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2 Safety Precautions

“Ten minutes" for your safety.

2.1 In general

All persons in general contact with the machine tool.

2.1.1 General safety precautions

2.1.1.1 Danger

The machine tool is also seen as a hazard when it is not standardized used in accordance with regulations, or operated or maintained by untrained personnel. Dangers may arise from this to:

  • health and life.
  • the machine tool and other equipment assets of the user.
  • effective working of the machine tool.

The user must ensure that only appropriately qualified and authorized personnel can participate in machine tool operation.

Employees must be checked regularly if they are working with the safety and risk awareness. Attention must be paid to following the provisions in the operating manual and safety precautions.

2.1.1.2 Machine tool condition

Technical condition

Requirements for the technical condition of the machine for safe and perfect operation:

  • Unauthorized modifications and incorrect operations are not allowed on this machine tool.
  • Regular maintenance work should be carried out for the machine tool.
  • Safety guards must ensure normal operation
  • Access to the machine tool and peripherals must be unobstructed.

Operation of the machine tool

Before the machine tool is powered on, check the liquid level and add the liquid if necessary.

Check the machine tool for leakage and eliminate the cause.

Keep the workplace clean and in full view.

Only chip hooks and brooms can be used to remove chips.

Never throw scrap into the coolant or chip collection cart.

The lubrication pulse time should be readjusted after a long downtime (more than 2 days).

Use as required

The operator and the user plant must ensure that the machine tool is used in accordance with the regulations.

Use as required means:

  • Cut and process the metal or plastic parts with suitable tools and equipment.
  • Transport workpieces and materials to be processed after connecting with the peripheral equipment supplied with the machine.
  • Carry out the functions and methods in accordance with the operating manual.
  • Use the content introduced in the training course of our company.
  • Use the machines with supplied CNC (Computer Numerical Control) - parameters, SPS (Symbolic Programming System) programs and hardware configurations.
  • Comply with safety precautions.

2.1.1.3 Personnel

Obligations of the user plant

Maintain all safety and hazard signs on the machine tool readable.

Replace immediately the damaged or detached safety and hazard signs.

Train the operators regularly.

Comply with relevant labor protection regulations.

Operators are obliged to wear personal labor protective equipment whenever required.

Use only additional devices equipped or permitted by the manufacturer.

Use only spares and wear parts provided by the manufacturer.

Comply with and implement the maintenance period and maintenance operations specified in the operating manual.

Obligations of the operators

Wear work clothes that comply with regulations, such as those conform European Standard EN 510 and use personal protective equipment if necessary.

The following measures are required when changes affecting safety occur in the machine tool.

  • The machine tool should be stopped and locked immediately.
  • Superior leaders should be informed.
  • Troubleshooting should be requested immediately.

Safety

  • Following things are strictly prohibited:
  • Wear jewelry, including round earrings and long exposed hair.
  • Wear clothes or accessories that may be caught in the machine tool (e.g., ties, unfastened belts).
  • Grip the running machines or self-rotating clamping devices and workpieces by hand or with an aid
  • Program the speed which is greater than the maximum speed of the clamping devices and tools used.
  • Alter safety guards or no operate, such as safety position switches, interlocks and cover plates.
  • Nameplates and reminder signs are illegible or removed.
  • Operate the machine tool by unauthorized and untrained personnel.
  • Process parts made of plywood joined by ceramics, magnesium and synthetic resins.
  • Modify the program of the programmable control system (software).
  • Modify the processing period of our company -(the manufacturer) and the standard period of the control device manufacturer.
  • Lay wires that can generate electromagnetic radiation near the machine tool.
  • Use, within 2 meters of the machine tool, the devices that generate serious electromagnetic radiation (e.g., welding machine)
  • Use the mobile phones, as the operator’s concentration is significantly disturbed (e.g., increased risk of collision when commissioning the machine tool)
  • Operate a machine tool with a damaged safety glass window.
  • Enter the processing room during processing.
  • Take pills, drugs and other narcotics or drink alcohol that affect a person's concentration or reaction time.
  • Conduct the welding work on the machine tool.
  • Wear no safety shoes at work.
  • Operate machines in a potentially explosive environment.

2.1.1.4 Noise protection

The machine tool is designed in such a way that the noise pollution values at the workplace do not exceed the values specified in the technical data. The cutting noise may exceed the above value under unfavorable conditions. In this case, the noise pollution value must be reduced by changing the cutting, the tools or clamping condition.

The safety representatives and the supervisors of the owner of the machine tool should be informed if the specified value of noise from the machine is exceeded.

Wear hearing protection earmuffs when the emitted noise is too loud.

2.1.1.5 Safety circuit

The calculation of the components of the safety circuit is based on the International Standard ISO 13849-1the failure probability of a service life of 20 years. Parts and components can also fail prematurely. It is impossible to take into account the environmental impact of emissions such as oil mist and dust in the machine user's workshop when calculating their service life. For this reason, it is meaningless to evaluate the service life of the components of the machine’s CNC system.

Depending on the specific risks, this safety circuit performs the requirements of the C-standard special type or, if not available, it performs based on the risk diagram specified in the International Standard ISO 13849-1 for each safety function PLr* or the safety level (SIL) of the International Electrical Standard IEC 62061.

This means that single-channel system is used when there are PLr = a, PLr = b and PLr = c applications, where the failure of a safety component may result in a loss of safety.

Further details of PL (Feature Category) are expressed in the International Standard ISO 13849-1.

In the case of a two-channel structure, i.e., a safety circuit that complies with the PLr = d and PLr = e measures, the failure of one channel does not lead to a safety risk because there is redundancy or monitoring.

Risks and residual hazards.

In the case of single-channel system based on PLr = a, PLr = b and PLr = c, the failure of one component may result in a safety risk.

  • The internal manipulation, operational and running procedures which are formulated based on their country's accident prevention regulations, as well as the operator's job qualifications, safety precautions and personal labor protection equipment are essential.
  • Work practices that may seriously affect the safety of personnel are strictly prohibited.

PLr= Required Feature Category

2.1.2 Basic safety precautions

2.1.2.1 Surroundings

Keep the area around the machine tool clear.          

Avoid the stumbling obstacles and dangerous parts.

Caution!

There exist cooling lubricants and cutting liquid around the machine tool.

Injury accident caused by slip and fall.

  • Avoid excessive use of cooling lubricants and grease.
  • Suitable flooring should be used, such as non-slip floor strips or rubber mats in the workplace.
  • Wear non-slip safety shoes.
  • Clean the surroundings if it is dirty.

Smoking around the machine tool is strictly prohibited.

There exist flammable materials and liquids around and on the machine tool.

Fire Danger.

  • It is strictly prohibited to throw cigarette butts into the chip conveyor, cooling lubricant equipment and processing rooms.

2.1.2.2 Step-in processing room

  • There must be available not-slip pedals (floor grid)

Minimum requirements for stepping bars, e.g., in accordance with the specified requirements in Germany or comparable country:

Regulations of Trade Association BGR 181;

When processing the metals, for example: turning, milling and ranges with load-raising oily lubricant requires R11 or better.

