BRITISH STANDARD BS EN

692:2005
+A1:2009
Incorporating
corrigendum
December 2007

Machine tools —
Mechanical presses —
Safety

ICS 25.120.10

12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:
BS EN 692:2005

National foreword

This British Standard is the UK implementation of EN 692:2005+A1:2009.

It supersedes BS EN 692:2005, which is withdrawn.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 to Technical Committee

MTE/1, Machine tools.
A list of organizations represented on this committee can be obtained on
request to its secretary.

WARNING
BSI, as a member of CEN, is obliged to give EN 692:2005 the status of a
British Standard. However, attention is drawn to the fact that during the
development of this European Standard the UK committee consistently voted
against its approval as a European Standard.
In the opinion of the UK committee, certain safety requirements in this
standard are inadequate in respect of some state of the art machines
currently in use in the UK. As a result, BS EN 692:2005 can be considered
not to offer a presumption of conformity with the relevant essential
requirements of the EC Machinery Safety Directive (98/37/EC), as
implemented in the UK by the Supply of Machinery (Safety) Regulations
1992 (as amended), which is claimed for it. The concerns of the UK committee
specifically relate to the protection of personnel against access to the danger
zone at manually loaded/unloaded machines as specified in Annex IV of the
Directive.
The attention of users is drawn to clauses 5.3.2 and 5.3.3 in so far as the use
of two-hand control device(s) is concerned. Where these devices are provided
as the sole safeguard, it is the view of the UK committee that they do not
adequately control the risk of serious crushing and shearing injuries to the
upper limbs of workers other than the operator of the device.
Users of this standard are therefore strongly advised to implement this
provision with caution.

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 Amd. No. Date Comments
on 14 December 2005
17169 31 December 2007 Addition of WARNING to national
Corrigendum No. 1 foreword

© BSI 2009 31 July 2009 Implementation of CEN amendment

A1:2009

ISBN 978 0 580 61243 5

EUROPEAN STANDARD EN 692:2005+A1
NORME EUROPÉENNE
EUROPÄISCHE NORM February 2009

ICS 25.120.10 Supersedes EN 692:2005

English Version

Machine tools - Mechanical presses - Safety

Machines-outils - Presses mécaniques - Sécurité Werkzeugmaschinen - Mechanische Pressen - Sicherheit

This European Standard was approved by CEN on 22 July 2004 and includes Amendment 1 approved by CEN on 29 December 2008.

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: rue de Stassart, 36 B-1050 Brussels

© 2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 692:2005+A1:2009: E
worldwide for CEN national Members.
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Contents

page
1 Scope .............................................................................................................................................................. 5
2 Normative references .................................................................................................................................... 6
3 Terms, definitions and abbreviations .......................................................................................................... 7
3.1 Terms and definitions ................................................................................................................................... 7
3.2 Abbreviations ............................................................................................................................................... 10
4 List of significant hazards .......................................................................................................................... 11
5 Safety requirements and/or measures ...................................................................................................... 14
5.1 Introduction .................................................................................................................................................. 14
5.2 Basic design considerations ...................................................................................................................... 14
5.2.1 Brakes and clutches .................................................................................................................................... 14
5.2.2 Presses with part revolution clutches (friction clutches)........................................................................ 15
5.2.3 Hydraulic and pneumatic systems - Common features........................................................................... 15
5.2.4 Pneumatic systems ..................................................................................................................................... 16
5.2.5 Hydraulic systems ....................................................................................................................................... 16
5.2.6 Slide adjustment and stroke adjustment .................................................................................................. 16
5.3 Mechanical hazards in the tools area ........................................................................................................ 17
5.4 The control and monitoring system........................................................................................................... 21
5.4.1 Control and monitoring functions.............................................................................................................. 21
5.4.2 Part revolution clutch presses: redundancy and monitoring of clutch/brake control systems,
and overrun monitoring for single cycle use ............................................................................................ 22
5.4.3 Muting ........................................................................................................................................................... 24
5.4.4 Programmable electronic systems (PES), programmable pneumatic systems (PPS) and safety
related functions .......................................................................................................................................... 24
5.4.5 Selector switches......................................................................................................................................... 24
5.4.6 Isolation switch ............................................................................................................................................ 25
5.4.7 Position switches......................................................................................................................................... 25
5.4.8 Control devices ............................................................................................................................................ 25
5.4.9 Valves ............................................................................................................................................................ 25
5.5 Tool-setting, trial strokes, maintenance and lubrication ......................................................................... 26
5.6 Mechanical hazards - other ......................................................................................................................... 27
5.7 Slips, trips and falls ..................................................................................................................................... 27
5.8 Protection against other hazards ............................................................................................................... 27
5.8.1 Electrical hazards ........................................................................................................................................ 27
5.8.2 Thermal hazards .......................................................................................................................................... 28
5.8.3 High pressure fluid ejection hazards ......................................................................................................... 28
5.8.4 Hazards generated by noise ....................................................................................................................... 28
5.8.5 Hazards generated by vibration ................................................................................................................. 29
5.8.6 Hazards generated by materials and substances .................................................................................... 29
5.8.7 Hazards generated by neglecting ergonomic principles ......................................................................... 30
6 Verification of the safety requirements and/or measures ....................................................................... 39
7 Information for use ...................................................................................................................................... 47
7.1 Marking ......................................................................................................................................................... 47
7.2 Instruction handbook .................................................................................................................................. 48
Annex A (normative) Interlocking guards .............................................................................................................. 50
A.1 Presses with part revolution clutches ....................................................................................................... 50
Annex B (normative) Calculation of minimum safety distances ......................................................................... 53
Annex C (informative) Electro-sensitive protective equipment (ESPE) using active opto-electronic
protective devices (AOPDs)........................................................................................................................ 55
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EN 692:2005+A1:2009 (E)

Annex D (informative) Closed tools ....................................................................................................................... 56

Annex E (informative) The setting of the rotary cam arrangement ..................................................................... 57
E.1 Basic features of the eccentric adjustment and rotary cam arrangement ............................................ 57
E.2 Determination of the position where muting begins ............................................................................... 63
Annex F (informative) Determination of the overall response time T ................................................................. 66
Annex G (normative) Conditions for noise measurement of mechanical presses ........................................... 70
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/EC, amended by Directive 98/79 EC ........................................... 72
Annex ZB (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC"
" ........................................................................................... 73

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EN 692:2005+A1:2009 (E)

Foreword
This document (EN 692:2005+A1:2009) has been prepared by Technical Committee CEN/TC 143 “Machine tools -
Safety”, the secretariat of which is held by SNV.

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 August 2009, and conflicting national standards shall be withdrawn at the latest by
December 2009.

This document includes Amendment 1, approved by CEN on 2008-12-29.

This document supersedes !692:2005".

The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".

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."

!Annexes A, B and G to this standard are normative, whereas Annexes C, D, E, F, ZA and ZB are informative.
"

Organisation contributing to the preparation of this European Standard include the European Manufacturer
Association CECIMO.

NOTE The safety requirements related to the use of PES or PPS will be dealt with at its next revision.

The European Standards produced by CEN/TC 143 are particular to machine-tools and complement the relevant A
and B standards on the subject of general safety (see introduction of EN 292-1:1991 for a description of A, B and C
standards).

!deleted text"

!EN 692:2005" constitutes a revision of EN 692:1996 for which it has been technically revised : the main
modifications are listed below :

 Withdrawal of mechanical presses with full revolution clutches,

 Tacking into account of some additive requirements about the use of closed tools and fixed' enclosing guard(s)
as protective devices (sub clauses 5.3.4, 5.3.9, 5.3.10 and 5.4.5.3),

 Addition of requirements on the implementation of protective devices for powering on the machine,

 Redrafting in order to ensure the coherence with the requirements of EN 693.

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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EN 692:2005+A1:2009 (E)

Introduction
This standard has been prepared to be a harmonised standard to provide one means of conforming with the
essential safety requirements of the Machinery Directive and associated EFTA Regulations.

This document is a C-type standard as stated in EN ISO 12100-1.

The machinery concerned and the extent to which hazards, hazardous situations and events are covered are
indicated in the scope of this standard.

When provisions of this C type standard are different from those which are stated in A or B standards, the provision
of this C type standard take precedence over the provisions of the other standards for machines that have been
designed and built according to the provisions of this C type standard.

Complementary guidance is given in the A and B standards to which reference is made in the text (see clause 2).
The figures are intended to be examples only and not to give the only interpretation of the text.

The requirements of this European Standard concern designers, manufacturers, suppliers and importers of
machines described in the scope.

This standard also includes information to be provided by the manufacturer to the user.

1 Scope
1.1 This European Standard specifies technical safety requirements and measures to be adopted by persons
undertaking the design, manufacture and supply of mechanical presses with part revolution clutch hereinafter
called presses which are intended to work cold metal or material partly of cold metal.

NOTE The design of a machine includes the study of the machine itself, taking into account all phases of its “life”,
i.e. construction, transport and commission (including assembly, installation and adjustment), use (including setting,
teaching/programming or process changeover, operation, cleaning, fault finding and maintenance) and de-
commissioning, dismantling and, as far as safety is concerned, disposal, and the drafting of the instructions related
to all above-mentioned phases of the “life” of the machine (except construction), dealt with it in 6.5 of EN ISO
12100-2:2003.

1.2 This European Standard also covers presses, whose primary intended use is to work cold metal, which are
to be used in the same way to work other sheet materials (such as cardboard, plastic, rubber or leather), and metal
powder.

1.3 The requirements in this standard take account of intended use, as defined in 3.22 of EN ISO 12100-1:2003.
This standard presumes access to the press from all directions, deals with the hazards during the various phases
of the life of the machine described in clause 4, and specifies the safety measures for both the operator and other
exposed persons.

1.4 This European Standard also applies to ancillary devices which are an integral part of the press. This
standard also applies to machines which are integrated into an automatic production line where the hazards and
risk arising are comparable to those of machines working separately.

1.5 This European Standard does not cover mechanical presses with full revolution clutch.

1.6 This European Standard does not cover machines whose principal designed purpose is:

a) sheet metal cutting by guillotine;

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BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

b) attaching a fastener, e.g. riveting, stapling or stitching;

c) bending or folding;

d) straightening;

e) turret punch pressing;

f) extruding;

g) drop forging or drop stamping;

h) compaction of metal powder;

i) single purpose punching machines designed exclusively for profiles, e.g. for the construction industry.

1.7 This European Standard is not applicable to machines which are manufactured before the date of publication
of this document 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 294:1992, Safety of machinery - Safety distances to prevent danger zones being reached by the upper limbs.

EN 349:1993, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.

EN 418:1992, Safety of machinery - Emergency stop equipment, functional aspects - Principles for design.

EN 563:1994, Safety of machinery - Temperatures of touchable surfaces - Ergonomics data to establish

temperature limit values for hot surfaces.

EN 574:1996, Safety of machinery - Two-hand control devices - Functional aspects - Principles for design.

EN 626-1:1994, Safety of machinery - Reduction of risks to health from hazardous substances emitted by
machinery - Part 1: Principles and specifications for machinery manufacturers.

EN 842:1996, Safety of machinery - Visual danger signals - General requirements, design and testing.

EN 953:1997, 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.

EN 982:1996, Safety of machinery - Safety requirements for fluid power systems and their components -
Hydraulics.

EN 983:1996, Safety of machinery - Safety requirements for fluid power systems and their components -
Pneumatics.

EN 999:1998, Safety of machinery - The positioning of protective equipment in respect of approach speeds of parts
of the human body.

EN 1005-2:2003, Safety of machinery - Human physical performance - Part 2: Manual handling of machinery and
component parts of machinery.

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EN 692:2005+A1:2009 (E)

EN 1037:1995, Safety of machinery - Prevention of unexpected start-up.

EN 1050:1996, Safety of machinery - Principles for risk assessment.

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 - Part 1: Basic concepts and
methodology.

EN 1299:1997, Mechanical vibration and shock - Vibration isolation of machines - Information for the application or
source isolation.

EN 60204-1:1997, Safety of machinery - Electrical equipment of machines - Part 1: General requirements (IEC
60204-1:1997).

EN 61310-2:1995, Safety of machinery - Indication, marking and actuation - Part 2: Requirements for marking
(IEC 1310-2:1995).

EN 61496-1:2004, Safety of machinery - Electro-sensitive protective equipment - Part 1: General requirements and
tests (IEC 61496-1:2004, modified).

CLC/TS 61496-2:2003, Safety of machinery - Electrosensitive protective equipment - Part 2: Particular

requirements for equipment using active opto-electronic protective devices (AOPDs) (IEC 61496-2:1997).

EN ISO 3746:1995, Acoustics - Determination of sound power levels of noise sources using sound pressure -
Survey method using an enveloping measurement surface over a reflecting plane (ISO 3746:1995).

! EN ISO 4871:1996, Acoustics - Declaration and verification of noise emission values of machinery and
equipment (ISO 4871:1996)"

EN ISO 11202:1995, Acoustics - Noise emitted by machinery and equipment - Measurement of emission sound
pressure levels at work station and at other specified positions - Survey method in situ (ISO 11202:1995).

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)

ISO 8540:1993, Open front mechanical power presses - Vocabulary.

3 Terms, definitions and abbreviations

For the purposes of this European Standard, the terms and definitions given in EN ISO 12100-1:2003 and
EN ISO 12100-2:2003 and in relevant type A and type B standards, and the following apply.

