BRITISH STANDARD

BS EN
1218-2:2004
+A1:2009
Incorporating
corrigendum
December 2006

Safety of woodworking
machines — Tenoning
machines —
Part 2: Double end tenoning and/or
profiling machines fed by chain or
chains

ICS 79.120.10

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


BS EN 1218-2:2004+A1:2009

National foreword
This British Standard is the UK implementation of
EN 1218-2:2004+A1:2009, incorporating corrigendum December 2006.
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/23, Woodworking machines — Safety.
A list of organizations represented on this committee can be obtained
on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
Compliance with a British Standard cannot confer immunity
from legal obligations.

Amendments/corrigenda issued since publication

This British Standard was
published under the authority
of the Standards Policy and
Strategy Committee on
22 July 2004

© BSI 2009

ISBN 978 0 580 62152 9

Amd. No.

Date

Comments

17022

30 April 2007


Addition to the key to Figure A.3,
and replacement of Annex ZA

31 August 2009

Implementation of CEN amendment
A1:2009

Corrigendum No. 1


EUROPEAN STANDARD

EN 1218-2:2004+A1

NORME EUROPÉENNE
EUROPÄISCHE NORM

June 2009

ICS 79.120.10

Supersedes EN 1218-2:2004

English Version

Safety of woodworking machines - Tenoning machines - Part 2:
Double end tenoning and/or profiling machines fed by chain or
chains

Sécurité des machines pour le travail du bois Tenonneuses - Partie 2: Machines à tenonner et/ou à
profiler à chne ou chnes

Sicherheit von Holzbearbeitungsmaschinen Zapfenschneid- und Schlitzmaschinen - Teil 2:
Doppelseitige Zapfenschneid- und Schlitzmaschinen
und/oder Doppelendprofiler mit Kettenbandvorschub

This European Standard was approved by CEN on 24 March 2004 and includes Corrigendum 1 issued by CEN on 20 December 2006 and
Amendment 1 approved by CEN on 21 May 2009.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the respons bility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2009 CEN

All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.


Ref. No. EN 1218-2:2004+A1:2009: E


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

Contents
page
Foreword...................................................................................................................................................................... 4
Introduction ................................................................................................................................................................. 5
1

Scope .............................................................................................................................................................. 6

2

Normative references .................................................................................................................................... 6

3
3.1
3.2
3.3

Terms and definitions ................................................................................................................................... 9
General............................................................................................................................................................ 9
Terms .............................................................................................................................................................. 9
Definitions .................................................................................................................................................... 10

4


!List of significant hazards"
" ................................................................................................................ 11

5
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.4
5.4.1
5.4.2
5.4.3
5.4.4

5.4.5
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
5.4.12
5.4.13

Safety requirements and/or measures ...................................................................................................... 14
General.......................................................................................................................................................... 14
Controls ........................................................................................................................................................ 14
Safety and reliability of control systems................................................................................................... 14
Position of controls ..................................................................................................................................... 15
Starting ......................................................................................................................................................... 15
Stop controls ................................................................................................................................................ 16
Emergency stop ........................................................................................................................................... 17
Integrated feed ............................................................................................................................................. 17
Mode selection ............................................................................................................................................. 17
Speed changing ........................................................................................................................................... 18
Control duplication ...................................................................................................................................... 19
Failure of the power supply ........................................................................................................................ 19
Failure of the control circuits ..................................................................................................................... 19
Protection against mechanical hazards .................................................................................................... 19
Stability ......................................................................................................................................................... 19
Risk of break-up during operation ............................................................................................................. 19
Tool holder and tool design........................................................................................................................ 20
Braking.......................................................................................................................................................... 22
Devices to minimise the possibility or the effect of ejection .................................................................. 23

Workpiece supports and guides ................................................................................................................ 23
Prevention of access to moving parts....................................................................................................... 24
Protection against non-mechanical hazards ............................................................................................ 31
Fire ................................................................................................................................................................ 31
Noise ............................................................................................................................................................. 31
Emission of chips and dust ........................................................................................................................ 33
Electricity ...................................................................................................................................................... 33
Ergonomics and handling........................................................................................................................... 33
Lighting ......................................................................................................................................................... 34
Pneumatics ................................................................................................................................................... 34
Hydraulics..................................................................................................................................................... 34
!Electromagnetic compatibility"
" ......................................................................................................... 34
Static electricity ........................................................................................................................................... 34
Errors of fitting ............................................................................................................................................. 34
Isolation ........................................................................................................................................................ 35
Maintenance ................................................................................................................................................. 35

