Safeguarding cutting and turning machines

4620 Hydraulic Road \u2022 Rockford, Illinois 61109-2695 T oll - Free 1-800-922-7533 \u2022 Phone 815-874-7891 \u2022 Fax 815-874-6144 sales@rockfordsystems.com \u2022 www .rockfordsystems.com Catalog SFM Shop online at www .r ockfor dsystems.com SFM/HPS30M/1 1 1010 RSI-005008_Cover_Spine_Layout 1 11/9/10 2:53 PM Page 1 Copyright © 2010 by Rockford Systems, Inc. All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A. YOUR SINGLE-SOURCE SUPPLIER FOR ALL YOUR SAFEGUARDING REQUIREMENTS Rockfo rd Sys tems is on e of the larges t sin gle-source suppl iers of sa fety p roducts for machiner y. W e offer a total solution for all machine gua rding and c ontrol requirement s for upd ating machine ry in the metal-fab- rica ting, metal -cutt ing, wood workin g, and roboti c indu strie s. Other mark ets serve d inc lude packa ging, tex- tiles, ma terial handl ing, and assembl y ma chines. Our complete line of p roducts allows ind ustry to meet or exceed the OSH A and ANS I standard s for mac hine guard ing. Ou r g oal s are to su ppl y sup eri or saf ety e qui pme nt whi ch co mpl ies wi th th e s afe ty st and ards a nd to ed uca te in div idu als i n po sit ion s of resp ons ibi lit y in t hes e are as. To ach iev e the se goa ls, w e are a lw ays s tri vin g to fin d ne w an d b ett er w ay s of pro vid ing eq uip men t to sa feg uar d pe rso nne l w ho w ork on or aro und mac hin ery . W e offe r a va rie ty of ser vic es to he lp mak e y our pl ant as sa fe as pos sib le. T hes e s erv ice s i ncl ude : Design Engineering Product development and engineering per - sonnel are constan tly developing new safe- guarding products which are compatible wi th to da y\u2019s man uf ac- tu rin g e nvi ron men t. Installation of Equipment Highly skille d inst allation c re ws a re a va il ab le t o p ro vi de co mp le te in te gr at ion a nd in - st al la ti on se rv ic es of s af e- gu ar din g sy st em s in yo ur pl an t or to ins tr uc t yo ur pe r - s on n el . Th e se c re w s ar e hi g hl y q u a li f ie d a nd h av e m an y ho u rs o f on - th e -j ob e xp er i en c e on a l l ty pe s of cut ti ng and turn in g e qu i pm e nt . Machine Surveys Our sales pers onnel know machi nery, kn ow wh at is req uir ed to me et th e OSH A and ANSI standards, and what it takes to up- date your machinery. De tai led sur vey forms are used to gathe r all the info r mation re- quired to bring your machin ery up to the safety standa rds and be yon d. T raining Seminars W e of fer a series of monthly machine safeguardi ng seminar s which educate the employer/user on safety standar ds. These seminars use visual aids, mac hine dem onstr ation s and hand s-on exp erien ce so the stude nt can learn to interpret the per for mance language of the standards and r egulations. Each perso n atte nding also receiv es CEU s (con tinuing educa tion units ) and a binder filled with information on machine safegu arding. Customi zed on- site s eminars can also be provide d at cust omer loca tions. Proposals Af te r com pl et ing a ma ch in e su rv ey , a de ta il ed pro po sa l is ge nerat ed whi ch cove rs the safet y equ ipme nt re- qui red to mee t or excee d OS HA and ANS I st an da rds . Catalog MSD Looking for mor e products? Call 1-800-922-7533 and ask for any of our other catalogs or view them online today at www .r ockfordsystems.com Catalog EXAL Catalog SS Catalog CVR Catalog CNTRLS Catalog SEM Catalog DSB RSI-005008_Cover_Spine_Layout 1 11/9/10 2:54 PM Page 2 www .rockfordsystems.com 3 T able of Cont ents The app lic atio ns d escr ibed in this cat alog are for ins truc tion al a nd i nfor mati ona l pu rpos es o nly; the pho tos in t his cat- alo g are fo r illus tra tive pur pose s only . They may not rep rese nt act ual us age. Thi s cata log ha s been car eful ly che cked for acc urac y an d is tho ught to be f ully con sist ent wit h the pro duc ts d escr ibed her ein. How ever , Ro ckfo rd S yste ms, Inc. doe s not as sume li abil ity fo r the co nten ts of th is pu blic atio n or for th e use of an y prod ucts desc ribe d here in. Ro ckfo rd Sys tem s, Inc. re serv es the rig ht to ma ke chan ges to th e produ cts and do cume ntat ion wi thou t furt her no tice . This document contains proprietary information protected by copyright. No part of this catalog may be reproduced, transmitted, stored in a retrieval system, or translated into any language, in any form or by any means without prior written permission from Rockford Systems, Inc., P.O. Box 5525, Rockford, Illinois 61125-0525. Rockford Systems reserves the right to make changes or revisions to the material contained in this catalog and cannot be held liable for incidental or consequential damages resulting from the furnishing, performance or use of this material. INTRODUCTION ............................................4-9 SAFEGUARDING ..........................................10-61 