  • Take out sharp knives or march them to a position where they do not endanger personnel before operations begin.
  • Only enter the processing room after wearing the appropriate protective equipment in accordance with the relevant standards.
  • For example:
  • work clothes in accordance with the European Standard EN 510
  • safety shoes,
  • protective glasses
  • safety gloves.
  • If it is necessary to stay while the protective devices (processing room doors) are open and apart, it is only permissible, for example, to stay within the operating range of the table and gantry while the spindle and CNC-axis are moving. Please note that in this case the risk of accidents is increased because the axes are in motion. Only technical professionals are allowed to enter.
  • Make sure that no one is left in the processing room and the access area of the peripheral equipment before the door is closed and locked.
  • The emergency-unlocking function of the processing room door must be checked regularly, for the intervals and completion, please refer to the Chapter “Maintenance”.

There exist cooling lubricant residues in the processing room.

Slip and fall in the processing room may cause injury, and may lead to death or serious personal injuries.

  • Please wear non-slip safety shoes in accordance with European Standard EN 510, appropriate work clothes and goggles.

There exist metal chips in the processing room.
As the sharp-edged chips in the processing room may cause personal injuries at work,

  • please wear non-slip safety shoes in accordance with European Standard EN 510, appropriate work clothes and goggles.

Unsuitable areas for entry.

Entering into restricted areas may cause property damage.

  • Areas marked with a "No Stepping" warning sign, such as rail covers or guards, are strictly prohibited from stepping on.

2.1.3 Fire prevention

2.1.3.1 Fire extinguishing devices

When using fire extinguisher, the machine tool owner should sign a after-sales service contract or maintenance contract with the fire extinguisher manufacturer (German Standard DIN VDE 0833-1, EU Regulation 89/655/EG, BGR 134, Article 6.3).

If the contract is not signed, the owner will lose the qualification statement of the machine tool 3 months after the acceptance with the fire extinguisher manufacturer.

The extinguishing agent is CO2 (carbon dioxide). Other gases can also be used under certain conditions. Regulations for health protection and safe production must be observed.

The fire alarm must be protected from UV light sources to avoid being triggered unintentionally.

Prohibition

Cell phones, radio instruments or cameras with flashes are not allowed due to the sensitivity of the sensor.

Fire extinguishers should be turned off before starting maintenance work in the processing room.

Fire extinguishing device manufacturer must provide corresponding training to the machine users.

The space filled with fire extinguishing gas is permitted to enter only after thorough ventilation.

2.1.4 Measures in dangerous situations and in case of accidents

2.1.4.1 In dangerous situations

Press the NOT-HALT (operation emergency stop) button if

  • personal safety is endangered.
  • there are damage risks to the machine tool or workpiece.
  • the following behavior regulations are in effect in the event of an accident or fire. It does not replace the internal rules and requirements of the company.

In case of accidents

  1. Take emergency measures at the accident site
  2. Report the accident, including
    • the type.
    • the location.
    • what happened?
    • how many people are injured?
    • which form of injuries?
    • who is the reporter?
    • waiting for a reply.

  3. Perform first aid.

  4. Guide the emergency center to the site.
     The following information should also be given: 

    • who is the first aider?
    • where is the nearest first aid kit to the machine?
    • where is the accident alarm site?
    • the emergency number and accident alarm number.
    • internal regulations and operating procedures of the company.

In case of fire

Hot gas and naked fire.

The explosion or fire may cause injury accident, and may lead to death or serious personal injuries.

  • Extinguish fire or stop its spread only when there is no danger to people.

Warning! Explosion-risk materials!

Hot oil in the machine tool.

The explosion of oil may cause injury accidents, and may lead to death or serious personal injuries when water is used as a fire extinguishing agent.

  • Fires in hydraulic pumping stations can only be extinguished with carbon dioxide, foam or powder.

Warning! Dangerous voltage!

The machine tool is also connected to the workshop power supply.

The electric shock may cause injury accidents, and may lead to death or serious personal injuries when water is used as a fire extinguishing agent.

  • Only carbon dioxide (CO2) is allowed to extinguish electrical installations.
  1. Take emergency measures
  2. Report the fire, including
    • the type.
    • the location.
    • what catches the fire?
    • how many people are injured?
    • which form of injuries?
    • who is the reporter?
    • waiting for a reply.

  3. Perform first aid.

  4. Firefighting

  5. Guide the fireman to put out the fire.

    The following information should also be given:

    • where is the closest fire extinguisher to the machine and how does it work?
    • where is the fire alarm point?
    • where is the nearest telephone machine?
    • what is the telephone number of the fire brigade?
    • what fire alarm and suppression measures must be observed?
    • who is the first aider?
    • where is the nearest first aid kit to the machine?
    • where is the accident alarm site?
    • the emergency number and accident alarm number.
    • internal regulations and operating procedures of the company.

2.2 In and on the machine tool

Operate all matters of machine tool and peripheral equipment.

2.2.1 Safety devices

2.2.1.1 Overview

The machine tool has the following safety devices. Further safety measures are integrated as part of the machine and control system, which comply with the EG EU Machine Regulation 2006/42/EG.

These safety devices must be restored to their safe state after maintenance.

Safety devices should be included in the regular maintenance.

All processing room doors, gates and covers must be closed before the machine tool is put into commissioning operation, and during the process of operation

Not allowed to open.

Do not disable the function of the installed safety devices.

2.2.1.2 Processing room

All sides of the machine tool should be enclosed by guards. Access to this area during commissioning and maintenance work should be electronically monitored until the end of dangerous movements in this area.

Door of the Processing Room

The processing room is particularly dangerous because of the mechanical movements involved. It is equipped with protective covers on all sides. Access is only possible through a lockable processing area door. Movement can only be started when the processing area door is locked or when the commissioning is running with the help of an approval key.

Failure of safety devices.

There exist risks of injury caused by moving machine tool parts!

  • The safety monitoring switch of the processing room door is not allowed to be shorted-circuited.

Additional protection is required when working with the processing room door open and when there is no direct contact protection for the rotating tool/workpiece.
The strength of the guards and the processing room door with viewing glass should be able to reliably stop the tools or fixtures from flying out due to collision or breakage.

This only applies if the speed and size (diameter) of the tool/fixture used is not exceeded。

Breakage or collision may occur if the clamping device has an impermissible size or speed.

The throwing of the fixtures or tools may cause injury accidents, and may lead to death or serious personal injuries.

  • The machine tool is only allowed to be used in accordance with the regulations and operated under the permitted operating parameters.

After a collision, be sure to replace the damaged pieces. This applies especially to the safety glass and its frame of the process room door.

The door can only be opened when the spindle and feed drive are stopped.

Door of electrical control cabinet

The door must be closed.

Running the machine tool while the electrical control cabinet door is open will contaminate the components in the electrical control cabinet.

Component failure due to contamination is not covered by the product

warranty.

2.2.1.3 Emergency stop button

This button has a conspicuous red-yellow appearance and is pressed in dangerous situations.

Functions of the button:

  • All movements will be stopped.
  • Drives that may cause danger will be powered off.
  • The button unlocks after the hazardous situation is over.

2.2.1.4 Approval button

Only when the approval button is pressed with one hand and the function key is pressed with the other, movement is permitted when the processing room door is opened and the manual operation is started.

The movement stops when one of the keys is released.

