EN 954-1 for CE-marking can now be used until December 31st, 2011

December 29^th the new Machinery Directive, 2006/42/EC became effective. On the same day, the Official Journal of the European Union, published a two year extension of the validity of EU safety standard, EN 954-1.

The new date of cessation of presumption of conformity for EN 954-1 is 31 Dec 2011. The two-year extension granted by the EU Commission is less than the three years requested by the EU Standards-making bodies.

The official announcement can be read at

http://eur-lex.europa.eu/JOHtml.do?uri=OJ:C:2009:321:SOM:EN:HTML

During the transition period, which started in 2006, machinery manufacturers can assess compliance of their control systems to the EU Machinery Directive (for CE marking) using either the superseded standard, EN 954-1, or its successor standards, EN ISO 13849-1 (2006 and 2008 editions) and EN 62061 (2005).

Impact on machinery destined for USA and Canada

“It is increasingly likely that machinery purchasers will specify the use of the latest standards (including ISO 13849-1 and EN ISO 13849-1), regardless of whether an “old” standard is still allowed for presumption of conformity in EU.  They have good reason to do this.  They are assured that their equipment meets all of the current EU and International standards, which is extremely important if they choose to re-locate the equipment at a later date when the “older” standards are no longer valid.  And of course from a liability standpoint, machinery purchasers may choose to use the latest standards as an element of their risk management programs,” says Roberta Nelson Shea, General Manager of Michigan-based Pilz Automation Safety.

International Impact

It should be noted that while EN 954-1 is recognized throughout the world, it is not an international standard. This is an important aspect, particularly for machine manufacturers and users that operate internationally. At an international level, ISO 13849-1:2006 (second edition) has already replaced the first edition of ISO 13849-1: 1999, which was based on EN 954-1.

EN 954-1 no longer represents the state of the art

First and foremost, the EN 954-1 represented the state-of-the-art in machinery safety design in 1996. There have been many changes in machine safety and control technology in the last 14 years.

Product-Specific Standards

Many Type B and Type C (product-specific) standards listed under the current Machinery Directive already refer to EN ISO 13849-1 and EN/IEC 62061. These include, for example:

• EN 61496: Safety of machinery – Electro-sensitive protective equipment
• EN ISO 13850: Safety of machinery – Emergency stop – Principles for design
• EN 848: Safety of woodworking machines

Other C standards will gradually be amended accordingly. Once these standards are amended, application of EN 954-1 would no longer enable presumption of conformity for these standards. This leaves machine builders and integrators with the unsettling situation where they either use

• EN 954-1, but instead of using the applicable C level standard instead they comply with the Machinery Directive

OR

• the applicable C level standard which requires EN ISO 13849-1 or EN/IEC 62061

Builders and integrators would then have to ask themselves, What does this mean from a liability standpoint if the machinery is different depending on the approach used?  What does this mean if the machinery is moved in two years? 

Support in converting to the new standards

Pilz has already certified its products to EN ISO 13849-1 and EN/IEC 62061 and has also tailored its services to suit, from training to implementation of providing CE marking services.

What’s more, Pilz’s PAScal Safety Calculator provides a convenient software tool for calculating the performance level and safety integrity level that safety functions can achieve based on the components used. A free trial copy of PAScal is available for download from www.pilz.us. Unlike SISTEMA, PAScal supports EN/IEC 62061 as well as EN ISO 13849-1.

Pilz supports design engineers in the United States, Canada and around the world who have already converted to EN ISO 13849-1 and EN/IEC 62061. At the same time, Pilz continues to provide products, services and technical support for those design engineers who have chosen to continue to apply EN 954-1.

Pilz, the company

The world leader in SAFE automation; Pilz offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions.

Products include sensor technology, electrical monitoring relays, and automation solutions with motion control, safety relays, programmable safety and control systems and an operating and monitoring range. Wireless and safe bus systems are also available for industrial networking.

Pilz also provides a comprehensive range of consulting, engineering and OSHA-approved training services. Certified consultants provide a wide range of services in USA, Canada and worldwide including risk assessment, safety concept, safety design, LeanSafe™ services, CE-marking and safety sign-off. Pilz also performs facility safety reviews for due diligence relating to mergers and acquisitions.

For more information visit www.pilz.us or call 1-888-650-PILZ (7450)

The must have book to keep manufacturing employees safe, profits up and compliance with OSHA

The New Safety Compendium has just been released by Pilz Automation Safety L.P.This e-book contains the basics on safety as well as advanced concepts that everyone who works in manufacturing must know. 

Due to the downsizing many manufacturers have experienced, engineering responsibilities have increased into areas like controls and safety; this free book will help them understand how to make their plants and machines safe and compliant.

Machine safety encompasses everything from incorporating guards to designing safe motion into machines.Topics include: standards, directives and laws; safeguards; safe control technology; safe communication; and safe motion.Inside you will find diagrams, charts and examples as well as equations that will aid in ensuring employee safety.

The book has been authored by eleven leading practitioners in the safety field. They include Pilz engineers, international academic lecturers and lawyers from manufacturing law firms.

This compendium answers questions like: What you must know in order to export machines to Europe, it addresses the Machinery Directive changes and CE Marking.

