(BS EN 12981 - 2005+A1 - 2009) - Coating Plants. Spray Booths For Application of Organic Powder Coating Material. Safety Requirements.

BRITISH STANDARD BS EN
12981:2005

Coating plants —
Spray booths for
application of organic
powder coating
material —
Safety requirements
ICS 87.100

BS EN 12981:2005+A1:2009
National foreword
This British Standard is the UK implementation EN 12981:2005+A1:2009.

It supersedes BS EN 12981:2005, which is withdrawn.
The start and finish of text introduced or altered by amendment is indicated
in the text by tags. Tags indicating changes to CEN text carry the number of
the CEN amendment. For example, text altered by CEN amendment A1 is
indicated by .

The UK participation in its preparation was entrusted by Technical Committee

MCE/3, Safeguarding of machinery, to Subcommitee MCE/3/8,
Thermoprocessing equipment — Safety.
A list of organizations represented on this subcommittee can be obtained on
request to its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was Amendments/corrigenda issued since publication

published under the authority
of the Standards Policy and
Strategy Committee Date Comments
on 20 June 2005
31 May 2009 Implementation of CEN amendment A1:2009
© BSI 2009
ISBN 978 0 580 63168 9

EUROPEAN STANDARD EN 12981:2005+A1
NORME EUROPÉENNE
EUROPÄISCHE NORM April 2009
ICS 87.100 Supersedes EN 12981:2005
English Version
Coating plants - Spray booths for application of organic powder

coating material - Safety requirements
Installations d'application - Cabines d'application par Beschichtungsanlagen - Spritzkabinen für organische

projection de produit de revêtement en poudre organique - Pulverlacke - Sicherheitsanforderungen
Exigences de sécurité
This European Standard was approved by CEN on 21 March 2005 and includes Amendment 1 approved by CEN on 22 February 2009.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12981:2005+A1:2009: E
worldwide for CEN national Members.
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Contents Page
Foreword ..............................................................................................................................................................4
0 Introduction ............................................................................................................................................5
1 Scope ......................................................................................................................................................6
2 Normative references ............................................................................................................................7
3 Terms and definitions ...........................................................................................................................9
4 List of significant hazards ................................................................................................................. 14
4.1 General ................................................................................................................................................. 14
4.2 Mechanical hazards ............................................................................................................................ 14
4.2.1 Shearing, crushing, cutting, entanglement, drawing-in, impact hazards ..................................... 14
4.2.2 Entrapment hazard ............................................................................................................................. 14
4.2.3 Personnel's slip, trip and fall hazards .............................................................................................. 14
4.3 Electrical hazards ............................................................................................................................... 14
4.3.1 Electrical shock (by direct or indirect contact) ............................................................................... 14
4.3.2 Faulty earthing .................................................................................................................................... 15
4.3.3 Electromagnetic influences ............................................................................................................... 15
4.3.4 Electrostatic phenomena ................................................................................................................... 15
4.4 Hazards generated by noise .............................................................................................................. 15
4.5 Hazards generated by dangerous substances ................................................................................ 15
4.5.1 Hazards resulting from contact with coating powder ..................................................................... 15
4.5.2 Hazards resulting from inhalation of coating powder .................................................................... 15
4.6 Fire and explosion hazards ............................................................................................................... 15
4.7 Hazards caused by failure of the energy supply and malfunction of the control system .......... 16
5 Safety requirements and/or protective measures ........................................................................... 16
5.1 General ................................................................................................................................................. 16
5.2 Mechanical safety requirements ....................................................................................................... 16
5.2.1 Safeguarding of danger points.......................................................................................................... 16
5.2.2 Protective measures against entrapment ........................................................................................ 18
5.2.3 Protective measures against personnel’s slip, trip and fall ........................................................... 19
5.2.4 Control system .................................................................................................................................... 19
5.2.5 Warning devices, indicators, markings and actuating devices ..................................................... 20
5.3 Electrical safety requirements........................................................................................................... 20
5.3.1 General ................................................................................................................................................. 20
5.3.2 Protective measures against contact with electrically live parts .................................................. 20
5.3.3 Protective measures regarding earthing .......................................................................................... 21
5.3.4 Protective measures on electromagnetic influences...................................................................... 21
5.3.5 Protective measures against electrostatic phenomena ................................................................. 21
5.4 Safety requirements and protective measures against noise ....................................................... 21
5.5 Safety requirements against dangerous substances ..................................................................... 22
5.5.1 Protective measures against contact with coating powder ........................................................... 22
5.5.2 Protective measures against inhalation of coating powder ........................................................... 22
5.6 Safety requirements and protective measures against fire and explosion .................................. 24
5.6.1 Fire ....................................................................................................................................................... 24
5.6.2 Explosions ........................................................................................................................................... 25
5.7 Safety requirements and protective measures in case of failure of energy supply .................... 27
6 Verification of safety requirements and/or protective measures .................................................. 27
6.1 General ................................................................................................................................................. 27
6.2 Verification of the mechanical safety requirements ....................................................................... 28
6.2.1 General ................................................................................................................................................. 28
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6.2.2 Control system .................................................................................................................................... 28

6.3 Verification of the electrical safety requirements ............................................................................ 28
6.3.1 Protective measures of contact with live parts ................................................................................ 28
6.3.2 Protective measures of earthing ........................................................................................................ 28
6.3.3 Protective measures against electromagnetic influence ................................................................ 28
6.3.4 Protective measures against electrostatic phenomena .................................................................. 28
6.4 Verification of the safety requirements and measures against noise ........................................... 28
6.5 Verification of requirements against dangerous substances......................................................... 28
6.5.1 Protective measures from contact with coating powder ................................................................ 28
6.5.2 Preventive measures of inhalation of coating powder .................................................................... 28
6.6 Verification of the safety requirements and protective measures against fire and
explosion .............................................................................................................................................. 32
6.6.1 Fire ........................................................................................................................................................ 32
6.6.2 Explosions ........................................................................................................................................... 32
6.7 Verification of the safety requirements and protective measures against failure of energy
supply ................................................................................................................................................... 33
7 Information for use .............................................................................................................................. 33
7.1 General ................................................................................................................................................. 33
7.2 Instruction handbook .......................................................................................................................... 33
7.2.1 General ................................................................................................................................................. 33
7.2.2 Instructions for use ............................................................................................................................. 34
7.2.3 Information relating to maintenance ................................................................................................. 35
7.3 Marking ................................................................................................................................................. 36
Annex A (normative) Diagrams relative to hazardous zones of potentially explosive atmosphere ........ 37
Annex B (normative) Determination of concentration of combustible coating powder in terms of
LEL ........................................................................................................................................................ 39
B.1 Equations ............................................................................................................................................. 39
B.2 Examples of calculation – Determination of concentration of combustible coating powder
on base of a given average design air velocity ................................................................................ 40
Annex C (informative) Diagrams relative to powder spray booths classification ...................................... 43
Annex D (informative) Classification of construction material’s reaction to fire - National
standards.............................................................................................................................................. 45
Annex E (informative) References to National Exposure Limit Values ....................................................... 46
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/EC !, amended by 98/79/EC" ......................................... 47
Annex ZB (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC" .................................................................................. 48
Bibliography ...................................................................................................................................................... 49
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Foreword
This document (EN 12981:2005+A1:2009) has been prepared by Technical Committee CEN/TC 271 “Surface
treatment equipment — Safety”, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by October 2009, and conflicting national standards shall be withdrawn at
the latest by December 2009.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).
!For relationship with EU Directive(s), see informative Annexes ZA and ZB, which are integral parts of this
document."
This document includes Amendment 1, approved by CEN on 2009-02-22.
This document supersedes EN 12981:2005.
The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".
NOTE Although a spray booth, as an integral whole, formally does not fall under the scope of the ATEX Directive
94/9/EC, the standard is based upon a fundamental risk analysis according to this directive.
This European Standard includes a Bibliography.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and United Kingdom.
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0 Introduction
This European Standard is a Type C standard as stated in EN ISO 12100.
The machinery concerned and the extent to which hazards, hazardous situation and events are covered are
indicated in the scope of this European Standard.
When provisions of this type C standard are different from those which are stated in type A or B standards, the
provisions of this type C standard take precedence over the provisions of the other standards, for machines
that have been designed and built according to the provisions of this European Standard.
The specific requirements which manufacturers shall include in the information for use are given in Clause 7.
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1 Scope
1.1 This European Standard is applicable to spray booths for spray application of organic coating powder,
called in this European Standard “powder spray booths”, i.e. machinery and related equipment for automated
and/or manual powder coating application processes.
This European Standard covers powder spray booths consisting of the following equipment:
⎯ forced ventilation system;
⎯ air filtering and coating powder recovery system;
⎯ coating powder recycling system;
⎯ delivery and circulating systems for coating powder (for instance hopper or tank, preparation and transfer
new powder feeding);
⎯ air conditioning system;
⎯ automatic cleaning system;
⎯ monitoring and/or control systems;
⎯ fire detection and interlocking system;
⎯ explosion protection system;
⎯ mechanical aspects of product handling systems and reciprocators inside the powder spray booth;
⎯ electrical equipment;
⎯ powered doors and gates
joined together within or at a partially or totally enclosed structure (limited by walls, called space) for the
controlled processing of spray application of organic coating powder.
This European Standard deals with the significant hazards, hazardous situations and events relevant to
powder spray booths when they are used as intended and under the conditions foreseen by the manufacturer
(see Clause 4).
NOTE Powder spray booths are classified in Annex !C".
In addition, it defines:
⎯ the content of marking;
⎯ the minimum requirements for use.
1.2 This European Standard does not cover:
a) powder spray booths in which the coating is applied by immersion in a fluidised bed;
b) powder spray booths for application of non combustible and inorganic coating powder and flock;
c) spraying equipment as covered by EN 1953, EN 50050, EN 50177;
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d) machinery for the supply or circulation of coating material under pressure as covered by prEN 12621;
e) all loading and unloading systems;
f) automatic systems, e.g. robots as covered by EN 775 and control systems of powder spray booths
influencing these systems (e.g. teaching of the spraying process);
g) powder spray booths for application of coating powder for food-stuffs and pharmaceuticals;
h) spraying areas characterized by an open space for application of organic powder coating material
which is limited only by one side wall used for extraction of exhaust ventilation;
i) limiting walls of powder spray booths if they are constituent parts of a building.
1.3 This European Standard is not applicable to powder spray booths which are manufactured before the
date of publication of this European Standard by CEN.
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.
EN 179, Building hardware — Emergency exit devices operated by a lever handle or push pad !, for use on
escape routes" — Requirements and test methods
EN 294, Safety of machinery — Safety distance to prevent danger zones being reached by the upper limbs
EN 349, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body
EN 418, Safety of machinery — Emergency stop equipment, functional aspects — Principles for design
EN 619, Continuous handling equipment and systems — Safety and EMC requirements for equipment for
mechanical handling of unit loads
EN 775, Manipulating industrial robots — Safety (ISO 10218:1992, modified)
EN 811, Safety of machinery — Safety distances to prevent danger zones being reached by the lower limbs
EN 842, Safety of machinery — Visual danger signals — General requirements, design and testing
EN 953, Safety of machinery — Guards — General requirements for the design and construction of fixed and
movable guards
EN 954-1:1996, Safety of machinery — Safety-related parts of control systems — Part 1: General principles
for design
CR 954-100, Safety of machinery — Safety-related parts of control systems — Part 100: Guide on the use
and application of EN 954-1:1996
EN 971-1:1996, Paints and varnishes — Terms and definitions for coating materials — Part 1: General terms
EN 981, Safety of machinery — System of auditory and visual danger and information signals
EN 999, Safety of machinery — The positioning of protective equipment in respect of approach speeds of
parts of the human body
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EN 1037, Safety of machinery — Prevention of unexpected start-up
EN 1088:1995, Safety of machinery — Interlocking devices associated with guards — Principles for design
and selection
EN 1127-1:1997, Explosive atmospheres — Explosion prevention and protection — Basic concepts and
methodology
EN 13463-1:2001, Non-electrical equipment for potentially explosive atmospheres — Part 1: Basic method
and requirements
EN 13463-5, Non-electrical equipment intended for use in potentially explosive atmospheres — Part 5:
Protection by constructional safety "c"
EN 13478, Safety of machinery — Fire prevention and protection
!EN 14462:2005, Surface treatment equipment — Noise test code for surface treatment equipment
including its ancillary handling equipment — Accuracy grades 2 and 3"
!EN 14986", Design of fans working in potentially explosive atmospheres
EN 50015, Electrical apparatus for potentially explosive atmospheres — Oil immersion "o"
EN 50017, Electrical apparatus for potentially explosive atmospheres — Powder filling "q"
EN 50020, Electrical apparatus for potentially explosive atmospheres — Intrinsic safety "i"
EN 50050, Electrical apparatus for potentially explosive atmospheres — Electrostatic hand-held spraying
equipment
EN 50177:1996, Automatic electrostatic spraying installations for flammable coating powder
EN 50281-1-2, Electrical apparatus for use in the presence of combustible dust — Part 1-2: Electrical
apparatus protected by enclosures — Selection, installation and maintenance
EN 60079-0, Electrical apparatus for explosive gas atmospheres — Part 0: General requirements
(IEC 60079-0:2004)
EN 60079-1, Electrical apparatus for potentially explosive atmospheres — Part 1: Flameproof enclosure "d"
(IEC 60079-1:2003)
EN 60079-7, Electrical apparatus for explosive gas atmospheres — Part 7: Increased safety “e”
(IEC 60079-7:2001)
EN 60079-17, Electrical apparatus for explosive gas atmospheres — Part 17: Inspection and maintenance of
electrical installations in hazardous areas (other than mines) (IEC 60079-17:2002)
EN 60079-18, Electrical apparatus for explosive gas atmospheres — Part 18: Construction, test and marking
of type of protection encapsulation “m” electrical apparatus (IEC 60079-18:2004)
EN 60204-1:1997, Safety of machinery — Electrical equipment of machines — Part 1: General requirements