2.2.1.5 Speed control

Only fixtures designed for the maximum speed of the machine tool are allowed to be used.

Obtain the maximum speed of the machine tool from the technical data of the operating manual.

2.2.1.6 Clamping devices/workpieces

The clamping distance and release distance of the tool/workpiece clamping device should be checked regularly.

2.2.2 Operation

In all work involving operation, attention must be paid to following the on and off operating procedures specified in the manual.

The monitoring function of the processing room door must be checked after switching on the machine tool.

The safety precautions and instructions given in the Operations Chapter must have been read and understood.

Please check before running the machine tool:

  • that all safety devices are functioning properly.
  • that the operator must be able to see where the emergency stop button is located.
  • that make sure that no one is in the processing area. Also make sure that no one stays in the processing area that is not visible from the operating position.
  • that if there are dislodged, damaged or worn parts on the machine tool.

Possible oil leakage from damaged pipes or hoses。

Damaged wires may lead to electric shock.

Always follow the normal sequence of turning the machine tool on and off and the procedures for turning it on again after an interruption. Misoperation may result in damage to the machine tool.

It is not allowed to turn off the main switch during machine operation, which may result in damage to the machine tool.

Do not change the operating mode while the work spindle is running. When switching the operating mode, feed suspension and spindle pause will occur.

2.2.3 Operating mode

Attention must be paid when purchasing personal protective equipment, which should comply with the requirements of EU Regulation 89/686/EWG.

Danger!

If the safety guards are damaged, the axis placed vertically or obliquely may fall in the absence of electricity.

There exit risks of death or serious physical injury due to extrusion.

  •  Keep the safe distance from vertical or oblique placement of the axis. 

It is prohibited to stay under the vertical axis or oblique axis.

Wear safety gloves only when moving workpieces.

Operating Mode 1: Automatic operation (standard operation)

Operating Mode 2: Adjustment operation (with approval button)

Commissioning operation is a type of operation in which the operator performs the commissioning of processing procedure.

When the safety guards in work area are open and the speed is reduced, the machine is operated manually or in a restricted CNC state.

2.2.3.1 Safety instructions for operating mode 2

Simultaneous operation at the operator panel or on the electronic handwheel when the human body is in contact with the machine axis

may lead to risks of death or serious physical injury due to extrusion.

  • Before and during processing, it must be checked whether the work can be performed with the door closed or in Operating Mode 1.
  • Processing is allowed only by specially trained and authorized professionals on site while the processing room door is open.
  • Keep the safe distance from the moving machine tool axis.
  • The operator may have to be ready to press the emergency stop button at any time.

  • Before and during processing, it must be checked whether the work can be performed with the door closed or in Operating Mode 1.
  • Processing is allowed only by specially trained and authorized professionals on site while the processing room door is open.
  • Keep the safe distance from the spindle.
  • The operator may have to be ready to press the emergency stop button at any time.

Simultaneous operations on the operator panel or on the electronic handwheel, such as operating buttons or soft keys when the human body is contact with machine tool axes or spindles, are strictly prohibited.

2.2.3.2 Operating mode 2

Conforming applications:

Only specially trained and qualified and authorized personnel are allowed to use this mode of operation.

Unprofessional, unauthorized personnel and beginners are not allowed to use the Mode 2.

Before and during processing, it must be checked whether the work can be performed with the door closed or in Operating Mode 1.

Measures must be taken to protect operator’s safety and health.

Personnel protective equipment such as goggles, safety shoes, skin care products, hair guards must be prescribed by the machine owner's safety representative. Safety gloves are not allowed.

It is not allowed to run the machine tool without supervision in Operating Mode 2.

Our company takes into account the factors of technical state, risks and safety standards and limits the spindle and feed speed in accordance with the corresponding European Standard (CEN).

Although there are these limitations, there still exist high level of safety risks for authorized professionals to operate under mode 2, such as hazards due to crushing, shearing, being drawn, entangling, flying parts or sprayed liquids and vapors. The machine user plant should train its employees accordingly.

The machine tool user is responsible for the implementation of the measures listed in the safety precautions to reduce the existing risks (personal injury and/or property damage).

2.2.4 Avoid dizziness warning

Eyes may be dazzling when look directly at the process area lighting.

Looking directly at the lighting may cause short-term dysopia or adverse sensations such as discomfort and fatigue.

This may lead to adverse consequences such as misoperation or accidents.

  • Avoid looking directly at the light.

2.2.5 Inspection window

2.2.5.1 The impact resistance of inspection window

The window of the machine shall be specially designed for the processing center in accordance with the German Standard DIN EN 12417 and for the machine in accordance with the German Standard DIN EN 23125.

On processing center the standard is based on small items with m = 100g as a starting point and is in line with large tool fragments.

For rotary running, a resistance level should be specified which corresponds to the possible fixture mass and its speed.

The required resistance level is achieved by using polycarbonate composite windows.

The machine control device of the processing center limits the spindle speed by depending on the programmed tool size.

With this measure, only a maximum of 200 Nm energy can be generated in the event of a tool breakage. This ensures sufficient safety even after two years of aging of the polycarbonate glass.

2.2.6 Composite glass

2.2.6.1 Overview

Composite glass windows are made of polycarbonate glass, which is glued together completely flat with silicate glass.

The polycarbonate glass on the outside of the window is protected with a film to prevent the polycarbonate from exposure to chemicals and consequent aging or scratching.

Compositeglass windows must be replaced regularly (see “Composite Glass Windows” in the Chapter "Maintenance Instructions").

2.2.6.2 Post-crash operation

If the silicate glass cracks after a collision while the polycarbonate glass is not damaged, it is required to be replaced every three months.

If the polycarbonate glass is damaged, it should be replaced with laminated glass immediately.

2.2.7 Staying under the lift gate

The vertical lift door or vertical lift window may fall in the unclosed position, for example, due to a failure or breakage of the component.

There exits risks of death or serious physical injury due to extrusion.

  • Commissioning or preparatory work can only be carried out through vertical lift doors or vertical lift windows in clearly open terminal positions.
  • If the position is not reached, the machine tool should be stopped immediately and the vertical lift door or vertical lift window should be lowered.
  • The vertical lift doors or windows should be lowered below or hung high during maintenance.

It is strictly prohibited to support a vertical lift door or vertical lift window in an open terminal position. Hold it or apply pressure downward.

2.2.7.1 Medium supply

2.2.7.1.1 Hydraulic pressure

The hydraulic tubing must be visually inspected in scheduled period. Replaced it immediately if defects such as leaks are discovered. Please refer to Chapter “Maintenance” if necessary.

The hydraulic tubing must be replaced after the time specified in the Chapter "Maintenance" if not depending on the results of the visual inspection.

The pressure in hydraulic pump station must be zero before it can work.

Make a note in the machine tool logbook about the replacement of hydraulic tubing.

Pressure vessels should comply with the relevant pressure vessel regulations or the EU regulations for pressure devices.

Periodic inspections are required to be conducted through the user's plant.

2.2.7.1.1 Pneumatic

The pneumatic device must be completely free of pressure before working on it.

This is also suitable for systems in which the pressure must be maintained after the pneumatic compressed air supply has been switched off for functional technical reasons.