3.1 Terms and definitions

3.1.1
band brake
brake (see 3.1.2) where a flexible band lined with friction material is arranged around the circumference of a drum

3.1.2
brake
mechanism (usually friction) intended to stop and hold the slide when the clutch, if provided, is disengaged

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EN 692:2005+A1:2009 (E)

3.1.3
clutch
mechanism used to impart the movement of the flywheel to the slide

3.1.4
clutch - full revolution
type of clutch that, when tripped or actuated, cannot be disengaged until the slide has completed a complete
stroke, e.g. most positive key clutches. It also includes clutches which can only be disengaged at certain positions
in the operating cycle

3.1.5
clutch - part revolution
type of clutch that can be engaged or disengaged at any point in the stroke of the slide, e.g. most friction clutches

3.1.6
cycle - automatic
operating mode where the slide repeats continuously or intermittently, all functions achieved without manual
intervention into the danger zone after initiation

3.1.7
cycle - operating
movement of the slide from the cycle start position (normally the top dead centre) to the bottom dead centre and
back to the cycle stop position (normally the top dead centre). The operating cycle includes all operations carried
out during this movement

3.1.8
cycle - single
operating mode where each operating cycle of the slide has to be positively actuated by the operator

3.1.9
dead centres
points at which the tool, during its travel, is

 either nearest/closest to the die (generally it corresponds to the end of the closing stroke), known as the
bottom dead centre (BDC),

 or furthest from the die (generally it corresponds to the end of the opening stroke), known as the top dead
centre (TDC)

3.1.10
die
fixed part of the tools used in a press

3.1.11
die cushion
accessory for a die which accumulates and releases, or absorbs, force as required in some press operations

3.1.12
direct drive
type of driving arrangement wherein no clutch is used: movement of the slide is accomplished by energising and
de-energising the motor, possibly in conjunction with a brake

3.1.13
early opening interlocking guard
guard associated with an interlocking device which, if opened when any dangerous movement in the tools area has
ceased, does not interrupt the operating cycle

3.1.14
guard locking device
mechanical device to maintain an interlocking guard gate in the closed and locked position until the risk of injury
from the hazardous machine functions has passed
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EN 692:2005+A1:2009 (E)

3.1.15
limited movement control device; inching device
control device, a single actuation of which, together with the control system of the machine, permits only a limited
amount of travel of a machine element

[3.26.9 of EN ISO 12100-1:2003]

3.1.16
mechanical press
machine designed or intended to transmit energy from a prime mover to a tool by mechanical means for the
purpose of the working (e.g. forming or shaping) of cold metal or material partly of cold metal between the tools.
Such energy is transmitted by a flywheel and part revolution clutch or by means of a direct drive mechanism (see
Figure 1)

3.1.17
monitoring (M)
safety function which ensures that a safety measure is initiated if the ability of a component or an element to
perform its function is diminished, or if the process conditions are changed in such a way that hazards are
generated

3.1.18
muting
temporary automatic suspension of a safety function(s) by safety related parts of the control system during
otherwise safe conditions in the operation of a machine

[3.7 of EN 954-1:1996]

3.1.19
overall system stopping performance; overall response time
time occurring from actuating the protective device to the cessation of hazardous motion, or to the machine
assuming a safe condition

3.1.20
overrun
movement of the crankshaft past a defined stopping point, e.g. TDC

3.1.21
overrun monitoring device
device which provides a signal to inhibit further machine initiation when the overrun exceeds the pre-set limit(s)

3.1.22
position switch
switch which is operated by a moving part of the machine when this part reaches or leaves a predetermined
position

3.1.23
redundancy (R)
application of more than one device or system, or part of a device or a system, with the objective of ensuring that,
in the event of one failing to perform its function, another is available to perform that function

[3.47 of EN 60204-1:1997]

3.1.24
shut height
distance from the bed-plate surface to the slide surface measured with the maximum variable stroke, stroke down
and slide adjustment up

[3.12 of ISO 8540:1993]

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EN 692:2005+A1:2009 (E)

3.1.25
single stroke function
feature used to limit the motion of the tool to one operating cycle at each engagement of the clutch even if the
stroke initiating means (e.g. a pedal) is held in the operating position

3.1.26
slide
main reciprocating press member which holds the tool

3.1.27
tool
moving part of the tools

3.1.28
tools
term for the combination of tool and die

3.1.29
tools - closed
tools designed and constructed to be inherently safe (see Figure D.1)

3.2 Abbreviations

M Monitoring (see 3.1.17)

R Redundancy (see 3.1.23)

S Single channel

BDC Bottom dead centre (see 3.1.9)

TDC Top dead centre (see 3.1.9)

PES Programmable electronic system PPS Programmable pneumatic system

AOPD Active opto-electronic protective device

ESPE Electro-sensitive protective equipment

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EN 692:2005+A1:2009 (E)

Key
1 Flywheel guard 6 Slide
2 Clutch/brake 7 Slide flange, tool holder
3 Flywheel 8 Bed-plate/bolster
4 Motor pulley 9 Bed
5 Belt 10 Pedal

Figure 1 — Example of mechanical power press (tools area safeguards not shown)

4 List of significant hazards

4.1 The list of hazards contained in Table 1 is the result of a risk assessment, carried out as required by
EN 1050, for all mechanical presses covered by the scope of this standard. The technical measures and
information for use contained in Clauses 5 and 7 and Annexes A, B, C, E and F are based on the risk assessment,
and deal with the identified hazards by either eliminating them or reducing the effects of the risks they generate.

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EN 692:2005+A1:2009 (E)

4.2 Risk assessment assumes foreseeable access from all directions, as well as overruns, unexpected and
unintended strokes or gravity falls. Risks to both the operators and other persons who can have access to the
danger zones are identified, taking into account all hazards which can occur during the life of the press. The
assessment includes an analysis of the effect of failure in the control system.

4.3 In addition, the user of this standard, i.e. the designer, manufacturer or supplier, shall conduct a risk
assessment in accordance with EN 1050 with particular attention to:

 the intended use of the press including maintenance, tool-setting and cleaning, and its reasonably foreseeable
misuse;

 the identification of the significant hazards associated with the press (see 4.4).

4.4 Table 1 of this standard is a list of significant hazards and their related danger zones normally associated
with a mechanical power press. As part of the risk assessment, the designer shall verify whether the list of hazards
in Table 1 is exhaustive and applicable to the press under consideration.

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EN 692:2005+A1:2009 (E)

Table 1 — Significant hazards, danger zones, preventive measures

Preventive Relevant
Hazards Danger zone measures: relevant clauses of
clauses of this EN ISO 12100-
standard 1:2003
Mechanical hazards
Crushing hazard Tools area: 5.3 to 5.5 4.2.1
Shearing hazard - between moving tools Annexes A, B, C, D
Cutting or severing hazard - moving slide and E
Entanglement hazard - moving die cushions
Drawing-in or trapping hazard - work-piece ejectors
- guards
Impact hazard Moving parts of electrical, 4.2.1
hydraulic and pneumatic
equipment
Motor and drive machinery 5.6.1 to 5.6.3
Mechanical handling device 5.6.1 to 5.6.4
During installation, setting
operation , maintenance.
Ejection hazard Machine components 5.6.5
Work-pieces and tools 7.2.2 i)
High pressure fluid ejection Hydraulic systems 5.8.3 4.2.1
hazard
Slip, trip and fall hazards All work at heights 5.7 4.10
Floor area around the press
Electrical hazards
Direct contact hazard Electrical equipment 5.8.1 4.3
Indirect contact hazard Electrical equipment 5.8.1 4.3
Parts made live by electrical
equipment under fault conditions
Thermal radiation hazard (burns)
Thermal hazards resulting in Brakes, clutches, parts of the 5.8.2 4.4
burns and scalds, by a possible hydraulic system
contact of persons
Hazards generated by noise Any area at the press where 5.8.4 4.5
resulting in hearing losses (deaf- there is a risk to hearing
ness)
Hazards generated by vibra- Parts of the press where the risk 5.8.5 4.6
tion occurs, e.g. the workstation(s)
Hazards generated by mate-
rials and substances proces-
sed, used or exhausted by
machinery, for example:
Hazards resulting from contact Hydraulic systems; pneumatic 5.8.6.1 to 5.8.6.4 4.8
with or inhalation of harmful systems and their controls; toxic
fluids, gases, mists, fumes and work materials
dusts
Fire or explosion hazards Exhaust ventilation and dust 5.8.6.5 4.8
collection equipment
Hazards generated by neglect- The working position and 5.8.7 4.9
ing ergonomic principles in controls for operators and
machine design (mismatch of maintenance staff handling tools
machinery with human characte-
ristics and abilities) caused, for
example, by unhealthy postures
or excessive efforts

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EN 692:2005+A1:2009 (E)

5 Safety requirements and/or measures

5.1 Introduction

Mechanical presses covered by this standard range in size from small high speed machines with a single operator
producing small work-pieces to large relatively slow speed machines with several operators and large complex
work-pieces.

The methods or measures to be implemented to eliminate the significant hazards are specified in Table 1. The
methods and measures for reducing associated risks are as follows:

 basic design considerations for major press components or systems (see 5.2);

 safeguarding against mechanical hazards in the tools and associated area under different modes of production
(see 5.3 and Tables 2, 3 and 4);

 protection against hazards due to control system or control component failures (see 5.4);

 safeguarding against hazards which can occur during tool-setting, trial strokes, maintenance and lubrication
(see 5.5);

 safeguarding against other hazards (see 5.6 to 5.8).

Presses shall comply with the safety requirements and/ or measures of this clause. In addition, the machine shall
be designed according to the principles of EN ISO 12100-1 for hazards relevant but not significant which are not
dealt with by this standard (e.g. sharp edges).

5.2 Basic design considerations

5.2.1 Brakes and clutches

5.2.1.1 Fluid or air pressure shall not be used to apply a brake unless means are provided to ensure that, in
the event of loss of fluid or air pressure, the integrity of the brake is maintained and the clutch is disengaged.
Diaphragms shall not be used to apply a brake.

5.2.1.2 The designer shall ensure that:

a) the springs used for applying the brake or disengaging the clutch are of compression type;

b) multiple spring assemblies are used;

c) all the springs are closely uniform in dimension, quality and rating;

d) the means of loading the springs are such that, when adjusted, the spring anchorages can be locked to
prevent slackening back;

e) the arrangements for spring housing and guiding, and of guide pins, are such as to minimize binding;

f) the brake can function even if 50 % of the spring assembly has failed.

5.2.1.3 The engagement and disengagement of the clutch and brake shall not affect their safe function.

NOTE Combined clutch and brake units are recommended so as to reduce the possibility of the overlapping of their
engagement.

5.2.1.4 The brake and the clutch shall be designed so that failure of component e.g. for power transmission or
screws do not stress other components in such a way that rapid consequential dangerous failure is possible.

5.2.1.5 Any heat generated which can cause a hazardous situation shall be dissipated.
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5.2.1.6 Effective arrangements shall be made to prevent penetration of lubricants to the brake friction
surfaces, when this is not intended by the brake design.

5.2.1.7 The clutch and brake shall be designed in such a way that any moisture, dust or lubricating oil, which
breaks or corrodes packing material (e.g. gaskets and seals), cannot influence the required function adversely, e.g.
by obstructing an air channel or otherwise affecting their efficiency.

5.2.1.8 The design shall be such that the accumulation of dust, fluid or debris is minimized in areas likely to
give rise to inefficient brake performance and broken or loose components shall not cause brake failure.

5.2.1.9 Band brakes shall not be used on mechanical presses for the purpose of stopping the slide.

5.2.2 Presses with part revolution clutches (friction clutches)

5.2.2.1 Clutches shall be of a capacity capable of engaging and disengaging the stroke in the correct position,
without excessive temperature rise, under conditions of maximum use of the clutch.

5.2.2.2 Sufficient working clearances shall be provided so as to ensure that, under the severest conditions of
operation, friction drag leading to undesired movement of the driven members will not take place.

5.2.2.3 Arrangements shall be made to prevent the accumulation of debris evolved from frictional surfaces in
places where it can give rise to inefficient clutch performance, and for its effective dispersal.

5.2.2.4 The clutch and its control system shall be designed so that, in the event of failure of pneumatic,
hydraulic or electrical supply, the clutch is disengaged and the brake is immediately applied.

5.2.2.5 If diaphragms are used in a clutch system, measures shall be taken to avoid damage by the cutting
effect of sharp edges or wearing by rough surfaces. Evacuation of air shall not be prevented due to slackening of
the diaphragm, e.g. due to material fatigue.

5.2.3 Hydraulic and pneumatic systems - Common features

5.2.3.1 The requirements in EN 982 and EN 983 shall be taken into consideration in designing hydraulic and
pneumatic systems, which shall comply with the particular requirements in 5.2.3, 5.2.4 and 5.2.5.

5.2.3.2 Filters, pressure regulators and low pressure cut-off arrangements shall be provided.

5.2.3.3 Devices shall be provided to ensure that the permitted range of working pressure is maintained.

5.2.3.4 Bowls of glass and plastic shall be protected to prevent injury from flying particles without affecting
visibility.

5.2.3.5 All piping, pipe fittings, passages, surge or storage tanks and cored or drilled holes, shall be free from
burrs or foreign matter which can cause damage to valves or clutch and brake operating parts. See 5.3.4.2 of
EN 982:1996 and 5.5.3.2 of EN 983:1996.

5.2.3.6 Each run of piping shall, where practicable, be continuous from one piece of apparatus to another.
Precautions shall be taken to prevent damage by thermal expansion. Rigid piping shall be securely supported at
frequent intervals to avoid vibration or movement. Care shall be taken to avoid kinking of flexible pipes used to
carry fluids. Such kinking can cause traps which prevent the fluid exhausting. This applies particularly to piping
feeding the running joint of the clutch and brake.

5.2.3.7 Where a drop in pressure can lead to unintended dangerous motion of the slide, flexible piping shall
not be used, pipes and pipe connections shall be chosen to prevent such a loss of pressure. Such pipe
connections shall not be made with compression fittings, glued rings or similar devices. They shall be made by
means of positive connecting joints or by the welding of two fitted surfaces.