(IEC 60204-1:1997)
EN 60529, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)
EN 61000-6-1, Electromagnetic compatibility (EMC) — Part 6-1: Generic standards — Immunity for residential,
commercial and light-industrial environments (IEC 61000-6-1:1997, modified)
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EN 61000-6-3, Electromagnetic compatibility (EMC) — Part 6-3: Generic standards — Emission standard for
residential, commercial and light-industrial environments (IEC 61000-6-3:1996, modified)
EN 61000-6-4, Electromagnetic compatibility (EMC) — Part 6-4: Generic standards — Emission standard for
industrial environment (IEC 61000-6-4:1997, modified)
EN 61010-1, Safety requirements for electrical equipment for measurement, control and laboratory use —
Part 1: General requirements (IEC 61010-1:2001)
EN 61310-1, Safety of machinery — Indication, marking and actuation — Part 1: Requirements for visual,
auditory and tactile signals (IEC 61310-1:1995)
EN 61310-2, Safety of machinery — Indication, marking and actuation — Part 2: Requirements for marking
(IEC 61310-2:1995)
EN 61310-3, Safety of machinery — Indication, marking and actuation — Part 3: Requirements for the
location and operation of actuators (IEC 61310-3:1999)
EN 61496-1:2004, Safety of machinery — Electro-sensitive protective equipment — Part 1: General

requirements and tests (IEC 61496-1:2004, modified)
!deleted text"
EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology (ISO 12100-1:2003)
EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (ISO 12100-2:2003)
EN ISO 14122-1, Safety of machinery — Permanent means of access to machinery — Part 1: Choice of fixed
means of access between two levels (ISO 14122-1:2001)
EN ISO 14122-2, Safety of machinery — Permanent means of access to machinery — Part 2: Working
platforms and walkways (ISO 14122-2:2001)
EN ISO 14122-3, Safety of machinery — Permanent means of access to machinery — Part 3: Stairs,
stepladders and guard-rails (ISO 14122-3:2001)
ISO 3864-1, Graphical symbols — Safety colours and safety signs — Part 1: Design principles for safety signs
in workplaces and public areas
IEC 61496-2, Safety of machinery — Electro-sensitive protective equipment — Part 2: Particular requirements
for equipment using active opto-electronic protective devices (AOPDs)
3 Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN 971-1:1996,
EN ISO 12100-1:2003 and the following apply.
3.1
powder spray booth
assembly of linked components such as forced ventilation by one or more fans, air filtering and coating
powder recovery system, coating powder recycling system, measuring and control devices (e.g. interlocking of
forced ventilation and spraying device), fire detection and interlocking, explosion protection system, automatic
cleaning system, air conditioning system, warning devices, electrical apparatus, joined together within or at a
partially or totally enclosed structure (limited by walls, called space) for the controlled processing of spray
application of organic coating powder
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NOTE Different kind of powder spray booth are described in Annex !C", e.g.:
⎯ powder spray booth with operator inside the booth (see Figure !C.1" of Annex !C");
⎯ powder spray booth with operator outside the booth (see Figure !C.2" of Annex !C");
⎯ powder spray booth without operator but with supports for automatic spraying device outside the booth
(see !C.3");
⎯ powder spray booth with operator and supports for automatic spraying device outside the booth
(see Figure !C.4");
⎯ powder spray booth with operator and automatic spraying device inside the booth (see Figure !C.5" of
Annex !C").
⎯ This kind of powder spray booth can also be designed as a multizone powder spray booth.
3.2
powder coating material; coating powder
solvent-free coating material in powder form which, after fusing and possible curing, gives a continuous film
(see 1.41 of EN 971-1:1996)
3.3
application
action of depositing coating powder on a substrate so that it adheres to the surface to be coated
3.4
electrostatic process
sprayed coating powder electrostatically charged, and attracted by the surface of the earthed unheated or
preheated workpiece
3.5
flammable substance
substance in form of gas, vapour, liquid, solid, or mixtures of these, able to undergo an exothermic reaction
with air when ignited (see 3.1 of EN 1127-1:1997)
NOTE “Flammable substances” and “combustible material” are equivalently used terms in this European Standard.
3.6
forced ventilation system
ensures the air exchange by fan(s) or by other powered means
NOTE Forced ventilation systems are using exhaust air units with devices for material separation and – optional –
automatic cleaning, and, in addition, if applicable a supply air unit with devices for filtering, air conditioning and automatic
powder recycling.
3.7
supply air
consists either totally of outside air or by energetic reasons of a mixture of outside air with recirculation air.
The recirculation airflow may consist of exhaust air and/or recirculated clean air.
Air introduced in the powder spray booth serves to replace the collection air, to reduce the concentration of air
pollutants in the work region and to supply air for technological processes
3.8
explosive atmosphere
mixture with air, under atmospheric conditions, of flammable substances in the form of gases, vapours, mists
or dusts, in which, after ignition has occurred, combustion spreads to the entire unburned mixture (see 3.17 of
EN 1127-1:1997)
NOTE In this European Standard, explosive atmosphere is only due to dust resulting from used coating powder.
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3.9
explosion range
range of the concentration of a flammable substance in air, within which an explosion can occur (see 3.13 of
EN 1127-1:1997)
3.10
lower explosion limit (LEL)
lower limit of the explosion range (see 3.8 of EN 1127-1:1997)
3.11
average concentration of coating powder
mass of coating powder introduced into the powder spray booth divided by the volume of air extracted by the
forced ventilation system during the same period of time
3.12
exposure limits
concentration limits of dangerous substances in air required by worker health legislation
NOTE Limits are different according to the countries (see Annex !E").
3.13
reciprocator
alternating moving device holding guns
3.14
powder recovery system
system which collects overspray from the powder coating process which has not been deposited on the
workpiece
3.15
enclosed recovery system
separate enclosed coating powder collector (e.g. filter and/or cyclone) which is connected through ductwork to
the powder spray booth
3.16
open recovery system
coating powder collector usually fitted with filters integrated to the powder spray booth in open arrangement
3.17
explosion relief venting
protective measure at which an area of the panelwork of the enclosure (for example of the coating powder
collection unit) is designed and constructed to release the excess pressure in the event of an explosion to
prevent injury to persons and further damage to equipment
3.18
explosion suppression
system which can detect and suppress an explosion in the incipient growth stage
3.19
explosion decoupling
system preventing the propagation of flames and explosions from one apparatus to other parts of the
installation by special devices, e.g. mechanical high-speed shut-off, rotary valve, or flame suppression barriers
3.20
fire detection system
fire alarm system comprising components for automatically detecting a fire, initiating an alarm of fire and
initiating other action as appropriate (see 3.1.3 of ISO 8421-3:1989)
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3.21
hazardous areas
areas where hazards due to explosive atmosphere may exist. The probability of occurrence of explosive
atmosphere is classified in zones.
Limits of hazardous zones are given in Annex A
NOTE For this European Standard, only the zones 20 and 22 (as defined in 3.22 and 3.24) are suitable.
3.22
zone 20
area, in which an explosive atmosphere in the form of a cloud of combustible dust in air is present
continuously, or for long periods or frequently (see 6.3.3 of EN 1127-1:1997 and 6.2 of EN 50281-3:2002)
NOTE In general, these conditions, when they occur, arise inside containers, ducts and apparatus, etc.
3.23
zone 21
area, in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in
normal operation occasionally (see 6.3.3 of EN 1127-1:1997 and 6.2 of EN 50281-3:2002)
NOTE This zone can include, among others, areas in the immediate vicinity of e.g. coating powder filling and
emptying points and places where dust layers occur and are likely in normal operation to give rise to an explosive
concentration of combustible dust in mixture with air.
3.24
zone 22
area in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in
normal operation, but if it does occur, it will persist for a short period only (see 6.3.3 of EN 1127-1:1997 and
6.2 of EN 50281-3:2002)
NOTE This zone can include, among others, areas in the vicinity of equipment containing combustible dust, from
which dust can escape from leaks and form dust deposits.
3.25
Equipment category
NOTE Equipment for potentially explosive atmospheres is divided into groups and categories. Group II: Equipment for
places with a potentially explosive atmosphere, other than mines susceptible to firedamp; this group comprises three
categories according to the level of safety provided.
3.25.1
Equipment Group II Category 1D
equipment in this category is intended for use in areas in which explosive atmospheres caused by air/dust
mixtures are present continuously for long periods or frequently (see 3.2.3 of EN 13463-1:2001)
NOTE Equipment of category 1D is suitable for use in zone 20, 21 and 22.
3.25.2
mixtures are likely to occur (see 3.2.4 of EN 13463-1:2001)
NOTE Equipment of category 2D is suitable for use in zone 21 and 22.
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3.25.3
mixtures are unlikely to occur, or, if they do occur, are likely to do so only in frequently and for a short period
only (see 3.2.5 of EN 13463-1:2001)
NOTE Equipment of category 3D is suitable for use in zone 22.
3.26
multi-zone powder spray booth
spray booth including a number of sections for manual and/or automatic spraying and forced ventilation flash
off space
NOTE In flash off space no spraying takes place.
3.27
danger points
for the extent of this European Standard danger points are defined locations in the danger zone of machines
where persons can be injured by movements of
⎯ parts of machinery
⎯ workpieces or parts of workpieces
NOTE Danger points can exist, for example, on gear, chain drives, V-belt, flat belt, pulling and supporting elements
on continuous conveyors, spoke wheels, shafts and shaft ends, slides, push rods and similar parts, tools and clamping
devices.
Particular points of danger are:

⎯ crushing and shearing points;
⎯ trapping points;
⎯ inrunning nips;
⎯ cutting, punching and impact points.
3.28
accessible danger zone
"accessible danger zones" are areas where, for example, area guards or ESPDs allow whole-body access.
The objective is to prevent anyone starting the machine while persons are within the danger zone
3.29
hold-to-run control device
control device where the actuator automatically returns to the start position when released and where machine
operation is started and maintained only as long as the actuator is hold depressed
3.30
integrated feeding system
feed mechanism for the workpiece which is integrated with the powder spray booth and where the workpiece
is held and controlled mechanically during the processing
3.31
loading / unloading
operation where the workpiece is put on / taken from the integrated feeding system
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4 List of significant hazards
4.1 General
This clause contains the significant hazards, hazardous situations and events as far as they are dealt with in
this European Standard, identified by risk assessment as significant for these types of powder spray booths
and which require action to eliminate or reduce the risk.
NOTE 1 Examples for the classification of powder spray booths are given in Annex !C".
NOTE 2 Hazards can also occur from combinations of ancillary equipment (e.g. atomising and spraying equipment,
robots, reciprocators, conveyors, power driven turntables for workpieces) and other parts of the powder spray booth.
NOTE 3 Information on the method of risk analysis is given in EN 1050.
4.2 Mechanical hazards
4.2.1 Shearing, crushing, cutting, entanglement, drawing-in, impact hazards
These hazards may result from the mechanical interfaces of the following equipment especially with powder
spray booths:
⎯ product handling systems (e.g. hazard from inrunning nip);
⎯ fans and automatic damper adjusters (e.g. injuries caused by over-running of fan blades);
⎯ powered doors and gates;
⎯ automatic equipment or systems (e.g. reciprocator, atomising and spraying system and power driven
turntables for workpieces).
4.2.2 Entrapment hazard
This hazard may occur, for instance:
⎯ when obstacles or obstructions can impede a quick evacuation of the operator(s) from the powder spray
booth in case of mechanical accident or fire;
⎯ when there is an accidental significant lowering of pressure inside an enclosed spray booth (i.e.
obstruction of air inlet) capable to increase the door opening effort beyond human capability.
4.2.3 Personnel's slip, trip and fall hazards
Such hazards may occur, for instance, on gangways, platforms, ladders, stairs, gratings and excavations
equipping the powder spray booths.
These hazards may be increased as a result of poor lighting.
4.3 Electrical hazards
4.3.1 Electrical shock (by direct or indirect contact)
Such hazards may occur, for instance, by touching:
⎯ electrically live parts that are non insulated for operational reasons;
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⎯ conductive parts, which are not at dangerous voltage under normal operation, but in case of failure could
be;
⎯ electrically live parts when insulation is insufficient or damaged by mechanical influences.
4.3.2 Faulty earthing
Such hazards may occur, for instance:
⎯ by defective bonding to the protective earth system;
⎯ when resistance to earth is too high.
4.3.3 Electromagnetic influences
Such hazards can occur, for instance, when interaction of the electrostatic high voltage equipment with
construction elements of the control and safety systems can cause dangerous malfunctions (e.g. short circuits
on electronic safety circuits, entrance guards, alarm unit).
4.3.4 Electrostatic phenomena
Hazardous electrostatic discharges may occur for instance from unearthed conductive parts or non-conductive
large surfaces, especially if they are in contact with conductive material.
4.4 Hazards generated by noise
Such hazards may occur inside and outside the powder spray booths.
They can be originated from noises emitted for instance by:
⎯ fans;
⎯ excessive air velocity in ducts and accessories;
⎯ compressed air operating equipment (noises generated by reverse jet filter device, etc.).
4.5 Hazards generated by dangerous substances
4.5.1 Hazards resulting from contact with coating powder
Such hazards may be generated by contact with coating powder causing allergic irritation of skin and also
dermatitis.
4.5.2 Hazards resulting from inhalation of coating powder
Such hazards may be generated by inhalation of coating powder causing respiratory tract damage.
4.6 Fire and explosion hazards
Such hazards may occur if coating powder clouds (produced by spraying equipment or turbulences of
deposits or other means) are ignited. Fire and explosion are possible if effective ignition sources are present
and if the concentration of coating powder in air exceeds the lower explosion limit (LEL).
Examples of ignition sources are:
⎯ electrostatic discharges;
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⎯ electrical sparks;
⎯ hot surfaces;
⎯ sparks created by mechanically induced sources;
⎯ sources of thermal energy used during maintenance;
⎯ flames propagation by the forced ventilation into the powder recovery system.
LEL can be exceeded for example:
⎯ if forced ventilation of the powder spray booth breaks down;
⎯ if coating powder deposits are distributed within the powder spray booth;
⎯ in powder recovery systems during automatic filter cleaning.
4.7 Hazards caused by failure of the energy supply and malfunction of the control system
Failure of energy supplies may lead to:
⎯ reduction of ventilation flow rate;
⎯ unexpected shutdown of control devices;
⎯ increase of powder concentration;
⎯ reduction of recirculation flow rate;
⎯ loss of lighting.
Failure or malfunction of the control system (unexpected start-up, overrun) which can lead to:
⎯ increase of powder concentration;
⎯ wrong sequence of essential control functions.
5 Safety requirements and/or protective measures
5.1 General
Machinery shall comply with the safety requirements and/or protective measures of this clause. In addition,
the machine shall be designed according to the principles of EN ISO 12100-2 for hazards relevant but not
significant which are not dealt with by this European Standard (e.g. sharp edges).
5.2 Mechanical safety requirements
5.2.1 Safeguarding of danger points
5.2.1.1 General
Inrunning nips on cylinders, drums, rolls and similar parts shall be safeguarded e.g. by guards or by applying
the safety distances specified in EN 349.
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Guards shall be designed as follows:
As guards without openings or with openings for feeding the material (for example work pieces): The safety
distances shall be established in relation to the width of the opening in accordance with EN 294. Movable
guards shall be interlocked with the dangerous movements in accordance with 5.2.1.3 or they shall be fixed to
the machine. Movable guards shall satisfy the requirements of 5.2.1.3.
!When fixed guards are applied, they shall be fixed by systems that can be opened or removed only with
tools. Their fixing systems shall remain attached to the guards or to the machinery when the guards are
removed. Where possible, these guards shall be designed in such a way that they can only remain in place
using their fixing system."
For machines constituting moving parts (e.g. moving devices holding spraying equipment) see 7.2.2 first
indent.
5.2.1.2 Prevention of crushing and shearing
Moving parts of a powder spray booth such as power driven turntables, agitation system, powder feeding
system and ventilation system shall be designed in such a way that in normal operation and maintenance
crushing, shearing, cutting, entanglement, drawing-in, impact cannot occur. EN 349, EN 294, EN 811, EN 842,
ISO 3864-1, EN 619 shall be taken into account.
The manual shall contain a warning against residual risks resulting from the presence of non-guarded product
fixing devices, e.g. hooks (see 7.2).
Starting of handling systems and reciprocators shall be preceded by an acoustic or optical signal with a
duration of at least 5 s. EN 61310-1 and EN 61310-2 shall be taken into account.
5.2.1.3 Guards and interlocks
Guards shall satisfy the requirements of EN 953. Interlocking shall satisfy the requirements of Clauses 5 and 6
of EN 1088:1995.
For interlocking, see 5.2.4 (control system).
For fence-type enclosures, the safety distances according to EN 294 apply. A further requirement is that the
distance between floor and lower edge of the fence is 200 mm maximum and between floor and upper
edge 1,4 m.
Guards and doors giving access to moving parts that need to be accessed frequently shall be safeguarded by
interlocking with the hazardous movement (see 5.2.4).
Guards that do not have to be opened frequently shall either be fixed in such a way that their removal
necessitates the use of a tool or they shall be interlocked with the hazardous movement (see 5.2.4).
For the purpose of this European Standard guards and doors are removed "frequently", including for
maintenance purposes, if they are to be removed at least once per work shift.
NOTE Guards and doors are removed for "setting-up" purposes, for example:
⎯ to supply workpieces to be processed;
⎯ to supply the cleaning liquid;
⎯ for make-ready.
Automatic travel of movable guards shall not create danger points.
Accessible danger zones inside the powder spray booths shall be safeguarded as follows:
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⎯ If robots are installed of the type covered by EN 775 the powder spray booth may function as
safeguarding enclosure under the condition that access to the powder spray booth is safeguarded in
the same way as required in EN 775 for fence-type enclosures.
⎯ ESPDs shall be interlocked with the hazardous movement. ESPDs shall satisfy the requirements of
type 2 of EN 61496-1 and IEC 61496-2.
5.2.1.4 Moving parts
Access to power driven turntables shall be prevented by a fence-type enclosure or ESPD or be safeguarded
in a way resulting in the same level of safety. Access-doors and openings for feeding products which are
accessible by persons shall be interlocked with the turntable rotation.
The travel when opening automatic powered doors if installed shall be guarded in such way that the hazard
from crushing between the door leaf and fixed adjacent machinery parts or walls is prevented.
5.2.1.5 Location of controls
The main control panel shall be located in such a way that all doors and openings which give access to the
powder spray booth can be observed.
One-hand operated hold-to-run controls shall be located in a way that it is not possible for the operator to
reach hazardous moving parts.
Provisions shall be made that hazardous movements can only be started from a control located in such way
that it is not reachable from the inside of a guarded area.
An emergency stop control shall be located at the main control panel.
5.2.1.6 Devices for setting-up, make-ready, cleaning and trouble-shooting during the work process
When access to the powder spray booth is needed during the work process for setting-up, make-ready,
cleaning and trouble-shooting, hold-to-run devices shall be provided for controlling hazardous movements
inside guarded areas. A lockable selector switch shall be provided to allow only normal operation or hold-to-
run operation at a time. Where both hold-to run devices and two-hand controls are present, the selector switch
shall enable the choice between hold-to-run mode with one actuator and the two-hand control mode.
Hold-to-run control devices shall have a displacement limited to a maximum of 75 mm or with a maximum
operating speed of 5 m/min. For the application of hold-to-run devices designed as two-hand control device,
the same limitations of displacement and operating speed shall apply. The movement shall come to a stop in
a time that, taking into consideration the hand approach speed, ensures there is no danger for the operator.
The hand approach speeds specified in EN 999 shall be taken as a basis.
Where hold-to-run controls are being used to allow safe control of hazardous movements, starting the
machine in the hold-to-run mode after opening the corresponding interlocking guard shall only be possible
when all other interlocked guards are closed.
5.2.2 Protective measures against entrapment
Powder spray booths shall be designed so that in case of an emergency all persons entrapped can find their
way out of the powder spray booth in the quickest time possible, without being hindered by obstructions.
The doors provided for personnel:
⎯ shall be capable of being opened and closed from inside and outside;
⎯ shall always open outwards;
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⎯ shall be capable of being opened from inside by a mere push, independent of the air pressure (high or
low) within the spray booth according to EN 179;
⎯ shall be self-closing;
⎯ shall have a minimum 800 mm width and 2 000 mm height.
For access and egress of operators, powder spray booths for manual application shall be designed so that the
operator does not need to travel more than 10 m to reach a door.
If the powder spray booth is longer than 5 m, a second door shall be provided. If the loading door complies
with the requirements for operators' doors an additional door for operator access is sufficient.
In multizone powder spray booth doors for workpieces located between manual spraying area and automatic
spraying area shall not be operator's doors.
If a permanent opening for loading of workpieces is used at the same time as personnel exit, a clearance of
800 mm exceeding maximum workpiece width shall be provided.
Powder spray booths with operator inside the booth and powder spray booths with operator and with
reciprocator automatic spraying device inside the booth shall be equipped with a pressure control device
which is interlocked with the forced ventilation to prevent an accidental severe lowering of pressure inside the
powder spray booths, capable of hindering the opening of the doors either by increase of opening effort or by
deformation of the structure (see 5.5.2.3 a)).
5.2.3 Protective measures against personnel’s slip, trip and fall
Gangways and guard-rails that are part of the powder spray booths shall comply with EN ISO 14122-1,
EN ISO 14122-2 and EN ISO 14122-3.
The floor of powder spray booths with operator inside shall be non-skid (e.g. by applying floor gratings).
Where floor gratings are used, they shall be joined in a way that no projections or cavities can cause a risk to
slip, trip or fall.
The powder spray booth shall be provided with adequate lighting of 600 lux minimum.
5.2.4 Control system
5.2.4.1 General
The following control systems are considered safety-related:
⎯ monitoring of air velocity;
⎯ monitoring of recirculated air;
⎯ monitoring of minimum exhaust flow rate;
⎯ monitoring of spraying equipment activation before forced ventilation is working effectively;
⎯ detection of fire and fire alarm; interlocking circuits as dealt with in 5.6.1.3;
⎯ mode selector circuit;
⎯ main control circuit for each type of energy used.
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5.2.4.2 Safety-related parts
Control, monitoring and measurement circuits which are used in safety-related functions shall fulfil the
requirements of EN 954-1 category 3 and EN 1088. For safety-related functions see EN 954-1 and
CR 954-100.
NOTE 1 Safety-related functions are e.g. the monitoring formation of hazardous concentrations of powder, the
monitoring of the building up of excessive pressures or vacuums inside the spray booth or the monitoring of formation of
explosive atmospheres.
Control switches for starting hazardous movements shall be in accordance with the requirements of
EN 1037.
For powder spray booths which do not require routine and regular access to danger points, the following
requirements for control systems shall apply:
⎯ the safety related part of a hydraulic/pneumatic control system shall satisfy at least category 1 (see 6.2.2
of EN 954-1:1996);
⎯ the safety related part of a electric/electronic control system shall satisfy at least category 3 (see 6.2.4 of
EN 954-1:1996). It is allowed to provide single main contactors.
NOTE 2 Category 3 means that faults in the safety related part of a control system (e.g. auxiliary relays, auxiliary
contactors, computers for safety-related functions or special PLCs (Programmable Logic Control) for monitoring) are
detected and that measures are taken to bring the controlled equipment into a safe state (e.g. stop of hazardous
movements). According to EN 60204-1 programmable electronic control functions are not allowed considered safe in all
cases.
5.2.5 Warning devices, indicators, markings and actuating devices
The requirements of EN 61310-1, EN 61310-2 and EN 61310-3 shall be satisfied.
5.3 Electrical safety requirements
5.3.1 General
Electrical equipment shall comply with EN 60204-1 and EN 50281-1-2.
5.3.2 Protective measures against contact with electrically live parts
Protection against electrical shock shall comply with requirements of Clause 6 of EN 60204-1:1997.
Electrical devices and conductors shall be installed in such a way that damages from mechanical stresses and
environmental influences are prevented.
All mechanical conductive parts of the installation shall be earthed (see Clause 8 of EN 60204-1:1997).
Emergency stopping devices shall fulfil the requirements of EN 418 and shall be designed in accordance with
EN 60204-1 as category 1 stop.
When it is necessary to prevent access to high voltage areas, the requirements of 5.2.6 of EN 50177:1996
shall be met.
All electrical equipment shall be designed such that it will withstand the testing specified in 19.2 to 19.6 of
EN 60204-1:1997. Voltage tests as specified in 19.4 of EN 60204-1:1997 are not required for electronic
control circuits.
Measuring devices which are part of machines shall comply with EN 61010-1.
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NOTE 1 EN 50050 and EN 1953 specify requirements for spraying equipment (hand-held electrostatic guns).
NOTE 2 EN 1953 specifies requirement for powder equipment and conductive pipes.
NOTE 3 IEC 60364 and IEC 60384 for risk of explosion (code BE3) specify requirements for electrical conducts.
5.3.3 Protective measures regarding earthing
All conductive parts of the installation and all conductive structures such as floors, walls, ceilings, screens,
fences, conveyors, workpieces, spraying material containers, automatic moving devices etc. within the powder
spray booth except for those parts which are under high voltage in normal operation, shall be bonded together
with one another and with the earth terminal of the high voltage supply system to the protective earth system
of the electrical supply (see also 5.5.1 of EN 50177:1996).
NOTE More information on the earthing of electrostatic powder guns is given in EN 50050 and EN 50177.
5.3.4 Protective measures on electromagnetic influences
Electrical and electronic components of the powder spray booths shall be resistant against electromagnetic
influences. Every interference of control systems of powder spray booths that can lead to an unsafe situation
shall be prevented (see EN 61000-6-1, EN 61000-6-3, EN 61000-6-4).
5.3.5 Protective measures against electrostatic phenomena
Where walls of thin non-conductive materials are used the occurrence of electrostatic discharges which could
ignite coating powders (propagating brush discharges) shall be avoided. The minimum thickness of walls
made of plastic materials shall be 9 mm, if they are in contact with conductive material, unless the breakdown
voltage of plastic material is lower than 4 kV.
When operator is working inside the powder spray booth, the floor shall be electrostatically conductive.
The resistance to earth of booth floor with operator inside shall be less than 1MΩ.
NOTE 1 For more information see Figures !C.1" and !C.5" of Annex !C".
NOTE 2 Information on propagating brush discharges is given in 5.2.5 of EN 50177:1996.
5.4 Safety requirements and protective measures against noise
A powder spray booth as defined in 3.1 shall be so designed and constructed that risks resulting from the
emission of airborne noise are reduced to the lowest level, taking account of technical progress and the
availability of means of reducing noise in particular at the source.
For example the following measures can be adopted:
⎯ choice of the filter cleaning system(s) emitting minimum noise;
⎯ equipment set on anti-vibratory supports;
⎯ flexible connections between the ducts and especially between fans and ducts;
⎯ choice of fan speed according to most favourable noise curves;
⎯ use effective silencer(s) on air operated equipment;
⎯ ducts soundproofing;
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⎯ ancillary equipment permanently installed and connected to the powder spray booth shall not propagate
noise to the powder spray booth structure through vibration, resonance etc.
NOTE 1 This list is not exhaustive.
The determination, declaration and verification of airborne noise emission of powder spray booths shall be
carried out as stated in !EN 14462:2005".
NOTE 2 EN ISO 11688-1 gives general technical information on widely recognised technical rules and means to
design low-noise machinery.
!NOTE 3" EN ISO 11688-2 gives useful information on noise generation mechanisms in machinery.
!NOTE 4" Concerning noise emitted by air compressors and spraying equipment refer to EN 1012-1 and
EN 1953.
5.5 Safety requirements against dangerous substances
5.5.1 Protective measures against contact with coating powder
Contact with or absorption of dangerous substances sprayed shall be reduced by forced ventilation as far as
possible (see 5.5.2.1 and 5.6.2). See also the provisions for the content of the instructions for use in 7.2.2.
5.5.2 Protective measures against inhalation of coating powder
5.5.2.1 General
Powder spray booths shall be equipped with a forced ventilation system to reduce the concentration of coating
powder in the operator's working area below exposure limits.
Forced ventilation systems shall be designed according to type of application, size and shape of workpieces to
be coated, amount of coating powder used and exposure limits.
Forced ventilation systems shall prevent escape of coating powder from powder spray booths through
entrance and exit openings of workpieces, openings for manual application, reciprocators and conveyors slots,
where existing.
Air exhausted from the powder recovery system recirculated into the powder spray booth shall not contain
particle concentrations above exposure limits.
NOTE For information about exposure limit values see informative Annex !E".
5.5.2.2 Airflow direction
The airflow direction shall always keep coating powder away from the breathing zone of the operator and thus
reducing inhalation of coating powder. Information shall be given about required use of respiration protective
devices, see 7.2.
When it is required that the operator moves around a workpiece positioned at a fixed spot, the forced
ventilation shall be directed vertically downwards.
The length and the width of vertically ventilated powder spray booths with operator inside shall be at least one
metre more on each side than the length and the width of the biggest workpiece to be coated.
In the plane of the opening of the powder spray booths, airflow direction shall be from outside to inside to
avoid powder escaping from the powder spray booths.
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5.5.2.3 Air velocity
a) General
In order to avoid coating powder escape from any opening of the powder spray booths the following air
velocities are required under normal operating conditions, but without any workpiece inside the powder spray
booth.
1) Powder spray booth with operator inside (example given in Figure !C.1" of Annex !C").
The average of measured vertical air velocities shall be at least 0,3 m/s.
Single measured values shall be at least 0,25 m/s.
Corresponding measurement points are specified in 6.5.2.3 a) 1).
2) Powder spray booth with operator outside (example given in Figure !C.2" of Annex !C").
The average of measured air velocities through each opening shall be at least 0,4 m/s with a
minimum air velocity of 0,3 m/s.
3) Powder spray booth without operator inside but with reciprocators for automatic spraying device
outside the booth (example given in Figure !C.3" of Annex !C").
The average of measured air velocities through each opening shall be at least 0,4 m/s with a
minimum air velocity of 0,3 m/s.
4) Powder spray booth without operator but with reciprocators for automatic spraying devices
outside the booth (example given in Figure !C.4" of Annex !C")
The average of measured air velocities through each opening of powder spray booths with manual
spraying operation inside shall be at least 0,4 m/s with a minimum air velocity of 0,3 m/s (e.g. in
Figure !C.4" of Annex !C").
5) Powder spray booth with operator and reciprocator for the automatic spraying device inside the
booth (example given in Figure !C.5" of Annex !C").
The average of measured vertical air velocities shall be at least 0,3 m/s.
Single measured values shall be at least 0,25 m/s.
b) Particular cases
In the case of powder spray booths with operator outside, deviation from requirements in 5.5.2.3 a) 2) and
5.5.2.3 a) 3) is acceptable only if a large distance between the spraying area and workpiece openings
prevents coating powder escape from the openings.
At all times the air velocity shall be maintained as required in 5.5.2.3 a) 1) to 5.5.2.3 a) 5) for the manual
operator spraying area.
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Enclosed powder spray booths with operator inside to spray only large well-defined workpieces at a time (e.g.
wagons, containers) shall be vertically ventilated.
When large well-defined workpieces have to be coated, the required airflow shall be based on the air velocity
inside the powder spray booth accommodating the workpiece. Such powder spray booths shall not be used
for small workpieces.
The floor area of the workpieces shall be subtracted from the floor area of the powder spray booth and the
remaining area considered as in 5.5.2.3 a) 1) for conditions with operator inside. Corresponding measurement
points are specified in 6.5.2.3 a) 1).
5.5.2.4 Ventilation performance
Powder spray booths shall be provided with a device (e.g. pressure monitoring device, vacuum switch) to
monitor the performance and detect any malfunction of the ventilation system. According to the air velocity of
the forced ventilation specified in 5.5.2.3 this device shall be interlocked with coating powder spraying
equipment according to EN 50050 and EN 50177 (see also 5.2.4.1 and 5.2.4.2).
After failure of the forced ventilation system a manual restart shall be ensured.
5.6 Safety requirements and protective measures against fire and explosion
5.6.1 Fire
5.6.1.1 General
To preclude the fast propagation of fire, all elements of construction of the powder spray booth and its
equipment shall comply with the requirements for fire prevention and protection of machines as described in
EN 13478.
5.6.1.2 Elements of construction
Constituent elements shall be of materials, which do not support combustion and shall be sufficiently resistant
to fire.
The ductwork for make-up and exhaust air shall be of material, which does not support combustion.
The surface of the ductwork shall not accumulate electrostatic charges, which could lead to an ignition. It shall
be rigid enough, as short as possible, smooth inside and have no bends of small radius, which cause local
reductions in airflow velocity and allow hazardous amounts of coating powder deposits.
Powder deposits of hazardous amount shall be avoided within the powder spray booths.
NOTE Additional information is given in Annex !D".
5.6.1.3 Fire detection system and interlocking
Powder spray booths as defined in 3.1 shall be equipped with a fire detection system, independent of the type
of powder recovery system.
The fire detection system shall:
⎯ fulfil the requirements of 5.2.4;
⎯ have a response time less than 0,5 s;
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⎯ cut off in the following order: the power supply, coating powder supply, filter cleaning and the forced
ventilation system;
⎯ initiate a visible and audible alarm according to EN 981.
Additional information on fire protection systems is given in EN 50177.
NOTE In the next revision special attention will be paid to applicable alarm systems and their requirements.
5.6.2 Explosions
5.6.2.1 General
The requirements shall allow:
⎯ to maintain the flammable substances concentration below LEL by forced ventilation;
⎯ to eliminate or reduce ignition sources.
5.6.2.2 Limitation of coating powder concentration
In powder spray booths, a forced ventilation system shall be provided, so that the average concentration of
coating powder in air does not exceed 50 % of LEL. Where there is no reliable value of the LEL, an average
3
concentration of 10 g/m shall not be exceeded (see Annex B).
5.6.2.3 Classification in hazardous areas (according to 3.21)
The classification of hazardous zones is an integral part of the safety concept for explosion prevention. The
ignition prevention category of equipment and components implemented to powder spray booth is dependent
on limitation of flammable substance concentration by forced ventilation.
The internal volume of the powder spray booths and open recovery systems shall be classified as zone 22
(see 3.24).
The internal volume of enclosed powder recovery system shall be classified as zone 20 (see 3.22).
The external volumes to powder spray booths but within a distance up to 1 m from permanent openings, shall
be classified as zone 22 (see 3.24), see Annex A.
NOTE Doors are not considered to be permanent openings.
5.6.2.4 Avoidance or reduction of ignition sources
5.6.2.4.1 General
In order to prevent hazards by explosive atmospheres, the design and selection of electrical and non electrical
equipment shall ensure that ignition sources are avoided in any part of the system, where areas with
explosion hazard are classified (see 5.6.2.3). If electrical and non electrical equipment is implemented
according to their manufacturer’s instruction, then the completed installation is of the same category of
protection.
5.6.2.4.2 Electrical equipment
Electrical apparatus for use in the presence of combustible dust shall comply with EN 50281-1-2.
Electrical equipment installed and located in zone 21 shall be at least of group II category 2D complying with
EN 60079-0, EN 50015, EN 50017, EN 60079-1, EN 60079-7, EN 50020, EN 60079-18, as appropriate.
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Electrical apparatus installed and located in zone 22 shall be at least of group II category 3D complying with
EN 60079-0 and EN 50281-1-2.
NOTE 1 Electrical equipment constructed to the listed standards are suitable for use in a gas/ vapour explosive
atmospheres. When used in the presence of combustible dust additional seals, to prevent ingress of dust may be required.
Manufactures should be consulted on the suitability of the selected equipment.
Electrical apparatus installed in zones 20 shall be at least of group II category 1D complying with
EN 50281-1-2.
In particular the following measures shall be considered:
⎯ earthing shall comply with 5.3.3;
⎯ for lighting devices outside fitted behind transparent impact resistant panels sealed to the powder spray
booth structure IP 54 of EN 60529 is sufficient;
⎯ For motor outside the powder spray booths at least IP44 of EN 60529 shall be used. Motors shall not be
positioned within an exhaust air duct;
⎯ Undesirable static discharges shall be avoided by adopting the earthing and interconnecting measures
specified in EN 50177.
NOTE 2 Further information on this topic is given in the CENELEC report R044-001 "Safety of machinery –
Guidance and recommendation for the avoidance of hazards due to static electricity".
5.6.2.4.3 Non electrical equipment
All non electrical equipment and components installed and located in potentially explosive atmosphere shall
be designed and constructed according to good engineering practice and shall be subjected to an ignition
hazard assessment in accordance with 5.2 of EN 13463-1:2001 to provide the protection required. The
equipment shall satisfy the requirements of EN 13463-1 and EN 13463-5.
Group II category 3D equipment according to EN 13463-1 for installation in zone 22 shall not contain any
effective ignition source in normal operation. Group II category 2D equipment according to EN 13463-1 for
installation in zone 21 shall not contain any effective ignition source in normal operation or expected
malfunction. Group II D equipment shall be defined by the actual maximum surface temperature and shall be
marked accordingly (see 6.1.3 of EN 13463-1:2001).
In particular the following requirements shall be observed:
⎯ hot surfaces of all apparatus inside the powder spray booth shall not be able to ignite coating powder
clouds. The admissible temperatures of these hot surfaces shall be described in 6.4.2 of
EN 1127-1:1997;
⎯ electrostatic charges shall be avoided according 7.4 of EN 13463-1:2001 and 5.5 of