In the event of a malfunction, e.g., a cylinder function, immediately report this malfunction to qualified service personnel.

Only qualified service personnel are allowed to perform manual work on the stuck cylinder on a completely pressureless system.

The user plant is required to perform regular functional checks.

2.2.7.1.3 Cooling lubricant device

Cooling lubricant device can only be filled with well-mixed cooling lubricant.

The cooling lubricant must be replaced according to the scheduled period in the Chapter "Maintenance".

Note all instructions in the Chapter "Hazardous Materials".

Contamination of the cooling lubricant with waste oil, cigarette butts or other wastes should be avoided.

No adjustment of cooling lubricant nozzles is allowed during machine tool operation.

2.2.7.1.4 Cooling lubricant equipment

The cooling lubricant equipment must be powered off before it can work.

It is required to check the filter pads, ph-values, concentrations according to the scheduled period in the Chapter "Maintenance", as well as a visual inspection by the machine users.

Note all instructions in the Chapter "Hazardous Materials".

2.2.8 Chips clearing

2.2.8.1 Chips clearing on and in the machine tool

Recycling and disposal of sharp and sharp-edged chips.

There exist risks of cutting hands and hurting eyes.

  • Do not use compressed air when cleaning machines and workpieces.
  • Wear protective glasses and safety gloves when touching chips.
  • To clear chips, please use suitable tools such as chip hooks, brushes, hand brooms and industrial vacuum cleaners.

Wear protective gloves!

Wear safety gloves for clearing chips.

Wear protective glasses!

Wear protective glasses for clearing chips.

2.2.8.2 Chips conveyor

The chip conveyor in the machine bed, which clears chips in the machine space, is automatically activated.

There exist risks of personal injuries which may lead to seriously physical damage or even death by crushing or tugging the body.

  • Turn the machine tool off at the power disconnect device and lock the device with a padlock before maintenance work starts.
  • Do not grip anything at the ejection port of the chip conveyor.
  • Do not step on the chip conveyor in the machine tool.

The conveyor for clearing chips in the machine space is allowed to operate only when there is a lowered receiving box with a chip throwing shaft surrounding it on all sides.

2.2.8.3 Maintenance

Automatic operation of the machine tool.

Accidental machine tool movements will cause injuries if no protective measures are taken.

  • Turn the machine tool to AUS(power off) at the power disconnect device and lock the device with a padlock or other locking equipment before maintenance work starts.
  • To prevent unintentional connection, a warning sign "under repair, strictly forbidden to switch off" should be hanged.

Warning! Dangerous voltage!

There exist unprotected energized components in the electrical control cabinet.

The electric shock may cause injury accidents, and may lead to death or serious personal injuries.

  • Do not touch the unprotected components in the electrical control cabinet.
  • Disconnect the power cord, take safety measures to prevent it from being connected and hang the corresponding warning signs.

The power-off procedures specified in the operating manual should be observed when carrying out various tasks related to maintenance and repair.

If there is a problem in maintenance or if the machine tool breaks down, please turn to our company for help.

Safety precautions

For after-sales service department only.

Only qualified and authorized personnel are allowed to maintain and repair the machine tool in accordance with the instructions specified in the operating manual.

  • Only lint-free cleaning cloth is allowed for cleaning.
  • Use suitable environmentally friendly cleaners.

The use of corrosive solvents such as carbon hydrogen chloride, acetone or similar solvents is not permitted as they can harm the plastic parts or seals (oil wipers).

  • In any case, do not use compressed air, screw tools or high pressure purifiers (jet of steam) to clean the machine tool as chips may get into the guide, spindle bearings or tool holder gaps.
  • Before cleaning the machine tool, all ports and holes should be covered/glued into which liquid should not be allowed to penetrate for safety and/or functional reasons. This endangered particularly the motor and the electrical control cabinet.
  • The cover/ splicing tape must be completely removed after cleaning.
  • The removed covers and guards must be taken down after the maintenance.
  • After completing the maintenance work, the safety and protective devices should be checked for functional integrity.

The fire extinguisher(option) should be safely turned off before work begins in the processing room. The extinguisher will be activated again after finishing the job.

2.2.8.4 Vertical or obliquely placed axis

If the safety guards are damaged, the axis placed vertically or obliquely may fall in the absence of electricity.

There exit risks of death or serious physical injury due to extrusion.

  • If possible, operate the vertical or oblique axis to a non-hazardous position to prevent descent.
  • If can’t, the vertical or or oblique axis should be operated to the underneath or protected by a hanging device.

It is strictly prohibited for anyone to stay under a vertical or oblique axis without adequate safety devices.

2.2.9 Transport and placement

Attention must be paid to compliance with the following provisions.

  • specified transport and installation instructions.
  • Chapter "Planning, Transport and Installation" of the operating manual.

2.3 In the production process

All production and memory systems.

2.3.1 Hazardous materials

These grease, cooling lubricants and antifreeze and preservatives are all hazardous materials

Based on its composition (additives) these materials may be harmful to health and the environment.

It is up to the user plant to decide on the selection and application of these materials.

Harmful substances may be released when hazardous materials are used or prepared (e.g., the release of hazardous materials from steam).

The following points should be included in the regulations for the use of these materials developed by the user plant:

  • Name of hazardous substances.
  • Names of materials hazardous to humans and the environment.
  • Protection measures and behavioral norms should be adopted, such as:
    • Wear durable plastic safety gloves,
    • Avoid contacting the skin and eyes,
    • Do not allow inhalation of harmful vapors and mists,
    • No smoke and fire and direct light.
  • Actions be taken in the event of a dangerous situation: first aid.
  • Clearance in accordance with provisions.

2.3.1.1 Flammable/explosive materials

These flammable material dusts will be explosive when present in sufficient concentration in the space and when the particles are small enough.

Typical flammable/explosive materials.

  • Organic, natural coal ash or wood,
  • Inorganic magnesium ash magnesium, aluminum or zinc.

2.3.1.2 Emission of hazardous substances

This machine tool generates hazardous materials and substances during processing and therefore must be connected to a suitable oil/ smoke emission separation device. The existing opening in the processing room guards can be used.

This opening is equipped with a corresponding baffle plate for the central extraction fan which is only for the machine or the workshop, to extract generated steam and smoke.

The machine tool must be connected to the air extraction device which is necessary for the machining process during operation.

2.3.1.2 Non-aqueous hybrid cooling lubricant

Warning! Explosive hazard material!

When flammable oil is used as a cooling lubricant, an explosive cooling lubricant-vapor-aerosol-air mixture may be generated in the machine processing room.

The fire, explosion or spark deflagration may cause injury accidents, and may lead to death or serious personal injuries.

  • In the absence of special firefighting equipment, for safety reasons (explosion hazard), it is not allowed to use cooling lubricants (cutting oil) that cannot be mixed with water.
  • In processing, there must be a fire extinguishing device, whose monitoring system must be active.

2.3.2 Processing magnesium

Spontaneous combustion or explosive particles (powder, dust, chips) may be generated during the process of cutting materials containing magnesium (aluminum-/magnesium alloys).

Warning! Explosive hazard material!

Spontaneous combustion or explosive particles may be generated when processing light metals and alloys, especially magnesium parts.

The fire, explosion or spark deflagration may cause injury accidents, and may lead to death or serious personal injuries.

