device conforming to stop category 0 orstop category 1 of prEN 418, so that movement of theextruder screw and feed roller can be stopped.
5.1.4.3 Double roller feeding system
The intake area of the feed rollers shall be protectedagainst reaching in:
± by design, taking into account the safety distancesin EN 294 (for reaching over protective structurestable 2 applies); or
± by a fixed feed hopper or other fixed guardconforming to 3.22.1 of EN 292-1 : 1991.
If the double roll feeding system is opened, forexample by swinging away the feed hopper, movementof the rollers shall be stopped by an interlockingsystem conforming to 4.2.2.3b of EN 292-2 : 1991,3.22.4 of EN 292-1 : 1991 and category 1 ofprEN 954-1 : 1994.
If it is necessary, for certain operations, to rotate therollers with the feeding system open, a two-handcontrol device conforming to type II of prEN 574 shallbe provided. This two-hand control device shall bepositioned in the immediate vicinity of the roller. Fixedguards or equivalent protective devices shall be fittedwhere this is necessary to prevent access of a secondperson to the danger area.
If the double roller feeding device can be swivelledaway or dismantled, the opening shall be safeguardedin accordance with 5.1.3.1.
The double roller feeding system shall be providedwith a stopping device conforming to stop category 0or stop category 1 of prEN 418, so that movement ofthe extruder screw and the feed rollers can be halted.
5.1.4.4 Crammer feeding system
Danger areas of crammer feeding systems shall beprotected:
± by design; or
± by fixed guards conforming to 4.2.2.2 ofEN 292-2 : 1991; or
± by interlocking guards conforming to 3.22.4 ofEN 292-1 : 1991 and category 1 of prEN 954-1.
In all these cases the safety distances in EN 294 shallapply; for reaching over protective structures, table 2shall apply.
If the crammer feeding system can be swivelled away,protective measures to prevent access to thedangerous movement of the crammer feeding systemshall be taken:
± by design, taking into account the safety distancesin EN 294 (for reaching over protective structurestable 2 applies); or
± by an interlocking device conforming to 3.23.1of EN 292-1 : 1991 and category 1 of prEN 954-1,which stops the dangerous movement.
If the crammer feeding system can be swivelled awayor dismantled, the opening in the barrel shall besafeguarded in accordance with 5.1.3.1.
5.1.5 Excess pressure protection
Parts subject to pressure, e.g. melt/gear pumps, meltducts, static mixers, shear heads and extruder heads,shall be protected against exceeding the maximumadmissible internal pressure indicated by themanufacturer within the framework of the overallinstallation, for example by:
± safety breaking points;
± bursting discs;
± pressure sensing devices which switch off all thepressure inducing elements via the control system,to category 1 of prEN 954-1;
± expanding bolts.
Possible ejection of parts or material used for themeans of over pressure protection (e.g. safety breakingpoints, bursting discs, expanding bolts) should bedirected safely, e.g. downwards, or deflected safely bydesign, for example by the use of deflector panels.
5.1.6 Screen changer
Screen changers shall be protected:
± against hazardous movement of the screenchanging device; and
± against splashing from hot plasticized material, byinterlocking guards conforming to 4.2.2.3b ofEN 292-2 : 1991, 3.22.4 of EN 292-1 : 1991 andcategory 3 of prEN 954-1.
This does not apply to manually operated screenchangers which are actuated solely when the screw(s)is/are at rest.
The safety distances of EN 294 shall apply; for reachingover protective structures, table 2 shall apply.
5.1.7 Melt/gear pump
Melt/gear pumps shall be protected:
± against hazards arising from rotating parts of thedrive by protective measures conforming to 5.1.1;
± against exceeding the maximum admissibleinternal pressure as defined by the manufacturer, byprotective measures conforming to 5.1.5.
5.1.8 Melt ducts
Melt ducts shall be protected against exceeding themaximum internal pressure as defined by themanufacturer, by protective measures conformingto 5.1.5.
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5.1.9 Static mixer
Static mixers shall be protected against exceeding themaximum internal pressure as defined by themanufacturer, by protective measures conformingto 5.1.5.