6
6.1
6.2
6.3

Information for use ...................................................................................................................................... 35
Warning devices .......................................................................................................................................... 35
Marking ......................................................................................................................................................... 35
Instruction handbook .................................................................................................................................. 36

2



BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

Annex A (informative) Examples of safety related control systems ................................................................ 39
Annex B (normative) Tool spindle dimensional tolerances .............................................................................. 43
Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/EC"
" .............................................................................................. 45
Annex ZB (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC"
" .......................................................................................... 46
Bibliography .............................................................................................................................................................. 47

3


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

Foreword
This document (EN 1218-2:2004+A1:2009) has been prepared by the Technical Committee CEN/TC 142
"Woodworking machines -Safety", the secretariat of which is held by UNI.
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 December 2009, and conflicting national standards shall be withdrawn
at the latest by December 2009.
This document includes Amendment 1, approved by CEN on 2009-05-21 and Corrigendum 1 issued by CEN
on 20 December 2006.
This document supersedes EN 1218-2:2004.
The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".

The modifications of the related CEN Corrigendum have been implemented at the appropriate places in the
text and are indicated by the 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."
!EN 1218, Safety of woodworking machines — Tenoning machines consists of the following parts:
Part 1: Single end tenoning machines with sliding table
Part 2: Double end tenoning and/or profiling machines fed by chain or chains
Part 3: Hand fed tenoning machines with sliding table for cutting structural timbers
Part 4: Edge banding machines fed by chain(s)
Part 5: One side profiling machines with fixed table and feed rollers or fed by chain"
Organisations contributing to the preparation of this European Standard include European Committee of
Woodworking Machinery Manufacturers Association "EUMABOIS".
The European Standards produced by CEN/TC 142 are particular to woodworking machines and complement
the relevant A and B Standards on the subject of general safety (see introduction of EN ISO 12100-1:2003 for
a description of A, B and C standards).
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.

4


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

Introduction

This document has been prepared to be a harmonised standard to provide one means of conforming to the
essential safety requirements of the Machinery Directive, and associated EFTA regulations.
This document is a type C standard as stated in !EN ISO 12100-1:2003".
The machinery concerned and the extent to which hazards, hazardous situations and events covered are
indicated in the scope of this document.
When provisions of this type C standard are different from those which are stated in type A or B standards, the
provisions of this C type standard take precedence over the provisions of other standards, for machines that
have been designed and built in accordance with the provisions of this type C standard.
The requirements of this document are directed to manufacturers and their authorised representatives of
double end tenoning and/or profiling machines fed by chain or chains. It is also useful for designers.
This document also includes information which can be provided by the manufacturer to the user.
Common requirements for tooling are given in !EN 847-1:2005".

5


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

1

Scope

!This document deals with all the significant hazards, hazardous situations and events as listed in Clause 4
which are relevant to double end tenoning and/or profiling machines fed by chain or chains, hereinafter
referred to as the machine, designed to cut solid wood, chipboard, fibreboard or plywood and also these
materials where they are covered with plastic laminate or edgings. The workpiece is fed passed the tools by an
integrated feed."
!deleted text"
This document does not apply to:

a)

double end tenoning and/or profiling machines fed by chain or chains with a complete enclosure as
defined in 3.3.11;

b)

transportable machines.

This document does not deal with any hazards relating to:
c)

mechanical loading of the workpiece to a single machine; or

d)

single machine being used in combination with any other machine (as part of a line); or

e)

use of tools working between the machine halves (see 3.1); or

f)

use of laser.

For Computer Numerically Controlled (CNC) machines this document does not cover hazards related to
Electro-Magnetic Compatibility (EMC).
NOTE 1
The requirements of this document apply to all machines whatever their method of control e.g.

electromechanical and/or electronic.