  • It is obliged to report to the Social Mutual Insurance Cooperatives for Occupational Accidents and the fire department.
  • Take appropriate protective measures and follow the disposal rules when dealing with magnesium.
  • Conduct on-site safety education regularly for employees.
  • Prepare the appropriate air extraction devices and explosive unloading openings.
  • Prepare suitable firefighting equipment.

No water extinguishing!

Water and water-containing extinguishing agents can lead to dangerous chemical reactions (a mixture of hydrogen-oxygen) during magnesium combustion.

  • The magnesium fire can only be put out with a suitable and permissible extinguishing agent.
  • Never use water or CO2 as the extinguishing agent.

2.3.2.1 Precautions when processing magnesium metal

  1. Magnesium metal chips and dust are easy to ignite.
  2. Please wear protective work clothes that do not absorb chips or dust.
  3. Suspended magnesium metal dust may cause an explosion. The critical particle diameter is < 500 μm. Particles whose diameter is < 63 μm are prone to chemical reaction.
  4. Wet magnesium metal dust has the risk of spontaneous combustion.
  5. The hydrogen gas (detonating gas) is formed when the magnesium metal dust and chips are combined with water.
  6. Cutting magnesium metal parts may lead to dangers:
    • Processing with oil may lead to oil combustion, explosion and metal fire.
    • Processing with lubricants may lead to the formation of hydrogen-oxygen gas mixtures and metal fire.
    • Processing with minimal lubricants may lead to metal fire and dust emulsions.
  7. Attention must be paid when processing with emulsions:
    • Take protective measures for chip discharge. The chip conveyor must be monitored (monitoring motor protection switch).
    • No chip accumulation.
    • Use the large flow of cooling lubricant. Alkaline cooling lubricant reduces the possibility of forming hydrogen gas.
    • Cooling lubricant must be resistant to magnesium metal corrosion (violent hardening of water)
    • Keep extracting and discharging air while the machine tool is powered off, and monitor the power.
    • It is also possible to discharge automatically generated hydrogen gas during machine shutdown. Add openings at the upper part of the machine.
    • The magnesium metal chips with water should be taken into account when designing the chip receiver.
    • Suitable openings must be provided in the chip receiver so that the automatically generated hydrogen can be discharged.
    • Please use lubricating materials with high ignition point.
  8. Dry-processing of magnesium metal
    • Take protective measures for dust and chip extraction.
    • No dust and chip accumulation. Dust is explosive in nature, so wet separation of dust is required.
    • Monitor extraction and discharge power to ensure volume and flow rate.
    • Specify cleaning and maintenance schedules for extraction and separation devices.
    • Use only approved vacuum cleaners (marked B1) which are suitable for vacuuming magnesium metal dust and chips.
    • Do not use compressed air to avoid the suspension of dust.
  9. Machine tool/equipment maintenance:
    • Confirm a cleaning and maintenance schedule that includes all areas of the machine, such as the processing room.
  10. Take measures to prevent fire:
    • Use suitable firefighting equipment and inspect and maintain it regularly.
    • Establish a fire alarm center.
    • Require to make plans for the alarm to fire brigade. The brigade must know where the machine tool is and what materials are being processed.
    • Analyze the workplace and take appropriate fire prevention measures with the fire department and Industrial Injury Accident Insurance Union, confirming and implementing the safety education for employees.
    • Conduct fire-fighting drills and provide corresponding fire training to employees.
    • Post warning signs.
  11. Put out the magnesium metal fire:
    • No water. No carbon dioxide (CO2) and nitrogen (N2).
    • Inert gas (argon) and powder extinguishing agent with “D” fire class(metal fire powder) can be used to extinguish metal fire (such as magnesium, aluminum and titanium).
    • Sand or dry, rust-free gray cast iron chips or special salt can be used to cover the external leakage of magnesium metal.
    • Proof of the applicability of the extinguishing agent for putting out metal fire must be provided.
  12. Chip storage
    • Chips should be stored in a suitable container, which should be closed and must ensure that the hydrogen gas can be safely discharged. Take measures to ensure good ventilation.
    • Protect the container from direct sunlight to prevent the spontaneous combustion.
    • Take rainproof measures for chips.
    • Mark the storage areas and containers.
    • Consult with and confirm the storage location with the fire department and Industrial Injury Accident Insurance Union.

Detailed information on the fire protection of machine tool and contact with magnesium is available for download on the Internet, for example

  • BGR 204 contact with magnesium metal.
  • fire and explosion protection of machine tools-DGUV.

2.3.3 Workpiece processing

Parts that fly out when a tool breaks or a workpiece break.

There are risks of personal injuries from the expansion of the composite glass plate (sight glasses in the processing room) caused by the collision of the broken parts.

  • Avoid direct contact with composite glass.
  • Select the installation position of the machine tool in such a way that a safe distance to the composite glass window should be specified.
  • Check for damage of the composite glass at specified intervals.

When using magnetic chuck, the absorption force should be checked regularly with a suitable measuring tool.

Check the suitability of existing fixtures.

After a collision that damages a fixture, negotiate with the manufacturer of that fixture about whether the fixture can continue to be used.

After each change, the monitoring(parameters) of the fixture, including the clamping stroke and clamping pressure, must be readjusted.

Use only the original fixture key to operate the manual fixture. The fixture key must be removed before the spindle is started.

Follow the adjustment instructions for stroke monitoring and clamping pressure.

Use regularly the clamping force measuring instrument to check the function of the fixture.

Clamp the workpiece correctly and ensure the cleanliness of the clamping surface.

Injury accidents may be caused by extrusion when the workpiece is not clamped or not sufficiently reliably clamped when being clamped or unclamped.

  • Take safety measures to prevent the workpiece from falling when being clamped or unclamped.

Incorrect clamped workpiece.

The throwing of workpieces may cause injury accidents, and may lead to death or serious personal injuries.

  • Clamp the workpiece correctly.

Unallowable size and speed may lead to break or collision.

The throwing of workpieces may cause injury accidents, and may lead to death or serious personal injuries.

  • The machine tool is only allowed to be used in accordance with the regulations and operated under the permitted operating parameters.

Take out the workpiece from the fixture before turning off the machine tool.

Pay attention to the space limitations of the processing room when clamping the workpiece and rotating the tool holder.

2.3.4 Tools and tool change

2.3.4.1 Tools

Only suitable tools are allowed to be used on the machine tool.

Sharp blade.

Accidental contact with the blade can cause injury accidents.

  • Do not stay in the vicinity of a tool which is unclamped.
  • Please wear safety gloves.

Check tool state before starting processing.

When using a large tool, check its stroke and the space limitation of the processing area.

Never grip the tool while it is still rotating.

Wear protective gloves!

To avoid being cut, please be sure to wear safety gloves.

2.3.4.2 Manual tool change

In order to change the tool manually, the tool must be in dry run mode.

Always change the tool independently by one person in order to avoid the risk of misoperation by the second person.

  • Hold the tool firmly when unclamping the tool to avoid the tool falling.

Injury accidents may be caused by extrusion when suddenly move under high tension force during the clamping process.

  • Do not put your hand between the tool synchro flange and the spindle end.