EN 50177:1996;
⎯ mechanically moving parts shall not generate sparks in hazardous zones;
⎯ fans shall be designed and constructed according to !EN 14986".
5.6.2.5 Protective measures against explosion
To protect against possible explosions enclosed powder recovery systems (see Figure A.2 of Annex A) shall
be fitted with:
⎯ either explosion suppression according to prEN 14373 (see 3.18);
26
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
⎯ or explosion relief venting into a safe area (see 3.17) combined with explosion decoupling (see 3.19);
NOTE Explosion venting devices are described in prEN 14797 and dust explosion venting systems are described
in prEN 14491.
⎯ or explosion decoupling (see 3.19) combined with explosion pressure proof design of the enclosed
recovery system;
⎯ or rapid acting fire suppression to prevent flame propagation from the powder spray booth to the enclosed
recovery system, but only if the existence of ignition sources inside the enclosed recovery system can be
precluded.
5.7 Safety requirements and protective measures in case of failure of energy supply
If the failure of energy supply can give rise to powder coating material concentrations higher than those for
which the powder spray booth was designed and constructed and which could form an ignition source for an
explosion, this shall be taken into account during the design risk analysis and the selection of safety devices
to deal with the hazards identified by this European Standard, either single or in combination.
The following measures shall be considered in such circumstances e.g.:
a) interruption of the spraying process;
b) measures to prevent uncontrolled start-up (restart) – see EN 1037;
c) measures to negate or reduce the effect of reductions in forced ventilation flow rate such as:
⎯ emergency ventilation;
⎯ extended rundown characteristics of fan;
⎯ uninterrupted or back up power supply.
Failure and/or malfunction of control system can give faults, which are of the same nature as failure of energy
supplies.
To minimise the risks to safety the control systems shall be designed according to the requirements of
EN 954-1 and EN 60204-1 (see also 5.2.4).
Powder spray booths with the operator inside shall be equipped with a separate emergency power supply for
emergency lighting, fire detection and explosion protection system.
6 Verification of safety requirements and/or protective measures
6.1 General
Safety requirements detailed in Clause 5 shall be checked by testing, calculation, inspection or other methods
according to the following clauses.
Verification shall be checked before or after commissioning.
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EN 12981:2005+A1:2009 (E)
6.2 Verification of the mechanical safety requirements
6.2.1 General
The provision and efficiency of requirements defined in 5.2.1, 5.2.2 and 5.2.3 shall be made by physical
and/or visual verification.
The requirement of 600 lux minimum described in 5.2.3 can be checked by measurement. This measurement
may, for instance, be taken at the point of 1 m above the centre of the powder spray booth’s floor with the
luxmeter reading vertically upwards.
6.2.2 Control system
Verification of the requirements detailed in 5.2.4 shall be carried out by testing and visual inspection. The
presence, function and labelling of safety devices shall be checked.
6.3 Verification of the electrical safety requirements
6.3.1 Protective measures of contact with live parts
Compliance shall be checked according to requirements of EN 60204-1, EN 50050 and EN 50177.
Make sure that guards are fitted to prevent access to dangerous zones and that interlocking devices are
functioning.
6.3.2 Protective measures of earthing
The compliance of earthing shall be verified with ohmmeter.
6.3.3 Protective measures against electromagnetic influence
Compliance with EN 61000-6-1, EN 61000-6-3, EN 61000-6-4 shall be checked by means of documents of