Electrically Interlocked Heavy-Duty Shields ......10-15 Electrically Interlocked Drill Press Shields ..............................................10-11 Electrically Interlocked Lathe Chuck Shields ....................................................12 Electrically Interlocked Crosslide/Carriage Travel Lathe Shields ................................13 Electrically Interlocked Milling Machine Shields ..............................................14-15 Safety on Drill Presses ..............................16-21 Safety Chip Shields ....................................18 Heavy-Duty Aluminum Drill Press Shields ....................................................19 Telescoping Drill Press Shields ..............20-21 Spring-Loaded/Self-Ejecting Chuck Keys for Drill Presses ......................................21 Safety on Lathes ....... ...............................22-31 Sliding Lathe Shields ................................24 Crosslide-Travel Lathe Shields ..................25 Small Steel Lathe Chuck Shields ................26 Large Steel Lathe Chuck Shields ................27 Transparent Lathe Chuck Shields ..............28 Mounting Brackets ....................................29 Lathe Chuck Wrenches ........................30-31 Safety on Milling Machines ........................32-38 Chip Shields for Bridgeport Mills ..........34-35 Bridgeport Vertical Mill Controls ................35 Slide and Swing-Aside Shields ..............36-37 Rear Shield Assemblies ..............................37 Milling Machine Belt Covers ......................38 Electrical Interlock Assembly ....................38 Safety on Bench Grinders ............................39-42 Double-Wheel Grinder Shields ..................40 Single-Wheel Grinder Shields ....................40 Pivot-Mount Grinder Shields ......................41 Standard-Mount Grinder Shields ..............41 Bench Grinder Safety Gauge ......................42 Safety on Band Saws ....................................43 Safety on Disc/Belt Sanders ............................44 Safety on T able Saws ....................................45 All-Purpose Shields ..................................46-61 Adjustable Slide Shields ............................46 Rigid-Arm Magnetic-Base Shields ..............47 Universal Ball & Socket Shields ............48-50 Flexible Copolymer Lock-Arm Shields ..51-54 Flexible Spring-Steel Arm Shields ........55-58 On/Off Magnetic-Base Shields ..............59-60 Free-Standing Shield Assembly ..................61 FLEXIBLE-ARM LAMPS ....................................62 DISCONNECT SWITCHES, MOTOR ST ARTERS, AND ACCESSORIES ........................................63-69 Lockouts ....................................................63 Tagouts ......................................................63 Lockout Valves ..........................................64 Single-Phase Disconnect/Starter ................64 Sensing Saf-Start ® Packages ......................65 Enclosed Transformers ..............................66 IEC Fused Disconnect Switches, Magnetic Motor Starters, and Combinations ..........66 Disconnect and Starter Part Numbering System Chart ..........................................67 Remote Operator Station Part Numbering System Chart ..........................................68 Remote Stations ........................................69 DANGER SIGNS AND LABELS ..........................70-71 SU RV EY FO R CU TT IN G A ND TUR NI NG MA CH IN ES .... 72 -7 3 OSHA ST ANDARDS ..........................................74 MACHINE SAFEGUARDING SEMINAR ................75-79 INDEX ......................................................80-81 TERMS & CONDITIONS OF SALE ..........................82 SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 3 4 Call T oll-Free 1-800-922-7533 Introduc tion 1. SAFEGUARDING: When safeguarding the point of operation on a cutting or turning machine, shields (barriers) can be installed between the hazard and the operator. These shields can also deflect chips, sparks, and coolant that are generated at the point of operation. 2. CONTROLS: Most cutting and turning machines are directly driven by a motor. When the motor is turned on, the tool or workpiece rotates causing a point-of-operation hazard. When the motor is turned off, the tool or workpiece coasts to a stop and the hazard is eliminated. The basic requirement, for con- trols, is that all cutting and turning machines must have an emergency-stop device located within reach of the operator. Some of the motor stop/start operator stations offered in this catalog are equipped with an emergency-stop push button to meet this requirement. These emergency-stop buttons can also be supplied separately. 3. DISCONNECTS: All cutting and turning machines must have a disconnecting means to shut off all electrical power coming to the machine. It must be capable of being locked only in the off position. Also under OSHA 29 CFR 1910.147 (lockout/tagout), this same disconnecting means can be used when repairing or maintaining the machine. 