5.2.3.8 Operating valves shall not depend on connected piping for support. This is to avoid undesirable effects
from vibration which can affect both valves and piping.

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5.2.3.9 Operating valves shall be so designed as to ensure that, when in the non-operating position, leakage
past the inlet valve will escape sufficiently freely to prevent build-up of pressure in the clutch operating cylinder.

5.2.3.10 Operating valves shall be so designed that it is not possible for both the inlet port and the exhaust
ports to remain closed at the same time.

5.2.3.11 Exhaust ports and piping between clutch operating cylinders and valves shall be of sufficient capacity
to ensure prompt release of fluid from clutch operating cylinders. Precautions shall be taken to ensure that the
exhaust ports of operating valves are of adequate size to prevent residual pressure in the cylinder. The valve shall
be selected so that the pressure ratio between clutch and brake is such that the residual pressure in the cylinder
will not become excessive in the event of a valve fault.

NOTE Normally, a ratio of at least 3,5 to 1 between spring pressure in the brake and residual pressure in the cylinder is
satisfactory.

5.2.3.12 Control valves and other control components (e.g. regulators and manometers) shall be mounted in
positions which provide adequate accessibility and avoid damage (see 5.2.1 of EN 982:1996).

5.2.3.13 Where valves are manually or mechanically (as distinct from electrically) operated, the arrangements
for restoring the valves to the position of clutch disengagement at the end of the cycle shall be positive in character
(i.e. when the actuator of the valve is released the valve shall automatically move to the safe position). See also
5.4.9.

5.2.4 Pneumatic systems

5.2.4.1 Where valves or other parts of the press control system require lubrication, visible automatic means of
lubrication shall be provided to introduce the oil into the air line in suitable form.

5.2.4.2 Where silencing systems are fitted, they shall be provided and installed in accordance with the valve
manufacturer's instructions for use in safety systems, shall not affect safety function and their effect on braking
performance shall be taken into account. Only non-clogging direct to atmosphere silencers are permissible.

5.2.4.3 Water separators shall be provided.

5.2.5 Hydraulic systems

5.2.5.1 Suitable pressure relief valve(s) shall be provided in hydraulic systems having a hydraulic pumped
supply. Means shall be provided to release trapped air either by a bleed device or a self-evacuating system.

5.2.5.2 Hydraulic systems shall be designed so that escaping fluid shall not cause injury.

5.2.5.3 Hydraulic systems which include accumulators shall allow the fluid pressure to fall when the pressure
generating unit is stopped. If this is impossible, the parts of the circuit which are maintained under pressure shall be
supplied with a manual discharge valve in addition to the other devices required by standards or rules concerning
accumulators (relief valves, pneumatic gauges, etc.) and bear a very clear indication (by means of a descriptive
plate) of the hazard.

5.2.6 Slide adjustment and stroke adjustment

5.2.6.1 Provision shall be made to ensure that a slide adjustment motor cannot be set in motion while the
clutch control circuit is energised. This requirement shall not apply when the slide adjustment motor is operable in
presses for automatic cycle and programmable control systems to compensate, for example, for wear of the tools
during the press operation.

5.2.6.2 The means of controlling the slide adjustment shall be clearly identified.

5.2.6.3 The slide adjustment shall be limited by suitable means.

5.2.6.4 Means shall be provided for securing, e.g. by locking, the slide adjustment and the stroke adjustment
in the set position during production.
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5.2.6.5 Securing means shall be provided to prevent a stroke being made while the powered stroke
adjustment motor is in operation.

5.3 Mechanical hazards in the tools area

5.3.1 The major danger zone at mechanical presses is the tools area and preventive measures shall be taken to
deal with the relevant hazards. This standard indicates in 5.3 to 5.5 how the danger zone at the tools and
associated areas, such as moving die cushions and work-piece ejectors, shall be safeguarded. Tables 2, 3 and 4
list the safeguarding methods including mode of production/mode of operation and the requirements for the design
of the control and monitoring system:

 single cycle: manual feed or removal (Table 2);

 automatic cycle: manual feed or removal (Table 3);

 automatic cycle: solely automatic feed and removal (Table 4).

5.3.2 Designers, manufacturers and suppliers shall select the safeguarding methods which reduce the risks as
far as possible, considering the significant hazards (see Table 1) and the mode of production (see Tables 2, 3 and
4). Safeguarding measures described in EN ISO 12100-1 and EN ISO 12100-2 which are appropriate for the
protection of any operator at the tools are listed below:

a) closed tools (see EN 294, EN 349, 5.3.9 and Annex D);

b) fixed enclosing guards (see EN 294, EN 953 and 5.3.10);

c) interlocking guards with guard locking (see EN 953, EN 954-1, EN 1088, 5.3.11 and Annex A);

d) control guards with guard locking (see 5.3.2.5 of EN ISO 12100-2:2003, EN 953, EN 954-1, EN 1088 and
5.3.11);

e) early opening interlocking guards (see EN 953, EN 954-1, EN 999, EN 1088, 5.3.11, 5.3.15 and Annex A);

f) electro-sensitive protective equipment (ESPE) using active opto-electronic protective devices (AOPDs) (see
EN 999, EN 61496-1, CLC/TS 61496-2, 5.3.13, 5.3.15 and Annex C);

g) two-hand control devices (see EN 574, EN 999, 5.3.14 and 5.3.15);

h) hold-to-run control devices (see 3.26.3 of EN ISO 12100-1:2003) with a slow closing speed (equal or less than
10 mm/s) principally for tool-setting (see 5.5).

The above methods of safeguarding shall also protect against risks at ancillary loading and unloading devices
which are an integral part of the machine.

5.3.3 The selected combination of safeguarding measures described in 5.3.2 shall protect all exposed persons,
i.e. those who can gain access to the danger zone, during operation, setting, maintenance, cleaning and inspection
activities, as described in 4.2.

5.3.4 Where a mechanical press is capable of being manually loaded and/or unloaded the safeguarding method
shall not rely solely on the use of closed tools or fixed enclosing guard(s) unless the closed tools or fixed enclosing
guard(s) is supplied as a part of the press for a single specific purpose (see 7.2.2 j) and k)).

5.3.5 The requirements of the safety measures listed in 5.3.2 are given in 5.3.9 to 5.3.15 and shall be met in
addition to those established by the relevant standards (see Clause 2).

5.3.6 The guards and protective devices provided shall be at least interfaced with the control system of the press
in the same category as required for these guards and devices.

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5.3.7 If the work performed on the press requires access to the danger zone from more than one side,
arrangements shall be provided for the fitting of a guard or a device giving the same level of protection for the
operator on each side, as specified in Annexes A, D and C.

5.3.8 Where a very large press may be used for special "one-off" pressing of large components, for example
pressure vessel ends, and use of a guard is impracticable, the designer, manufacturer and supplier shall make
provision for allowing in such cases a safe method of work to be applied by the user, for example provision of
controls to be moved to a safe position with a good view of the tools/work-piece and if necessary additional audible
warning or visual danger signals according to EN 842. If this press is not exclusively dedicated to this work, 5.3.2 to
5.3.6 shall apply.

5.3.9 Closed tools shall be inherently safe. Their openings and the corresponding distances shall meet the
requirements laid down in Table 4 of EN 294:1992 or not exceed 6 mm. Any additional crushing hazard outside the
closed tools shall be avoided following Table 1 of EN 349:1993. See Annex D.

5.3.10 Fixed enclosing guards shall comply with EN 953. They shall be firmly secured to the machine, another
rigid structure or the floor. The feed openings shall comply with Table 4 of EN 294:1992

5.3.11 Interlocking guards, early opening interlocking guards and control guards shall comply with EN 953 and
prevent, in conjunction with fixed guards, access to the danger zone in the tools area, during any dangerous
movement. Initiation of the stroke shall be prevented until the guard gate is closed. The associated interlocking
devices shall be designed and constructed in accordance with 6.2.2 of EN 1088:1995, and the safety related parts
of the control system shall conform to category 4 of EN 954-1:1996. See Annex B. Control guards shall also
conform to 3.25.6 of EN ISO 12100-1:2003 and 5.3.2.5 of EN ISO 12100-2:2003.

5.3.12 When using an interlocking guard as a control guard, it shall not be possible to stand between the guard
and the danger zone. This can be prevented using additional safeguarding means. These additional safeguarding
means shall either be an AOPD (type 4) or a fixed guard kept in place permanently (e.g. by welding) or an
interlocking guard in accordance with 6.2.1 of EN 1088:1995.

Control guards shall only be used when the opening stroke length is equal to or less than 600 mm and the depth of
the press table is equal to or less than 1 000 mm. These restrictions do not apply when the control guard is
controlled by a hold to run control device. The control guard(s) shall be securely held open (e.g. by spring or
counterweight) to avoid gravity fall which can cause unintended cycle initiation.

The guards mentioned in 5.3.11 shall be provided

a) either with guard locking, to prevent the opening of the guard gate until any dangerous movement in the tools
area has ceased;

b) or without guard locking, but designed to bring the dangerous movement to a stop before the danger zone can
be reached.

Early opening interlocking guards can also be control guards without guard locking.

5.3.13 ESPE using AOPDs in the form of light curtain shall comply with the following:

a) AOPDs shall conform to type 4 of EN 61496-1:2004 and be designed and constructed according to
CLC/TS 61496-2:2003;

b) access to the danger zone shall only be possible through the detection zone of the AOPD. Additional
safeguarding shall prevent access to the danger zone from any other direction;

c) where it is possible to stand in a position between AOPD and the danger zone of the press, additional means,
for example further beams, shall be provided to detect a person standing there. The maximum permissible
undetected gap shall be equal to or less than 75 mm;

d) it shall not be possible to initiate any dangerous movement while any part of the body is interrupting the AOPD;

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e) the means of resetting shall be so positioned that, from that position, there is a clear view of the danger zone.
There shall not be more than one reset control device on each detection zone. If the press is safeguarded by
means of side and back AOPDs, a reset control device shall be provided on each detection zone;

f) where the AOPD operates by reflecting the transmitted light beam back along its own path and additional
reflector(s) are placed within the detection zone, then the configuration of the additional reflector(s) shall not
allow an item of thickness equal to or greater than the specified test piece size (see 4.1.2 of
CLC/TS 61496-2:2004) to be undetected by the AOPD within the whole of the detection zone, unless other
measures are taken to ensure that it is not possible to reach the danger zone;

g) where the AOPD is also used for cycle initiation, either single or double break:

i) the height of the press table shall be equal to or more than 750 mm above the standing level of the
operator. If the table is less than 750 mm in height, this height shall be achieved by the use of an
additional guard: this guard and all other guards preventing access to the tools area shall be kept in
place permanently, e.g. by welding, or by the use of an interlocking guard fitted close to the press
table. It shall not be possible to stand between the physical barrier and the table or tools, or beside
the table or tools;

ii) the opening stroke length shall be equal to or less than 600 mm, and the depth of the press table
shall be equal to or less than 1 000 mm;

iii) the detection capability shall not exceed 30 mm (see Table B.1);

iv) before the first cycle initiation the reset function(s) shall be actuated (e.g. push button, foot pedal);

v) the facility to initiate the press motion upon clearing of the AOPD curtain shall be limited to a period
commensurate with a single normal cycle, the pre-set time;

vi) this pre-set time shall not exceed 30 s starting from the end of the previous operating cycle. The
AOPD shall be required to be reset, if the pre-set time has been exceeded. Normal means of initiating
the press motion shall be provided for occasions when it is not automatically initiated within that
limited period;

vii) if there is more than one AOPD safeguarding the press, only one of them shall be selected for cycle
initiation at any one time.

h) switching off the AOPD by the selector switch shall also switch off the indicator lights.

See Annex E.

5.3.14 Two-hand control devices shall comply with the following:

a) two-hand control devices shall conform to type III C in Table 1 of EN 574:1996;

b) the number of two-hand control devices in operation shall correspond to the number of operators indicated at
the selection system;

c) initiation of output signals shall not be possible using one hand, hand and elbow of the same arm, forearm(s)
or elbow(s), hand and other parts of the body.

5.3.15 Interlocking guards without guard locking, control guards without guard locking, early opening interlocking
guards without guard locking, ESPE using AOPDs and two-hand control devices shall be placed in such a position
that the operator does not have time to reach the danger zone before any dangerous movement in the tools area
has ceased. Calculation of the safety distance shall be based on the overall response time of the press coming to a
stop and on the speed of movement of the operator. See EN 999 and Annex B.

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5.3.16 Conditions of interlocking the motor and the clutch

Reverse running shall only be possible in the setting mode. It shall not be possible to start the motor if the press
clutch is engaged or to engage it or leave it engaged if the motor is stopped, except under various setting
conditions.

5.3.17 Single stroke devices

Where a press is used in single cycle mode, a single stroke device shall be fitted. This device shall prevent a
subsequent stroke even if the control device is continuously actuated. A further stroke shall require the release of
the control device and a new initiation.

5.3.18 Prevention of gravity fall during maintenance or repair

5.3.18.1 Where there is a risk of injury (weight of the moving components exceeding 150 N from a gravity fall of
the slide) a mechanical restraint device, e.g. a scotch, shall be provided to be inserted in the press for use during
repair or any necessary intervention between the tools other than normal manual feeding. Where the device is not
capable of absorbing the entire press force, it shall be interlocked to the press control so that a stroke cannot be
performed while the device is in position, and the press slide is retained in the upper position according to
EN 1037:1995.

5.3.18.2 On presses with an opening stroke length of more than 500 mm and a depth of table of more than
800 mm, the device shall be permanently fixed and integrated within the press. If an integrated device, when active,
cannot be easily seen from the operator's position, an additional clear indication of the position of the device shall
be provided.

5.3.19 Other requirements

5.3.19.1 The press shall be designed and constructed so that tools can be secured to the press in such a way
that no hazard can arise in the event of a single component fault or power failure.

