II. Details of the machine Internal system designation

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1 FSS 5, Attachment 1: Issue Date: Revision: 02 Job No. I. Type of Initial Repeat II. Details of the machine Internal system designation Designation Type Serial No. Year of construction Manufacturer/ supplier Location III. Scope of the inspection: All safety related functions and components must satisfy the requirements of the FSS 5 General Machine Safety Checklist and local relevant standards as a minimum requirement. NOTE: If machines are used in conjunction with other machines or equipment, a supplementary safety check must be carried out with reference to the checklist for coordinated machinery and equipment (Attachment 2). IV. Results of the inspection The machine/apparatus/system complies with the current FSS 5 checklist. The machine / system does not meet every requirement of the FSS 5 checklist. However, the machine / system may be used as the functions concerned are not critical in terms of safety. The machine/apparatus/system does not comply with the current FSS 5 checklist. The machine/apparatus/system will be upgraded. Initial cost estimate: Date: Renewed inspection required! The machine/apparatus/system will be removed from service on at the latest. Technical and/or organizational measures as laid down in the appendix will be implemented to ensure safe operation up to this date. Date of next scheduled inspection: V. Distribution list Person responsible for corrective action and improvements: Person responsible for documentation, filing and archiving: VI. conducted by: Mechanical part Electrical part Production Other Name Date Signature Page: 1 of 11

2 Irrelevant Not 1 Documentation / Orderliness 1.1 Does the machine have a rating plate / name plate? (details of the manufacturer, type, year of construction, etc.) 1.2 Is the documentation available at the machine? Refer to the machinery directive for a list of the documents that make up an expedient complete set of documentation Is an up-to-date version of the operating manual available in the native language of the country where the machine is used? Does the operating manual contain information concerning the residual risks associated with the machine? Are documented procedures available for the machine / process? Does the operating manual contain all of the information on safety that is required for operation and maintenance? Do they include measures against residual risks? Has a hazard assessment been carried out in accordance with FSS 10? Is a electrical circuit diagram available and is it up to date? Is a hydraulic diagram available and is it up to date? Is a pneumatic diagram available and is it up to date? 1.3 Does the machine bear the necessary safety and hazard warning signs? 1.4 Is the maximum sound level given in the operating manual and is this less than 80 db? If the sound level cannot be reduced to less than 80 db, supplementary measures must be taken (PPE, enclosure etc.). 1.5 Does the maintenance schedule give details of when safety related parts / components of the machine are to be inspected and the ways in which they are to be checked and maintained? 1.6 Does the maintenance plan take the operating conditions into consideration? (3 shifts etc.) 1.7 For machines used in Europe that were brought into circulation after 1995: Is an EC declaration of conformity available for the machine / system as a whole? Provided by the manufacturer Provided by the owner Page: 2 of 11

3 Irrelevant Not 2 Intended purpose of machine and equipment Visual inspection with reference to the instructions issued by the manufacturer 2.1 Is the machine or equipment solely used for the purpose for which it was designed and built by the manufacturer? (speed, material, tools, etc.) 2.2 Is the machine or equipment solely operated under the ambient conditions specified by the manufacturer? (temperature, humidity, altitude, etc.) 2.3 Is the machine connected to the energy levels specified by the manufacturer? (maximum pressure, electrical fuses, voltage, nominal frequency, etc.) 3 Lighting Visual inspection 3.1 Are the working zones adequately illuminated for the work performed in them? 3.2 Are the maintenance and service areas adequately illuminated for the work performed in them? Safe conditions must be achieved in accordance with local legislation. 4 Anchorage of the machine(s) / equipment and parts Visual inspection with reference to the instructions issued by the manufacturer 4.1 Has the machine been anchored / secured in accordance with the manufacturer's instructions and have the normal loads and stresses, which may be encountered in operational service, been taken into consideration? 4.2 Have all machine parts, components, guards and safety devices been fitted properly and securely? Also refer to section 9 on "safety bolts" 5 Alarm facilities Visual inspection and function test 5.1 Can the operator see into the hazardous zone from the operator's station? Page: 3 of 11

4 Irrelevant Not 5.2 If the operator is unable to see into the hazardous zone(s): has a system been installed that detects the presence of a person in the hazardous zone, or does the monitoring system issue an acoustic or visual alarm signal before the machine is started? 5.3 Are the visual warning signals easily seen and can they be distinguished from other warning signals? 5.4 Are the acoustic warning signals easily heard and can they be distinguished from other warning signals?. 5.5 Does an employee have sufficient time to leave the hazardous zone prior to startup? The escape time must be calculated in such a way as to ensure that the worker can reach the nearest stop / emergency stop button safely 6 Command facilities 6.1 Are the command facilities clearly recognizable as such and are their functions easily distinguishable? e.g.: - emergency stop impact button - control panel switches etc. - master switch 6.2 Are the command facilities unambiguously and durably labeled in the native language of the country of use? 6.3 Can the command facilities be operated inadvertently? 6.4 If the machine/system can be operated from different operating stations, has a pre-selection facility been installed for the operating station? 6.5 Are the command facilities fitted outside the hazardous zone(s) and can they be operated safely? 6.6 Are the control facilities protected against damage? 6.7 Is the emergency stop device easily accessible and is it colored RED against a YELLOW background? Page: 4 of 11