5.1.10 Degassing equipment
The machine shall be so designed and constructed toallow for the installation of a suction fitting to be fittedto the machine, which takes away, in a controlledmanner, heat and gases injurious to health. Anappropriate cover shall be provided to divert anyextrusion compound which could be ejected.
5.1.11 Shear head device
The shear head device shall be protected:
± against hazards arising from rotating parts of thedrive, by protective measures conforming to 5.1.1;
± against exceeding the maximum internal pressureas defined by the manufacturer, by protectivedevices conforming to 5.1.5.
5.1.12 Extruder head
Danger areas of extruder heads shall be protected:
± by design, taking into account the safety distancesin EN 294 (for reaching over protective structures,table 2 applies); or
± by fixed guards conforming to 4.2.2.2 ofEN 292-2 : 1991; or
± by interlocking guards conforming to 4.2.2.3b ofEN 292-2, 3.22.4 of EN 292-1 and category 3 ofprEN 954-1.
If access is necessary to areas subject to dangerousmovements, the dangerous movements may only beinitiated by:
± a two-hand control device conforming to type III ofEN 574, which should be located in the immediatevicinity of the extruder head to give the operator aclear view of the danger area; or
± a hold-to-run control device conforming to 3.23.3of EN 292-1 : 1991 and category 1 of prEN 954-1,located a minimum distance of 2 m from the dangerarea.
Fixed guards or equivalent protective devices shall befitted, where necessary, to prevent access of a secondperson to the danger area.
The parts of the extruder head shall be capable ofbeing secured when open in order to prevent anydangerous movement caused by gravity-fall or amalfunction of the hydraulic, pneumatic or electriccontrol circuits.
Protective measures against exceeding the maximuminternal pressure as defined by the manufacturer shallbe provided, conforming to 5.1.5.
5.1.13 High level working places
For high level working places which are positionedmore than 1 m above ground level, 6.2.4 ofEN 292-2 : 1991 shall apply.
5.1.14 Power operated horizontal movement ofthe complete machine or parts of it
If the machine is so designed that the operator cannotsee all parts of the complete machine, an automaticallyoperated acoustic and/or optical signalling device shallbe provided giving warning of imminent movement ofthe machine.
To prevent crushing of the feet, the carriage wheelsshall be provided with fixed guards conformingto 4.2.2.2 of EN 292-2 : 1991, taking into account themaximum safety distance of 15 mm specified in table 1of prEN 811.
In all cases of movement, a trip device conformingto 3.23.5 of EN 292-1 : 1991 and category 1 ofprEN 954-1 shall be provided in the direction ofmovement, to ensure that the machine stops safelytaking into account the overrun. The maximum speedof movement of the machine shall notexceed 0,133 m/s. If this trip device cannot be fitted tothe carriage, a hold-to-run control device conformingto 3.23.3 of EN 292-1 : 1991 and category 1 ofprEN 954-1 shall be provided, only allowing movementof the machine at a maximum speed of 25 mm/s.
It shall be ensured that the machine cannot startmoving on its own. This can be achieved, for example,by a braking system. To prevent inadvertent start-up,see EN 1037.
If the machine is fitted with an operating platform onwhich an operator can stand, the workplace shall bearranged in accordance with EN 349, in such a way asto preclude any crushing hazard caused by fixed ormovable adjacent parts. If the safety distances cannotbe achieved, the movement of the carriage shall beprevented by the use of a trip device which cannot beoperated deliberately.
5.2 Electrical energy
5.2.1 General
EN 60204-1 applies, except that for connection andjunction boxes in the area of the heating zones,protection to IP 3X of EN 60529 is sufficient. This is adeviation from 13.3 of EN 60204-1.
Specification for emergency stop equipment and thestop categories to be chosen are given in 5.8 and othersubclauses.
5.2.2 Electrostatic phenomena
The development of electrostatic charges, which maybe caused by friction, separation of surfaces and othermovements (particularly at feed openings) shall beprevented by suitable measures such as earthing orconductive discharge achieved by the provision ofconductive surfaces which are earthed.