This document is primarily directed to machines which are manufactured after the date of publication by CEN.
NOTE 2 Single end tenoning machines with sliding table are dealt with in EN 1218-1:1999. Single end tenoning machines
where the tenon is produced only by means of saw blades are dealt with in EN 1218-3. Single end profiling machines fed
by chain or chains are dealt with in EN 1218-5.

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.
!deleted text"
!EN 614-1:2006, Safety of machinery — Ergonomic design principles — Part 1: Terminology and general
principles"
!EN 847-1:2005, Tools for woodworking — Safety requirements — Part 1: Milling tools, circular saw
blades"
!EN 894-1:1997, Safety of machinery — Ergonomics requirements for the design of displays and control
actuators — Part 1: General principles for human interactions with displays and control actuators

6


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
EN 894-2:1997, Safety of machinery — Ergonomics requirements for the design of displays and control
actuators — Part 2: Displays
EN 894-3:2000, Safety of machinery — Ergonomics requirements for the design of displays and control

actuators — Part 3: Control actuators"
!deleted text"
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 1005-1:2001, Safety of machinery — Human physical performance — Part 1: Terms and definitions
EN 1005-2:2003, Safety of machinery — Human physical performance — Part 2: Manual handling of
machinery and component parts of machinery
EN 1005-3:2002, Safety of machinery — Human physical performance — Part 3: Recommended force limits
for machinery operation
EN 1005-4:2005, Safety of machinery — Human physical performance — Part 4: Evaluation of working
postures and movements in relation to machinery"
EN 1037:1995, Safety of machinery — Prevention of unexpected start-up
!deleted text"
EN 1088:1995, Safety of machinery — Interlocking devices associated with guards — Principles for design
and selection
EN 1760-2:2001, Safety of machinery — Pressure sensitive protection devices — Part 2: General principles for
the design and testing of pressure sensitive edges and pressure sensitive bars
EN 1837:1999, Safety of machinery — Integral lighting of machines
!EN 50370-1:2005, Electromagnetic compatibility (EMC) — Product family standard for machine-tools —
Part 1: Emission
EN 50370-2:2003, Electromagnetic compatibility (EMC) — Product family standard for machine-tools —
Part 2: Immunity"
!EN 60204-1:2006", Safety of machinery — Electrical equipment of machines — Part 1: General
requirements !(IEC 60204-1:2005, modified)"
!EN 60439-1:1999, Low-voltage switchgear and controlgear assemblies — Part 1: Type-tested and partially
type-tested assemblies (IEC 60439-1:1999)"
EN 60529:1991, Degrees of protection provided by enclosures (IP Code) (IEC 60529:1989)
!EN 60947-4-1:2001", Low voltage switchgear and controlgear — Part 4-1: Contactors and motor starters

- Electromechanical contactors and motor starters !(IEC 60947-4-1:2000)"
!EN 60947-5-1:2004", Low-voltage switchgear and controlgear — Part 5-1: Control circuit devices and
switching elements — Electromechanical control circuit devices !(IEC 60947-5-1:2003)"
!EN 61310-1:2008, Safety of machinery — Indication, marking and actuation — Part 1: Requirements for
visual, acoustic and tactile signals (IEC 61310-1:2007)"

7


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
!CLC/TS 61496-2:2006", Safety of machinery — Electro-sensitive protective equipment — !Part 2:
Particular requirements for equipment using active opto-electronic protective devices (AOPDs) (IEC 614962:2006)"
!EN ISO 354:2003", Acoustics — Measurement of sound absorption in a reverberation room (ISO
354:2003)
EN ISO 3743-1:1995, Acoustics — Determination of sound power levels of noise sources — Engineering
methods for small, moveable sources in reverberant fields — Part 1: Comparison method for hard walled test
rooms (ISO 3743-1:1994)
EN ISO 3743-2:1996, Acoustics — Determination of sound power levels of noise sources using sound
pressure — Engineering methods for small, moveable sources in reverberant fields — Part 2: Methods for
special reverberation test rooms (ISO 3743-2:1994)
EN ISO 3744:1995, Acoustics — Determination of sound power levels of noise sources using sound pressure
— Engineering method in an essentially free field over a reflecting plane (ISO 3744:1994)
!EN ISO 3745:2003", Acoustics — Determination of sound power levels of noise sources using sound
pressure — Precision methods for anechoic and semi-anechoic rooms (ISO 3745:2003)
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 9614-1:1995, Acoustics — Determination of sound power levels of noise sources using sound intensity

