AZ Automotive Weld Tooling & Assembly Equipment Standards Revision 1.3 29Sep2004

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Deviations that improve safety, quality, or cost ARE ALWAYS WELCOME.

SECTION 16

16. Safety

16.1. General Requirements

16.1.1.

The design, construction, safety, and shipment of all tooling, equipment, controls, etc., shall conform to the latest version of all applicable AZ Standards located in Section 1, Items 1.1.1 and 1.1.2.

16.1.2.

Milestone	Activity	Procedure	Participants
Simultaneous Engineering	Process Concept Review	Review the process for general safety concerns and explore process alternatives. Preliminary plant layouts will be reviewed.	Corporate Safety AME Tool Process Process Supervisor OEM/Supplier Corporate Ergonomics

45% Safety Design Review	System Design Safety & Process Review	Review the design for safety concerns and explore design alternatives. This will include a final system review and sign-off on the **Tool and Equipment Safety Buy-off Status* form for tooling and equipment. All equipment and facilities shall be shown at this time including Robcad simulation, elevations, views and sections of all operator load stations. All safety concerns will be documented at this time.	Corporate Safety Plant Joint Safety Committee AME Tool Process Plant Tool Process Process Supervisor Control Des. Coord. Mech. Des. Coord. OEM/Supplier Technician Tool Follow-up Corporate Ergonomics

75% Safety & Process Build Review	Build Review	Review equipment at the OEM during build to verify conformance to the approved design. Any additional safety concerns will be discussed at this time. A punch list will be developed by the technician and maintained by the OEM.	Corporate Safety Plant Joint Safety Committee Technician OEM/Supplier Tool Follow-up AME Tool Process
100% Safety & Process Build Review	Tool & Equipment Buy-off	Review the Tool/System and verify the Tool and Equipment Safety Buy-off Status form, and that the punch list is complete	Corporate Safety Plant Joint Safety Committee AME Tool Process Plant Tool Process Technician OEM/Supplier Tool Follow-up Mech. Des. Coord.
Plant Install Complete	Plant Buy-off	Review the tool/System as installed at the user plant.	Plant Joint Safety Committee Technician

*Tool and Equipment Safety Buy-off Status form

16.1.3.

If required, a deviation form and deviation flow chart will be available from an AZ Controls or Mechanical Design Coordinator.

16.1.4.

Operation/Maintenance Service manuals shall be provided for each system (See Section 1, Item 1.1.5).

16.1.5.

All processed Operator workstations shall meet the requirements of Section 15 (Ergonomics Guidelines) and all consensus and mandatory standards.

16.1.6.

A Design Safety Buy-off is required at the 45% milestone (See Section 1, Item1.2.8).

16.2. Drawings

16.2.1.

All robot spaces shall be shown. The space shall define the maximum range of motion of all moving elements of the robot and manipulated tooling and product. The required spaces are:

A.Restricted space (hard-stopped) B.Work space (plus tip dress, service position etc... C.Restricted space (plus 18")

16.2.2.

Balcony Drawings - The Supplier shall provide a design layout of each balcony showing all equipment including the location of all stairways and/or ladders.

The layout shall have AZ Launch Technician approval prior to installation of equipment on balconies.

16.2.3.

Installation Drawing - The Supplier shall provide an installation drawing (scale: 1/16 inch equals 1 inch) for each tool. This drawing may be a part of a complete system layout.

This installation drawing shall include layout of press, fixture and all related equipment, including balcony, service drops, shuttles, sequence panels (with WD numbers), weld control panels, I/O panels, power and interface panels, consoles, hydraulic units, safety fencing, light screens, safety mats, emergency stop push-buttons, cycle stop push-buttons, cycle start push-buttons, and adjacent fixture where applicable. The drawing must include all dimensions necessary to permit the installation of equipment, as well as tooling.

This Installation drawing shall include a plan view and an elevation view. Additional elevation views and/or sections shall be provided as required.

Installation drawing must show operator and head clearance.

Completed Installation Drawings shall be submitted to AZ Launch Group personnel two (2) weeks prior to shipment of the tooling to the unit plant(s).

16.3. Mechanical

16.3.1.

Mechanical Design

16.3.1.1

Safety gates and fencing shall conform to NAAMS North American Automotive Metric Standards (formerly ACRGS). Use non-adjustable perimeter fence posts. (Refer to Website: http://www.a-sp.org)

16.3.1.2

Safety gates and fencing shall be provided around the perimeter of the line and/or machine. The safety fence shall be designed to provide the required safety utilizing a minimum of floor space. The location of all safety gates and fencing shall be approved by a AZ Launch Technician, Design Coordinator, Unit Plant Representative, and Corporate Safety Representative.