Topics like guarding, protective devices, fixed guards, movable guards, optoelectronic protective devices and design of safeguards are discussed. Pictures of undected faults in safety circuits and how to connect safety gates are also reviewed.  The Compendium contains diagrams of wiring, discussions of items like light curtains and formulas engineers need to know when making machines safe. Concepts such as functional safeguards are also reviewed.  Review and understand the terminology related to ‘manipulation of safeguards’, how and why it is done and what you can do to prevent it.

Other topics include safety relays; configurable safety relays and how safety is an integral part of the overall plant and machine function. Basic principles of safety-related communication are given as well as safe fieldbus communication principles and safe Ethernet communication definitions. Principles of safe motion are also reviewed.

To receive a free copy of The New Safety Compendium visit pilz.us, enter webcode 3000.

CE Services Help Customers Comply with Directives

Pilz Automation Safety L.P. offers a range of CE marking services to help customers exporting to Europe comply with the essential requirements of the European Union’s Machinery and other Directives. 

Machinery manufactured and imported from non EU countries or substantially modified equipment is subject to the CE marking process when put into service in the European market. By applying the CE mark, the supplier is claiming the machinery meets the essential requirements of the relevant EU Directives- mainly the Machinery Directive. Assemblies of machines such as robot cells and production lines must also be CE marked. 

The CE Marking process and the interpretation of relevant Directives and standards requires a high level of knowledge and expertise. Such a level of competence is difficult to maintain in an ever-changing regulatory environment. Fortunately, however, Pilz Automation Safety L.P. has consultants and engineers available who can assist customers with both the CE marking process and implementation of any additional safety measures that are found to be necessary to meet the essential requirements of the Directives. 

Pilz can manage the entire CE marking project on behalf of a client or provide input as needed and when called upon. Typically Pilz undertakes the following activities on behalf of clients: identification and application of the relevant Directives and standards; hazard analysis and risk assessment; creation of a safety concept and generation of related safety design; evaluation of compliance with the essential requirements and, if necessary, recommend actions required to achieve compliance; conduct all required checks, tests and measurements; compilation of the legally required documents including the technical construction file; management and archiving of documentation. In both individual machinery projects and projects involving the linking of machines (known in the Machinery Directive as complex assemblies), Pilz can optionally take overall responsibility for CE marking to the extend of signing the Declaration of Conformity.

Even with machinery already installed in the EU and that already displays the CE mark, customers still have a responsibility to ensure the safety of workplace machinery. Pilz can therefore examine such machinery onsite in the EU to ensure that the documentation and machinery meet the necessary standards and that the machine is, in fact, safe. Pilz also offers an equivalent service, based on US standards and OSHA requirements, for equipment installed in the United States.

Whatever the nature of the project, if the safety-related aspects of the machine need further work, customers have the choice of doing it themselves (provided they possess the necessary competences) or work with a third-party supplier, panel builder or system integrator. Alternatively, Pilz Can provide engineering services, as well as an extensive range of machinery safety products.

Have a safe and happy new year!

The New Machinery Directive is Here!

Five Steps to Safety

Safety doesn’t have to be complicated or confusing. Here are five steps you can take to ensure you are up-to-date with safety standards.

1) Join a standards committee.
Joining a standards committee gives you first hand knowledge of changes to standards.


2) Join an organization that provides trade shows and seminars.
By joining an organization that provides trade shows and seminars you expand your knowledge base and mindshare. Trade shows and seminars are great opportunities to not only learn about new standards but to also see new technologies available to help you meet those standards. Networking at these events also gives you the chance to utilize colleagues as sounding boards for issues or problems you may have with safety.

3) Create an internal safety committee
An internal safety committee is a great way to enforce safety regulations. Schedule monthly assessments of machinery and procedures to ensure that employees are performing duties in a safe manner. Monthly assessments also give you the opportunity to be proactive in solving issues before they become emergencies.

4) Benchmark another company that has a good safety history
By benchmarking a leader in safety you can assess your current safety policies and measures to ensure they line up with a company that has a proven track record with safety. Benchmarking allows you to see how other companies have handled similar situations and follow their lead.

5) Schedule a plant and risk assessment with an outside safety company.
Companies that perform plant and risk assessments are experts in safety. They have knowledge of the newest standards and what steps need to be taken to implement the latest regulations. When a risk assessment is performed a documented physical examination and inspection of either a single machine or an entire plant, is carried out under the guidelines of applicable national and/or international standards. Safety improvement on existing machines can be prioritized and implemented based on known risks, thereby extending the working life of the machine. Early identification of hazards on new machines will save time and money by facilitating the integration of appropriate safety measures.

A typical risk assessment includes:
• Identification of applicable standards, regulations and best industry practices.
• Statement of machine limits
• Examination of all hazards throughout the relevant machinery lifecycle phases
• Estimation and evaluation of risk
• Recommended approach for risk reduction

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

My company designs large machines and automated production lines. Are there new requirements to consider?

There are a number of requirements you should consider. the existing directive required that "From the main control position the operator must be able to ensure that there are no exposed persons in the danger zones" (before starting or restarting machines). Considering the risks in large machines and production lines the new directive demands the same can be achieved from all control positions. However, recognizing advances in technology the new directive introduces the obligation to consider in certain circumstances control systems and protective devices to automatically prevent start-up if it detects somebody in a danger zone.