Automatic tool change

Place the tool into the expected tool position in the magazine loading station.

2.3.5 Requirements for the tool magazine

2.3.5.1 Working outside the tool magazine

Attention must be paid when carrying out maintenance work and when loading and unloading tools on the tool magazine.

Sharp and pointed blades and tools!

There exist risks of cutting, stabbing and eye injury due to negligent contact with blades.

  • Wear protective gloves.
  • Wear protective glasses.

2.3.5.2 Working inside the tool magazine

Sharp and pointed blades and tools!

There exist risks of cutting, stabbing and eye injury due to negligent contact with blades.

  • Remove all tools.
  • Wear protective gloves.
  • Wear protective glasses.
  • Dress in accordance with regulations of EN510.

Please note when entering the storage room：

  • Turn the main switch off and padlock it.

2.3.6 Zero-point clamping system

2.3.6.1 Use as required

This system can only be used for clamping equipment, bench vices and workpieces on the machine tool.

Compliance with the commissioning, installation, operation, environmental and maintenance conditions specified by the manufacturer is also considered as use in accordance with the regulations. Use beyond the scope will be considered as non-compliant use. The manufacturer is not liable for damages resulting from such use.

2.3.6.2 Safety precautions

It is necessary to read and comply with the provisions in the operating or installation manual. The manufacturer is not liable for any damage resulting from ignoring these provisions.

The clamping system can only be used for the intended purpose. Since these may lead to danger, unauthorized technical changes and various uses not in accordance with regulations are strictly prohibited. If these regulations are ignored, warranty rights will be lost.

Only trained personnel are allowed to perform repair and maintenance! The manufacturer is not liable for any damage resulting from not repairing according to professional regulations.

Only trained personnel are allowed to operate this zero-point clamping system. The user plant must ensure the training to operators. It is recommended that this training be approved in writing by the signatures of the trained operators.

Warning! Risks of injuries to hand!

There may exist large clamping forces.

There exist risks of serious personal injury due to extrusion.

  • Do not put your hands into the machine tool while the clamping pin is open.
  • Do not put your hand between the replacement plate and the base plate.
  • Wear protective glasses.
  • Do not examine the chip box during hydraulic or pneumatic piping connection and venting. Wear protective glasses.

2.3.7 Tool-related speed monitoring

The tool speed will be limited according to the tool radius to ensure that the tool is not a danger to the operator. This monitoring only works when the tool radius is correctly described in the tool management.

This monitoring will be bypassed if an exception requires working with a zero tool radius.

Depending on the maximum spindle speed, it is safe to select the radius = 0 up to the following actual tool radius.

Spindle Speed [1/min]

Maximum Tool Radius [mm]

14000

65

20000

65

The processing room’s ability to block impacts cannot be guaranteed when speed monitoring is not enabled, or when too high a spindle speed is selected.

The flying tools from processing room may cause injury accidents, and may lead to death or serious personal injuries.

  • Do not exceed the allowable spindle speed of the tool used.

2.4 What else are important

In addition, all the following things should be noted.

2.4.1 Residual hazards

2.4.1.1 Residual hazards caused by extrusion

Caused by moving machine parts in Operating Mode 2
* Whether it exists depends on the machine’s configuration.

Measures to Avoid Residual Hazards

Recommended PPE

· Maintain a safe distance from moving machine parts.

· Check whether additional protective measures (e.g., a camera) are available so that the operator does not have to enter the adjacent area of the moving machine parts.

· Safety shoes,

·  Protective clothing in accordance with EN 510 standard,

· Goggles.

During the process of performing the installation and commissioning processes on the tool magazine or commissioning of special individual tool or measuring tool in the processing area.

Measures to Avoid Residual Hazards

Recommended PPE

· The method of gripping the tool is to avoid squeezing the hand or fingers when inserting into the fixed device.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

During the process of installation and commissioning of the workpiece in the processing area or in the commissioning position.

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from the moving workpieces, for example: when loading and unloading workpieces with the help of lifting equipment.

· Do not enter or put your hands under the area of hanging heavy objects.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

During maintenance work

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from the moving workpieces, for example: when loading and unloading workpieces with the help of lifting equipment.

· If possible, disconnect the machine tool or the parts that pose a danger from the drive energy.

· Take appropriate measures to fix the vertical or obliquely placed axis.

· Relieve pressure of pressurized components and fix them if necessary.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.2 Residual hazards caused by shearing

See the Chapter " Residual hazards caused by extrusion".

2.4.1.3 Residual hazards caused by cutting and cutting off

Caused by the rotating tool

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from rotating machine parts.

· Check whether additional protective measures (e.g. a camera) are available so that the operator does not have to enter the adjacent area of the moving machine parts or the tools.

· Do not open the split guards during operation.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Wear a hairnet if necessary,

· No gloves.

Depending on the shape of the cutting element and the weight of the tool in installation and commissioning of tools

Measures to Avoid Residual Hazards

Recommended PPE

·          

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

·  Suitable gloves.

Caused by workpieces or clamping devices with sharp edges

Measures to Avoid Residual Hazards

Recommended PPE

·          

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

Caused by sharp chips

Measures to Avoid Residual Hazards

Recommended PPE

·          

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles

· Suitable gloves.

2.4.1.4 Residual hazards caused by being drawn into the machine

Caused by moving machine parts in Operating Modes 2, 3 and 4*

* Whether it exists depends on the machine’s configuration.

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from moving machine parts.

· Check whether additional protective measures (e.g., a camera) are available so that the operator does not have to enter the adjacent area of the moving axis.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Wear a hairnet if necessary,

· No gloves. (However, avoid contact with cooling lubricants).

Caused by the rotating tool

Measures to Avoid Residual Hazards

Recommended PPE

·         Keep a safe distance from rotating machine parts.

·         Check whether additional protective measures (e.g., a camera) are available so that the operator does not have to enter the adjacent area of the moving axis.

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Wear a hairnet if necessary,

· No gloves. (However, avoid contact with cooling lubricants).

Caused by feeding of the filter felt on the cooling lubricant system

Measures to Avoid Residual Hazards

Recommended PPE

· Turn off the cooling lubricant system with the zone switch when all operations are performed on the system.

· Stand where it is not in contact with the moving filter felt.

· Do not reach for the moving filter felt.

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Wear a hairnet if necessary,

· Use gloves only when the chip conveyor is turned off; avoid contact with cooling lubricants.

2.4.1.5 Residual hazards caused by being drawn into and tripped up by the machine

See the Chapter"Residual hazards caused by being caught and entanglement".

2.4.1.6 Residual hazards caused by collision

Residual hazards from spattering parts

Inevitably, broken tools or workpiece fragments will strike the viewing glass of the processing area during processing.

The viewing glass absorbs energy by arching. If an employee, for example, places his or her head directly on the impact point, this action may lead to injury.

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from the processing area door.

· Not possible here.

Residual hazards caused by pointed part, even if it does not move

Measures to Avoid Residual Hazards

Recommended PPE

· Wear protective clothing.

· Choose a safe place to stand.

·  Safety shoes,

·  Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

Caused by moving machine parts in Operating Modes 2, 3 and 4*

* Whether it exists depends on the machine’s configuration.

Measures to Avoid Residual Hazards

Recommended PPE

· Wear protective clothing.