5.3.19.2 All fastenings on the press, such as screws, nuts or glue joints, shall be assembled in such a way that
parts will not loosen and cause injury.

5.3.19.3 The means of manual adjustment, e.g. to the stroke or slide adjustment, or speed change, the
alteration of which can cause a hazard, shall have a reliable locking device which only allows adjustment by means
such as a tool a key or an electronic password.

5.3.19.4 On automatically running presses with part revolution clutches and handling devices which are an
integral part of the press, the leading edge of the coil shall be automatically guided into progression tools, where it
is practicable.

If the leading edge of the coil cannot automatically be guided during loading through the handling device and the
progression tools, the manufacturer shall provide the press with:

a) either a hold-to-run control device with three positions and slow speed (equal or less than 10 mm/s).

The hold-to-run control device shall consist of a single button having the following positions:

 1st for stop;

 2nd for run;

 3rd for stop again.

After pushing the button over a pressure point in position 3, a restart shall only be possible after returning the
button to position 1;

b) or an inching device (see 5.5.11).

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EN 692:2005+A1:2009 (E)

These devices shall be operational when any guard on the press is moved from its protective position so that
the leading edge can be manually guided by the use of ancillary handling devices (grips, tongs, magnetic
holders).

5.3.20 Release of trapped persons

Means shall be provided to release any person trapped at the tool area (see also 7.2.2) e.g. auxiliary drive,
provision of slot to rotate flywheel by hand.

5.4 The control and monitoring system

5.4.1 Control and monitoring functions

5.4.1.1 General

This sub-clause shall apply to all safety related components which directly or indirectly control or monitor the
functioning of moving parts of the press or its tools. EN 60204-1:1997 shall be followed for the design of electrical
systems and EN 954-1:1996 for the safety related parts of electrical, hydraulic, pneumatic and mechanical
systems.

5.4.1.2 Control systems shall include safety functions designed in such a way that controls have to be re-
actuated in order for the press to perform a stroke:

a) after changing the mode of control or operation;

b) after an interlocking guard has been closed;

c) after a manual reset of the safety system;

d) after an operating power failure;

e) after a primary pressure failure;

f) following actuation of tool protective device or part detector;

g) after removal of an interlocked mechanical restraint device.

5.4.1.3 In the event of an intervention of a safety system (interlocking guard, ESPE using the AOPD), separate
manual reset functions are required to restore the normal intended operation:

a) if a person can pass through an interlocking guard;

b) if an ESPE using the AOPD used for cycle initiation is not interrupted in a pre-set time;

c) if an ESPE using the AOPD is interrupted during any dangerous movement in the cycle;

d) if an ESPE using the AOPD protects sides of the press from which the press is not operated.

Reset controls shall be within viewing distance of the danger zone, but out of reach from the danger zone. The
reset functions shall fulfil at least a single system with monitoring (S & M).

5.4.1.4 This sub-clause applies to presses fitted with protective devices of the following types, namely:

 ESPE using AOPDs;

 early opening interlocking guards and control guards;

 two-hand control devices used for normal operation.

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This sub-clause does not apply to presses used for automatic feed or removal working in automatic cycle and fitted
with an interlocking guard with guard locking (see Table 4).

If a fault occurs in the safety related parts of these protective devices or control system then:

a) an unintended start-up shall not be possible;

b) the safe functioning of the protective device shall be maintained;

c) it shall be possible to stop the machine during the dangerous movement;

d) the control system shall stop the machine immediately during the dangerous phase of the closing stroke or, in
other cases 1), at the latest at the end of the operating cycle;

e) the control system shall prevent any initiation of the next operating production cycle until the fault is eliminated.

In order to meet these requirements, the safety related parts of the control systems shall conform to category 4 of
EN 954-1:1996. The start and stop functions in the safety related parts of the press control system shall be
hardwired, redundant and monitored (R & M).

5.4.1.5 Where a press is subject to considerable shock and vibration, the design of the control system shall
take into account the requirements of:

a) 4.12.1 of EN ISO 12100-2;

b) 5.2.1 of EN 982:1996;

c) 5.2 of EN 983:1996;

d) 12.1 of EN 60204-1:1997.

5.4.1.6 The redundant and monitored press control system shall operate in two separate functioning systems.
Either system shall be independently capable of stopping the hazardous movement irrespective of the condition of
the other. Failure of either system shall be detected through monitoring and another closing stroke prevented. If
failure of one system is self revealing i.e. the loss of the function itself prevents the next operating cycle, further
monitoring of that system is not required.

5.4.2 Part revolution clutch presses: redundancy and monitoring of clutch/brake control systems, and
overrun monitoring for single cycle use

See Tables 2, 3 and 4.

5.4.2.1 Redundancy and monitoring of clutch/brake control systems, and overrun monitoring shall be provided
to protect an operator in all cases in which the safeguarding system does not prevent access to the danger zone
before the slide has stopped, e.g., for:

a) ESPE;

b) early opening interlocking guards;

1) Examples of this are:

1) where a fault occurs in one channel of a two channel control system, so that the other channel remains operative;

2) where a fault occurs during parts of the cycle other than the dangerous phase of the closing stroke.

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c) two-hand control devices.

"Monitoring" and "redundancy" are terms defined in 3.1.17 and 3.1.23 respectively.

5.4.2.2 Interlocking guards fitted with a guard locking device shall be provided with redundancy and monitoring
of the clutch/brake control system (overrun monitoring device is not required).

5.4.2.3 Where the provision is necessary for redundancy and monitoring of the clutch/brake control system,
this shall conform to the following requirements:

a) the press shall be fitted with either at least two single valves or a double bodied solenoid operated valve which
directly control the fluid to the operated clutch and brake, or the equivalent in the case of other forms of drive;

b) the valve solenoids shall be connected to the control circuit by separate wiring so that a single fault in the
wiring cannot activate both solenoids;

c) it shall be established that a short circuit between connections of the safety valve (e.g. solenoid to solenoid, or
solenoid to self-monitoring assembly) will be detected automatically and will not lead to additional or
unexpected motion of the slide;

d) where for the valve monitoring function there is a need for sensors detecting the valve state, these sensors
shall be an integral part of the valves. The valve may have an inherent monitoring system in which valve failure
is self-revealing;

e) the monitoring shall be dynamic with a frequency of at least once per cycle and shall ensure that, in the case of
a failure within the valve(s), the clutch is disengaged and the brake applied;

f) it shall only be possible to restore further operation of the press by a restricted means, e.g. by tool, key or
electronic password.

5.4.2.4 Where the provision is necessary for overrun monitoring, this shall conform to the following
requirements:

a) manually fed presses fitted with protective devices of the type listed in 5.4.1.4 shall include overrun monitoring
devices to ensure that, if the crankshaft overruns its normal stopping position by an amount specified by the
manufacturer, maximum 15° and preferably 10°, a stopping signal shall be immediately initiated and no new
cycle initiation shall be possible;

b) it shall only be possible to restore further operation of the press by a restricted means, e.g. by tool, key or
electronic password;

c) where the cams to the overrun monitoring device are driven from a camshaft which is indirectly driven from a
crankshaft, e.g. by a duplex chain drive between the camshaft and the crankshaft, indirect drive shall be
monitored in such a way that, if it fails, a stopping signal shall be initiated and no new cycle initiation shall be
possible until the fault is eliminated.

5.4.2.5 The cams and relevant switches for overrun monitoring, single cycle stop function and muting shall be
linked one with another in a positive way so that the relative position between the cams, and the relative position
between the switches cannot be altered. However, on presses fitted with a variable speed arrangement, the single
cycle stop function switch may be capable of separate adjustment. All cams shall be positively secured to the shaft.
All cams and relevant switches shall be in a locked enclosure.

5.4.2.6 In cases where the stroke length can be varied, adjustment of cams or cam operated switches used for
cycle control shall be linked in a positive way so that their relative position cannot be altered, in order to minimize
the probability of miss-setting by the user, e.g. to compensate for deterioration in braking performance which
should be remedied by maintenance of the brake.

5.4.2.7 If the camshaft is connected to the crankshaft by a clutch, the clutch engagement shall be positive, e.g.
by gearing.

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5.4.2.8 The maximum alteration of the rotary cam arrangement shall be mechanically limited to an angle of
60°, preferably 45°. See Annex F.

5.4.2.9 Cam discs shall be so applied that a wrong or unintended fitting cannot cause accidents, and:

a) the limit switches and cam for control of the press shall be fixed to each other and adequately secured.
Unsecured nuts or bolts are not permissible;

b) the position of the limit switches and cam plates in relation to each other shall be marked;

c) the possibility of re-adjustment of limit switches or cam shall be limited by fixed end stops, so that the muting
time during the closing movement of the press cannot exceed the press overall response time with any
combination of speed and length of stroke;

d) there shall be no possibility of damage to the impulse device when the press is reversed.

5.4.3 Muting

5.4.3.1 Muting (see 3.1.18) may be provided for ESPE using AOPDs and two-hand control devices. They shall
only be muted at a point in the opening stroke, or when the dangerous phase of the closing stroke is passed and
there is no risk of injury at the tools. Trapping points at ejectors and die cushions shall be taken into account. The
safeguarding system shall become operative again at or before the start of the down-stroke.

In addition:

a) the muting position shall be secured against un-authorized adjustment by provision of special tools, key entry
or electronic passwords;

b) any additional hazard existing during the opening stroke shall be prevented, e.g. by fixed guards;

c) the signal for the initiation of muting shall be monitored.

5.4.3.2 Muting may also be provided for the gate of an interlocking guard fitted to a press, where early opening
of the gate is allowed when the dangerous phase of the closing stroke has passed (see 5.4.2).

5.4.4 Programmable electronic systems (PES), programmable pneumatic systems (PPS) and safety
related functions

5.4.4.1 The use of PES and PPS shall not reduce any level of safety laid down in this standard.

5.4.4.2 Where a press is controlled by a PES or a PPS, the safety related functions shall not rely solely on the
PES or PPS.

5.4.5 Selector switches

5.4.5.1 Where there is a choice of modes of operation, cycle initiation or safety system of the press (e.g. single
stroke, inch or continuous, front or back, or front and back), selector switches shall be provided. The design shall
ensure that, for each position not in use, circuits are completely isolated by positively operated contacts, or by
redundant and monitored hardware. If the switch is set in an intermediate position, no operation shall be possible.
The control system shall ensure that no start-up is initiated when the selector switch is operated.

5.4.5.2 Where one selector switch is provided, it shall be used to select the appropriate mode of safeguarding,
which may be two or more guards or protective devices (see 5.3.3). Where two or more selector switches are
provided and the mode of safeguarding is connected to the control system, the chosen mode of operation shall be
automatically linked to the corresponding mode of safeguarding.

5.4.5.3 If a press is also intended to be used according to 5.3.2 a) or b) and at the same time operated, e.g. by
foot switch, without any other safeguarding, this mode of production shall be chosen by an additional selector
switch operated by a separate key or within a key locked enclosure. The selection of this mode shall automatically
give a clear indication at the press that only closed tools or fixed enclosing guards shall be used.
24
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EN 692:2005+A1:2009 (E)

5.4.5.4 If there is more than one operator at the press, the level of protection shall be the same for each
operator. Where a number of two-hand control devices or de-connectable control stations are used, the press shall
only be operable if the combination selected corresponds exactly to the combination physically connected to the
press.

5.4.5.5 Selector switches for safety related functions shall be key operated, according to 9.2.3 of
EN 60204-1:1997. The selection shall be visible and clearly identifiable.

5.4.6 Isolation switch

An isolation switch within reach of the operator shall be provided to allow the safe disconnection of the clutch.

5.4.7 Position switches

See 10.1.4 of EN 60204-1:1997.

5.4.7.1 General

There are two safety functions of position switches applied to presses which are particularly important:

a) the cyclic position switch(es), e.g. muting, overrun and top dead centre (TDC) limit switches;

b) the interlocking guard gate switches (see Clause 5 of EN 1088:1995).

5.4.7.2 The means of operation of the switch and the switch itself shall be designed to maintain their correct
relationship to one another, the operating cam and particularly the stroke.

5.4.7.3 The mechanism, e.g. cam and follower, shall be so designed that reverse rotation is possible without
damage.

5.4.7.4 On presses used for manual feed or removal, all shaft position switches controlling slide movement
shall be of electro-mechanical type. Requirements for redundancy and monitoring of the function are specified in
5.4.1.4.

5.4.7.5 Proximity switches may be accepted for the rotary cam arrangement of the crankshaft on solely
automatically running presses. If redundancy and monitoring are required (see Table 4), the proximity switch units
shall achieve redundancy and monitoring.

5.4.8 Control devices

5.4.8.1 Push button, foot switch and start control devices shall be shrouded to prevent accidental operation.
Foot switches shall permit access from one direction only and by one foot only. Treadles shall not be used.

5.4.8.2 Emergency stop buttons shall on actuation stop all dangerous movement, functioning as category 0 in
4.1.5 of EN 418:1992.

5.4.8.3 There shall be at least one emergency stop button within direct reach of each operator including the
operator(s) at the rear of the press. Any de-connectable two hand control station shall not incorporate an
emergency stop button if the press can be operated while this two hand control station is disconnected (see also
5.4.5.4 and 7.2.2j))

5.4.8.4 In order to avoid unintended start-up, portable pedestals or pendants incorporating start buttons shall
be designed in accordance with both 4.4.8 of EN 60204-1:1997, with regard to stability and support, and 10.6.

5.4.9 Valves

Manual override devices incorporated into valves shall be designed to include a captive lid or cover which requires
the use of a tool or key to open it. Electrical override devices shall be key operated and their operation shall only be
possible with the slide in BDC position, motor off and flywheel stopped.
25
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

5.5 Tool-setting, trial strokes, maintenance and lubrication

5.5.1 The machine shall be designed so that tool-setting, maintenance and lubrication can be carried out safely.
The need for access and manual intervention during setting and maintenance shall be minimized, e.g. an automatic
system or remote application may be used for lubrication.