5 Machine / system designation: Irrelevant Not 7 Control facilities (electrical, pneumatic and hydraulic) 7.1 Starting the machine / system Function test in accordance with the operating manual Are the elements required to START the machine / system protected to prevent them being operated inadvertently? Is it only possible to control an essential operating state by deliberately operating the command facilities provided for this purpose? 7.2 Shutting the machine / system down Function test in accordance with the operating manual Is there a master switch to turn the complete machine on and off? For example: the machine does not start when an alarm or emergency stop button is reset! Can the master switch be secured to prevent unauthorized or inadvertent operation? Are command facilities to deactivate potentially hazardous movements / parts or the machine as a whole provided at every workplace? When the system is shut down, does this result in the machine assuming a safe state? Is the machine SHUTDOWN command down given precedence over the command to START the machine? Are easily accessible and clearly recognizable facilities provided to disconnect the machine from every single energy source? Is it possible to disconnect the electrical power supply? Refer to FSS Is it possible to disconnect the pneumatic energy supply? Refer to FSS Is it possible to disconnect the hydraulic energy supply? Refer to FSS Is it possible to disconnect the steam energy supply? Refer to FSS Is it possible to disconnect all other energy supplies? Refer to FSS After disconnecting a source of energy, do no further hazards exist, e.g. movements triggered by stored energy or letting go of lifted loads? Page: 5 of 11

6 Irrelevant Not 8 Guards and safety devices (electrical, pneumatic and hydraulic) 8.1 Have all cables / hoses / pipes been fitted properly and are they protected against damage? 8.2 Do the safety devices and emergency stop facilities operate reliably? A safety device failure must lead to the machine coming to a standstill! It must not give rise to any potentially hazardous movements. 8.3 Are the installed safety functions in accordance with the hazard-specific and riskspecific safety level (category / PF-Level / SIL-Level)? 8.4 Have the emergency stop facilities been designed as pushbuttons? Emergency stop actuating components may also take the form of bars at waist height, cable-operated switches etc. as and when necessary. Have the emergency stop facilities been designed as red palm-size pushbuttons or mushroom-head pushbuttons with a yellow background? Do the emergency stop facilities enable a local reset? Have the emergency stop actuating elements been designed as latching components (it must not be possible to reset by simply removing the load from the actuating component)? 8.5 Does the emergency stop facility transpose potentially hazardous movements or processes into a safe state as quickly as possible? 8.6 After an emergency stop or safety stop, can the machine only be restarted by a command from the operator? Refer to EN 954 / ISO EN / ISO EN Refer to EN ISO / IEC Risk of mechanical contact with moving plant components Visual inspection and function test in accordance with the operating manual 9.1 Are safety devices or safeguards in place that prevent access to hazardous zones or bring potentially hazardous movements to a standstill before personnel can reach the hazardous zone? 9.2 Are all guards and safety devices in the right places and are they in good working order? 9.3 Have the safety devices or guards been designed and built as rugged elements? Page: 6 of 11

7 Machine / system designation: Irrelevant Not 9.4 Do the safety devices or safeguards not give rise to any additional hazards? 9.5 Are all guards and safety devices secured with safety bolts? (safety devices, guards, safety switches, light barriers, etc.) 9.6 Is sufficient clearance maintained between the safety devices or safeguards and the hazardous zone? 9.7 Do the guards and/or safety mechanisms obstruct the necessary observation of the processes? Are there no sharp or uneven edges or protruding components? Purpose of the safety bolts: it must not be possible to remove guards or safety devices without using special tools. Are all safety clearances in accordance with the requirements of the EN 294 / OSHA standards with respect to opening safeguards or ANSI B 11? 9.8 Fixed guards and safety devices Refer to EN Have all fixed guards / safety devices been fitted in their designated places properly, with at least 2 safety bolts? (at least 2 safety bolts are required for each fixed guard / safety device) Are safety switches in place, which monitor the fixed safety devices that are opened more than once a year? Purpose of the safety bolts: it must not be possible to remove guards or safety devices without using special tools. 9.9 Moving guards and safety devices Refer to EN Are all moving safety devices monitored by safety facilities (e.g. safety switches), and does the safety monitoring loop take place in the necessary safety category? Are the safety doors which allow access to moving parts with stopping time secured by means of interlocking elements? Have measures been taken to prevent manipulation of the fitted guards and safety devices? Refer to EN 954 / ISO EN / IEC Page: 7 of 11