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5.3 Hot machine parts and hot plasticizedmaterial
Hot machine parts e.g. melt/gear pumps, melt ducts,static mixers, shear head devices and extruder heads,and hot plasticized material in areas where people areworking or passing shall be protected againstaccidental contact by using insulating material ordeterring/impeding devices conforming to 3.24of EN 292-1 : 1991. For temperature limit values,EN 563 applies.
This is not applicable to hot surfaces needed foroperational reasons, which cannot be protected. Inthese cases, the manufacturer shall label the hot partsand shall state the safety precautions given in 7.2.1f.
5.4 Noise
The machine shall be designed and constructed inaccordance with A.1.5.8 of EN 292-2 : 1991/A1 : 1995.
5.4.1 Noise reduction at source by design
Particular attention should be given to the followingmajor sources of noise:
± motor drives;
± power transmission systems;
± pneumatic systems;
± pressure relieving/exhaust systems;
± ventilation systems;
± hydraulic pumping equipment;
± control valves;
± pipelines.
The following measures may be taken for noisesuppression:
± designs which reduce noise;
± enclosures;
± silencers;
± low noise emission pumps;
± damping;
± anti-vibration mountings.
5.4.2 Determination of noise emission values
In the absence of a noise test code, determination ofnoise emission values shall be performed using:
± one of the standards in the EN ISO 11201 series forthe determination of the emission sound pressurelevels at the work station. If practical, a method withgrade 2 accuracy (EN ISO 11204) should be used.Since a precise work station cannot be defined onextruders, the specified position where this quantityis to be measured is located at a distance of 1 mfrom the surface of the machinery and at a heightof 1,60 m above the floor or access platform, wherethe A-weighted emission sound pressure level ismaximum;
± if the equivalent continuous A-weighted soundpressure level at the workstation exceeds 85 dB(A),one of the standards in the ISO 3740 series orEN ISO 9614 series for the determination of soundpower levels. If practical, a method with grade 2accuracy should be used. The preferred method fordetermination of the sound power level isEN ISO 3744.
The noise declaration by the manufacturer shall givethe declared values of noise emission and indicateprecisely:
± the mounting and operating conditions of themachinery during noise emission measurement;
± the position (on a path at 1 m from the surface ofthe machinery and 1,6 m above the floor or theaccess platform) where the A-weighted emissionsound pressure level is maximum;
± the criteria on which the noise declaration is based(i.e. prEN ISO/DIS 4871).
5.5 Materials and substances processed, usedand/or exhausted by the machinery
The machinery shall be designed and constructed inaccordance with A.1.5.13 of EN 292-2 : 1991/A1 : 1995and EN 626-1. In addition, see 7.2.1h and 7.2.1i.
5.6 Fire
Machinery shall be designed and constructed inaccordance with A.1.5.6 of EN 292-2 : 1991/A1 : 1995.This may be achieved, for example, by choosingsuitable materials for construction, by arranginghydraulic lines to prevent leakage on to hot surfaces orby selection of appropriate insulation materials.
5.7 Temperature control for heating areas
Temperature control systems for heating areas onextruders shall detect any failure of the temperaturesensors in order to limit maximum permissibletemperatures. Any failure of the temperature sensorshall isolate the heating zones concerned. A signal shalldraw attention to this.
5.8 Emergency stop devices
Emergency stop device(s) conforming to stopcategory 0 or 1 of prEN 418 shall be provided.
At least one emergency stop device shall be providedat the control panel. If the distance between thecontrol panel and the feed opening or the outlet of thematerial is more than 3 m, an additional emergencystop device shall be provided there.
It is not mandatory to halt the circulation of heattransport fluids in cooling systems, exhaust systemsand heating systems.
Specific requirements for emergency stop devices arecontained in 5.1.4.2 and 5.1.4.3.
5.9 Machine control systems
Machine control systems shall take into account 3.7,1.2 and annex A of EN 292-2 : 1991/A1 : 1995.
Safety related parts of the control systems shall at leastconform to category B of prEN 954-1. Additionalrequirements are contained in other subclauses inaccordance with table 1.