4. ST ARTERS: All cutting and turning machines must have a starter that will automatically drop out when the control voltage is lost to the machine. To restart the machine when power is restored, some- one must start the motor with some type of overt action, for example, pressing the start push button. This prevents the machine from automatically restarting when the voltage is restored. 5. COVERS: All cutting and turning machines must have the mechanical power-transmission appara- tuses covered (guarded) if below a 7' level from the floor or working platform. This includes motor shafts, belts, pulleys, chains, sprockets, gears, etc. This catalog offers a pulley and belt cover for Bridgeport mills as shown on page 38. If special covers are required, ask for our Mechanical Motions Cover (CVR) cata- log, or contact the OEM or a local fabricator to satisfy this requirement. 6. OTHER CONSIDERA TIONS: Other auxiliary safeguarding equipment may be required to make cutting and turning machines as safe as possible. This equipment includes safety switches which can be used to interlock the shield or guard to the machine\u2019s starter. Electronic motor brakes are available for machines that have a long coastdown time. These brakes are used to decrease the long coasting time after the motor is turned off. This increases productivity because the operator does not have to wait for the machine components to coast to a stop. Signs are used to warn of the hazards on a machine. There are basic requirements for safeguarding cutting and turning machines. These basic safety require- ments include safeguarding, controls, disconnects, starters, covers, and other considerations. We have explained the basic safety requirements below and have arranged this catalog so you can make your safeguarding choices quickly and easily. SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 4 www .rockfordsystems.com 5 Introduc tion Whe n saf egua rdi ng cut ting and tur nin g mach ine s, th e gene ral req uir emen ts th at app ly to the se ty pes of mach ines are in OSH A (O ccup ati onal Saf ety a nd He alth A dmin ist rati on) T itle 2 9 of the Co de of Fe dera l Regu lat ions . The fo llo wing is a lis t: 1. An Act\u2013Public Law 91-596, 91st Congr ess, S. 2193, December 29, 1970, Duties, Section 5(a)(1)(2)(b) 2. OS HA 2 9 CF R se ct i on s th a t an em p lo ye r (u se r) m us t c om p ly wi th in clu de : 1910.211 Definitions 1910.212 Ge ne ra l re qu ir em en ts f or all ma ch in es 1910.213 Woodworking machinery requirements 1910.215 Abrasive wheel machinery 1910.219 Mechanical power-transmission apparatus 3. OSHA 29 CFR 1910.147 The control of hazardous energy (lockout/tagout). 4. OSHA 29 CFR 1910.301-1910.399 Electrical These publications can be acquired by contacting: U.S. Government Printing Office P.O. Box 371954 Pittsburgh, PA 15250-7954 (202) 512-1800 \u2022 http://bookstore.gpo.gov The basic OSHA standard, 29 CFR 1910.212, states that any machine that creates a hazard must be safeguarded to protect the operator and other employees. OSHA can also cite violations using other standards such as the ANSI (American National Standards Institute) B11 series. The following is a list of applicable and related ANSI standards available at the printing of this publication. ANSI Publications B11\u20132008 General Safety Requirements Common to ANSI B11 Machines B11.1 Mechanical Power Presses B11.2 Hydraulic Power Presses B11.3 Power Press Brakes B11.4 Shears B11.5 Iron Workers B11.6* Lathes B11.7 Cold Headers and Cold Formers B11.8* Drilling, Milling, and Boring Machines B11.9* Grinding Machines B11.10* Metal Sawing Machines B11.11* Gear and Spline Cutting Machines B11.12 Roll Forming and Roll Bending Machines B11.13 Automatic Screw/Bar and Chucking Machines B11.14 Withdrawn (now see ANSI B11.18) B11.15 Pipe, Tube, and Shape Bending Machines B11.16 Metal Powder Compacting Presses B11.17 Horizontal Hydraulic Extrusion Presses B11.18 Coil Processing Systems B11.19* Performance Criteria for Safeguarding B11.20 Integrated Manufacturing Systems B11.21 Machine Tools Using Lasers for Processing Materials B11.22* Turning Centers and CNC Turning Machines B11.23* Machining Centers and CNC Milling, Drilling, and Boring Machines B11.24 Transfer Machines B11.TR1 Ergonomic Guidelines B11.TR2 Mist Control Considerations B11 .TR 3* Risk Assessment and Risk Reduction B11.TR4 Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools B11.TR5 Sound Level Measurement Guidelines B11.TR7 Design For Safety and Lean Manufacturing * ANSI Standards for Cutting and Turning Machines ANSI Publications (continued) R15.06 Robotic Safeguarding B15.1 Mechanical Power Transmission Apparatus B56.5 Guide Industrial Vehicles and Automated Function of Manned Industrial Vehicles