· Choose a safe place to stand.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

Caused by the installation and commissioning procedures of the tool and workpiece

Measures to Avoid Residual Hazards

Recommended PPE

· Keep a safe distance from the moving workpieces, for example: when loading and unloading workpieces with the help of lifting equipment.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

Caused by slip and fall on the slippery ground

Measures to Avoid Residual Hazards

Recommended PPE

· The ground must be properly designed and maintained so that the non-skid property is in accordance with the Occupational Insurance Federation regulations.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard.

 Caused by stumble over uncovered pipes and hoses or console support arms 

Measures to Avoid Residual Hazards

Recommended PPE

· Cover the uncovered pipes and hoses accordingly.

· Do not climb over the support arms of the console.

·          

2.4.1.7 Residual hazards caused by piercing and penetration

Residual hazards caused by pointed part, even if it does not move, such as tools, workpieces, chips.

Measures to Avoid Residual Hazards

Recommended PPE

· Store the parts with appropriate protective measures.

· Choose a safe place to stand.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

·  Goggles.

2.4.1.8 Residual hazards caused by friction and wear

The stability of the component may be reduced by friction and wear. Depending on the different failure condition and failure phenomenon of the components, the breakage and failure of a damaged component can lead to different risks.

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.9 Residual hazards caused by sprayed liquid

There exist the following risks:

  • Formation of slippery floors, e.g., due to the overflow of oil, grease, hydraulic fluid, antifreeze and preservatives or cooling lubricants.
  • The oil, grease, hydraulic fluid or cooling lubricant enters the groundwater.
  • Contact of oil, grease, hydraulic fluid, antifreeze and preservatives or cooling lubricants with human body (skin, eyes, etc.)
  • Injuries may result from liquid jet (e.g., eyes).

Measures to Avoid Residual Hazards

Recommended PPE

· The access area must be properly designed and maintained so that the non-skid property is in accordance with the Occupational Insurance Federation regulations.

· The machine tool, especially the fluid supply must be turned off when opening the processing room door.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.10 Residual hazards caused by throwing out

Residual hazards caused by its own movement in case of tearing of high-pressure hose

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool and its surroundings regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

Safety Precautions

2.4.1.11 Residual hazards caused by collision and extrusion

See the Chapter “Residual hazards caused by extrusion”.

2.4.1.12 Residual hazards caused by collision and penetration due to slip

Residual hazards of slipping and hitting, for example, machine parts or workpieces depends on their shape and arrangement.

This may result in puncturing human body.

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool and its surroundings regularly.

· The access area must be properly designed and maintained so that the non-skid property is in accordance with the Occupational Insurance Federation regulations.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.13 Falling, residual hazards caused by falling

There exist hazards

  • caused by all types of pipes and hoses which are loosely laid on the access plane.
  • caused by the use of unsuitable ladders and climbing auxiliary devices.
  • caused by non-use of personal protective equipment.

Measures to Avoid Residual Hazards

Recommended PPE

·  Pipes and hoses must be laid accordingly.

· Only suitable ladders and climbing auxiliary devices, which must be non-slip, are allowed.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.14 Residual hazards caused by direct electric shock

There exist hazards of electric shock caused by touching charged objects, such as broken wires.

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool and its surroundings regularly.

· Impossible

2.4.1.15 Residual hazards caused by indirect electric shock

There exist hazards of electric shock due to direct human contact with objects that are electrically charged due to leakage elsewhere.

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool and its surroundings regularly.

· Impossible

2.4.1.16 Residual hazards caused by high voltage

Electric shock hazards caused by approaching or touching parts with high voltage

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.17 Residual hazards caused by static electricity

Damage of electrical or electronic components due to static electricity

Measures to Avoid Residual Hazards

Recommended PPE

· Only specially trained professionals are allowed to handle such parts.

· Check the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Antistatic wrist strap for static electricity discharge.

Ignition of explosive gases, vapors and dust

Measures to Avoid Residual Hazards

Recommended PPE

· The machine tool operator must take measures here depending on the processing to be performed (e.g., installation of a fire extinguishing system). A targeted solution can be provided upon request.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

1.4.1.18 Residual hazards caused by short circuit and overload

Thermal hazards caused by parts overheating due to short circuit. Scald hazards from contact

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

Throwing out molten parts components or chemical processes, e.g., generation of steam and dust, in case of short circuit, overload

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.19 Residual hazards caused by scald and frostbite

Contact with high and low temperature objects, e.g., workpieces, tools, chips, machine components.

Measures to Avoid Residual Hazards

Recommended PPE

· If possible, cool parts before contact.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

2.4.1.20 Residual hazards caused by hot and cold working environment

If the machine tool is to be operated outside the specified permissible temperature range, damage to individual component with the corresponding residual hazards may occur (see other sections).

Measures to Avoid Residual Hazards

Recommended PPE

· Do not operate the machine tool out of the allowable temperature range.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

· Suitable gloves.

2.4.1.21 Residual hazards caused by scald

Residual hazards caused by uncontrolled overflow of heated fluids, e.g., hydraulic oil

Measures to Avoid Residual Hazards

Recommended PPE

· Replace the hoses regularly.

· Check the sealing of screwed joints.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles,

·  Suitable gloves.

2.4.1.22 Residual hazards caused by hearing damage due to noise

Not wearing hearing protection earmuffs may cause permanent hearing damage.

Measures to Avoid Residual Hazards

Recommended PPE

·  If possible, reduce machine noise.

· Hearing Protection.

2.4.1.23 Residual hazards caused by sound signal obstruction due to noise

Noise near the machine tool may make it impossible to hear sound signals and emergency calls.

Measures to Avoid Residual Hazards

Recommended PPE

· If possible, reduce machine noise.

· Impossible.

Residual hazards caused by radiation, low frequency, radio frequency, microwave

No direct risks of accident.

2.4.1.24Residual hazards caused by radiation, infrared ray, visible and ultraviolet Light

Measures to Avoid Residual Hazards

Recommended PPE

· Be sure to avoid contact with the skin and the eyes.

· Never look at rays, including with optical instruments.

· Provide safety education to all employees working on the machines to make them recognize the dangers of direct laser exposure to the eyes or prolonged exposure to the skin.

· Protective glasses in accordance with the standard EN207, and in accordance with the standard EN 60825-1 if laser level is 3 or above.

2.4.1.25 Residual hazards caused by exposure or inhalation of vapors and dust

Measures to Avoid Residual Hazards

Recommended PPE

· Do not inhale vapors formed by cooling lubricants.

· Avoid direct contact with cooling lubricant and clean the wet contact area immediately.

· Do not inhale the dust formed in course of working.

· Install the suction devices by machine operators and inform employees.

· Goggles，

· Suitable gloves.

· Protective clothing in accordance with EN 510 standard.

2.4.1.26 Residual hazards caused by fire or explosion

Measures to Avoid Residual Hazards

Recommended PPE

· Process explosion-hazardous materials (e.g., magnesium, silicon) are only permitted after additional protective measures (e.g., fire suppression systems) have been applied.

· The machine operator must take measures depending on the processing to be performed. A targeted solution can be provided upon request.