the manufacturer of the supplied components.
6.3.4 Protective measures against electrostatic phenomena
Verification by means of measuring instruments check, whether the requirements are fulfilled within the
specified limits.
6.4 Verification of the safety requirements and measures against noise
The measurement of emission sound pressure levels at operator’s positions and of sound power level shall be
carried out according to !EN 14462:2005".
6.5 Verification of requirements against dangerous substances
6.5.1 Protective measures from contact with coating powder
Existence of instructions given in 7.2.2 shall be checked.
6.5.2 Preventive measures of inhalation of coating powder
6.5.2.1 General
Requirements of forced ventilation to prevent inhalation of coating powder shall be verified as follows:
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EN 12981:2005+A1:2009 (E)
6.5.2.2 Verification of airflow direction
Place a smoke generator in the coating powder application zone and check if forced ventilation extracts the
smoke.
6.5.2.3 Air velocity measurement
a) General case
The chosen equipment shall be directional and shall allow a measurement in the range from 0,15 m/s to 1 m/s
and shall be calibrated.
Measurements shall be performed in normal operating conditions without workpieces to be coated, except in
particular case of 5.5.2.3 b).
All doors and windows of the building opening onto the outside, capable of influencing the forced ventilation
shall be closed.
The duration of measurement for the average air velocity at each point shall be at least one minute.
1) Powder spray booth with operator inside (see Figure !C.1" of Annex !C").
The measurement plane is a horizontal plane located at 1 m from the ground of the powder spray
booth, whose dimensions are equal to the ground dimensions of the powder spray booth decreased
by 0,25 m on all sides (see Figure 1).
The measurement plane is divided in N equal rectangular areas (area over or equal to a 1 m square
side and less than or equal to a 1,5 m square side).
The centre of each area determines a measurement point.
The distance between measurement points of two adjacent areas shall be less than or equal to 1,5 m.
Only the nearest value to 1,5 m shall be retained.
For small powder spray booths, the number of measurement points shall be at least two in the length
and two in the width.
At each measurement point, air velocity shall be measured in the airflow direction, seeking for the
maximum value, which only shall be retained. Measured values shall comply with requirement given
in 5.5.2.3 a) 1).
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
1 m ≤ a ≤ 1,5 m
1 m ≤ b ≤ 1,5 m
Key
1 Measurement point
Figure 1 — Powder spray booth with operator inside - Measurement points
2) Powder spray booth with operator outside (see Figure !C.2" of Annex !C").
For each opening of the powder spray booth (see Figure 2) air measurement points shall be
determined by the centres of rectangular areas having sides not larger than 0,6 m.
At each measurement point, air velocity shall be measured in the airflow direction, seeking for the
maximum value, which only shall be retained. Measured values shall comply with requirements given
in 5.5.2.3 a) 2).
a<6m
b<6m
Key
1 Measurement plane
2 Opening
Figure 2 — Powder spray booth with operator outside - Measurement points
3) Powder spray booth without operator inside but with reciprocators for automatic spraying device
outside the booth (see Figure !C.3" of Annex !C").
The measurement points are the same as those defined in 6.5.2.3 a) 2).
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Measured values of air velocity through each opening shall comply with requirements given in
5.5.2.3 a) 3).
4) Powder spray booth with operator and with reciprocators for automatic spraying device outside the
booth (see Figure !C.4" of Annex !C").
The measurement points are the same as those defined in 6.5.2.3 a) 2).
5.5.2.3 a) 4).
5) Powder spray booth with operator inside and with reciprocators for automatic spraying device inside
the booth (see Figure !C.5" of Annex !C").
The measurement points are the same as those defined in 6.5.2.3 a) and in 6.5.2.3 a) 1).
5.5.2.3 a) 5).
b) Particular cases
Large well-defined workpiece shall be inside the powder spray booths and measurement points are located as
indicated in Figure 3 and at 1 m above floor.
Measured values shall comply with requirement given in 5.5.2.3 a) 1).
1 m ≤ a ≤ 1,5 m
1 m ≤ b ≤ 1,5 m
Key
1 Powder spray booth wall