B65.1 Printing Press Systems B65.2 Binding and Finishing Systems B65.5 Stand-Alone Platen Presses B151.1 Horizontal (Plastic) Injection Molding Machines B152.1 Hydraulic Die Casting Presses B154.1 Rivet Setting Machines B155.1 Packaging and Packaging-Related Converting Machinery 01.1* Woodworking Machinery * ANSI Standards for Cutting and Turning Machines These standards can be purchased by contacting: ANSI (American National Standards Institute, Inc.) 25 West 43rd Street, 4th Floor New York, New York 10036 (212) 642-4900 \u2022 www.ansi.org Anoth er good re ference f or safety on machine tools is the followi ng public ation fr om the Nat ional Safet y Counc il: Safeguarding Concepts Illustrated\u20147th Edition This publication can be purchased by contacting: National Safety Council 1121 Spring Lake Drive Itasca, IL 60143-3201 1-800-621-7619, ext. 2199 \u2022 www.nsc.org O th er s ou rc es th at ca n be us ed fo r re fe r en ce i nc lu de : 1. NFPA 79, Electrical Standard for Industrial Machinery 2. NEC (National Electrical Code) Handbook 3. NEMA (National Electrical Manufacturers Association) For additi onal safety inform ation and a ssistan ce in devis ing, impl ementin g or revisi ng your saf ety pro- gram, pleas e con tact the mac hine manufactu rer, your state and local safety counc ils, insura nce car- riers , national trade ass ociation s, and your state\u2019 s occup ational safety and health admini stratio n. SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 5 6 Call T oll-Free 1-800-922-7533 Introduc tion Thi s cat alog off ers a vari ety of eq uipm ent in clud ing a com ple te l ine of sh ield s (bar rier s), cor d and plu g loc kou ts, fus ed disc onn ect swi tche s, magn etic motor starters, self-latching emergency stops, and acces- sorie s whic h are avail able to meet the electri cal energ y sourc e porti on of these standa rds. T he s hi e ld s (b ar ri er s) of fe re d i n th i s ca ta lo g ar e us ua ll y i ns t al l ed o n dr i ll i ng m a ch i ne s , la th es , mi l li n g ma ch in es , g ri nd in g m ac h in es , b an d s aw s , be l t sa n de rs , d is c s an d er s , a n d t ab le sa w s. M an y of th e sh i el d s c a n b e u se d on ot he r ty pe s of e qu i pm e nt i nc lu di ng w oo d wo r k- i ng m ac h in es . Mo s t of t he se s hi e ld s ar e in te nd ed t o d ef l ec t c h ip s ( s wa r f) , s pa rk s, s pl as hi ng c o ol a nt , o r l u br i - c an t a w ay fr o m t he op e ra t or an d o t he r e m pl o ye e s i n t he m ac h in e ar e a. Mo st sh i el d s pr o vi d e vi s ib i li t y to th e po i nt o f o p er a ti o n. A lt h ou g h th e se s hi el ds pr o vi d e so m e d eg re e o f gu ar di ng f or th e o pe r at o r, th ey ca n no t b e c on s id e re d g ua rd s. W he n u si n g th es e s hi e ld s an d be f or e a ny of t he sh i el d s i ll u st r at e d in t hi s c at al og a re m ov ed f ro m t he ir n o rm a ll y a pp l ie d po s it i on , po w er m us t al w ay s be t ur n ed o ff . In some cases, more than one type of shield per machine may be necessary to provide protection. For example, on lathes, a chuck shield may be required along with a magnetic-base shield where the tool comes into contact with the workpiece. This catalog offers several different types of shields. When considering shielding for your machines, be sure to choose the shield that fits your machining applications and still maintains current levels of pro- ductivity. DRILLING MACHINES As w ith o ther cutt ing machi nes , the oper ator must be pro tec ted fro m t he rota ting ch uck and swa rf that is pro duc ed b y the dri ll b it. Spec iall y de sign ed s hiel ds can be att ach ed to the quil l and use d to prot ect this are a. A te lesc opi ng p ort ion of t he shie ld can retr act as the dri ll bi t co mes d own into the work pie ce. O n la rger gan g or rad ial d rill s, a mor e univ ers al-t ype shie ld is usu all y appl ied. T h e A NS I s ta nd a r d fo r d ri ll i n g m ac hi ne s i s AN SI B1 1. 8. LA THES T he r e ar e tw o m ai n sa f et y c on si de ra ti on s f or l at he s ( en g in e , t ur r et , et c. ). On e i s t he ro ta ti n g c hu ck th a t c ou l d ca t ch th e op er at or \u2019s cl o th i ng , je w el r y, ha ir , or h an d a nd p u ll i t i nt o t he ma ch in e . Th e o th er is th e h az - a rd o us f ly in g ch i ps a nd sp l as h in g co o la n t th a t ar e g en e ra t ed a t th e po in t of o pe r at i on ( wh e re th e to ol c on - t ac t s th e wo r kp i ec e be i ng m ac h in e d) . To pr ot ec t th e se a re a s, t wo s hi e ld s ca n be a pp l ie d \u2014o n e ar o un d a p or ti on o f t he ch u ck an d t h e o th e r a t t he po i nt of op er at io n. Se e t he p ho to o n p a ge 2 4. La r ge r sl id in g s h ie l ds c an p ro te ct b ot h ar e as , pr o vi d in g th e wo r kp i ec e is n ot t oo l on g . O n VT L s (v er ti ca l t ur r et l at h es ) , th e sa f et y co n ce r n is t he r ot a ti n g ta b le an d th e p oi n t- o f- o pe r at i on sw ar f. S pe c ia l b ar r ie r s ma y ha v e to be fa br ic at ed a ro u nd th e ta bl es of t he s e ma ch in es ; s hi e ld s ca n b e pr ov id ed a t t he po i nt of o pe r at i on . I f r ai li ng s a re us e d t o k ee p o pe ra to r s a wa y f r om h az a rd a re as , th e se r a il i ng s mu st b e 4 2" a bo v e th e fl oo r o r p l at f or m . T he A NS I st a nd a rd f or l at h es i s A N SI B 11 . 