— Part 1: Measurement at discrete points (ISO 9614-1:1993)
EN ISO 11202:1995, !Acoustics — Noise emitted by machinery and equipment — Measurement of
emission sound pressure levels at a work station and at other specified positions — Survey method in situ
(ISO 11202:1995)"
EN ISO 11204:1995, Acoustics — Noise emitted by machinery and equipment — Measurement of emission
sound pressure levels at the workstation and at other specified positions — Method requiring environmental
corrections (ISO 11204:1995)
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)
EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology (ISO 12100-1:2003)
EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (ISO 12100-2:2003)
!EN ISO 13849-1:2008 Safety of machinery — Safety-related parts of control systems — Part 1: General
principles for design (ISO 13849-1:2006)"
!EN ISO 13850:2008, Safety of machinery — Emergency stop — Principles for design (ISO 13850:2006)"
ISO 286-2:1988, ISO system of limits and fits — Part 2: Tables of standard tolerance grades and limit
deviations for holes and shafts
ISO 7960:1995, Airborne noise emitted by machine tools — Operating conditions for woodworking machines
!HD 21.1 S4:2002, Cables of rated voltages up to and including 450/750 V and having thermoplastic
insulation — Part 1: General requirements"

8


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
!HD 22.1 S4:2002, Cables of rated voltages up to and including 450/750 V and having cross-linked
insulation — Part 1: General requirements"


3
3.1

Terms and definitions
General

For the purposes of this document, the terms and definitions given in !EN ISO 12100-1:2003" apply.
Additional definitions specifically needed for this document are shown in 3.2 and 3.3.

3.2 Terms
The main parts of the machine and their terminology are illustrated in Figure 1.

9


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

1
2

2

3

3

4

Key

1
2
3
4

Machine half
Top pressure beams
Chain beams
Feed cross drive shaft

Figure 1 — Terminology

3.3 Definitions
3.3.1
double end tenoning and/or profiling machine fed by chain or chains
woodworking machine primarily designed for production of tenons and/or profiles on opposing ends of a
workpiece in one pass. The tenons and/or profiles are cut by means of milling tools, saw blade(s) and/or
sanding units mounted on one or more spindles on each machine half. The workpiece is presented by means
of a chain or chains using pads and/or dogs mounted on a continuous chain belt or similar conveyor
3.3.2
machine half
part of a machine consisting of a frame, chain beam, top pressure beam and working units. Each machine half
processes one, different, end of the workpiece. One or both machine halves move to accept workpieces of
different dimensions
3.3.3
profile
shaping of an edge of a workpiece by milling tools, saw blades and/or sanding units. Profiling also includes
panel sizing
3.3.4
integrated feed

feed mechanism for the workpiece or tool which is integrated with the machine and where the workpiece or
machine element with incorporated tool are held and controlled mechanically during the machining operation
3.3.5
ejection
unexpected movement of the workpiece or parts of it or part of the machine from the machine during
processing

10


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
3.3.6
machine actuator
power mechanism used to effect the motion of the machine
3.3.7
run-up time
time elapsed from the actuation of the start control device until the spindle reaches the intended speed
3.3.8
unbraked run-down time
time elapsed from the actuation of the stop control, but not the braking device (if fitted) up to spindle standstill
3.3.9
braked run-down time
time elapsed from the actuation of the stop control and the brake devices up to spindle standstill
3.3.10
integral enclosure
guarding designed to fit close to the machine and provide a measure of sound attenuation and where certain
setting adjustments may be available outside the enclosure. Each machine half is provided with separate
guarding and on the adjustable machine half/halves this guarding moves with it when adjustment is made for
workpiece width

3.3.11
complete enclosure
total machine enclosure primarily designed for noise attenuation and to permit the operator to move around
freely within it and where all machine setting and adjustments are available inside it
3.3.12
!displaceable machine"
"
machine which is located on the floor, stationary during use and equipped with a device, normally wheels,
which allow it to be moved between locations
3.3.13
!information from the supplier"
"
statements, sales literature, leaflets or other documents where a manufacturer (supplier) declares either the
characteristics of e.g. a material or product or the compliance of the material or product to a relevant standard

4

!List of significant hazards"
"

!This clause contains all the significant hazards, hazardous situations and events (see EN 1050:1996) as far
as they are dealt with in this document, identified by risk assessment as significant for the machines as defined
in the scope and which require action to eliminate or reduce the risk. This document deals with these
significant hazards by defining safety requirements and/or measures or by reference to relevant standards.
These hazards are listed in Table 1 in accordance with Annex A of EN 1050:1996.