2 Well defined workpiece
3 Measurement points
Figure 3 — Powder spray booth with large well-defined workpiece - Measurement points
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EN 12981:2005+A1:2009 (E)
6.5.2.4 Verification of ventilation performance
Verification of the requirement and/or measures detailed in 5.5.2.4 may be carried out by inspection and/or
testing of the function of the measures by placing a smoke generator in the openings of the powder spray
booth as required in 6.5.2 and checking that forced ventilation extracts the smoke.
6.6 Verification of the safety requirements and protective measures against fire and
explosion
6.6.1 Fire
6.6.1.1 Materials of construction
Check compliance with 5.6.1 according to material data in the specification by visual inspection and tests.
6.6.1.2 Fire detection system and interlocking
Check if the automatic fire detection system operates and control the equipment.
Check if all interlocks and controls work.
6.6.2 Explosions
6.6.2.1 Limitation of coating powder concentration
Verify if the maximum output of coating powder does not exceed the value for which the exhaust airflow is
calculated (see 5.6.2.2).
NOTE Information for the procedure in multizone powder spray booths is given in Annex B.
6.6.2.2 Classification in hazardous areas (according to 3.21)
Annex A gives figures relative to hazardous zones.
Verify if the installation and choice of the equipment is carried out according the required category relative to
the zone.
6.6.2.3 Measures to avoid or reduce ignition sources
Compliance of electrical and non-electrical equipment with required categories for ignition protection shall be
checked.
The good functioning of safety devices described in 5.2.4 shall be checked.
For earthing refer to 6.3.2.
6.6.2.4 Explosion protection
Check adequate size and setting up of explosion relief venting or explosion suppression or explosion
decoupling inside the enclosed powder recovery system.
Check if explosion relief is also venting where persons are not present or liable to be affected.
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EN 12981:2005+A1:2009 (E)
6.7 Verification of the safety requirements and protective measures against failure of
energy supply
Safety devices, fire detection and explosion protection systems shall be checked after connecting the powder
spray booth to a separate emergency power supply simulating an interruption of the main power supply.
7 Information for use
7.1 General
Information for use shall be drawn up in accordance with Clause 6 and in particular with 6.5 of
EN ISO 12100-2:2003 for instruction handbook.
The information for use shall be drawn up in one of the languages of the EEA. On being put in service, powder
spray booths shall be accompanied by a translation of the instructions into the language of the country in
which the powder spray booth is to be used and by the instructions in the original language issued by the
manufacturer.
Specifications for the installation, commissioning and use shall be provided together with normal maintenance
information for the powder spray booth and the intended use.
7.2 Instruction handbook
7.2.1 General
The instruction handbook shall contain the following minimum information:
⎯ description of the powder spray booth, the powder recovery system and safety devices;
⎯ design data, characteristics;
⎯ schematic diagrams for safety functions;
⎯ maximum allowed pressure drop through the air filtering system;
⎯ maximum size of the workpiece to be coated when an operator works inside the powder spray booth;
⎯ air velocity in m/s (measured according to this European Standard);
⎯ noise emission values determined according to EN 14462:2005;"
⎯ warnings against:
⎯ use of naked flames, incandescent objects, equipment or workpieces capable of generating