6. MILLING MACHINES T he ma i n sa fe ty c on s id e ra t io n f o r mi ll in g ma c hi n es is t he sw a rf th at is ge n er a te d at th e p o in t o f op er at io n. A no t he r sa f et y co nc er n is t he t oo l cu t te r , wh ic h c ou l d c at c h op e ra t or \u2019 s cl o th i ng , je w el r y, ha ir , or a ny ot he r pa rt o f t he bo d y. Us u al l y o n s ma l le r m il l s, th e o pe r at o r a nd o th e r e mp l oy e es in th e m ac h in e a re a ar e pr ot ec te d by s hi e ld s . T he s e s hi e ld s ca n b e a pp li ed a ro un d t he p er i me t er of t he ta bl e o r be d a r ea or c lo s e t o t he c ut t er , d ep e nd i ng o n th e si z e o f t h e w or kp ie ce an d th e ap pl ic a- tion. On larger millin g machine s, operato rs are s om e ti m es p ro t ec t ed b y lo c at i on ; ho w ev e r, w he n wo r k- i ng cl o se to a c ut ti ng to o l, op er at or s m us t be pr ot ec te d f ro m sw a rf . T h e A N S I s t an d a r d f o r m i l li n g m a c h in e s i s A N S I B 1 1 . 8 . GRINDING MACHINES S hi e ld s a re u su al ly ap p li e d to g ri nd in g ma c hi n es to p ro - t ec t t he op e ra t or fr o m ch ip s (s w ar f ), sp a rk s , s pl a sh i ng c oo l an t , o r lu b ri c an t . O th e r sa fe ty co n ce rn s fo r g ri nd er s ar e th e a dj us tm en t o f t he wo rk re s ts a nd th e ad j us t ab l e to ng ue s or en ds of t he p er i ph e ra l m em b er s a t th e to p of ea c h wh ee l. Wo rk r es t s s ha l l b e k e pt a dj u st e d c lo se ly t o t he w he el wi t h a ma x i- m um o pe n in g of 1 / 8 " . Th e di st an c e be tw ee n th e wh e el p er i ph e ry an d th e ad j us t ab l e to n gu e or th e en d of t he p er i ph e ra l me m be r at t he t op s ha l l n e ve r ex c ee d 1 / 4 " . Grind ing machi nes are co vered by O SHA in 2 9 CF R 19 1 0. 2 15 . Th e A NS I st a nd a rd s fo r gr i nd i ng m ac h in e s a r e B 1 1. 9 an d B7 . 1. BAND AND T ABLE SA WS S hi e ld s a re ap pl ie d to b a nd s aw s a nd t a bl e s aw s to p r o- t ec t t he op e ra t or fr o m f ly i ng ch i ps , s pl i nt e rs , a nd du s t. A s wi th ot h er c ut t in g m a ch i ne s , c a re m us t b e ta ke n a ro u nd t h e mo vi ng bl ad e of t he m a ch i ne . A vo i d we ar in g l oo s e c l ot h in g an d je w el r y; p ro p er l y r e st r ai n lo n g h a ir . B an d s aw s a nd t a bl e s aw s fo r w oo dw or ki ng a re co v er ed b y O S HA i n 29 C FR 1 91 0. 21 2 a nd 19 1 0. 2 13 . Th e AN SI s ta n da r d f o r m e ta l sa w in g ma c hi n es i s A N SI B 11 . 10 . DISC/BEL T SANDERS/GRINDERS S hi e ld s c an b e a pp l ie d to di sc /b el t s an d er s /g r in d er s to p ro t ec t t he o pe r at o r f ro m f ly in g c h ip s , s pl i nt e rs , a nd d us t . As wi th ot he r ma c hi n es wi t h ro ta ti ng pa r ts , ca re m us t be ta k en a ro u nd t he po i nt o f op e ra t io n . Av o id w ea r in g lo os e c lo t hi n g a nd je we lr y; pr o pe r ly re st ra in l on g ha i r. D is c an d be lt sa nd er s fo r wo o dw o rk i ng ar e c ov e re d by O SH A in 29 CF R 1 91 0 .2 1 2 a nd 19 10 .2 13 . T h e A NS I s ta n da r ds f or g ri n di n g m a ch i ne s ar e B1 1 .9 a nd B 7. 1 . SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 6 www .rockfordsystems.com 7 Introduc tion ELECTRICAL REQUIREMENTS A s st a te d i n OS HA 2 9 CF R 1 91 0. 14 7 Th e c on t ro l of h az - a rd o us en e rg y (l oc ko ut /t ag ou t) : \u201c( a) (1 )( i) T hi s st an da rd c ov e rs th e se rv ic in g an d m ai n te n an c e o f m ac hi ne s an d e qu i pm e nt in w hi c h t he u ne x pe c te d en er gi zi ng or st a rt - u p o f t he ma c hi n es or eq u ip m en t , or re le as e of st o re d e ne r gy co ul d ca u se i nj u ry to e mp l oy e es . T hi s st an da rd e st a bl i sh e s mi n im u m pe rf or ma nc e r eq ui re me nt s f or t h e c on t ro l of s uc h ha z ar d ou s en e rg y .\u201d To lockout electrical energy sources: 1. Unplug the machine and use an electrical plug lockout or use a disconnect switch with padlocks, lockouts, and tags. 2. Disconnect and ensure that all power sources are locked and tagged out. 3. Stored electrical energy must be bled to obtain zero energy state. 4. Use a volt meter to make sure all circuits are dead. NFP A 79, ELECTRICAL ST ANDARD FOR INDUSTRIAL MACHINERY Incoming Supply Circuit Conductor T erminations Under 5.1.1 , it states that \u201cwhere practicable, the electrical equipment of a machine shall be connected to a single power supply circuit.