11


BS EN 1218-2:2004+A1:2009

EN 1218-2:2004+A1:2009 (E)

Table 1 — List of significant hazards
No

Hazards, hazardous situations and
hazardous events

EN ISO 12100
Part 1:
2003

1

Part 2:
2003

Mechanical hazards related to:

a) shape;

- machine parts or workpieces:
4.2
4.2.1,
4.2.2, 5

b) relative location;

5.3.3, 5.3.7,
5.4.5, 6.3

5.2.2, 5.2.5,
5.3.7
5.2.7, 5.3.5,
5.3.7

d) mass and velocity (kinetic energy of
elements in controlled or uncontrolled
motion);
e) mechanical strength.
- accumulation of energy inside the machinery:

5.3.2, 5.3.3

g) liquids and gases under pressure;

4.2

1.1
1.2
1.3

Crushing hazard
Shearing hazard
Cutting or severing hazard

4.2.1

1.4

Entanglement hazard


1.5
1.6
1.9

Drawing-in or trapping hazard
Impact hazard
High pressure fluid injection or ejection
hazard

2
2.1

Electrical hazards due to:
Contact of persons with live parts (direct
4.3
4.9, 5.5.4
5.4.4,
5.4.6,
contact)
5.4.12, 5.4.13
4.3
4.9
5.4.4,
5.4.6,
Contact of persons with parts which have
5.4.12, 5.4.13
become live under faulty conditions
(indirect contact)
Hazards generated by noise, resulting in:

Hearing loss (deafness), other
4.5
4.2.2, 5
5.4.2
physiological disorders (loss of balance,
loss of awareness)
Interference with speech communication,
5.4.2
acoustic signals.
Hazards generated by materials and substances (and their constituent elements)
processed or used by the machinery
Hazards from contact with or inhalation of 4.8
4.3b, 4.4
5.4.3, 6.3
harmful fluids and dusts
Fire hazard
4.8
4.4
5.4.1, 5.4.3
Hazards generated by neglecting ergonomic principles in machinery design
related to:
Unhealthy postures or excessive effort
4.9
4.7, 4.8.2, 5.2.2, 5.4.5, 6.3
4.11.12,
5.5.5, 5.5.6
Hand-arm or foot-leg anatomy
4.9
4.8.3
5.2.2, 5.4.5, 6.3

Local lighting
4.8.6
5.4.6, 6.3
Human error, human behaviour
4.8, 4.11.8, 6.3
4.11.10,
5.5.2, 6

2.2
4
4.1
4.2
7
7.1
7.2
8
8.1
8.2
8.4
8.6

12

Relevant subclause of this
document

4.10, 5.5.4

5.4.7, 5.4 8
5.3.7

5.3.7
5.3.2, 5.3.3,
5.3.4, 5.3.7
5.3.3,
5.3.4,
5.3.6, 5.3.7
5.3.7.1
5.3.7
5.3.4,
5.4.7,
5.4.8


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
8.7
8.8

Design, location or identification of
manual controls
Design or location of visual display units

4.8.7,
4.11.8
4.8.8, 6.2

5.2.2
5.2.2

14


4.11
5.2.6, 5.2.7
Combination of hazards
Unexpected start up, unexpected overrun/overspeed (or any similar malfunction)
from:
Failure/disorder of the control system
4.11, 5.5.4
5.2.1, 5.2.11
Restoration of energy supply after an
4.11.4
5.2.10, 5.3.3.7
interruption
External influences on electrical
4.11.11
5.4.4, 5.4.9
equipment
Errors made by the operator (due to 4.9
4.8, 4.11.8, 5.2.1, 5.4.5,
6.3
mismatch of machinery with human
4.11.10,
characteristics and abilities, see 8.6)
5.5.2, 6
5.2.2,
5.2.4,
Impossibility of stopping the machine
4.11.1,
5.2.9
in the best possible conditions

