AS 4024-1 Safeguarding of

Machinery

Background, content and

implications.
 AS 4024-1 Safeguarding of
Machinery

¾Background Issues
¾International Standards
¾Timeliness
¾Format
¾Scope/Application
 AS 4024-1 Safeguarding of Machinery
European Hierarchy
EN 292
A Safety of machines
EN 1050
Risk Assessment

EN 954-1 EN 60204-1
B Safety-rel. Pts. of control El. Equipm. of mach.
EN 574 EN 418 EN 61496
Two-hand control Emergency-stop Light curtains,...

C EN 692/693
Mech. & hydr. presses
EN 201
Inj. moulding machines
EN 775
Industrial robots
AS 4024-1 Safeguarding of Machinery

¾The changes
¾First – A new name:
“Safety of Machinery, Plant and Equipment”
¾Second – Some deletions
– Section 4 Pictorial illustration of Hazards
– Section 7 Selection of Safeguards
– Section 10 Circuit schematics & Table 10.2 -
Interlock Categories
– Section 15 Safework Procedures
– Appendix G Selection of Interlock Categories
AS 4024-1 Safeguarding of Machinery

¾Third – a hierarchical structure

¾PART ONE Compulsory

¾PART TWO Optional

¾PART THREE Machine specific

AS 4024-1 Safeguarding of Machinery

¾ Part One – a compilation of Type A and some

Type B Standards

¾ Design Parameters

¾ Safety Principles

¾ Ergonomics
AS 4024-1 Safeguarding of Machinery

PART TWO - purchased as required (DIY) - eg:

¾ EN 574 Two hand control devices

¾ EN 12198 Risks arising from radiation.
¾ EN 1837 Integral lighting of machines
¾ IEC 61496 Electrosensitive Protective equip.
¾ EN 999 Approach speeds of parts of body
¾ ISO 14159 Hygiene reqt’s for design of m/c’s
¾ EN 60825 Guarding of laser processing m/c’s
AS 4024-1 Safeguarding of Machinery
PART THREE - purchased as required (DIY) - eg:

¾ EN 201 Injection Moulding machines

¾ EN 415 Packaging Machines
¾ EN 422 Blow Moulding machines
¾ EN 692 Mechanical presses (AS 1219)
¾ EN 693 Hydraulic presses (AS 1219)
¾ EN 775 Industrial robots (AS 2939) etc

¾ Note! All machine specific parts refer to PART ONE of

the Standard for fundamental design elements .
AS 4024-1 Safeguarding of Machinery

• Brief summary of detail:

– EN 1070 Terminology
– Definitions – Common tri-lingual terms

– ISO 12100.1 Basic terminology and

methodology
– Description of Hazard and Risk and Risk Control
Principles – Hierarchical structure.

– ISO 12100.2 Technical principles

– Descriptive design application of Part 1
AS 4024-1 Safeguarding of Machinery
– ISO 14121 Principles for Risk
Assessment
– Development of the risk assessment principles
introduced in ISO 12100 – 1

– EN 626.1 Reduction of risks from

hazardous substances emitted
by machinery
– Expansion of principles from ISO 12100 – 1

– EN 614.1 Ergonomic design principles.

– General principles related to MSD and broader
ergonomics e.g. displays & signals, actuators
AS 4024-1 Safeguarding of Machinery

– ISO 13849.1 Safety related parts of

control systems – design
– Selection of categories
– Fault consideration, fault exclusion
– Validation – validation plan and report
– Maintenance

– ISO 13849.2 Safety related parts of

control systems – validation
– Validation by analysis – FTA, ETA, FMEA,
– Validation by testing
– Validation tools – informative tables of faults and principles for
fault exclusion.
AS 4024-1 Safeguarding of Machinery
AS 4024-1 Safeguarding of Machinery

– ISO 14120 Design and const. of fixed and

moveable guards
– ISO 14119 Selection of interlocking devices
– ISO 14118 Prevention of unexpected start-up
– ISO 13850 Emergency stops

– Generally in line with the current standard. ISO 14118 is a little

more extensive and the specific detail in the current standard
relating to lanyard E-stop devices is not included in ISO 13850
AS 4024-1 Safeguarding of Machinery

– ISO 7250 Basic human body

measurements
– EN 547.1 Dimensions required for whole
body access into machinery
– EN 547.2 Dimensions for access openings
– EN 547.3 Anthropometric data

• All new material related to the need to access machinery,

plant and equipment as opposed to the following section
which deals with prevention of access.
AS 4024-1 Safeguarding of Machinery

– ISO 13852 Safety distances – upper

limbs
– ISO 13853 Safety distances – lower limbs
– ISO 13854 Minimum gaps to prevent
crushing

– Virtually identical material to current standard. Minor

variations in safety distances – conservative. Safety
distances based on Anglo/Saxon (middle European)
data, lower end uses 5th percentile 14 yr old female.
AS 4024-1 Safeguarding of Machinery

– EN 894.1 Displays and control actuators –

principles for human interaction
– New material covering ergonomic principles

– ISO 9355.2 Displays – design

– New material – visual, digital, analogue and tactile
displays – use of scales, pointers, perception,
discrimination

– EN 894.3 Control actuators – design

– New material – design and shape of manually
operated actuators relative to shape, transmission of
force, posture
AS 4024-1 Safeguarding of Machinery

– IEC 61310.1 Req’ts for visual, auditory and

tactile signals
– IEC 61310.2 Visual, auditory and tactile signals -
marking
– IEC 61310.3 Location and operation of actuators

– ISO 11429 Auditory and visual danger and

information signals.
– New material covering ergonomic principles – brightness,
contrast, colour, symbols, marking e.g specification plates,
rated values, correlation between actuation and final effect,
quality and distinction for purpose in auditory and visual
signals
AS 4024-1 Safeguarding of Machinery

• Potential Impacts
– Incorporation of ISO 13849.1 & 2 – Fault
exclusion, Functional Spec. & Validation
– Emphasis on displays, control actuators, and
visual, auditory and tactile signals.
– Users familiar with current standard will need
to spend some time in reorientation regards
content and expression
AS 4024-1 Safeguarding of Machinery

Thankyou
and

(make sure you review the Draft)