16.3.1.3

Adequate protective safety devices, including but not limited to guards, shielding, light screens, and safety mats, shall be provided for protection of all personnel and equipment subject to an AZ Safety Representative approval.

16.3.1.4

Provide safety lockout/energy control graphics (See Safety PlaqCard 16-1.0).

16.3.1.5

Safety pins, jumper plugs and receptacles shall be provided to lockout each movement at the extreme of its stroke in each direction for all long-stroke motions (i.e. rockers, lifters, pivots, tip-ups, rotates, hold-downs, slides, transfer system movements, etc.). Pins and plugs must be accessible without exposure to any moving part or unit. Long-stroke shall be considered any motion in which the actuator or any portion of the driven member moves six (6) inches or more.

16.3.1.6

The safety pins and plugs shall be accessible from floor level and without physical entry into danger zone.

16.3.1.7

The safety pins shall be adequately sized to restrain the load under drive power.

16.3.1.8

The safety pins shall have the capability of being pad-locked.

16.3.1.9

Do not support the weight of a close-coupled type weld gun using only the tapped holes in the transformer. A steel safety strap must be provided. Strap must be easily removed for weld gun removal.

16.3.1.10

Safety gates shall conform to the following:

Gate switch installation shall allow personnel exit from within gated area.
Gate switch shall be mounted so the key cannot be reinserted from within gated area.
Gate switch key shall require manual insertion; automatic closure of the key to the gate switch is not permitted.
All gate switches shall be yellow in color.

16.3.1.11

All auto load applications must include complete manual back-up capabilities including all safety requirements.

16.3.1.12

Mechanical restraining devices shall be applied to long-stroke motions (See 16.3.1.5) where:

A. Uncontrolled motion (drifting, falling) can create a machine out-of-location condition.

B. Air leakage can result in uncontrolled motion hazardous to equipment or personnel.

Such devices shall be capable of restraining the load at any point in its travel and shall be applied in a fail-to-safe manner.

16.3.1.13

All equipment that has die type punches shall have a means of removing the slugs from the punching operation; either by trough, conveyor, or removable pan or tray. Automatic overflow shall be provided in such a manner as to not impede or endanger the operation of the equipment or the operator.

16.3.1.14

All tooling units except clamps and locating pins held against the force of gravity by pneumatic or hydraulic power shall be retained mechanically.

16.3.1.15

Clamping applications where parts-in-process are retained against gravity and inertial forces (i.e. robot end-effectors, overhead lifters, etc.) shall be provided with FAIL-SAFE features to insure maintained control of the product. These features shall include, but are not limited to:

A. Adequate nesting and trapping to insure product is positively mechanically secured.

B. Use of clamps or equivalent mechanisms to insure product retention in the event of a loss of power.

C. Redundancies where loss of power may result in a primary device becoming ineffective (i.e. clamps to back-up suction cups).

16.3.2

Mechanical Assist Device Guidelines

16.3.2.1

Paint dot (and safety wire on arms) all torqued bolted connections after torque verification. (Use bright florescent orange).

16.3.2.2

Safety cable ALL single supported / bolted connections, as well as both ends of all runways.

16.3.2.3

All trolleys shall be safety-chained or cabled to bridge rails, using standard, commercially available, materials.

16.3.2.4

All pivot mechanisms shall be fail-safe. All pivots shall be protected by a secondary safety device or owner-approved alternate.

16.3.2.5

Each specification shall include the Ergonomic Guideline and Checklist. (See Section 15.0 Item 15.5.2)

16.3.2.6

On moving line operations an end-of-travel design requirement shall be built into every original trolley rail and support steel design. (Sound warning 3 feet beyond work cell, and stop conveyor 3 feet after that).

16.3.2.7

Suppliers/Fabricators shall provide a fixed orifice for pneumatically operated mechanical assist mechanisms to prevent free gravity fall in the event of an air loss. The rate of fall shall not exceed the rate of normal descent.

16.3.2.8

Drop stops shall be added to any production assist hoist having a vertical motion in excess of twelve inches (12"), and where the static load is 20 pounds or grater.

16.3.3

Mechanical Construction

16.3.3.1

All rough and sharp edges shall be broken except for PLP's.

16.3.3.2

Use self-locking fasteners (nylon or plastic patch thread locking elements) with flat washers (no washers on counter bored fasteners or machined surfaces) to fasten all tooling components. (See Illustration 3-25.1) for American standard torque requirements and NAAMS Assembly and Fabrication Book (Section F-pg. F-2) for metric torque requirements.

Note: For tooling constructed for aluminum and using helicoil inserts torque requirements should be 75% of torque values shown in the NAAMS Assembly and Fabrication Book (this is the recommendation of the fastener manufacturers.)

Fasteners must be safety wired when:

A. Damage may be caused to the tooling in the event that a fastener fails and the screw head falls into the tooling (Ex. Gear racks, hemming dies, overhead details etc.)