4.11.3,
5.5.2
5.2.10
Failure of the power supply
4.11.1,
4.11.4
5.2.11
Failure of the control circuit
4.11, 5.5.4

15

Errors of fitting

4.9

4.7, 6.5

5.4.11, 6.3

16

Break-up during operation

4.2.2

4.3

5.2.2


17

Falling or ejected objects or fluids

4.2.2

4.3, 4.10

18

Loss of stability / overturning of
machinery

4.2.2

5.2.6

5.2.6, 5.2.8,
5.3.2, 5.3.3,
5.3.5, 5.3.6,
5.4.12
5.3.1

9
10
10.1
10.2
10.3
10.6


11

13

"

13


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)

5

Safety requirements and/or measures

5.1

General

The machine shall comply with the safety requirements and/or protective measures of this clause. In addition,
the machine shall be designed in accordance with the principles of Clause 5 of EN ISO 12100-1:2003 for
hazards relevant but not significant, which are not dealt with by this document (e.g. sharp edges).
For guidance in connection with risk reduction by design, see Clause 4 of EN ISO 12100-2:2003, and for
safeguarding measures, see Clause 5 of EN ISO 12100-2:2003.

5.2 Controls
5.2.1

Safety and reliability of control systems


For the purposes of this document a safety related control system is one from and including the initial manual
control or position detector to the point of input to the final actuator or element e.g. motor. The safety related
control systems of this machine are those for:


starting (see 5.2.3);



normal stopping (see 5.2.4);



emergency stop (see 5.2.5);



moveable interlocked guards (see 5.3.7);



moveable interlocked guards with guard locking (see 5.3.7);



trip device, limiting device and hold-to-run control devices required in 5.3.7.3;




mode selection (see 5.2.7);



integrated feed (see 5.2.6);



step less speed changing (see 5.2.8);



spindle unit locking (see 5.3.3.4);



braking (see 5.2.4, 5.2.5, 5.3.4).

Unless otherwise stated in this document these control systems shall, as a minimum, be designed and
constructed in accordance with category 1 as defined in !EN ISO 13849-1:2008".
For the purposes of this document "well tried components and principles" means:
a)

14

electrical components if they comply with relevant standards including the following as:
1)

!EN 60947-5-1:2004" (section 3) for control switches with positive opening operation used as
mechanical actuated position detectors for interlocking guards and for relays used in auxiliary circuits;


2)

!EN 60947-4-1:2001" for electromechanical contactors and motor-starters used in main circuits;

3)

!HD 22.1 S4:2002" for rubber-insulated cables;


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
4)

!HD 21.1 S4:2002" for polyvinyl chloride cable if this cable is additionally protected against
mechanical damage by positioning (e.g. inside frames).

b)

electrical principles if they comply with the first four measures listed in 9.4.2.1 of
!EN 60204-1:2006". The circuits shall be either “hardwired”, or if electronic components are used in
safety related control systems “well tried” is fulfilled if they are in accordance with the requirements of
9.4.2.2
(i.e.
redundancy
with
cross-monitoring)
or
9.4.2.3
(i.e.

diversity)
of
!EN 60204-1:2006" (see Annex A for examples of safety related control systems);

c)

mechanical components if, for example they operate in the positive mode in accordance with the
description given in 4.5 of EN ISO 12100-2:2003;

d)

mechanically actuated position detectors for guards if they are actuated in the positive mode and their
arrangement/fastening and the cam design/mounting comply with the requirements of 5.2 and 5.3 of EN
1088:1995;

e)

interlocking devices with guard locking if they satisfy the requirements of 5.3.7.1;

f)

pneumatic and hydraulic components and systems if they comply with the requirements of
EN 983:1996 and EN 982:1996 respectively.