5.5.2 Facilities shall be provided to allow the movement of the slide during tool-setting, maintenance and
lubrication to be carried out with guards and protective devices in position and operational (see 5.3.2).

Where this is not practicable, at least one of the following facilities shall be provided:

a) rotation of the crankshaft by hand, with power isolated;

b) slow speed (equal or less than 10 mm/s) and hold-to-run control device;

c) two-hand control device in accordance with 5.5.9 and arranged so that it cannot be used for production, e.g.
when the cycle stops at least three times during one revolution of the crankshaft;

d) using the inching device.

5.5.3 All trial strokes (single operating cycle) after tool-setting or adjustment are considered in this standard as
production strokes, and the safeguarding shall meet the requirements laid down in 5.3.

5.5.4 Manually adjustable feeder devices shall be capable of being set with the slide stationary.

5.5.5 If a bar or other device is used to rotate the crankshaft by hand:

a) when the main motor is switched off, a device shall prevent re-engagement of the clutch before the flywheel
has come to rest. This device may be a timer not adjustable by the user or a motion detector, and shall be
monitored;

b) it shall not be possible inadvertently to leave the bar in position during normal operation;

c) it shall be possible to see at least part of the flywheel to ensure that it is stationary.

5.5.6 Unless the protective devices used in normal production can be retained in use, the manufacturer shall
provide control devices on each accessible side of the press so that at least one person at each side, with a clear
sight of the access zone, is required to participate in initiation.

If, taking into account the intended use, it is foreseeable that there will be more than one person on a side,
additional devices (e.g. enabling devices, selector switches, warning signals) shall be provided.

5.5.7 If a movable guard has to be opened for tool-setting, or maintenance it shall be interlocked (see 6.4.3 of
EN 953:1997).

5.5.8 The minimum standard of interlocking at movable guards opened or removed only for tool-setting or
maintenance is a switch of the positive opening operation type complying with EN 1088. The interfacing to the
operative parts of the control system shall not rely solely on one relay.

5.5.9 Two-hand control devices shall comply with the following:

a) two-hand control devices shall conform at least to type II in Table 1 of EN 574:1996;

b) initiation of output signals shall not be possible using one hand, hand and elbow of the same arm.

5.5.10 Hold-to-run control devices and inching devices shall be hardwired and the safety related parts of the
control system shall conform to category 2 of EN 954-1:1996.

26
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EN 692:2005+A1:2009 (E)

5.5.11 The movement produced by the inching device shall be so small as to prevent a hazardous situation and
shall be limited by a time control or by a distance control. The slide movement shall not exceed 6 mm per inching
step with the crankshaft at 90°.

5.5.12 Two-hand control devices or hold-to-run control devices provided only for tool-setting shall be arranged in
such a way as to be unsuitable for normal use.

5.5.13 The interfacing between hold-to-run control devices, two-hand control devices, inching devices and the
safety related parts of the control system shall not rely solely on one relay.

5.5.14 The press and its safeguarding shall be designed so that periodic examinations can be carried out using
such tools as are provided with the press.

5.6 Mechanical hazards - other

5.6.1 Drive and transmission machinery, and ancillary devices which are an integral part of the press and are
supplied with the press shall be at least safeguarded by means of:

a) fixed guards, where access is required once or less than once per shift (see 6.4.1 of EN 953:1997);

b) movable guards interlocked with the control system, where access is required more than once per shift (see
6.4.1 of EN 953:1997);

c) an interlocking guard with guard locking and delayed unlocking, if the dangerous movement does not come to
a rest before the danger zone can be reached (see 7.4 of EN 1088:1995).

The guards listed above are not required if the danger zone is out of reach according to Tables 1 and 2 of
EN 294:1992 and access is not required for regular maintenance (e.g. lubrication, setting, cleaning).

5.6.2 The delayed unlocking shall be arranged in such a way that a timer or a motion detector controls the guard
locking.

5.6.3 The safety related parts of the control systems for interlocking devices (see EN 1088) shall conform at least
to category 1 of EN 954-1:1996.

5.6.4 Ancillary devices which are not controlled by the press shall be additionally interlocked to the press control
system so that during any intervention no hazardous situation can arise. See 1.4.

5.6.5 Ejection hazards created by machine components or parts of them shall be eliminated by design or by
additional shielding, which are both capable of withstanding the foreseeable forces. See 8.1 of EN 953:1997. See
also 7.2.2 i) in relation to work-piece and tools.

5.7 Slips, trips and falls

5.7.1 Where raised work stations are provided with the machine, they shall be provided with adequate guard rails
and toe-boards. Safe means of access shall be provided to the work station (see EN 14122).

5.7.2 The press shall be designed, constructed and supplied so as to minimize the risk of slips, trips and falls in
the press area.

5.8 Protection against other hazards

5.8.1 Electrical hazards

All electrical equipment shall be designed and constructed to prevent electrical hazards (e.g. shocks, burns) in
accordance with Clause 6 of EN 60204-1:1997.

27
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

5.8.2 Thermal hazards

Means such as shielding, insulation shall be provided to prevent burns by accessible parts of the press, e.g.
brakes, clutches and parts of the hydraulic system, which can exceed the recommended temperature limit values
specified in EN 563.

5.8.3 High pressure fluid ejection hazards

Additional shielding, e.g. screens, shall be provided to flexible piping installed adjacent to an operator's working
position to reduce the risk resulting from a failure in the flexible piping system.

5.8.4 Hazards generated by noise

5.8.4.1 The press 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 source.

When designing a press, the information and technical measures to control noise at source given in
EN ISO 11688-1 shall be followed.

5.8.4.2 The design shall take into account noise from each source. Appropriate technical measures for
reducing noise at the main sound sources of the press are listed below:

a) transmission noise flywheel and gearwheel damping facilities;

b) pneumatic exhaust silencers;

c) power generation source acoustic panels (partial or total);

d) noise at the tools damping facilities on the press;

e) work-piece ejection silenced nozzles;

f) feeding and transfer systems acoustic enclosures, damping facilities;

g) structurally transmitted noise anti-vibration machine mounts.

Additional or alternative measures giving an identical or higher reduction efficiency may be used. In any case,
declared noise emission values are the decisive criterion for the noise emission of a given machine. The
manufacturer shall be able to supply the necessary information concerning the measures incorporated in order to
reduce noise at source.

5.8.4.3 The measurement and declaration of noise emission values shall be made according to
EN ISO 3746 and EN ISO 11202, as appropriate. The declaration of noise emissions values shall he made
according to EN ISO 4871 with a preference to the dual number form.

5.8.4.4 The minimum information to be provided concerning the measurement of airborne noise emissions is
the following:

 machine data:

a) name and address of the manufacturer,

b) year of construction,

c) designation of series or type,

d) serial/prototype number of the press under test,

e) nominal force,
28
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

f) continuous stroking rate, in strokes per minute; minimum and maximum if variable speed range;

 operating conditions during measurement:

g) speed in strokes per minute,

h) stroke length,

i) installation and mounting conditions (see G.1),

and, either

j) force applied in kN (see b) of G.3),

k) tooling details (see c) of G.3),

l) type and thickness of the material used (see d) of G.3),

or

m) test conditions under no load, replacing j), k) and l) (see G.4);

 measurement:

n) location of the press under test, with respect to the reflecting plane (see G.2),

o) measurement procedure (see G.5),

p) measurement positions (see G.6),

q) measurement time (see G.7);

 results:

r) background sound pressure levels, if the correction factor is required,

s) equivalent continuous A-weighted sound pressure level in the operator's position,

t) peak C-weighted instantaneous sound pressure level in the operator's position,

u) !sound power emitted where the equivalent continuous A-weighted sound pressure level exceeds
80 dB (A)."

(In the case of very large presses, i.e. in excess of 10 000 kN, instead of the sound power level, the equivalent
continuous sound pressure levels at specified positions around the press can be indicated).

5.8.4.5 Information on the conditions for noise measurement of mechanical presses is given in Annex G.

5.8.5 Hazards generated by vibration

The design of the press shall be such that vibration which can cause injury shall be avoided, e.g. by isolation of the
press from the floor foundations according to EN 1299.

5.8.6 Hazards generated by materials and substances

5.8.6.1 Hazardous substances shall not be used wherever possible in the construction of the press, and the
use of materials which can cause injury or damage to health shall be eliminated (e.g. asbestos).

5.8.6.2 Asbestos linings for clutch and brake shall not be used.

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EN 692:2005+A1:2009 (E)

5.8.6.3 Adequate means shall be provided to prevent the formation of aerosols and respirable oil mists in
unhealthy concentration, e.g. from oil used to lubricate pneumatic systems.

5.8.6.4 If it is known that hazardous substances are intended to be processed by the user, e.g. hard metal
powder, the safeguarding systems shall be designed to minimize operator exposure and to accept, if necessary,
exhaust ventilation according to EN 626-1.

5.8.6.5 Design measures for exhaust ventilation and dust collection equipment shall include features to
minimize the risk from fire and explosion according to EN 1127-1.

5.8.7 Hazards generated by neglecting ergonomic principles

5.8.7.1 The press and its controls shall be designed to provide a good work posture which is not fatiguing.

5.8.7.2 The positioning, labelling and illumination (if necessary) of control devices, and facilities for materials
and tool set handling shall be in accordance with ergonomic principles.

5.8.7.3 Where necessary on the press, work stations and the zones in which control devices, guards and
protective devices are located shall be lit sufficiently to ensure that all work equipment and materials can be
properly seen, and that eye strain is also avoided.

5.8.7.4 Parts of the press which weigh more than 25 kg and require to be lifted with a lifting device shall
include necessary attachments to accommodate the fitting of a lifting device according to EN 1005-2.

5.8.7.5 Tanks containing hydraulic fluid shall be placed or oriented in such a way that the filler and drain pipes
can be easily reached.

5.8.7.6 Further guidance is given in EN 60204-1, EN 614-1, EN 894-2 and EN 894-3. (See also Bibliography).

30
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EN 692:2005+A1:2009 (E)

Table 2 — Summary of requirements for the operator safeguarding of tools for different modes of operation – Mode of production: single cycle, manual feed or
removal

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note 2) function

El. Valve

Closed tools Any S S - - - See 5.3.9.

Fixed enclosing guard Any S S - - - See 5.3.10.

Interlocking guard with guard locking Any other See See - - - See 5.3.11.
(see note 3) than the remark 1 remark 1 1. R & M shall be required when
guard itself there is no mechanical interlock.
See annex A.
2. Early opening gates not permitted.
See 5.3.11. As remarks 1 and 2
Control guard with guard locking Guard itself See See - - -
above. See 3.25.6 of EN ISO
remark 1 remark 1
12100-1:2003 and 5.3.2.5 of EN
ISO 12100-2:2003.

Early opening interlocking guard Any other R&M R&M Yes M R&M Either use of required safety distance
than the (see 5.3.15) or guard locking which is
guard itself effective during the dangerous
movement of the tools (see 5.3.11).

(continued)

31
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 2 (continued)

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note 2) function

El. Valve

Control guard without guard locking Guard itself R&M R&M Yes M R&M As above. See 3.25.6 of EN ISO
12100-1:2003and 5.3.2.5 of EN
ISO 12100-2:2003 .
See 5.3.13.
ESPE using the AOPD Any, R&M R&M Yes M R&M
1. Use of required safety distance
but see (each S & M)
(see 5.3.15).
remark 2
2. Where there is a gap between
tools which is large enough to be fully
entered, a separate stroke initiation
device shall be provided (see
5.3.13g).
See 5.3.14. Use of required safety
Two-hand control device Two-hand R&M R&M Yes M R&M
distance (see 5.3.15).
control (each S & M)
device

Hold-to-run control device and slow Hold-to-run S S - - - 1. Principally for tool setting (see
closing speed control 5.5).
device 2. Maximum closing speed: 10 mm/s.
3. Where this speed is adjustable
above 10 mm/s, the manufacturer
shall provide safety devices
appropriate for all closing speeds.
(continued)

32
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 2 (concluded)

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note 2) function

El. Valve

SYMBOLS AND ABBREVIATIONS

a) El. For electrical

b) M for monitoring (see 3.1.17)

c) R for redundancy (see 3.1.23)

d) S for single system

e) - for not applicable

NOTE 1 For tool setting, see 5.5.

NOTE 2 See 5.4.1.2 for the objectives of the control system.

NOTE 3 An additional interlocking device actuated by the return signal of the clutch in non repeat position may also be provided.

33
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 3 — Requirements for the operator safeguarding of tools for different modes of operation - Mode of production: automatic cycle, manual feed or removal

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note 2) function

El. Valve

Closed tools Any S S - - - See 5.3.9.

Fixed enclosing guard Any S S - - - See 5.3.10.

No entry of the hand between tools
during production (manual feeding
from outside the guard, e.g. through a
slot).

Interlocking guard with guard locking Any other See See - - - See 5.3.11.
than the remark 1 remark 1 1. R & M shall be required when
guard itself there is no mechanical interlock.
See annex A.
2. Early opening gates not permitted.
3. If on large presses it is possible to
be in the danger zone with guard
closed, use special reset outside this
zone (S & M).

(continued)

34
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 3 (concluded)

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note 2) function

El. Valve

ESPE using the AOPD Any other R&M R&M Yes M R&M See 5.3.13.
than the (each S & M) Use of required safety distance (see
guard itself 5.3.15).

SYMBOLS AND ABBREVIATIONS

a) El. for electrical

b) M for monitoring (see 3.1.17)

c) R for redundancy (see 3.1.23)

d) S for single system
e) - for not applicable
NOTE 1 For tool-setting, see 5.5.