B. The screw head would fall onto an operator load station if the fastener failed.

C. Used to attach end effectors (including weld guns) to robots.

D. See Illustration 3.25.0 for safety wiring.

16.4. Electrical

16.4.1.

Electrical General

16.4.1.2

Each safety gate shall be wired into the magnetics. And, in addition, wired to a discrete input and have a visual indicator to determine which safety gate is open.

16.4.1.3

Whenever automatic load and/or unload equipment is intended for use with a machine the Supplier shall provide:

A. Positive fail-safe interlocks for the safety of the machine and personnel.

B. Adequate safety devices to permit safe manual load or unload of the station where loaders of other automated equipment can travel in a load or unload station.

C. Manual back-up capability for all automatic load/unload stations. This shall include all safety related items required to manually back-up the process

16.4.1.4

Each safety pin shall be hardwired. And, in addition, wired to a discrete input and have a visual indicator to determine which safety pin is open.

16.4.1.5

The "Fully Engaged" and "Fully Disengaged" position of all Safety Pins that employ remote actuating devices shall be monitored by sensors.

16.4.1.6

Stations where parts are loaded or unloaded by automation shall include a "Part Out Of Position" fault indication. This fault indication will require a reset before the automation is allowed to continue.

16.4.1.7

All Programmable Logic Controllers connected to multiple system networks that can permit remote program changes must have hardwired circuitry to prevent unintended or unexpected motion when personnel are exposed to any hazardous motion.

16.4.2

Electrical Design

16.4.2.1

Each output driven device (i.e. solenoid, relay, motor starter etc.) that generates movement shall be controlled by (2) isolated outputs, (1) on each side of the coil.

16.4.2.2

Each output driven device (i.e. solenoid, relay, motor starter etc.) shall be independently controlled by one set of outputs.

16.4.2.3

Shuttle and station controls must include a cycle stop and cycle enable circuit, which will provide a safe hold and then continue in cycle without repositioning components. Safety circuits (emergency stop, cycle stop) are designed to the latest AZ standard. The line shall also be able to return to a full automatic mode from an emergency stop within two (2) minutes of initiating a restart sequence.

16.4.2.4

Supplier shall provide the following for each processed manual operator station:

A. Emergency Stop pushbutton (maintained & lockable).

B. Cycle Stop pushbutton (maintained & lockable) if the design has Cycle Stop circuitry.

C. Two (2) hand run button assemblies when presence-sensing devices are not employed.

D. A single run button assembly when guarded by presence sensing devices.

The controls shall be located to optimize ergonomics. All locations shall be approved by an AZ Launch Technician.

16.4.2.5

Supplier shall provide approved safety light screens with clear to enter light and cycle initiate button at all manual process locations on:

A. Multi-station lines.

B. Multi-station work cells.

C. Simflex work cells.

16.4.2.6

The supplier shall provide a Cycle Stop and Emergency Stop assembly or pendant for each station of multi-station line/system, on both sides of the line; and at each fixture of a simflex where pushbutton boxes or HMI enclosures cannot be utilized. These assemblies shall include an indicator and any required zone reset devices .

16.4.2.7

The de-energizing of any Safety Pin circuit shall prohibit control power (MR) to only the power and interface panel to which the plug is wired.

16.4.2.8

All Safety pin jumper plugs, receptacles, and gate access sensing devices shall be Yellow.

16.4.3

Construction/Installation

16.4.3.1

This information is intended for the use of personnel involved in maintaining, inspecting or installing electrical equipment. This information is not intended to supersede any local, State or Federal codes and regulations. Detailed information on each specific category described can be found in the National Electric Code. Equipment manufacturer's specifications shall also be consulted for special installations.

16.4.3.2

Live parts of electrical equipment shall be guarded against accidental contact by an approved enclosure, vault, screen or fence, minimum eight feet (8') high, or by elevating on a platform a minimum of eight feet (8') above the working surface.

16.4.3.3

The entrance to all rooms and enclosures containing exposed live parts or conductors rated over 600 volts shall be kept locked at all times.

16.4.3.4

Entrances to locations containing exposed live parts shall be provided with warning signs forbidding unqualified personnel to enter.

16.4.3.5

Where live parts of electrical equipment operating at over 150 volts to ground are guarded against accident contact by means of location only, and where adjustments or attendance may be necessary during the operation of the equipment, insulating mats shall be provided so that the operator is not exposed to live parts unless standing on the mat.

16.4.3.6

Conductors rated more than 300 volts shall be installed a minimum of three feet (3') away from windows, doors, fire escapes, or similar locations.

16.4.3.7

Power cables connected to mobile machines shall be provided with a metallic enclosure to enclose the cable terminals.