\u201d Supply Circuit Disconnecting (Isolating) Means In 5.3.1.1 , it states that a supply circuit discon nect- ing means shall be pr ovided for each incom ing supply circu it to a machine . Accordin g to 5.3.1. 1.1 , each disco nnectin g means shal l be legibl y marked to indi- cate its purpose. Under 5.3.1 .3 , \u201cThe supply circuit disconnecting means other than attachment plugs and receptacles shall be mounted within the control enclosure or immediately adjacent thereto. Exception: Externally mounted supply circuit dis- connecting means, whether interlocked or not interlocked with the control enclosure, supplying machines totaling 2 hp or less shall be permitted to be mou nted up to 6 m (20 f t) a way f ro m the e nc los ur e pr ov idi ng th at th e di sco nn ec tin g me ans is in sig ht fr om an d re adi ly a cce ss ib le to th e ope ra to r. \u201d U nde r 5. 3. 3 , th e dis co nne ct in g mea ns sh all b e pro vi ded w it h p er - ma ne nt mea ns for loc ki ng in the off pos it io n on ly (fo r ot he r tha n at tac hm en t plu gs ). In acc ord an ce wi th 5.3. 4.1 , \u201cThe cente r of the gri p of the oper ating han - dle of t he dis co nne ct ing me an s, whe n in it s h igh es t po si tio n, s ha ll not b e mor e th an 2.0 m (6 ft 7 in. ) ab ov e th e fl oor . A p erm an ent ope ra tin g pl at for m, re adi ly ac ce ssi bl e by me an s of a p erm an ent st air or la dde r, sh al l be co nsi de re d as th e flo or fo r the pur pos e of th is re qu ire me nt. \u201d Ac cor di ng to 5. 3.2 (6) , th e sup pl y cir cu it di sc onn ec tin g me ans can be an at tac hm ent pl ug an d re ce pta cl e (pl ug /so ck et co mb ina ti on) fo r cor d con ne c- ti on to mot or l oad s to ta lin g 2 hp or le ss . Control Circuit Supply , Voltage, and Protection In 9.1.1.1 , it states that \u201cControl transformers shall be used for supplying the control circuits.\u201d According to 9.1.1.3 , \u201cTransformers shall not be required if the supply voltage does not exceed 120 volts ac.\u201d In accordance with 9.1.2.1 , \u201cThe ac voltage for con- trol circuits shall not exceed 120 volts, ac single phase.\u201d According to 9.1.3 , control circuits shall be provided with overcurrent protection. Overload Protection of Motors According to 7.3.1 , \u201cOverload devices shall be pro- vided to protect each motor, motor controller, and branch-circuit conductor against excessive heating due to motor overloads or failure to start.\u201d Stop Functions According to 9.2.2 , \u201cThe three categories of stop functions shall be as follows: (1 ) C ate go ry 0 is an un con tr oll ed sto p by imm ed i- at el y re mov in g po wer to th e ma ch ine act ua tor s. (2 ) C ate go ry 1 is a con tr ol led sto p wi th pow er to th e ma ch ine ac tu at ors av ai lab le to ac hi eve t he st op th en re mo ve po we r wh en t he st op is ac hi eve d. (3 ) C ate go ry 2 is a co nt rol le d st op w it h pow er le ft av ai lab le t o the mac hi ne a ctu at ors .\u201d In 9. 2.5.3.1 , it state s that \u201cE ach mach ine shall be equip ped with a Catego ry 0 stop.\u201d Accor ding to 9.2. 5.3.2 , \u201cCategor y 0, Category 1, and/or Category 2 stops shall be provid ed where indicat ed by an analy sis of the risk assessme nt and the funct ional requirements of the machine. Category 0 and Categ ory 1 stops sha ll be op eration al regar dless of opera ting modes, and Categor y 0 shall take priority . Stop functi on shall operate by de-en ergizing that rel- evant circuit and shall override related start funct ions.\u201d Emergency Stop Functions In accordance with 9.2.5.4.1 , emergency stop funct ions shall be de signed to be initia ted by a si n- gle human actio n. In additio n to the requir ements for stop, 9.2.5.4.1.1 states that \u201cthe emergency stop shall have the following requirements: (1 ) It shall override all other functions and operations in all modes. (2) P ow e r to t he ma c hi n e ac t ua to rs , wh i ch c au s es a h az ar d ou s co nd i ti on (s ), s ha ll be r em ov e d as quick ly as possible without creating othe r h az ar ds ( e. g ., by t he pr ov i si o n of m ec h an i ca l m ea ns o f s to pp i ng re q ui r in g no ex t er n al p ow e r, b y re ve r se c ur r en t b ra ki n g fo r a Ca te g or y 1 s t op ) . (3) The reset of the command shall not restart the machinery but only permit restarting.\u201d SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 7 8 Call T oll-Free 1-800-922-7533 Introduc tion In 9. 2.5.4. 1.2 , it states that \u201c Where requir ed, pro- visions to connect additional emergency stop devices shall be provided. \u201d According to 9.2. 5.4.1. 3 , \u201cThe emergenc y stop shall func tion as eithe r a Categor y 0 or a Categ ory 1 stop. The choice of the category of the emergency stop shall be determined by the risk assessment of the machine.