NOTE 2 See 5.4.1.2 for the objectives of the control system.

35
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 4 — Requirements for the operator safeguarding of tools for different modes of operation - Mode of production: automatic cycle, solely automatic feed and
removal

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note2) function

El. Valve

Closed tools Any S S - - - See 5.3.9.

Fixed enclosing guard Any S S - - - See 5.3.10.

Interlocking guard with guard locking Any other See See - - - See 5.3.11.
than the remark 1 remark 1 1. R & M shall be required when
guard itself there is no mechanical interlock.
See annex A.
2. Early opening gates not permitted.
3. If on large presses it is possible to
be in the danger zone with guard
closed, use special reset outside this
zone (S & M).

Interlocking guard with guard locking Any other R&M S - - - See 5.3.11.
than the If on large presses it is possible to be
guard itself in the danger zone with guard closed,
use special reset outside this zone
(S & M).

(continued)

36
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 4 (continued)

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note2) function

El. Valve

Early opening interlocking guard Any other R&M R&M - - - 1. Either use of required safety
than the distance (see 5.3.15) or guard locking
guard itself which is effective during the
dangerous movement of the tools
(see 5.3.11).
2. If on large presses it is possible to
be in the danger zone with guard
closed, use special reset outside this
zone (S & M).

ESPE using the AOPD Any other R&M R&M - - - See 5.3.13.
than the Use of required safety distance (see
guard itself 5.3.15).

(continued)

37
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 4 (concluded)

Clutch & brake Single

Operator safety system Cycle Overrun
control system Muting stroke Remarks
(see note 1) initiation monitoring
(see note2) function

El. Valve

SYMBOLS AND ABBREVIATIONS

a) El. for electrical

b) M for monitoring (see 3..1.17)

c) R for redundancy (see 3.1.23)

d) S for single system
e) - for not applicable
NOTE 1 For tool-setting, see 5.5.
NOTE 2 See 5.4.1.2 for the objectives of the control system.

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 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

6 Verification of the safety requirements and/or measures

Table 5 indicates the method(s) by which the safety requirements and measures described in Clause 5 shall be
verified, together with a reference to the corresponding sub-clauses in this standard.

Table 5 — Means of verification of the safety requirements and/or measures

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.2 BASIC DESIGN CONSIDERATIONS

5.2.1 BRAKES AND CLUTCHES

5.2.1.1 Pressure media X X X X
Diaphragms X
5.2.1.2 a) Compression springs in the brake X X X
Compression springs in the clutch X X X
5.2.1.2 b) Multiple spring assemblies X X X
5.2.1.2 c) Uniform springs X X
5.2.1.2 d) Prevention of slackening back X x
5.2.1.2 e) Spring housing and guiding X X
5.2.1.2 f) Function with 50 % springs X X X
5.2.1.3 Safe function X X X
5.2.1.4 Consequential failure X X X
5.2.1.5 Dissipation of heat X X
5.2.1.6 Prevention of lubricant penetration X X
5.2.1.7 Foreign matters X X X
5.2.1.8 Accumulation of stuff X X X
5.2.1.9 Band brakes X
5.2.2 and B.2 PRESSES WITH PART REVOLUTION CLUTCHES
5.2.2.1 Clutch capacity X X X X
5.2.2.2 Working clearances X X X
5.2.2.3 Accumulation and dispersal of debris X X X
(continued)

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EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.2.2.4 Failure of energy supply X X X

5.2.2.5 Sharp edges and rough surfaces X X X
Evacuation of air X X X
A.1 Interlocking guard
A.1 a) Two position switches X X X
Action of switches in closed position X X X
A.1 b) Redundancy and monitoring X X X
A.2 Early opening guard
Control system X X X
Braking system X X X
Closed before BDC X X X
A.3 Automatic cycle: switches in series X X X
5.2.3 HYDRAULIC AND PNEUMATIC SYSTEMS - COMMON FEATURES
5.2.3.2 Filters X X
Pressure regulators X X X
Low pressure cut-off arrangements X X X
5.2.3.3 Pressure range devices X X X
5.2.3.4 Bowls X
5.2.3.5 Burrs or foreign matters X X
5.2.3.6 Continuous piping X
Thermal expansion X X
Rigid piping supporting X X
Kinking of flexible pipes X X
5.2.3.7 Pipes and pipe connections X X
5.2.3.8 Operating valve supporting X X
5.2.3.9 Escape of leakage X X
5.2.3.10 Inlet port and exhaust ports X X X
5.2.3.11 Exhaust from cylinders X X X
Valve exhaust ports X X X
5.2.3.12 Control valves location X X
5.2.3.13 Valve restoring X X X
(continued)

40
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.2.4 PNEUMATIC SYSTEMS

5.2.4.1 Visible means of lubrication X X
5.2.4.2 Non-clogging silencers X X X
5.2.4.3 Water separators X X
5.2.5 HYDRAULIC SYSTEMS
5.2.5.1 Pressure relief valves X X X
Trapped air release X X X
5.2.5.2 Escaping fluid X X
5.2.5.3 Accumulators discharge X X X
5.2.6 SLIDE ADJUSTMENT AND STROKE ADJUSTMENT
5.2.6.1 Slide adjustment motor motion X X X
5.2.6.2 Slide adjustment means identification X
5.2.6.3 Limiting means X X X X
5.2.6.4 Securing means X X X
5.2.6.5 Stroke prevention X X X

5.3 MECHANICAL HAZARDS IN THE TOOLS AREA

5.3.2 Safeguarding of part revolution clutch presses

Ancillary devices X X X
5.3.3 Protection of all exposed persons X X
5.3.4 Safeguarding method X

5.3.6 Interfacing category X X X

5.3.7 Protection on each side X X
5.3.8 "One-off" pressing X X X
5.3.9 Closed tools X X X
5.3.10 Fixed enclosing guards X X X
5.3.11 Interlocking guards , control guard, early opening X X X X
guard
5.3.12 Interlocking guard as control guards X X X X
(continued)

41
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.3.13 AOPDs (ESPE) X X X X

5.3.13 a) Type 4 X
5.3.13 b) Possible access X X X
5.3.13 c) Possible standing position X X X
5.3.13 d) Initiation prevention X X X
5.3.13 e) Reset function X X X
5.3.13 f) Additional reflectors, safeguarding X X X
5.3.13 g) Single/double break X X X
5.3.13 g i) Height: 750 mm X X
5.3.13 g ii) Stroke length: 600 mm and/or table depth: X X
1 000 mm
5.3.13 g iii) Detection capability ≤30 mm X X

5.3.13 g iv) Reset function X X

5.3.13 g v) Pre-set time: 30 s X X
5.3.13 g vi) Cycle initiation by one AOPD only X X
5.3.13 h) Indicator lights X X X
5.3.14 Two-hand control devices X X X X
5.3.14 a) Type III C X X X
5.3.14 b) One device for each operator X X X
5.3.14 c) Defeat X X X
5.3.15 Safety distance X X X X
5.3.16 Motor and clutch interlocking X X X
5.3.17 Single stroke devices X X X
5.3.18 Prevention of gravity fall during maintenance or repair
5.3.18.1 Strength X X X
Interlocking X X X
5.3.18.2 Integral to the press X X X
Position indication X X X
Additional restraint device X X
(continued)

42
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.3.19 Other requirements

5.3.19.1 Tool securing X X X
5.3.19.2 Fastenings X X
5.3.19.3 Adjustment locking X X
5.3.19.4 Leading edge of a coil X X X
5.3.19.4 a) Hold-to-run control device and slow speed X X X X
5.3.19.4 b) Inching device X X X X
5.3.20 Release of trapped persons X X

5.4 THE CONTROL AND MONITORING SYSTEM

5.4.1 Control and monitoring functions
5.4.1.2 Re-actuation of controls X X X
5.4.1.3 Manual reset functions X X X
5.4.1.4 Fail-safe condition, redundant and monitored X X X
functions
5.4.1.5 Shock and vibration X X X
5.4.1.6 Separate channels X X X
5.4.2 Part revolution clutch presses: redundancy and monitoring
5.4.2.1 and Redundancy and monitoring of clutch/brake X X X
5.4.2.2 control systems
5.4.2.1 Overrun monitoring X X X X
5.4.2.3 a) Double valve X X
5.4.2.3 b) Separate wiring X X
5.4.2.3 c) Short circuit detection X X
5.4.2.3 d) Sensors integral to the valves X X
5.4.2.3 e) Dynamic monitoring of the valves X X X
Clutch and brake function X X
5.4.2.3 f) Restore X X X
5.4.2.4 a) Normal overrun: 10º to 15º X X X
Stop signal X X
(continued)

43
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.4.2.4 b) Restore X X X
5.4.2.4 c) Indirect cam drive X X X
5.4.2.5 Positive linking X X X
Locked enclosure X X
5.4.2.6 Stroke adjustment positive linking X X
5.4.2.7 Positive clutch engagement X X X
5.4.2.8 Cam arrangement alteration X X X X
5.4.2.9 a) Limit switches and cam securing X X
5.4.2.9 b) Marking of limit switches and cam position X X
5.4.2.9 c) Fixed end stops X X X X
5.4.2.9 d) No damage due to reverse rotation X X X X
5.4.3 Muting
5.4.3.1 All dangerous movement passed X X
5.4.3.1 a) Provision against un-authorized adjustment X X X
5.4.3.1 b) Additional hazards prevention X X X X
5.4.3.1 c) Monitored signal X X X
5.4.3.2 Interlocking guard muting X X X
5.4.4 Programmable systems and safety related functions
5.4.4.2 Safety related functions X X X
5.4.5 Selector switches
5.4.5.1 Isolation of circuits X X X
Positively operated contacts X X
Redundant and monitored hardware X X X
Intermediate position X X
Control system X X
(continued)

44
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.4.5.2 Selection of safeguarding modes X X

Operation/safeguarding linking X X
5.4.5.3 Closed tools/fixed enclosing guards X X X
Indication X X
5.4.5.4 Two-hand control devices selected X X X
5.4.5.5 Key operated selector switches X X
5.4.6 isolation switch X X X
5.4.7 Position switches
5.4.7.2 Relationship X X X X
5.4.7.3 Reverse rotation X X
5.4.7.4 Electro-mechanical cyclic switches X X
5.4.7.5 Proximity switches X X X
5.4.8 control DEVICES
5.4.8.1 Adequate shrouding X X X
5.4.8.2 Stopping of all dangerous movements X X X
5.4.8.3 Emergency stop buttons location X X X
5.4.8.4 Portable start buttons X X
5.4.9 Valves
Manual override: captive lid or cover X X
Electrical override: key operation X X X

5.5 Tool-setting, trial strokes, maintenance, lubrication

5.5.1 Minimized need for access X X
5.5.2 Movement of the slide with guards and protective X X
devices operational according to 5.3.2
5.5.2 a) Rotation by hand X X
(continued)

45
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (continued)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.5.2 b) Slow speed and hold-to-run control device X X X

5.5.2 c) Two-hand control device X X X
5.5.2 d) Inching device X X X
5.5.3 Trial strokes X X X
5.5.4 Feeder devices X X X
5.5.5 a) Prevention of clutch re-engagement X X X
Timer/motion detector, monitored X X X
5.5.5 b) Bar removal X X
5.5.5 c) View of the flywheel X
5.5.6 Control devices on accessible sides X X X
Clear sight X
Additional devices X X
5.5.7 Interlocked movable guard X X X
5.5.8 Positive opening switch X X
Interfacing X X X
5.5.9 Two-hand control devices of type II X X X
Defeat X X X
5.5.10 Hold-to-run control device and inching device X X X
5.5.11 Inching movement limitation: time control or X X X X
distance control
5.5.12 Control devices for tool-setting X X X
5.5.13 Interfacing X X X
5.5.14 Periodic examination X X

5.6 Mechanical hazards – other

5.6.1 Drive and transmission machinery, and ancillary devices
5.6.1 a) Fixed guards X X X X
5.6.1 b) Movable interlocking guards X X X X
(continued)

46
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table 5 (concluded)

Drawings/
Visual Performance Calculations
Safety requirements Measurement
Sub-clause inspection check/test Technical
and/or measures (see note 3)
(see note 1) (see note 2) data
(see note 4)

5.6.1 c) Interlocking guards with guard locking X X X X

5.6.2 Delayed unlocking X X X X
5.6.3 Control system for interlocking of category 1 X X X
5.6.4 Ancillary devices interlocking X X X
5.6.5 Ejection hazards X X X

5.7 Slips, trips and falls

5.7.1 Guard rails and toe-boards X X X X
Means of access X X X
5.7.2 Press area X

5.8 Protection against other hazards

5.8.1 Electrical hazards X X X
5.8.2 Thermal hazards X X X
5.8.3 High pressure fluid ejection hazards X X
5.8.4 Hazards generated by noise X
5.8.5 Hazards generated by vibration X X X
5.8.6 Hazards generated by materials and substances X X X X
5.8.7 Hazards generated by NEGLECTING X X X X
ERGONOMIC PRINCIPLES

7 INFORMATION FOR USE

7.1 Marking X X
7.2 Instruction handbook X

Annex B Safety distances X X X X

NOTE 1 Visual inspection is used to verify the features necessary for the requirement by visual examination of the components
supplied.
NOTE 2 A performance check/test verifies that the features provided perform their function in such a way that the requirement is
met.
NOTE 3 Measurement verifies by the use of instruments that requirements are met, to the specified limits.
NOTE 4 Drawings/calculations verify that the design characteristics of the components provided meet the requirements.

7 Information for use

7.1 Marking

7.1.1 The general requirements laid down both in 6.4 of EN ISO 12100-2:2003 shall be followed. EN 61310-2
shall be taken into consideration.