As an exception, time delay devices used in hardwired safety related control circuits which are designed for at
least 1 million actuations and the components consisting of the initial manual control of the hold-to-run control
device may be of category B in accordance with the requirements of !EN ISO 13849-1:2008".
In addition the control system for stepless speed changing shall be as a minimum designed and constructed in
accordance with the following principles:
The actual speed or exit frequency can be converted in a comparator, e.g. by the electronic system, and can

there be compared either by the inverter itself or by an external comparator with the selected frequency.
Verification : By checking the relevant drawings and/or circuit diagrams and inspection on the machine.
!deleted text"
!NOTE For components characteristics the information from the component supplier can be useful."

5.2.2

Position of controls

The main control devices of the machine for starting the tool spindles, normal stopping, beam movement and
mode selection, shall be located together and situated at a position from which the loading area can be seen.
Where controls are located on a separate control desk, their position shall be indicated by the machine
manufacturer in the instruction handbook (see 6.3).
Hold-to-run control devices shall be located so that the operator, when actuating them, can see the controlled
movements (also see 5.2.7.2d)).
For the position of emergency stop controls see 5.2.5.
Where a mobile set of controls is used, it shall be connected by cable to the machine.
Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
5.2.3

Starting

Before starting or restarting the machine all the safeguards shall be in place and functional. This is achieved by
the interlocking arrangements described in 5.3.7. Start or restart shall only be possible by actuation of the start
control device provided for that purpose.

15



BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
When power is supplied to a tool spindle motor, this shall be indicated. The means of identification are e.g. by
a light signal near to the start control or integrated in the start button or by using a two position switch or
through the operator interrogating the control computer.
The shearing and/or crushing area between the workpiece and part(s) of the machine shall be visible from the
main control position either directly or indirectly e.g. by a mirror or a television camera.
It shall be possible to start each tool spindle motor and the feed mechanism separately (see 5.2.6).
For electrically started machines see 9.2.5.2 of !EN 60204-1:2006".
Verification : By checking the relevant drawings and/or circuit diagrams, inspection and functional testing of
the machine.
5.2.4
5.2.4.1

Stop controls
Normal stopping

A stop control shall be fitted which, when actuated, stops all machine actuators and cuts power to them once
stopping is complete.
The category of this stop function (category 0 or 1) shall be in accordance with the requirements of
9.2.2 of !EN 60204-1:2006", where the “safety and/or functional” requirements of the machine are fulfilled
by avoiding impact between the workpiece and running down or stationary tools and allows power to be
maintained to the electrical brake (if provided) until the braking sequence is complete.
The above requirements shall be satisfied at the level of control circuits. If a time-delay device is used, the time
delay shall at least be more than the maximum run-down time of the machine, and either the time delay shall
be fixed or the adjustment mechanism shall be sealed.
If the emergency stop provided by virtue of 5.2.5 also achieves at least the above requirements, then the
emergency stop can be regarded as fulfilling the requirements of the normal stop control. In this case
precautions shall be taken to prevent automatic or unexpected restarting (also see 7.5 of
!EN 60204-1:2006",).

Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
5.2.4.2

All other stop controls

Any other stop controls provided shall be of category 0, 1 or 2 in accordance with the requirements of
!EN 60204-1:2006", depending upon their intended function. If a category 2 stop control is used and it is
active in the setting mode for all movements or in machining mode only for the feed, it shall fulfil all the safety
requirements associated with the particular mode.
When initiated, the stopping sequence shall be:
a)

stop the axes movements;

b)

stop spindle rotation and actuate the brake (if provided);

c)

when braking sequence is complete, cut power to brake (if electrical brake is fitted).

Unexpected start up of all movements in the setting mode or the feed movement in the machining mode shall
be prevented in accordance with the requirements of EN 1037:1995. Where it is not possible to cut power to all
machine actuators, standstill monitoring in accordance with the requirements of 6.4 of EN 1037:1995 is
necessary. In case of a failure the standstill monitoring system shall cut the power to these movements.
Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
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BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
5.2.5

Emergency stop

Shall be according to !EN ISO 13850:2008" and in addition:
Machines shall be fitted with emergency stop control(s) which conform to the requirements of 9.2.5.4 and 10.7
of !EN 60204-1:2006". However the requirements of 10.7.5 of !EN 60204-1:2006" do not apply.
The requirements for normal stopping in 5.2.4 shall apply.
Emergency stop controls shall be fitted at the following locations:
a)

at the loading and unloading positions of the machine on both ends of each machine half;

b)

on each mobile or fixed set of controls;

c)

not more than 0,5 m from each hold-to-run device;

d)

inside each enclosure where a mode selection switch is provided (see 5.2.7) and positioned such that it is
possible to reach an emergency stop control from any position.