\u201d In accordance with 9.2.5.4.1.4 , \u201cWhere a Category 0 or Category 1 stop is used for the emergency stop function, it shall have a circuitry design (including sensors, logic, and actuators) according to the relevant risk as required by Section 4.1 and 9.4.1. Final removal of power to the machine actuators shall be ensured and shall be by means of electromechanical components. Where relays are used to accomplish a Category 0 emergency stop function, they shall be nonreten- tive relays. Excepti on: D rivers, or solid state output devices, designed for safety-related func- tions shall be allowed to be the final switching element, when designed according to relevant safety standards .\u201d Devices for Stop and Emergency Stop In accor dance with 10 .7.1.1 , \u201cS top and emerge ncy stop pushbutt ons shal l be conti nuously operable and readily access ible.\u201d Accordin g to 10.7. 1.2 , \u201cStop or emerg ency stop pushbutt ons shall be locat ed a t ea ch o perator con trol stat ion and at other loc ations wher e emergenc y stop is requir ed.\u201d In 10.7.2.1 , it states that \u201cThe types of devices for emergency stop shall include, but are not limited to, the following: (1) Pushbutton-operated switches (2) Pull-cord-operated switches (3) Foot-operated switches without a mechanical guard (4) Push-bar-operated switches (5) Rod-operated switches\u201d According to 10.7.2.2 , \u201cPushbutton-type devices for emergency stop shall be of the self-latching type and shall have direct opening operation.\u201d In accordance with 10.7.2.3 , \u201cEmergency stop switches shall not be flat switches or graphic rep- resentations based on software applications.\u201d For resto ration of no rmal functio n af ter emergenc y switc hing o ff, 1 0.8.3 sa ys tha t \u201cIt shall not b e pos- sible to resto re an emergenc y switchin g off circuit until the emerge ncy switchi ng off circ uit has been manua lly reset.\u201d According to 10.7.3 , \u201cActuators of emergency stop devices shall be colored RED. The background immediately around pushbuttons and disconnect switch actuators used as emer- gency stop devices shall be colored YELLOW. The actuator of a pushbutton-operated device shall be of the palm or mushroom-head type and shall effect an emergency stop when depressed. The RED/YELLOW color com binatio n sh all be r eserved exclusively for emergency stop applications. Exception: The RED/YELLOW color combination shall be permitted for emergency stop actuators in accordance with 10.8.4. \u201d Under 10.8.5 , \u201cWhere the supply disconnecting means is to be locally operated for emergency switching off, it shall be readily accessible and shall meet the color requirements of 10.8.4.1.\u201d According to 10.8.4.1 , \u201cActuators of emergency switching off devices shall be colored RED. The background immediately around the device actua- tor shall be permitted to be colored YELLOW.\u201d Pushbutton Actuators According to 10.2.1 , \u201cPushbutton actuators used to initiate a stop function shall be of the extended operator or mushroom-head type.\u201d As stated in 10.2.2.1 , \u201cThe preferred color of start or on shall be GREEN, except that BLACK, WHITE, or GRAY shall be permitted. RED shall not be used for start or on.\u201d In 10.2.2.2 , it states that \u201cthe preferred color for stop or off shall be RED, except that BLACK, WHITE, or GRAY shall be permitted. GREEN shall not be used for stop or off.\u201d According to 10.2.2.6 , \u201cPushbuttons that cause movement when pressed and stop movement when they are released (e.g., jogging) shall be BLACK, WHITE, GRAY, or BLUE, with a prefer- ence for BLACK.\u201d In accordance with 10.2.3.1 , \u201cA legend shall be provided for each operator inter- face device to identify its function and shall be located so that it can be easily read by the machine operator from the normal operator posi- tion. The legends shall be durable and suitable for the operating environment.\u201d Start Devices Ac co rd ing to 10 .6 , \u201cA ct ua tor s us ed to in iti at e a sta rt fu nc ti on or th e mo vem en t of ma ch in e ele me nts (e .g ., sl id es , sp ind le s, car ri ers ) sha ll be con st ru cte d and mo un te d to mi ni mi ze i nad ve rt ent ope ra ti on. \u201d Protection Against Supply Interruption or Voltage Reduction and Subsequent Restoration Un der 7.5 .1 , \u201cWhe re a su pply int erru pti on or a vo ltag e re duc tion can cau se a haz ardo us con diti on or dama ge t o th e mac hin e or to th e wo rk in pr ogre ss, unde rvo ltag e pro tec tio n sha ll be prov ide d (e .g., to swi tch off th e ma chi ne) at a pred ete rmin ed vo ltag e lev el. \u201d For rest art ing, 7 .5.3 s tat es th at \u201cU pon res tor atio n of the vol tag e or upon swi tch ing on the inc omin g supp ly, aut omat ic or uni nte ntio nal re star tin g of the mach ine shal l be prev ent ed when su ch a rest art cau ses a haz ard ous co ndit ion .