7.1.2 The press shall be marked with the following:

a) !name and address of the manufacturer and, where applicable, business name and full address of the
authorised representative;"

b) year of construction;
47
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

c) serial number;

d) !the designation of machinery and the designation of series or type;"

e) mass of the press, without tools or ancillary devices;

f) lifting points for transportation and installation purposes;

g) nominal force and nominal force travel;

h) normal stop position of the crankshaft, e.g. TDC;

i) maximum tool dimensions and mass;

j) maximum permissible flywheel speed in rpm, and direction of rotation;

k) continuous stroking rate, in strokes per minute; minimum and maximum if variable speed range;

l) maximum permissible number of clutch engagements per minute;

m) minimum and maximum stroke length;

n) slide adjustment and shut height;

o) supply data for electrical, hydraulic and pneumatic systems (e.g. minimum pneumatic pressure);

p) minimum and maximum fluid pressure in the clutch/brake system;

q) a chart indicating the appropriate air pressure in the counterbalance cylinders for the mass of the tool;

r) overall response time and corresponding safety distance(s). See Annex B;

s) any limitation on the type of protective device(s) and mode of operation, e.g. closed tools, for which the press
is suitable.

Protective devices supplied with the press shall also be marked with identification data.

7.2 Instruction handbook

7.2.1 The requirements laid down in 6.5 of EN ISO 12100-2:2003 shall be followed.

7.2.2 The instruction handbook shall include the following information:

a) a repeat of the information with which the press is marked (see 7.1.2);

b) a reference to this standard and any other standard used in the design of the press;

c) copies of any EC certification documents and reports on pressure vessel or control system tests from the
Technical Construction File;

d) instructions for safe transport, mounting, installation and dismounting (floor conditions, services, anti-vibration
mountings, handling conditions, etc.);

e) instructions for how the initial test and examination of the press and guarding system shall be carried out
before first use and being taken into service;

f) instructions on control systems including circuit diagrams for electrical, hydraulic and pneumatic systems.
Where a PES or PPS is provided, the circuit diagrams shall show the clear relationship at the interface
between any hardwired part and the PES or PPS;

48
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

g) information on noise levels likely to be generated during the noise test (see 5.8.4);

h) details of any further protection for the operator which is necessary to deal with residual risks, e.g. hearing
protection, eye protection or foot protection;

i) information on the protective measures against material generating hazardous substances e.g. exhaust
ventilation;

j) instructions for safe use, selection of modes of operation, initiation and the operator's protective system (in
particular where closed tools or fixed enclosing guards are allowed or several operators can control the press
including the need to disconnect any control station not in use in particular any two hand control station)
setting, trial strokes, maintenance, cleaning and programming (where required) on avoidance of danger from
all hazards, including ejection hazards created by work-pieces, tools or parts of them, fluids, linings, etc.;

k) particular training needed by persons who are appointed to prepare mechanical presses for use, including
suitable and sufficient instruction in:

 press mechanisms;

 protective devices;

 accident causation and prevention;

 the work of the tool-setter;

 tool design;

 the use of closed tools and fixed enclosing guards (see 5.3 .9).

l) details of any pre-production inspection of the guard or protective device required after tool-setting or
adjustment of the tools;

m) specification for any fluid to be used in hydraulic systems and for lubrication, braking or transmission system;

n) descriptions of foreseeable failure modes and advice on detection, prevention and correction by periodic
maintenance;

o) instructions for any test or examination necessary after changes or modifications to the press which may affect
the safety functions;

p) instructions for periodic maintenance, test and examination of the press, guards and protective devices,
including maintenance, testing and examination intervals. Periodic examinations shall be capable of being
carried out with equipment or tools which are generally available or such tools or equipment shall be provided
with the press;

q) instructions for the use of the means for releasing trapped persons (see 5.3 .20).

It is recommended that check lists be prepared for the operations covered by items e), l) and p). In particular, for
the safety examinations there shall be a specific check list which can be signed by the examiner.

!NOTE Information on noise emission should also be provided in the sales literature."

49
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Annex A
(normative)

Interlocking guards

A.1 Presses with part revolution clutches

A.1.1 Where the press is hand fed, the guard shall have:
a) electrical interlocking embodying two mechanically actuated position switches operating in opposite modes
(see 6.2.2 of EN 1088:1995). The switches shall not be operated until the guard shutter has reached a closed
position preventing access to the danger zone;
b) redundancy and monitoring (see Figures A.1 and A.2). This is to minimize the danger from repeat strokes and
unexpected strokes from rest, e.g. each of the two guard interlocking switches above are connected in series
with a solenoid which operates a valve spool. The spools shall be separated, either in separate valves or in
one double-bodied valve. Safety is achieved through duplication in wholly separate circuits, except for
connection to the control supply. This arrangement ensures that the press clutch system will exhaust correctly
provided that one spool is operational. The movement of each spool shall be monitored and this may be
achieved :
 either by switches being connected into fail-safe monitoring circuits so that failure of either spool to return
to the off position at the end of a cycle will prevent initiation of another cycle;
 or by an inherent monitoring system.

A.1.2 Where the guard is early opening so that the guard gate can be opened before TDC, the press shall have
the type of control and braking system specified in 5.4.2. The guard gate shall not open before BDC. Where the
press is hand fed and the guard gate can be opened before TDC, the guard shall conform to the requirements
outlined in A.1.1 above, except that the switches need not to be connected in series to the solenoid.

A.1.3 When the press is to be provided on automatic cycle with solely automatic feed or removal, the two guard
switches may be connected in series with a single solenoid valve.

Figure A.1 — Example of an interlocking guard with redundancy and monitoring

(see b) of A.1.1)
The guard shall be interlocked with the press control devices by means of two independent electrical circuits, as
shown in Figure A.1. Two limit switches, G and H, actuated by guard A and installed in opposite modes are
connected in separate circuits to a double monitored solenoid operated air valve J which controls the air supply to
clutch/brake combination C/B (see also Figure A.2).
50
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Valve outlet 2 without pressure Guard open

Valve outlet 2 under pressure Guard closed

(Cycle initiated)

Valve outlet 2 without pressure Guard open

The left-hand section of the valve has failed to close but

the right-hand section ensures that the clutch cylinder is
exhausted to the atmosphere.

Figure A.2 — Examples of a circuit diagram related to Figure A.1

51
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Valve J, which is in effect two solenoid operated three way air valves connected pneumatically in series, is provided
with additional contacts, b2 and b4, for monitoring the movement of the two valve spools. Each spool is capable of
exhausting the down stream air so that, if one spool fails to move to the safe position when the guard is opened,
the press will nevertheless stop. The failed spool will then hold the corresponding switch, b2 or b4, so that another
cycle cannot be initiated until the fault has been eliminated.

NOTE The example is not a complete solution since, e.g., in the electrical circuits the monitoring of C1 and C2 is not shown.

52
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Annex B
(normative)

Calculation of minimum safety distances

B.1 The minimum distance at which

 early opening interlocking guards without guard locking

 ESPE using AOPDs

 two-hand control devices

shall be placed from the danger zone is to be calculated according to the general formula laid down in clause 5 of
EN 999:1998, and namely:

S = (K x T) + C

where

a) S is the minimum distance in millimetres, from the danger zone to the detection point, line or plane;

b) K is a parameter in millimetres per second, derived from data on approach speeds of the body or parts of the
body;

c) T is the overall system stopping performance (overall response time) in seconds;

d) C is the additional distance in millimetres, based on the intrusion towards the danger zone prior to actuation of
the protective device.

B.2 In order to determine K, an approach speed of 1 600 mm/s shall be used for horizontally arranged AOPDs
and for two-hand control devices. For vertically arranged AOPDs, an approach speed of 2 000 mm/s shall be used
if the minimum distance is equal to or less than 500 mm. An approach speed of 1 600 mm/s may be used if the
minimum distance is greater than 500 mm.

B.3 In order to determine C for ESPE using AOPDs, see B.6. For un-shrouded two-hand control devices, C shall
be equal to at least 250 mm. For shrouded two-hand control devices and early opening interlocking guards without
guard locking, C may be zero.

B.4 When calculating the overall system stopping performance, the following features shall be taken into account
under the severest normal conditions:

e) the maximum stroke length;

f) the highest slide speed on the closing stroke (e.g. half-stroke range for eccentric presses);

g) the maximum number of strokes per minute;

h) the influencing temperature of the relevant parts of the system;

i) the maximum tool mass, according to the intended use of the press;

j) the maximum fluid pressure in the clutch/brake system;

k) the minimum air pressure allowed by the low pressure cut-off arrangement of the counterbalance cylinders;

53
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

l) the wear of the relevant parts of the stopping function;

m) the effect of any rapid exhaust valve and its silencers.

B.5 When the position of the protective devices which are mechanically linked to the press can be altered, the
devices shall, in order to maintain the minimum distance, be interlocked or capable of being locked in position, so
that they can only be moved with the use of tools or keys.

B.6 With regard to the detection capability of the AOPD, the additional distance C in Table B.1 shall at least be
used when calculating the minimum distance S.

Table B.1 — Additional distance C

Detection capability Additional distance C Cycle initiation by
mm mm the AOPD

≤ 14 0
> 14 ≤ 20 80 Allowed
> 20 ≤ 30 130

> 30 ≤ 40 240 Not allowed

> 40 850

54
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Annex C
(informative)

Electro-sensitive protective equipment (ESPE) using active opto-electronic

protective devices (AOPDs)

See Figure C.1

Key
1 AOPD 2 Safety distance 3 Borderline of the danger zone

NOTE Values against reaching over (4), reaching under (5) and reaching around (6) in accordance with EN 294.

Figure C.1 — Example of a typical application of an AOPD to a manually fed press

used for cycle initiation (side guards omitted for the purpose of this illustration)
55
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Annex D
(informative)

Closed tools

Key
1 Tools 2 Stripper plate 3 Die

Figure D.1 — Closed tools at a mechanical press

The use of closed tools is usually practicable when blanking operations from strip are carried out and when more
than one operation is combined in a single set of tools. Enclosure can be achieved by arranging for the stripper
plate, which is attached to the die, to be sufficiently thick to prevent the tool from being withdrawn (See Figure D.1)
from it. See 5.3.9.

56
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Annex E
(informative)

The setting of the rotary cam arrangement

E.1 Basic features of the eccentric adjustment and rotary cam arrangement

Fixing the angle during adjustment of different lengths of stroke. Figure E.1 shows the eccentric adjustment.

Crank-shaft Eccentric bush

Eccentric shaft Eccentric bush

e1 is the eccentric distance of the crankshaft or eccentric shaft

e2 is the eccentric distance of the eccentric bush
e is the (half stroke length) vectorial sum of e1 and e2
γ is the angle between e1 and e (i.e. change in angle between e1 and e on the basis of the change in stroke length). This
is the angle the crankshaft has to be turned in order to reposition the slide to the same angle position as before the stroke
adjustment.

Figure E.1 — Eccentric adjustment

57
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Assuming starting from the maximum stroke length and the slide in TDC, e1 and e2 are then in line, and the rotary
cam arrangement indicates that the slide is positioned in TDC (see Figure E.2 a).

Figure E.2 — Position of eccentric bush on crankshaft

By turning the eccentric bush e2, a new and shorter stroke length equal to e2 is achieved (see Figure E.2 b).

To reposition the slide to TDC, the crankshaft (and thus the rotary cam arrangement) is turned by an angle γ in the
opposite direction to the turning of the eccentric bush. The stroke length is now reduced 2 y (see Figure E.2 c). The
rotary cam arrangement indicates a slide position deviating an angle γ from TDC. This is the reason why the rotary
cam arrangement needs to be adjusted.

The angle γ can thus achieve values between 0º and a value of γmax., which is dependent on the ratio between e1
and e2.

γmax. is achieved if e2 is turned in such a way that the angle between e2 and e is 90º (see Figure E.3).

Figure E.3 — Maximum angle of rotary cam arrangement max

γmax. is obtained from sin γmax. = e2/e1

with e1 ≥ e2, it means that γmax. cannot be greater than 90º

(γmax. = 90º can occur for e1 ≤ e2).

If the eccentric bush is adjustable 180º, γmax. can also be calculated by using the maximum and minimum stroke
lengths Smax. and Smin.. See Table E.1.

58
 BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

Table E.1 — Recommended values of maximum angle of rotary cam arrangement in relation to stroke lengths and power
using:

S max. - S min. e 2
sin γ max. = =
S max. + S min. e1

max.
63 71 80 90 100 112 125 140 160 180 200
Stroke length in mm
12 16 20 25
min.

S max. - S min. 51 59 68 74 84 92 105 120 135 155 175

S max. + S min. 75 83 92 106 116 132 145 160 185 205 225

sin γmax. 0,68 0,711 0,739 0,698 0,724 0,697 0,724 0,75 0,73 0,756 0,778

γmax. in ° 42,9 45,4 47,7 44,4 46,5 44,3 46,5 48,7 47,0 49,3 51,2

Pressing force in kN 100 160 250 400 630 (800) 1 000 (1 250) 1 600 (2 000) 2 500

γp + ε2 shall not exceed 60º, preferably γp + ε2 ≤ 45°.

NOTE The table is based on EPPMP (European Power Press Manufacturers' Panel) recommendation on stroke lengths enlarged with angle γmax. and a stopping displacement

position λ ≈ overrun monitoring margin ε2.

59
BS EN 692:2005+A1:2009
EN 692:2005+A1:2009 (E)

S max. - S min.
sin γ max. =
S max. + S min.

If the press stopping position coincides with TDC at maximum and minimum stroke length (γ = 0º), the stopping
position is displaced according to the angle from TDC at every other set stroke length.

To compensate for this and to maintain the stopping position at TDC, it shall be possible to adjust the rotary cam
arrangement to a corresponding angle. This adjustment can be made by rotating the limit switches, or cams, in
relation to the crankshaft.

