Safety Requirements for ESPD Systems

When it comes to the safety of packaging machines, experienced designers value the DIN EN 415 Type C standard series. This ten-part standard defines a wide range of safety requirements for machines.

Currently these are:
These machines are typically enclosed, fully automated systems. To transport products and materials in and out of the safety area, non-contact protective devices are commonly used for larger openings and are controlled by safety functions. It must be ensured that products and materials can move freely while preventing unauthorized access to the hazard zone through these openings. One method for securing such openings is bypassing or deactivating the protective system, known as muting.

DIN EN 415-10:2014, Section 5.2.1.4, specifies the key requirements for muting systems:

a) The bypass duration must be limited to the time required for the product to pass through.
b) Sensors must distinguish between a person and the material;
c) All bypass functions must meet the same performance level;
d) No product may remain in the bypass area as a waiting position.

 

 

For further details, DIN EN 415-10:2014 refers to DIN EN IEC 62046:2019.
Section 5.5.3 of this standard requires that the bypass function must be initiated and terminated automatically. This can be achieved by using appropriately selected and arranged sensors or, in some cases, by signals from the safety-related control system. A bypass condition state must not be enabled due to faulty signals, incorrect sequences, or timing errors of the bypass sensors or signals.
The control circuit executing the bypass function must meet an appropriate safety-related performance level (SIL or PL, see DIN EN 62061:2016 or DIN EN 13849-1:2016).
Additionally, machine safety during muting must be ensured through alternative measures, such as maintaining the specified side clearances and ensuring that the load has a minimum height of 900 mm.
If compliance with these safety requirements is not feasible, other solutions, such as an interlock function, may be used.

 

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• Both sensors must be located within the hazardous area
• Both beams must be occupied within a certain time
• Muting must be deactivated when the protective device is clear or 4 seconds after leaving the first sensor
• If deactivation occurs only after 4 seconds, an additional distance d8 must be maintained

 

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• The intersection point must be within the hazardous area
• The intersection point should be as close as possible to the protective device ( ≤ 200 mm) ( ≤ 200 mm)
• The distance between the load and the separating protective device should not exceed 200 mm
• A round test body with a diameter of 500 mm must not trigger the muting

• If there is a risk of body parts being pinched between the load and stationary parts, DIN EN 349:2008 recommends a minimum distance of 500 mm to avoid the risk of crushing or shearing between the moving load and the stationary parts of the systems. More detailed information can be found in EN 349.

 

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• The muting sensors should be as close as possible to the "protective device" (distance < 200 mm)
• The distance between sensors S1 and S4 must be greater than 500 mm
• The distance between sensors S1 and S2, as well as between S3 and S4, must be greater than 250 mm
• The distance between the load and the separating protective device must not exceed 200 mm

 

• If there is a risk of body parts being pinched between the load and stationary parts, DIN EN 349:2008 recommends a minimum distance of 500 mm to avoid the risk of crushing or shearing between the moving load and the stationary parts of the system. More detailed information can be found in EN 349.