sparks (tools, equipment, etc.) in the powder spray booth;
⎯ smoking in the hazardous zone. A display showing "No smoking" shall be affixed to all entrances
to the powder spray booth;
⎯ use of organic solvents for cleaning inside the powder spray booth;
⎯ any storage of coating powder in the powder spray booth or in front of any doors.
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EN 12981:2005+A1:2009 (E)
Furthermore, the instruction handbook shall point at:
⎯ the use of qualified, trained and authorised personnel to carry out adjustments concerning the
powder spray booth for the operating conditions according to the manufacturer's specifications;
⎯ the wear of personal protection or breathing mask connected to fresh air when an operator shall work
in an insufficiently purified atmosphere (for instance when spraying on a preheated workpiece);
⎯ the availability of at least suitable manually operated fire extinguishers, if applicable (see 5.6.1).
7.2.2 Instructions for use
The instructions for use shall at least contain the following:
⎯ Information and instruction for fixing the booth and any constituting equipment to the floor. This
includes information about the necessary space to be reserved for the location of the machine in
such way that no additional crushing and shearing risk is created between the moving parts of the
machine or work-piece and other fixed adjacent machines, part of the building or stocks of material
etc.;
⎯ instructions on how to keep up the safety of surrounding areas where ventilation ducts, pipes and
chimneys pass through a wall. The fire resistance of this wall shall not be modified;
⎯ information relating to safe conditions of transportation and handling;
⎯ commissioning report (e.g. on compliance of earthing measures, air velocity, safety interlocks);
⎯ information relating to fitted safety devices and their function;
⎯ description of controls and their function;
⎯ instruction for start-up (operation);
⎯ information on earthing of workpieces before starting spraying;
⎯ instructions on making any adjustments;
⎯ information on cleaning;
⎯ information on the recommendations of the coating powder manufacturer;
⎯ instructions on the provision of antistatic footwear for operators;
⎯ instructions on the realisation of an antistatic flooring everywhere the operator is normally working
outside the powder spray booth;
⎯ instructions on appropriate arrangements (for example provision of suitable protective clothing) when
contact with materials used for coating powder or cleaning could cause dermatitis or other skin
complaints;
⎯ instructions on the use of personal protection or a breathing mask connected to fresh air, when an
operator enters the powder spray booth for adjustment, control or maintenance purposes;
⎯ the operating method to be followed in the event of accidents, breakdowns of blockages that are
likely to occur."
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
7.2.3 Information relating to maintenance
a) Prevention maintenance
The manufacturer shall inform, with consideration of the measures in 5.2.1.6, the user about the necessity to:
⎯ check at regular intervals the clogging of filtration and exhaust systems and as well as the deposits
on, walls and floor of the powder spray booth;
⎯ check at regular intervals the earthing of the powder spray booth;
⎯ measure at regular intervals the resistance to earth of max. 1 MΩ from the suspending point of each
workpiece by using an ohmmeter and a test voltage of 500 V (further details see 5.5 of
EN 50177:1996);
⎯ clean at regular intervals the workpiece suspension hooks to avoid the build-up of insulating layers of
coating powder;
⎯ replace filters at periodic intervals and how this can be done in a safe way.
Furthermore, the manufacturer shall provide
⎯ the necessary safety precautions to be taken in non-operating steps if a naked flame, incandescent
object or equipment or workpiece capable of generating sparks is brought into the powder spray
booths for maintenance work (for instance entire cleaning of the powder spray booth to remove
coating powder deposits).
In addition, information shall be given on:
⎯ measures to be taken in case of emergency;
⎯ decommissioning, dismantling and, as far as safety is concerned, disposal.
b) Corrective maintenance
The manufacturer shall inform the user that corrective maintenance shall only be carried out by a competent,
qualified person according to EN 60079-17 following the specifications of the manufacturer. The specification
shall mention:
⎯ means to detect and correct breakdowns and failures which might occur;
⎯ methods to identify all parts or materials that are replaceable;
⎯ causes of breakdowns or failures and how they appear;
⎯ the specifications of the spare parts to be used, when these affect the health and safety of
operators."
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
7.3 Marking
Whatever the type of powder spray booth, it shall be marked clearly and indelibly as laid out in 6.4 of
EN ISO 12100-2:2003 on one of the powder spray booth walls:
⎯ the business name and full address of the manufacturer and, where applicable, his authorised
representative;"
⎯ the year of construction, that is the year in which the manufacturing process is completed;"
⎯ designation of the machinery;"
⎯ type of powder spray booth (according to 3.1);
⎯ serial number;
⎯ maximum output of coating powder for which the recovery system and the forced ventilation has
been designed [g/h];
⎯ total surface of all openings [m²];

3
⎯ airflow output...................................... m /h;
⎯ power installed:
⎯ electric...................... (kVA);
⎯ other.............................
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex A
(normative)
Diagrams relative to hazardous zones

of potentially explosive atmosphere
Key
1 Internal volume/Zone 22 3 Open recovery system/Zone 22

2 Permanent opening/Zone 22
Figure A.1 a) – Powder spray booth with open Figure A.1 b) – Powder spray booth with open
recovery system with operator outside the booth recovery system with operator inside the booth
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Key
1 Internal volume/Zone 22 3 Duct/Zone 22

2 Permanent opening/Zone 4 Enclosed recovery system/Zone 20
Zone 22 formed by explosive area due to combustible dust/air mixture
Zone 20 formed by explosive area due to combustible dust/air mixture
Figure A.2 - Powder spray booth with enclosed recovery system
38
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex B
(normative)
Determination of concentration of combustible coating powder in terms

of LEL
B.1 Equations
In order to simplify the comparison with the lower explosion limit (LEL), the concentration is expressed as CLEL
(percentage of LEL).
100 × C
CLEL = (B.1)
LEL
The average concentration (mass) inside the powder spray booth depends on input of coating powder and
airflow:
M max
C= (B.2)
Qmin
The minimum airflow Qmin can be calculated from the air velocity v and the total cross section of openings:
Qmin = v × A × 3 600 (B.3)
where
C is the average concentration of combustible coating powder in air
in the powder spray booth g/m3
LEL is the Lower Explosion Limit of a combustible coating powder -air mixture. If
the data is not available, then the value of 20 g/m3 shall be used g/m3
CLEL is the concentration of combustible coating powder in terms of LEL in % of LEL
Mmax is the maximum quantity of organic coating powder sprayed per hour g/h
Qmin is the minimum airflow drawn in the powder spray booth which dilutes the m3/h
combustible coating powder to the required concentration level
v is the average air velocity m/s
A is the total cross section of openings (The total cross section includes all the m2
permanent openings - e.g. for ingress and egress for workpieces, openings
for the operators and spraying equipment)
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BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
If the powder spray booth is a multizone spray booth, each section shall be considered separately for the
calculation of CLEL. The concentration of the most unfavourable section shall be used (see 6.6.2).
B.2 Examples of calculation – Determination of concentration of combustible

coating powder on base of a given average design air velocity
Assumptions:
Powder spray booth (or section of application) parameters for airflow:
⎯ total cross section of openings A = 6 m2

⎯ average design air velocity v = 0,4 m/s
Mmax = 90 000 g/h
LEL = 20 g/m3
According (B.3):
Qmin = 6 m² x 0,4 m/s x 3 600 s/h = 8 640 m³/h
According (B.2):
90 000 g / h
C= = 10,42 g /m³
8 640m³ / h
According (B.1):
100 x 10,42 g / m³
C LEL = = 52,1 %
20 g / m³
Result:
If the forced ventilation of a powder spray booth is designed for an average air velocity of v = 0,4 m/s, (and
further assumptions described above are valid) then a nominal concentration of CLEL = 52,10 % is maintained.
In accordance to 5.6.2 only a maximum concentration of 50 % of LEL is allowed. In that case either the input
of coating powder Mmax or the total cross section of openings A has to be reduced or the air volume flow Qmin
has to be increased.
Starting from a maximum allowed concentration of 50% of LEL, according (B.1)
20 g / m³ × 50
C= = 10 g/m 3
100
According (B.2):
⎯ either the maximum output of coating powder is determined and the minimum air volume flow Qmin and
the average air velocity v can be calculated:
M max 90 000 g / h
Qmin = = = 9 000 m³ / h
C 10 g / m³
40
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Qmin 9 000 m³ / h
v= = = 0,42 m/s
A x 3 600 6 m² x 3 600
⎯ or the minimum air volume flow and the maximum output of coating powder Mmax can be calculated:
Mmax = Qmin x C = 8640m³/h x 10g/m³ = 86 400 g/h
Independent of the calculation above the design of the internal space of the powder spray booth shall consider
that the chosen air velocity allows an effective electrostatic coating process.
41
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
!deleted text"
42
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex C
(informative)
Diagrams relative to powder spray booths classification
The figures only describe examples for access and airflow direction for different kind of powder spray booths.
Arrows are indicating examples of airflow direction according to 5.5.2.2.
Figure !C.1" — Powder spray booth with operator inside the booth
Figure !C.2" — Powder spray booth with operator outside the booth
Figure !C.3" — Powder spray booth without operator but with reciprocators for automatic
spraying device outside the booth
43
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Figure !C.4" — Powder spray booth with operator and reciprocators for automatic spraying
device outside the booth
NOTE This could be an example for a multizone powder spray booth.
Figure !C.5" — Powder spray booth with operator and with reciprocators for automatic spraying
devices inside the booth
44
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex D
(informative)
Classification of construction material’s reaction to fire - National

standards
According to 5.6.1 of this European Standard, the specific properties for the materials of construction are
necessary for fire prevention and protection.
Presently there are no harmonised EN-standards for the fire behaviour of materials for construction for the fire
prevention and protection of machines.
Therefore, national standards shall prevail until harmonised CEN standards are available.
They are:
Austria ÖNorm B 3800-1 Behaviour of building materials and components

in fire; building materials: requirements and tests
ÖNorm B 3800-2 Behaviour of building materials and components
in fire – Components: Definitions, requirements,
tests
in fire – Special components: Definitions,
requirements, tests
in fire; components: assignation to the classes of
fire resistance
United Kingdom H.F.L '72 "Highly flammable liquids and liquefied

petroleum gases regulations"
and relevant parts of BS 476 "Fire tests on building materials and structures".
France NF P 92-501 "Safety against fire. Building materials. Reaction

to fire tests, radiation test used for rigid
materials, or for materials on rigid substrates
(flooring and finishes) of all thickness, and for
flexible materials thicker than 5 mm"
NF P 92-507 “Safety against fire – Materials for construction –

Reaction to fire tests – Classification according
to the reaction against fire”
Germany DIN 4102-1 "Fire behaviour of materials and components for
construction - Materials for construction –
Definitions, requirements and tests"
Italy UNI 9177 "Classification of materials - Reaction to fire of
combustible materials"
45
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex E
(informative)
References to National Exposure Limit Values