\u201d SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 8 www .rockfordsystems.com 9 Introduc tion Protective Interlocks In 9.3.6 , it states that \u201cWhere doors or guards have interlocked switches used in circuits with safety related functions, the interlocking devices shall be listed, have either positive (direct) opening operation, or provide similar reliability and prevent the operation of the equipment when the doors or guards are open (difficult to defeat or bypass).\u201d Under 9.3.1 , \u201cThe reclosing or resetting of an interlocking safeguard shall not initiate machine motion or operation that results in a hazardous condition.\u201d OTHER SAFETY CONSIDERA TIONS Each machine should be surveyed as an individual system. This includes, but is not limited to, the proper shield(s), controls, drives, tooling, feeding methods, material handling methods, configuration and weight of workpiece, rotating and reciprocating parts, machine production requirements, and future machine needs. The proper disconnect switch, motor starter, lockout equipment and covers for machine rotating components must also be considered. See pages 72 and 73 for a survey report. When operating the various machines to which shields can be applied, the operator must wear proper personal protective safety equipment and be properly trained. The operator must not wear loose cloth- ing, have unrestrained long hair, and must not wear jewelry. When operating any cutting or turning machine, the hands or any part of a per- son\u2019 s body must never be put into the point of operation or any other hazard area of the machine. Hand tools, fixtures, and other methods must be used so that operators are not exposed to hazards. If the hands or any part of a person\u2019s body is put into the hazard, it could cause serious physical injury or death. SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:45 PM Page 9 Made From Durable Pressed Steel 10 Call T oll-Free 1-800-922-7533 Elec tric ally Interlocked Hea v y-D ut y Shields INTERLOCK SWITCH SPECIFICA TIONS Contact Arrangement ..........1 NO and 1 NC Operating T emperature ......23º to 1 13º F (-5º to 45º C) Switching Ability ..................4 A @ 24 V AC, 4 A @ 120/250 V AC 2 A @ 24 V DC, .4 A @ 120 V DC, .3 A @ 250 V DC Mechanical Life ..................1 Million Switching Cycles Enclosure Rating ................IP 67 Goes beyond OSHA and ANSI safety requirements\u2014 (Continued on next page.) Electrically interlocked shield for small to medium size drill presses. Electrically interlocked shield for larger drill presses and radial drill presses. ELECTRICALL Y INTERLOCKED DRILL PRESS SHIELDS PTR 03/140 Shield Th is el ec tri ca ll y int er loc ke d hea vy -d uty sh ie ld is id eal fo r sm all to me diu m siz e dr il l pr es se s an d si mi la r ma ch ine s. Whe n the sh ie ld i s sw un g ou t of pos it ion , the pos it iv e co nta ct s on the mi cr os wit ch op en, se ndi ng a sto p sig na l to th e ma ch in e co n- tr ol . T he sa fe ty mi cr os wit ch el ec tr ica l wir es a re fu rni sh ed wi th a pr ot ec tiv e co ve r an d con ne ct to th e sa fe ty ci rc ui t of th e ma ch in e tha t sw it ch es of f th e co nt rol to th e mo ve men t of the sp in dl e. Al l sa fet y mi cr osw it ch es ar e mo un ted in an en cl os ed ho us in g wi th a n en clo su re ra ti ng of IP 6 7. The shield consists of a high impact-resistant, transparent polycarbonate semi-octagonal front shield that provides operator protection from flying chips and coolant. The adjustable shield clamps to a steel support rod that rotates 180 ° and operates the shield safety microswitch. The shield mounts to the left side of the machine using a steel mount- ing bracket. PTR 02/130, PTR 02/180, PTR 20/300, PTR 20/350 These electrically interlocked heavy-duty shields are ideal for larger drill presses and radial drill presses. When the shields are swung out of position, the positive contacts on the microswitch open, sending a stop signal to the machine control. The safety microswitch electrical wires are furnished with a pro- tective cover and connect to the safety circuit of the machine that switches off the control to the movement of the spindle. All safety microswitches are mounted in an enclosed housing with an enclosure rating of IP 67. The shields consist of a high impact-resistant, transparent poly- carbonate semi-octagonal front shield that provides operator protection from flying chips and coolant. The adjustable shields clamp to a steel support rod that rotates 180 ° and operates the shield safety microswitch. The shields mount to the left side of the machine using a steel mounting bracket. These shields are available in different sizes and provide double vertical adjustment. The PTR 20-series shields have a tubular steel telescopic shield support rod. SFM-2010-FULL_SFM Catalog - 2010 11/9/10 3:46 PM Page 10

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