The largest angle by which the rotary cam arrangement can be rotated between mechanical stops is designated γp,
which is the maximum permissible adjustment of the rotary cam arrangement.

It is not permissible for the average stopping position of the slide to exceed the TDC by more than 60º (it should not
be exceeded by more than 45º) at any combination of speed, stroke length and/or adjustment of the rotary cam
arrangement. Therefore, the angle γp shall be limited between the mechanical stops.

The margin of the angle brake monitor (overrun) ε2 shall also be included in the permissible overrun (60° or
preferably 45°). (ε2 is defined in annex F).

Therefore, the sum of γp and ε2 shall not exceed 60° (preferably 45°) at the maximum stroke rate of the press (see
Figure E.4).

Key

1 Max. overrun (=γp+ε2) 2 Direction of rotation 3 TDC

Figure E.4 — Overrun in relation to rotary cam arrangement

γp is normally equal to γmax., so that the stopping position of the slide will always be at the TDC at different stroke
lengths.

If the angle γmax. is large, however, γp shall be limited so that the permissible overrun is not exceeded.

Consequently, the stopping performance of the slide at certain stroke lengths (these are dealt with below) cannot
be nearer to TDC than within the angle λ (see Figure E.5).

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EN 692:2005+A1:2009 (E)

Key

1 Max. overrun (=γp+ε2) 2 Direction of rotation 3 TDC

λ is the displacement of the stopping position

Figure E.5 — Stopping position in relation to rotary cam arrangement

The Figure E.5 shows γp = γmax. - λ .

The size of γmax. is dependent on the maximum or minimum stroke length of the press. The minimum stroke length is
the factor which has most effect on the size of the angle. For this reason, maximum and minimum stroke lengths
should be used as shown in Table E.1.

If γp cannot equal γmax., thus a stop of TDC cannot be achieved (λ > 0). This can alternatively arise at:

n) maximum and minimum stroke length;

o) the stroke length created at γ = γmax. .

The limits for adjustment of the rotary cam arrangement are determined:

p) with crankshaft direction of rotation: by the maximum overrun γp + ε2;

q) against crankshaft direction of rotation: the maximum permissible part of the mute angle before BDC, which is
designated ϕmax. (see Figure E.6).

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EN 692:2005+A1:2009 (E)

Key

1 Max. overrun (=γp+ε2) 2 Direction of rotation 3 Start of muting

4 TDC 5 BDC

Figure E.6 — Position of maximum mute angle

One of the rotary cam arrangement end stops shall, in order not to exceed the maximum permissible overrun, be
fixed in relation to the excenter shaft when the slide is in TDC either by alternative a) or b) in Figure E.2. That is γ =
0 or γ = γmax. .

It should be noted that the eccentric bush (e2) can be turned clockwise or counter-clockwise by e1 (see Figures E.7
and E.8). However, the necessary limitation of the adjustability of the rotary cam arrangement allows only one half
of a full revolution of the eccentric bush to be used. For this reason, the stroke adjustment shall be designed so that
only the correct half can be used.

Key Key
1 Direction of rotation 1 Direction of rotation
2 TDC 2 TDC

Figure E.7 — e2 turned clock wise Figure E.8 — e2 turned counter-clockwise

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EN 692:2005+A1:2009 (E)

E.2 Determination of the position where muting begins

The movement of the press is shown schematically in Figure E.9.

Key
1 TDC 2 Direction of rotation 3 Muting signal

4 BDC 5 Stopping signal

Φ is the muting angle (angle between the muting signal and the stopping signal)
ϕ is the part of the muting angle before BDC, which varies with stroke length and rotary cam arrangement and is calculated
negative after BDC
ϕmax. is the maximum permissible part of the muting angle before BDC, in degrees, which is calculated from the overall
response time and the speed as described below.

Figure E.9 — Position of muting point

The time from the moment the press receives the muting signal until BDC is traversed (corresponds to angle ϕmax.)
shall not exceed the overall response time of the press with any combination of speed and stroke lengths and/or
setting of the rotary cam arrangement.

Figure E.10 shows ϕmax. ≥ ϕ + γmax. , so that the muting cannot occur before the angle resulting from the above
formula.

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EN 692:2005+A1:2009 (E)

Key
1 TDC 2 Direction of rotation 3 BDC

Figure E.10 — Position of muting point in relation to overall response time

This means that it is not permissible for ϕ to exceed a specific value.

ϕ can be calculated ϕ = ω x T

where

ω is the angular velocity, in degrees per second;

T is the overall response time, in seconds (see annex F).

The maximum permissible value ϕmax. , in degrees, is:

ϕmax. = 6Tn

where

n is the number of strokes per minute.

NOTE ϕmax. shall be calculated at the lowest number of strokes nmin. of the press, if adjustable.

The value obtained for ϕmax. by the above formula applies basically to presses with a fixed stroke length and fixed
rotary cam arrangement. Hence the point where muting begins shall not be able to occur earlier than angle ϕmax.
before BDC as a result of a change in the stroke length and/or setting of the rotary cam arrangement (see
Figure E.10).

This means that the rotary cam arrangement shall have a fixed (mechanical) stop in one end position, so that ϕ +
γmax. (or γp) does not exceed ϕmax. when the stroke length (or rotary cam arrangement) is adjusted.

NOTE It means that the angle ϕ can be negative at a certain setting.

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EN 692:2005+A1:2009 (E)

The following settings then give the two end positions of the rotary cam arrangement (between which the angle is
γp):

r) with crankshaft direction of rotation: the end position is determined from γp (or γmax.) + ε2 ≤ 60° (preferably 45°)
after TDC (see Figure E.1);

s) against crankshaft direction of rotation: the end position is determined by ϕ + γmax. (or γp) ≤ ϕmax. before BDC.

This applies to the least favourable setting.

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Annex F
(informative)

Determination of the overall response time T

The following angles and times are described in Figure F.1 to Figure F.4:

Key
1 Direction of rotation

Figure F.1 — Relation between response time t1, angle of free rotation a and braking time b

Key
1 Slide passes 90°

Figure F.2 — Angular velocity variation during stopping

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EN 692:2005+A1:2009 (E)

where

α is the angle of free rotation, in degrees;

β is the braking angle (assumed to be linear), in degrees;

ε2 is the safety margin of the brake monitor (overrun monitoring margin), in degrees;

ω is the angular velocity, in degrees per seconds;

T is the overall response time, in seconds;

t1 is the response time measured at working pressure, in seconds;

t2 is the safety margin of the brake monitor (overrun monitoring margin), in seconds,

2ε 2
referred to time t 2 = ω

t3 is the pressure differential response time, in seconds;

∆t is the uncertainty in measuring method, in seconds;

α+β is the measured stopping angle on a press with a brake in good condition, in degrees;

α + β + ε2 is the measured stopping angle on the same press with a worn brake, in degrees;

ε2 is normally ∆α + ∆β, but can consist only of ∆β in the worst case.

The overall response time is determined as described below:

t) the time t1 should be measured under the conditions specified in B.4 a) to i).

NOTE The overall response time can only be determined for each individual press;

u) the time t3, which corresponds to ε3, and t2, which corresponds to ε2 (i.e. the pressure differential time plus the
safety margin of the brake monitor), should now be added to t1. (See Figures F.3 and F.4).

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EN 692:2005+A1:2009 (E)

Key
1 Brake monitor 2 Direction of rotation
3 Stopping signal 4 TDC
E Angle at working pressure F Angle at min. pressure

Figure F.3 — Stopping position in relation to pressure differential time t3 and safety margin of brake
monitor t2

Key
1 Stopping signal 5 TDC
2 Brake monitor 6 TDC
3 Working pressure 7 Stopping point at min. pressure
4 Min. pressure 8 α work

Figure F.4 — Sequence diagram of stopping

Figures F.3 and F.4 show that, when the stopping signal and the position of the brake monitor are fixed, the angles
between these two points are constant although the size of the partial angles can vary.

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EN 692:2005+A1:2009 (E)

In Figure F.3, E is the stopping angle that occurs at normal working pneumatic pressure when the cam
arrangement is adjusted so that the average stop position is as close to the TDC as possible, and F is the new
average stopping position that occurs at the same setting of the rotary cam arrangement, but at the minimum
pneumatic pressure determined by the pressure monitor switch setting.

Figure F.4 shows that a smaller braking angle occurs with minimum pressure in the clutch/brake than with normal
working pressure, as air at the lower pressure exhausts more rapidly. If the brake deteriorates while working at
minimum pressure, the overall response time T can be exceeded although the brake monitor angle has not been
exceeded. This occurs because the crankshaft rotates at full speed during α (the response angle) but on average
at half speed during β (the mechanical braking angle).

Theoretically, t3 can be measured directly (t1 at working pressure minus t1 at minimum pressure equals to t3 as
pressure differential time), but a more practical way is to measure ε3 manually and convert it to t3.

ε3 ε3
t3 = =
ω 6 nmax.

This assumes free rotation of the crankshaft with:

ε3 in degrees

nmax. in strokes per minute (the maximum stroke rate).

The safety margin of the brake monitor ε2 is converted to the time t2:

2ε 2 ε2
t2 = =
ω 3 nmax.

This assumes rotation of the crankshaft under braking with:

ε2 in degrees

nmax. in strokes per minute (the maximum stroke rate);

v) possible additions for uncertainties in the measuring method is taken into account by ∆t;

w) the overall response time T is then:

T = t1 + t2 + t3 + ∆t

NOTE The overall response time T is the time

used to calculate the safety distance

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EN 692:2005+A1:2009 (E)

Annex G
(normative)

Conditions for noise measurement of mechanical presses

G.1 The installation and mounting conditions shall be representative of the typical or normal use of the press, and
shall be the same for both sound power levels and emission sound pressure levels.

G.2 The location of the press under test shall be indicated by means of a sketch giving the position and details of
any reflecting surfaces likely to influence the noise emission values obtained.

G.3 The recommended operating conditions are the following:

a) the speed in strokes per minute shall be at least 80 % of the maximum;

b) the force applied shall be at least 80 % of the nominal force;

c) tooling details:

 if the press is capable of carrying out blanking operations, this shall be a blanking tool with simple shear
surfaces, of specified dimensions to give the recommended force on a given material (see d))

 if the press is capable of carrying out forming, drawing and coining operations, this shall be a forming tool
with simple forms, of specified dimensions to give the recommended force on a given material (see d));

d) material used.

This shall be Fe P01 mild steel (see EN 10130). For blanking, thickness of the material shall correspond with the
point up the stroke where the required force is calculated.

G.4 Operating conditions, and in particular those listed in G.3 b), c) and d) are subject to the availability of
representative tools and material with respect to the intended use.

If it is not reasonable to make a representative set of tools and material available for the noise measurement, it
shall be carried out under no load in the following conditions:

 cycle initiations and stops at least as frequent as 80 % of the maximum permissible number of clutch
engagements per minute

 speed in strokes per minute at least 80 % of the maximum.

This test is intended to highlight the noise emission from the press itself, without the variable influence of different
tools.

G.5 The noise measurement procedure used for obtaining the noise emission values shall be described by
indicating the measurement procedure and the microphone positions chosen from the options listed in
EN ISO 11202.

G.6 A sketch of all measurement positions indicating those at which sound pressure/power levels have been
recorded, and the normal position of the operator(s) shall be included. It may be combined with the description of
the press location mentioned in 5.8.4.4 n).

G.7 Under the operating conditions specified in G.3 a) and b) or G.4, the measurement time shall last until the A-
weighted value of the equivalent sound pressure level has stabilized within 1 dB:

a) when running in continuous cycle mode

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EN 692:2005+A1:2009 (E)

or, if continuous cycle mode is not available;

b) when running in single cycle mode at the intended number of operating cycles per minute.

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Annex ZA
(informative)

Relationship between this European Standard and the Essential

Requirements of EU Directive 98/37/EC, amended by Directive 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 a means of conforming to Essential Requirements of the New
Approach Directive:

Machinery Directive 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 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.

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EN 692:2005+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 New
Approach Directive 2006/42/EC on machinery.

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 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."

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EN 692:2005+A1:2009 (E)

Bibliography

The following informative references refer to work items of CEN Technical Committees where standards are in
preparation but not yet publicly available. Their titles and texts are therefore subject to change.

[1] EN ISO 14122, Safety of machinery - Permanent means of access to machinery

Part 1: Choice of a fixed means of access between two levels (ISO 14122-1:2001).

Part 2: Working platforms and gangways (ISO 14122-2:2001).

Part 3: Stairways, stepladders and guard rails (ISO 14122-3:2001).

Part 4: Fixed ladders (ISO/FDIS 14122-4:2002).

[2] prEN 547-4, Safety of machinery - Human body measurements - Part 4: Ergonomic requirements for the
design of workplaces at machinery - Standing and sitting postures.

[3] EN ISO 14738, Safety of machinery - Anthropometrics requirements for the design of workstations at
machinery (ISO 14738:2002).

[4] EN 12464-1, Light and lighting - Lighting of workplaces - Part 1: Indoor workplaces.

[5] ISO 230-5, Test code for machine tools - Part 5: Determination of the noise emission.

[6] ISO/DIS 8500, Airborne noise emitted by machine tools - Operating conditions for mechanical presses up to
2500 kN.

[7] EN 10130, Cold-rolled low carbon steel flat products for cold forming - Technical delivery conditions.

[8] EN 614-1:1995, Safety of machinery - Ergonomic design principles - Part 1: Terminology and general
principles.

[9] EN 894-2:1997, Safety of machinery - Ergonomics requirements for the design of displays and control
actuators - Part 2: Displays.

[10] EN 894-3:2000, Safety of machinery - Ergonomics requirements for the design of displays and control
actuators - Part 3: Control actuators.

[11] ISO 11161:1994, Industrial automation systems - Safety of integrated manufacturing systems - Basic
requirements.

[12] 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).

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 BS EN
692:2005
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