Exposure limit values are commonly defined by member states regulations. The national reference - as far as
known - are as follows:
Technical
References to national exposure limit values
Country terms for
for dangerous substances
limits
Amtliche Mitteilungen des Bundesministeriums für soziale Verwaltung (2/93) MAK
A
TRK
Koninklijk Besluit tot wijziging van Bijlage II van Titel II, Hoofdstruk II bis van
het ARAB wat de vaststelling van de grenswaarden voor blootstelling aan VLE
chemische agentina betreft
Order in council on the modification of Annex II of title II, chapter II bis from the
B VLE
ARAB that establishes the limit of exposure to chemical agents
Ordinance prise en conseil privé sur la modification de l’Annexe II du titre II,
chapitre II bis de l’ARAB qui établit les limites d’exposition des agents VLE
chimiques
Directive of Ministry of Health No. 58/1981 Coll., about principal hygienic
NPK
CzR requirements for maximum permitted concentration of the most important
NPK-P
injurants in air and assessment of Level of pollution
Instruction No 3.1.0.2., December 1996, Exposure Limit Values for Substances
DK GV
and Materials
SF At present unknown
Ministère du Travail: Décret 84-1093: aération et assainissement des locaux
VME
de travail
F
INRS ED 633: Guide pratique de ventilation - 9.Ventilation des cabines et
VLE
postes de peinture
Technische Regeln für Gefahrstoffe MAK TRK
D
TRGS 900 "Luftgrenzwerte" BAT
G At present unknown
ISL At present unknown
IRL At present unknown
Threshold Limit Values and Biological Exposure Indices published by American
I TLV
Conference of Governmental Industrial Hygienists, ACGIH
L At present unknown
NL Min. v. sociale Zaken en Werkgelegenheid P145: de nationale MAC-lijst 1996 MAC
N Administrative normer for forurensing i arbeidsatmosfaere 1996 AT 361
P At present unknown
ES At present unknown
(Threshold Limit values) AFS 1996:2 NGV,
S TGV
Hygieniska Gränsvärden KTV
CH Suva Publikation: Grenzwerte am Arbeitsplatz 1997 MAK
Maximale Arbeitsplatzkonzentrationswerte gesundheitsgefährdender Stoffe. BAT
Biologische Arbeitsplatztoleranzwerte – Arbeitshygienische Grenzwerte für
physikalische Einwirkungen
Health and Safety Executive MEL
GB
H&SE EH 40/97, Part 2: "List of occupational exposure limits and other tables" OES
46
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EN 12981:2005+A1:2009 (E)
Annex ZA
(informative)
Relationship between this European Standard and the Essential

Requirements of EU Directive 98/37/EC !, amended by 98/79/EC"
This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide one means of conforming to Essential Requirements of
the New Approach Directive for Machinery 98/37/EC, amended by Directive 98/79/EC.
!Once this standard is cited in the Official Journal of the European Communities under that Directive and
has been implemented as a national standard in at least one Member State, compliance with the normative
clauses of this standard confers, within the limits of the scope of this standard, a presumption of conformity
with the relevant Essential Requirements (except Essential Requirements 1.2.3, 1.2.4, 1.1.2 c), 3) of that
Directive and associated EFTA regulations."
WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard.
47
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Annex ZB
(informative)
!Relationship between this European Standard and the Essential

Requirements of EU Directive 2006/42/EC
This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide a means of conforming to Essential Requirements of the
Recast Machinery Directive 2006/42/EC.
Once this standard is cited in the Official Journal of the European Communities under that Directive and has
been implemented as a national standard in at least one Member State, compliance with the normative
clauses of this standard confers, within the limits of the scope of this standard, a presumption of conformity
rd
with the relevant Essential Requirements ((except Essential Requirements 1.2.1, 3 paragraph, 1.2.3, 1.2.4,
1.1.2 c), 1.7.4.2 o), 3)) of that Directive and associated EFTA regulations.
WARNING – Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard."
48
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
Bibliography
[1] EN 563, Safety of machinery — Temperatures of touchable surfaces — Ergonomics data to establish
temperature limit values for hot surfaces
[2] EN 574:1996, Safety of machinery — Two-hand control devices — Functional aspects — Principles for
design
[3] EN 614-1, Safety of machinery — Ergonomic design principles — Part 1: Terminology and general
principles
[4] EN 982, Safety of machinery — Safety requirements for fluid power systems and their components —
Hydraulics
[5] EN 983, Safety of machinery — Safety requirements for fluid power systems and their components —
Pneumatics
[6] EN 1005-4, Safety of machinery — Human physical performance — Part 4: Evolution of working postures
and movements in relation to machinery
[7] EN 1012-1, Compressors and vacuum pumps — Safety requirements — Part 1: Compressors
[8] EN 1050:1996, Safety of machinery — Principles for risk assessment
[9] EN 1760-1:1997, Safety of machinery — Pressure sensitive protective devices — Part 1: General
principles for the design and testing of pressure sensing mats and pressure sensitive floors
[10] EN 1760-2, Safety of machinery — Pressure sensitive protective devices — Part 2: General principles for
the design and testing of pressure sensing edges and pressure sensing bars
[11] EN 1953:1998, Atomising and spraying equipment for coating materials — Safety requirements
[12] prEN 12621:1996, Machinery for the supply and/or circulation of coating materials under pressure —
Safety requirements
[13] EN 14462:2002, Surface treatment equipment — Noise test code for surface treatment equipment
including its ancillary handling equipment — Accuracy grades 2 and 3
[14] EN 50053-2, Requirements for the selection, installation and use of electrostatic spraying equipment for
flammable materials — Part 2: Hand-held electrostatic powder spray guns with an energy limit of
5 mJ and their associated apparatus
[15] EN 60079-10, Electrical apparatus for explosive gas atmospheres — Part 10: Classification of hazardous
areas (IEC 60079-10:2002)
[16] EN 60079-14, Electrical apparatus for explosive gas atmospheres — Part 14: Electrical installations in
hazardous areas (other than mines) (IEC 60079-14:2002)
[17] EN 61000-6-2, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards; Immunity for
industrial environments (IEC 61000-6-2:1999, modified)
[18] EN 61241-10 Electrical apparatus for use in the presence of combustible dust – Part 10: Classification of
areas where combustible dust are or may be present (IEC 61241-10:2004)
[19] EN 61260, Electro acoustics — Octave band and fractional-octave-band filters (IEC 61230:1995)
49
BS EN 12981:2005+A1:2009
EN 12981:2005+A1:2009 (E)
[20] EN ISO 3743-1, Acoustics — Determination of sound power levels of noise sources — Engineering
methods for small, movable sources in reverberant fields — Part 1: Comparison method for hard-walled
test rooms (ISO 3743-1:1994)
[21] EN ISO 3744, Acoustics — Determination of sound power levels of noise sources using sound pressure
— Engineering method in an essentially free field over a reflecting plan (ISO 3744:1994)
[22] EN ISO 3747, Acoustics — Determination of sound power levels of noise sources using sound pressure
— Comparison method for use in situ (ISO 3747:2000)
[23] EN ISO 9614-1, Acoustics — Determination of sound power levels of noise sources using sound intensity
— Part 1: Measurements at discrete points (ISO 9614-1:1993)
[24] EN ISO 9614-2, Acoustics — Determination of sound power levels of noise sources using sound intensity
— Part 2: Measurement by scanning (ISO 9614-2:1996)
[25] EN ISO 11688-1:1998, Acoustics — Recommended practice for the design of low-noise machinery and
equipment — Part 1: Planning (ISO/TR 11688-1:1995)
[26] EN ISO 11688-2, Acoustics — Recommended practice for the design of low-noise machinery and
equipment — Part 2: Introduction to the physics of low-noise design (ISO 11688-2:1998)
[27] EN ISO 5167-1, Measurement of fluid flow by means of pressure differential devices inserted in circular
cross-section conduits running full — Part 1: General principles and requirements (ISO 5167-1:2003)
[28] ISO 8130-4, Coating powders — Part 4: Calculation of lower explosion limit
[29] ISO 8421-3:1989, Fire protection — Vocabulary — Part 3: Fire detection and alarm
[30] IEC 60364 (all parts), Electrical installations of buildings
[31] IEC 60384 (all parts), Fixed capacitors for use in electronic equipment
50
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BS EN
12981:2005
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(BS EN 12981 - 2005+A1 - 2009) - Coating Plants. Spray Booths For Application of Organic Powder Coating Material. Safety Requirements.

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BRITISH STANDARD BS EN

This British Standard is the UK implementation EN 12981:2005+A1:2009.

The UK participation in its preparation was entrusted by Technical Committee

This British Standard was Amendments/corrigenda issued since publication

ISBN 978 0 580 63168 9

ICS 87.100 Supersedes EN 12981:2005

Coating plants - Spray booths for application of organic powder

Installations d'application - Cabines d'application par Beschichtungsanlagen - Spritzkabinen für organische

EUROPEAN COMMITTEE FOR STANDARDIZATION

Management Centre: Avenue Marnix 17, B-1000 Brussels

6.2.2 Control system .................................................................................................................................... 28

This document includes Amendment 1, approved by CEN on 2009-02-22.

This document supersedes EN 12981:2005.

This European Standard includes a Bibliography.

⎯ forced ventilation system;

⎯ air filtering and coating powder recovery system;

⎯ coating powder recycling system;

⎯ air conditioning system;

⎯ automatic cleaning system;

⎯ monitoring and/or control systems;

⎯ fire detection and interlocking system;

⎯ explosion protection system;

⎯ powered doors and gates

NOTE Powder spray booths are classified in Annex !C".

⎯ the content of marking;

⎯ the minimum requirements for use.

1.2 This European Standard does not cover:

c) spraying equipment as covered by EN 1953, EN 50050, EN 50177;

e) all loading and unloading systems;

EN 775, Manipulating industrial robots — Safety (ISO 10218:1992, modified)

EN 1037, Safety of machinery — Prevention of unexpected start-up

EN 13478, Safety of machinery — Fire prevention and protection

!EN 14986", Design of fans working in potentially explosive atmospheres

EN 50177:1996, Automatic electrostatic spraying installations for flammable coating powder

EN 60204-1:1997, Safety of machinery — Electrical equipment of machines — Part 1: General requirements

EN 60529, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)

EN 61496-1:2004, Safety of machinery — Electro-sensitive protective equipment — Part 1: General

3 Terms and definitions

Limits of hazardous zones are given in Annex A

NOTE Equipment of category 2D is suitable for use in zone 21 and 22.

NOTE Equipment of category 3D is suitable for use in zone 22.

NOTE In flash off space no spraying takes place.

⎯ workpieces or parts of workpieces

Particular points of danger are:

4 List of significant hazards

NOTE 3 Information on the method of risk analysis is given in EN 1050.

4.2 Mechanical hazards

4.2.1 Shearing, crushing, cutting, entanglement, drawing-in, impact hazards

⎯ product handling systems (e.g. hazard from inrunning nip);

⎯ powered doors and gates;

4.2.2 Entrapment hazard

This hazard may occur, for instance:

4.2.3 Personnel's slip, trip and fall hazards

These hazards may be increased as a result of poor lighting.

4.3 Electrical hazards

4.3.1 Electrical shock (by direct or indirect contact)

Such hazards may occur, for instance, by touching:

⎯ electrically live parts when insulation is insufficient or damaged by mechanical influences.

4.3.2 Faulty earthing

Such hazards may occur, for instance:

⎯ by defective bonding to the protective earth system;

⎯ when resistance to earth is too high.

4.3.3 Electromagnetic influences