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Table 1. Additional requirements for control system categories in accordance with prEN 954-1
Clause Paragraph/sentence Part of control system Category
5.1.3.1 2/2 interlocking system 1
5.1.3.4 1/2nd indent interlocking system 1
5.1.4.1 1/2nd indent interlocking system 1
5.1.4.2 2/1st sentence interlocking system 1
5.1.4.2 3/1st indent interlocking system 3
5.1.4.2 3/2nd indent hold-to-run control device 1
5.1.4.3 2/1st sentence interlocking system 1
5.1.4.4 1/3rd indent interlocking system 1
5.1.4.4 2/2nd indent interlocking system 1
5.1.5 1/3rd indent pressure monitoring system 1
5.1.6 1/2nd indent interlocking system 3
5.1.12 1/3rd indent interlocking system 3
5.1.12 2/2nd indent hold-to-run control device 1
5.1.14 3/1st sentence trip device 1
5.1.14 3/3rd sentence hold-to-run control device 1
6 Verification of compliance with thesafety requirements and/or measuresVerification of compliance with the requirementsand/or measures shall be performed in accordancewith table 2.In the `verification method' column:
1 = visual inspection;2 = functional test;3 = measurement;4 = calculation.
`Functional test' includes verification of the functionand efficiency of the guards and safety devices on thebasis of:
± descriptions given in the information for use;± safety related plans and circuit diagrams;± clause 5 and the applicable quoted standards.
7 Information for users7.1 Minimum marking on the machineEach machine shall carry indications conforming to 5.4of EN 292-2 : 1991 and their layout shall conform to thedescription of that clause.In addition, indications shall be marked where thefollowing hazards occur:
a) hot machine parts, if their surface temperatureexceeds the limit values in EN 563 and if they cannotbe protected against inadvertent contact by means ofinsulating material or additional guards;b) hot plasticized material and hot extrudate, whichcan be released at certain locations, e.g. at screenchangers, shear heads and extruder heads.
If required, these indications shall also includeadditional information about commissioning, operation,maintenance, cleaning and requirements to wearpersonal protection, for instance during screenchanging operations, etc.
7.2 Instruction manual
Instruction manuals shall be drafted in accordancewith 5.5 of EN 292-2 : 1991.
7.2.1 Contents
Each machine shall be accompanied by an instructionmanual which includes the minimum informationin 7.1 in addition to the fundamental instructions inaccordance with 5.5.1 of EN 292-2 : 1991.
In addition, the instruction manual shall include:
a) indications about the various operations duringwork carried out at the openings of the extruderbarrel, e.g. instructions for the operators, wearing ofpersonal protection devices, warnings againstresidual risks, etc.;
b) indications to the user that openings foraccessories, etc., shall be protected either by theaccessory itself or by fixed guards provided;
c) indications about permissible internal pressures ofextruder and ancillary equipment, e.g. melt/gearpumps, melt ducts, static mixers, screen changers,shear head and extruder head;
d) indications about the protective measures to betaken during screen changing, e.g. the use ofprotective equipment, etc.;
e) indications about movement of the entiremachine:
± indications about the risks of crushing hazardsbetween the moving machine and parts of thebuilding or other machines;
± the requirement that the space between themoving machine and parts of the building or othermachines shall be large enough to ensure that noone can be crushed between them (see EN 349);
± indications, e.g. by the posting of prohibition signs,not to step up on to the moving machine;
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f) instructions about the safety measures to be takenagainst accidental contact with hot machine parts,hot extrudate or hot plasticized material, if thesurface temperature exceeds the limit valuesin EN 563;
g) the following information concerning noise:
± the declared noise emission values of themachinery and the related information in 5.4.2;
± if applicable, information on possible noiseenclosures, screens or silencers fitted to themachinery, etc.;
± if applicable, recommendations to use cabinsand/or operating and maintenance modes withreduced noise emission, specifications forinstallation and assembly for reducing noise,e.g. vibration dampers, if applicable,recommendation to use personal hearing protection;
h) indications about locations on the machine whereventilation devices can be fitted in order to avoidescape of gases, vapours or dusts hazardous tohealth;
i) for maintenance operations on the degassingequipment, the machine builder shall inform the userthat during unscrewing of the degassing dome or theconnection lines, depending on the materials used,release of vapours or gases hazardous to health mayoccur, as well as hazards due to contact withcondensate hazardous to health being released fromthe lines. For such operations, protective measuresshall be mentioned, e.g. employment of speciallytrained personnel, wearing of protective gloves andglasses, etc.;
j) in particular cases, the risks of explosion shall beindicated, e.g. where pentane is used as a blowingagent.