8 Irrelevant Not Are the edges of powered guards and safety devices protected by safety shutdown facilities? (safety contact bars) Have measures been taken to prevent vertically moving safety devices falling? The maximum force may be limited to 150 N as an alternative measure, but attention must be given to maintenance. EN Other safeguarding methods (e.g. light barriers, laser scanners, two-hand triggering facilities, pressuresensitive mats) Have the safety clearance, stopping time and stopping distance been defined? Is the information concerning safety clearance, stopping time and stopping distance given on the machine or in the operating manual? Are the safety clearance, stopping time and stopping distance in accordance with the manufacturer's specifications and/or EN 999? (measurements) Does the safety device remain active until the contact gap is less than 4 mm wide? Have the guards and safety devices been installed in such a way that it is impossible for a person to stand behind them? (maximum clearance less than 75 mm) If a two-hand triggering facility has been installed, is the permitted interval between pressing the two buttons no longer than 0.5 seconds? If a two-hand triggering facility has been installed, has the workplace been designed as a one man workplace? Refer to EN 999. Positioning protective equipment with respect to approach speeds of parts of the human body. Refer to EN 574 The monitoring system may only exclude the space actually occupied by the operator's body. Guards and safety devices must be provided for all other parts of the machine (front, side and rear)! Page: 8 of 11

9 Irrelevant Not 10 Facilities that prevent parts falling Applies where there are protective facilities / loads, which are raised by means of electric / hydraulic / pneumatic drives Have facilities been installed that prevent machine components falling or dropping? Hydraulic / pneumatic check valves or mechanical fall arresters. 11 Hot and cold parts Visual inspection 11.1 Have appropriate technical safety measures been taken to reliably prevent personnel coming into contact with very hot or very cold parts? 11.2 Where this is not possible, is contact prevented by handling equipment or personal protective equipment worn by the personnel? 11.3 Are the hot and cold surfaces marked accordingly? 12 Hazards caused by gas, vapor, mist, liquid and dust Visual inspection, working zone analysis, test record 12.1 Have safeguards / extraction facilities been provided to restrain and/or to discharge such emissions at source? 13 Hazards caused by breakage, bursting or shattering Visual inspection, checking with reference to the operating manual 13.1 Have protective measures been implemented to protect personnel from hazards caused by machine parts breaking, bursting and shattering? 13.2 Have all parts of the machine been fitted properly and securely and are all cables, pipes, leads and hoses protected and secured? (e.g. by hydraulic, pneumatic and thermal means) Page: 9 of 11

10 Irrelevant Not 14 Performing such production activities as setting, loading and unloading Visual inspection and function test, checking with reference to the operating manual, the instructions for use and the work instructions 14.1 Do personnel have safe access to all of the areas required to perform the work? 14.2 Is it safe to remain in these areas while performing the work? 15 Maintenance, service, cleaning and debugging work Checking with reference to the operating manual and the manufacturer's instructions Do personnel have safe access to all of the areas required to perform the work? 15.2 Can maintenance, service, cleaning and debugging work be carried out without removing the guards and safety devices? 15.3 Can all work associated with maintenance, service, cleaning and debugging be performed with the machine at a complete standstill? 15.4 Are protective measures implemented when work has to be performed under raised loads? 15.5 Are there any potential hazards associated with stored / residual energy? (e.g. pressure vessels, hydraulic accumulators, electrical capacitors) 15.6 Are facilities provided that offer a means of releasing stored energy and deenergizing the system, and are these facilities marked accordingly? 15.7 Are warning notices provided where it is not possible to release energy that is stored in certain systems? (on the machine and in the operating manual) 15.8 Are the areas in which stored energy cannot be released completely marked in an unambiguous manner? 15.9 Have checking cycles been defined for the guards and safety devices and are these observed? (light barriers / emergency stop facilities) Have work instructions been drawn up to stipulate the way in which the machine is to be handed over for maintenance and repair purposes? Please use the LOCKOUT procedure for this machine / equipment when performing the safety check! (FSS 1 requirements) Page: 10 of 11

11 Irrelevant Not 16 Protection against electric shock and indirect contact with electricity Visual inspection 16.1 Do the machine and control facilities have protective equipment that prevents electric shock? (e.g. proper safety class for enclosure, cable insulation, operator control elements etc.) 16.2 Does the machinery / electrical system have protective equipment that prevents personnel coming into indirect contact with electric current in the event of an insulation fault? (e.g. proper grounding, correctly dimensioned ground conductor, grounding of the machine housing, insulation monitoring etc.) IEC Risk of personnel slipping, tripping or falling (in connection with machines) Visual inspection 17.1 Have measures been taken to ensure that personnel cannot slip, trip or fall? 17.2 Have suitable catwalks, platforms or intermediate platforms been installed to ensure safe access to the equipment? For maintenance, cleaning, loading with raw materials or removing the product at parts of the plant, which cannot be reached from the floor, for example? 18 Ergonomics 18.1 Are the controller and operator control elements easily accessible? 18.2 Are the displays, indicators and measuring instruments required for operation easy to read? 18.3 Are maintenance panels, manholes, inspection doors etc. accessible? Page: 11 of 11

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