· Safety shoes

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.27 Residual hazards caused by biological/microbial hazards

Incorrect or no cleaning of the machine tool may lead to health hazards such as the formation of mycete. Also be aware of chemical reactions of coolants and other fluids.

Measures to Avoid Residual Hazards

Recommended PPE

· Here, the machine operator must fulfill his duty of diligence.

· Clean the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.28 Residual hazards caused by liquid outflow

Hazards from the formation of slippery Table surfaces

Measures to Avoid Residual Hazards

Recommended PPE

· The access surface must be properly designed and maintained so that the non-skid property is in accordance with the Occupational Insurance Federation regulations.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

Flammable liquid flowing out may lead to spontaneously combustion

Measures to Avoid Residual Hazards

Recommended PPE

· Professionally remove the liquid.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

Liquid may flow into groundwater or drainage systems

Measures to Avoid Residual Hazards

Recommended PPE

· Professionally remove the liquid.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.29 Residual hazards caused by neglect of ergonomic principles, unhealthy posture, fatigue

Residual hazards caused by body overload or incorrect weight bearing

Measures to Avoid Residual Hazards

Recommended PPE

· Load and unload workpieces with the help of auxiliary devices.

· Load and unload tools with the help of auxiliary devices.

· Before starting maintenance work, observe the precautions listed in the maintenance chapter. The machine operator must fulfill his duty of diligence.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.30 Residual hazards caused by carelessness in the use of PPE

There exist high potential hazards to personal health if personal protective equipment, such as protective glasses, gloves, hearing protection, and suitable protective clothing, is not used.

Measures to Avoid Residual Hazards

Recommended PPE

·  The user factory must be liable for safety production and implement corresponding safety measures. The use of personal protective equipment is essential.

 

2.4.1.31 Residual hazard caused by unsuitable local lighting

There exist high potential hazards if work is performed when lighting is insufficient.

Measures to Avoid Residual Hazards

Recommended PPE

· The machine operator must fulfill his duty of diligence and provide the required lighting for the operation to be processed.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.32 Residual hazards caused by mental overload or excessively low requirements

Residual hazards from mental overload or excessively low requirements

Measures to Avoid Residual Hazards

Recommended PPE

· The machine operator must fulfill his duty of diligence and be ensured sufficient rest periods. Only suitable professionals are appointed to work on the machine tool.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.33Residual hazards caused by human action/incorrect action

There exist residual hazards caused by incorrect use of the machine tool.

Measures to Avoid Residual Hazards

Recommended PPE

· The machine operator must fulfill his duty of diligence and be ensured sufficient rest periods. Only suitable professionals are appointed to work on the machine tool.

· Regular training and inspections are required.

· Use prescribed personal protective equipment,

· For example, check regularly the safety shoes, protective clothing in accordance with EN 510 standard, goggles etc.

2.4.1.34 Residual hazards caused by hazardous combinations

If individual small hazard is present in the form of combination, they can become a very large hazard, e.g., explosive hazard mixtures and sparks that cause explosions.

Measures to Avoid Residual Hazards

Recommended PPE

· The machine operator must fulfill his duty of diligence and work with designate trained professionals.

· Safety shoes

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.35 Residual hazards caused by accidental rotational overflow due to control system failure/fault

The manipulation of the safety technology may lead to failure of safety circuit. As a result, faults in the control system may lead to uncontrolled movements in the machine tool.

Measures to Avoid Residual Hazard

Recommended PPE

·  The machine operator must fulfill his duty of diligence and work with designate trained professionals and check the machine tool regularly.

· Safety shoes,

·  Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.36 Residual hazards caused by accidental rotational overflows due to accidental start-up, external influences to electric equipment

Unknown external influences may lead to uncontrolled movement

Measures to Avoid Residual Hazards

Recommended PPE

· Turn off the main power switch of the machine tool and padlock the switch.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.37 Residual hazards caused by accidental rotational overflow due to accidental start-up, unrecognized software faults

Unrecognized software faults may lead to this residual hazard.

Measures to Avoid Residual Hazards

Recommended PPE

· Turn off the main power switch of the machine tool and padlock the switch.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.38 Residual hazards caused by accidental rotational overflow due to accidental start-up, incorrect operation

Unrecognized incorrect operation may lead to this residual hazard.

Measures to Avoid Residual Hazards

Recommended PPE

·  The machine operator must fulfill his duty of diligence and work with designate trained professionals.

· Safety shoes

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.39 Residual hazards caused by component breakage during operation, maintenance or repair

For example, components may break unexpectedly due to wear, friction or abrasion, which can be potentially dangerous.

Measures to Avoid Residual Hazards

Recommended PPE

· Check the machine tool regularly.

· Do not stay under heavy objects (workpieces, tools, etc.) or axes that are placed vertically or obliquely.

· Take appropriate measures to fix the vertical or obliquely placed axis.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.40 Residual hazards caused by thrown objects or sprayed liquids

The use of unsuitable tools, measuring tools or clamping devices for workpieces may lead to this residual hazard

Measures to Avoid Residual Hazards

Recommended PPE

· The machine operator must fulfill his duty of diligence and work with designate trained professionals and check the machine tool regularly.

· Safety shoes,

·  Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.41 Residual hazards caused by lack of maintenance work

Measures to Avoid Residual Hazards

Recommended PPE

· Observe the regulations in the operating manual.

· The machine operator must have the machine tool checked regularly.

· Safety shoes

· Protective clothing in accordance with EN 510 standard,

·  Goggles.

2.4.1.42 Residual hazards caused by incorrect positioning/installation of the machine

Defective foundations, electrical connections that do not comply with technical regulations, etc. may lead to the hazards.

Measures to Avoid Residual Hazards

Recommended PPE

·Observe the regulations in the operating manual.

· Operate the machine tool according to the regulations.

· Check the machine tool regularly.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.43 Residual hazards caused by accidentally or inadvertently being locked in the processing area

There exist risks of accidental closure of moving split guards (processing area doors) with protective locks for serviceable processing areas. In the event of a power failure or failure of the power supply used to trigger the safety switch, the processing area door will be locked. The trapped person can only use an emergency unlocking device to open the moving split guard (processing area door) with protective lock. The trapped person may be panic.

Measures to Avoid Residual Hazards

Recommended PPE

· Conduct personnel training.

· Check regularly whether the emergency unlocking device functions normally.

· Safety shoes,

· Protective clothing in accordance with EN 510 standard,

· Goggles.

2.4.1.44 Residual hazards caused by power supply interruptions

If the power supply stops, the action of the electronic control goes out of control, which may cause the machine tool to stop or the gearing to run on inertia and out of control. Relevant parts are, for example, the work spindle, the supply pump and the pallet changer/workpiece changer.

The electric drive system for shutdown is out of control when the power supply is stopped.

Uncontrolled power supply interruptions may lead to hazards of death or serious injuries.

  • Only enter the processing room until the work spindle or workpiece has come to a complete stop.
  • Never attempt to brake the work spindle or workpiece supply device by hand.
  • The supply pump is not accessible until the machine tool is stopped.
  • The pallet changer/workpiece changer should be operated to the reference position before starting maintenance work.
  • Disconnect the machine tool from the power supply on the power-cutting device when perform all maintenance work on or near electronically controlled parts and padlock the device.

Thank you for your time.