A single emergency stop control can fulfil, by virtue of its installed position, the function of more than one of the
above requirements.
Verification : By checking the relevant drawings and/or circuit diagrams, measurement, inspection and
relevant functional testing of the machine.
5.2.6

Integrated feed

The integrated feed shall only operate when the tool spindles which are adjusted under power, are either all
running under power or when those not running under power are retracted so that they are in the non-cutting
position for the maximum tool diameter for which the machine is designed. This may be achieved either by:
a)

a limit switch of at least category B in accordance with the requirements of !EN ISO 13849-1:2008";
or

b)

by the programmable electronic system.

See 6.3 for such tools which are adjusted manually, this manual adjustment includes hold-to-run control.
Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
5.2.7
5.2.7.1

Mode selection
General

A mode selection switch shall be provided if the guard(s) has to be opened for adjusting whilst certain parts of

the machine are in motion. This control mode shall override all other control systems except the emergency
stop.
Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
5.2.7.2

Mode selection for the adjustment of tools

For tools, a mode selection switch may be provided. If a mode selection switch is provided, the following
requirements shall apply:
a)

in the adjustment mode the normal (automatic) control mode shall be disabled;
17


BS EN 1218-2:2004+A1:2009
EN 1218-2:2004+A1:2009 (E)
b)

its use shall not initiate any adjustment;

c)

moving it to the adjusting position shall initiate stopping of the feed and tool spindles;

d)

it shall be lockable e.g. by a key-operated switch in accordance with the requirements of 4.11.10 of
EN ISO 12100-2:2003;


e)

movement of the feed shall be controlled by a hold-to-run control device (also see 5.2.2). The feed and the
tool spindles shall stop if the hold-to-run control for the feed is continuously activated for more than 5 min.
The hold-to run control device shall only be located on a mobile set of controls;

f)

powered adjustment shall be controlled by a hold-to-run control device (also see 5.2.2);

g)

some or all of the tool spindles may run after intentional starting. When intentional starting in the adjusting
mode is possible, the area around the tool shall be visible to the operator;

h)

a deterring/impeding device(s) shall be fitted as necessary to prevent horizontal access from inside the
enclosure. For materials and properties of this device see 5.3.2.

Verification : By checking the relevant drawings and/or circuit diagrams, inspection and relevant functional
testing of the machine.
5.2.7.3
Mode selection for fine adjustment of the tools whilst they and the feed are running during
machining
A mode selection switch may be provided for fine adjustment of the tools. If a mode selection switch is
provided, the following requirements shall apply:
a)


in the fine adjustment mode the normal (automatic) control mode shall be disabled;

b)

its use shall not initiate any adjustment;

c)

it shall be lockable, e.g. by a key-operated switch in accordance with the requirements of 4.11.10 of
EN ISO 12100-2:2003;

d)

overriding of the interlocking of a single door, not more than 2,0 m long, a single time shall be permitted
for a maximum period of 3 min. The feed and tools shall stop if this time limit is exceeded;

e)

a deterring/impeding device(s) shall be fitted as necessary to prevent horizontal access to any rotating tool
from inside the enclosure. For materials and properties of the device see 5.3.2.

Also see 5.2.2 and 5.3.7.
Verification : By checking the relevant drawings and/or circuit diagrams, measurement, inspection and
relevant functional testing of the machine.
5.2.8

Speed changing

On machines fitted with a device (e.g. a frequency inverter) for infinitely variable (step-less) speed changing for
tool spindles, the device shall be such that it does not allow the actual speed to exceed the selected speed by

more than 10 %. The actual speed or exit frequency can be converted in a comparator e.g. by the electronic
system and can there be compared with the selected value either by the inverter itself or by an external
comparator (also see 9.4.2 of !EN 60204-1:2006" and A.4).
Verification : By checking the relevant drawings and/or circuit diagrams, measurement !and" inspection
!deleted text".
!NOTE For the component characteristics a confirmation from the component manufacturer can be useful."

18