7.2.2 Interfaces with machines mountedupstream and downstream of the extruder
Indication of the intended use of the machine shallalso include information about the interfaces withmachines/installations mounted upstream anddownstream of the extruder, as well as informationabout the external energy supply.
In doing so, account has to be taken of, for example:
± the function of emergency cut-out switch;
± the overall control system.
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Table 2. Concordance of verification methods
Clause/Subclause Verification method* Reference prEN, EN
1 2 3 4
5.1.1 Drive and power transmission X X 292-2, 294, 953, 1088
5.1.2 Screw shaft X X 292-2, 294, 953, 1088
5.1.3.1 Main feed opening X X X 292-1, 292-2, 294, 574, 953, 954-1, 1088
5.1.3.2 Secondary feed openings± without pressure± pressurized
*see 5.1.3.1*see 5.1.3.3, 5.1.5
5.1.3.3 Openings for the attachment ofaccessories
X X 294, 292-2
5.1.3.4 Degassing openings X X X 292-1, 292-2, 294, 953, 954-1, 1088
5.1.4.1 Hopper feed systems X X X 292-1, 292-2, 294, 953, 954-1, 1088
5.1.4.2 Single roller feeding systems X X X 292-1, 292-2, 294, 418, 574, 953, 954-1, 1088
5.1.4.3 Double roller feeding system X X X 292-1, 292-2, 294, 418, 574, 953, 954-1, 1088
5.1.4.4 Crammer feeding systems X X X 292-1, 292-2, 294, 953, 954-1, 1088
5.1.5 Over pressure protection X X X X 954-1
5.1.6 Screen changer X X X 292-1, 292-2, 294, 954-1
5.1.7 Melt/gear pump X X 292-2, 294, 953, 1088
5.1.8 Melt ducts X X **see 5.1.5
5.1.9 Static mixer X X **see 5.1.5
5.1.10 Degassing equipment X 5.5
5.1.11 Shear head device X X X 292-2, 294, 953, 954-1, 1088
5.1.12 Extrusion heads X X X 292-1, 292-2, 294, 574, 953, 954-1
5.1.13 High level working places X 292-2
5.1.14 Power operated horizontalmovement of the complete machine orparts of it
X X X 292-1, 292-2, 349, 811, 1037
5.2 Electrical energy
5.2.1 General X X X 60204-1, 60529
5.2.2 Electrostatic phenomena X
5.3 Hot machine parts/plasticized material X X X 292-1, 563
5.4 Noise X X 292-2, EN ISO 11201, EN ISO 11204,EN ISO 3744, ISO/DIS 4871, EN ISO 9614-1
5.5 Materials and substances processed,used and/or exhausted by the machinery
X 292-2, 626-1
5.6 Fire X 292-2
5.7 Temperature control for heating areas X X X
5.8 Emergency stop devices X X X 418, 954-1
5.9 Machine control systems X X 292-2, 954-1
*1 = visual inspection; 2 = functional test; 3 = measurement; 4 = calculation.
**of this standard.
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Page 29
BS EN 1114-1 : 1997
Annex ZA (informative)
Clauses of this European Standard addressing essential requirements or otherprovisions of EU DirectivesThis European Standard has been prepared under a mandate given to CEN by the European Commission and theEuropean Free Trade Association and supports essential requirements of the following EU Directives:
± Machinery Directive 89/392/EEC;
± its amendments 91/368/EEC, 93/44/EEC and 93/68/EEC.
Compliance with this standard provides one means of complying with the specific essential requirements of theDirective concerned and associated EFTA regulations.
WARNING. Other requirements and other EU Directives may apply to the products falling within the scope ofthis standard.
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BS EN 1114-1 : 1997
List of references
See national foreword.
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