16.4.3.8

Bare terminals of switches, transformers, or controllers shall be enclosed to prevent accidental contact by personnel with energized parts.

16.4.3.9

Fuses, circuit breakers and switches shall be located or shielded so that personnel will not be exposed or injured by their operation.

16.4.3.10

All Panel doors, junction boxes, junction box covers, and switch covers, shall be kept closed.

16.4.3.11

Conductors rated more than 300 volts, passing over roofs, and not installed in conduit shall require a minimum clearance of eight feet (8') from the highest point of the roof from which they pass.

16.4.3.12

Wiring primary power supplies such as busway, switchgear, etc., to distribution panels shall be enclosed in a wiring duct, rigid conduit, or flexible liquid tight conduit with suitable fittings.

16.4.3.13

Wiring from distribution panels to operating machinery not enclosed in conduit shall consist of a multi-conductor cord or cable designated for "hard usage" with no exposed connections.

16.4.3.14

Where flexible metallic conduit is used, it shall not exceed six feet (6') lengths and it shall not be less than one-half inch (1/2") in diameter.

16.4.3.15

Wiring routed in an open cable tray system shall be approved and rated for such applications.

16.4.3.16

Sufficient access and working space shall be provided and maintained around all electrical equipment to permit safe operation of such equipment. Clearances in front of electrical equipment shall not be less than thirty inches (30"). If live parts are enclosed, the distance shall be measured from the enclosure front. Where live parts are exposed, the working space in front of such equipment shall not be less than thirty-six inches (36"), measured from the exposed live part.

16.4.3.17

Work clearance shall not be required in back of assemblies with dead-front construction or where all connections and removable parts are accessible from other locations.

16.4.3.18

A minimum of one entrance, twenty-four inches (24") wide by six feet, six inches (6'6") high, shall be provided for access and entrance to the workspace for electrical equipment.

16.4.3.19

Headroom of working space about electrical equipment such as panels, motor control center, switchgear, etc., shall be six feet, three inches (6'3").

16.4.3.20

Illumination shall be provided around electrical equipment. Lighting fixtures shall be arranged so that personnel changing lamps or making repairs on the lighting circuit will not be endangered by exposed live parts.

16.4.3.21

All electrical equipment shall be provided with the means for complete isolation of power from the main power source for inspection and repair purposes.

16.4.3.22

Circuit breakers and switches shall be marked indicating "on" (closed) and "off" (open) positions, and shall be legibly marked-to indicate their purpose.

16.4.3.23

Equipment operating at 220 volts or higher shall be provided with a disconnecting means at the source of operation.

16.4.3.24

Where more than one piece of equipment is operated from the same circuit, each piece of equipment shall be provided with a disconnecting means. The disconnecting means shall be constructed enclosed, or located so as to avoid contact by employees with its live parts.

16.4.3.25

Where remote controls are used to apply power to a circuit, a selector switch shall be interlocked with the remote control and the local disconnecting device to assure power is provided only from one source at a time.

16.4.3.26

Portable plug-in equipment rated 220 volts or more shall be equipped with combination conductors having sealed-in start buttons and fused disconnects.

16.4.3.27

A circuit breaker or disconnect switch installed indoors shall be a metal clad unit or fire resistance cell mounted unit. Open mounting of circuit breakers is permitted only in existing installations and where only accessible to qualified personnel.

16.4.3.28

Wiring shall be installed in a rigid metal conduit to protect it from physical damage. Bare conductors, bus bars, or open runs of nonmetallic sheathed cable may be run exposed in locations that are accessible to qualified personnel only.

16.4.3.29

Wiring shall be located or guarded so as to protect it from physical damage. Conductors within seven feet (7') of the floor are considered to be exposed to physical damage.

16.4.3.30

Wires connecting portable equipment shall not be routed on the floor in length exceeding six feet (6') and shall not be run across aisles or other area where possible exposed to traffic.

16.4.3.31

Wires shall not be run through building walls but shall be run parallel to building structures.

16.4.3.32

Wiring shall not be installed in duct systems used to transport dust or flammable vapors.

16.4.3.33

Flexible cord or cable suspended from building structure shall be supported at lengths not exceeding four feet, -six inches (4'6") and shall not be exposed to sharp edges.

16.4.3.34

Warning labels indicating -DANGER - HIGH VOLTAGE- shall be attached on electrical equipment rated over 250 volts and shall be plainly visible even when the enclosure doors are open or removed.

16.4.3.35

The operating voltage of exposed live parts of electrical equipment shall be indicated by warning signs or visible markings on the equipment.

16.4.3.36

A warning sign shall be required on the disconnecting device of a panel if the panel interconnected to other equipment and remains energized from a source other than it's disconnecting device. The sign shall-be legible and shall read "WARNING YELLOW WIRING IS NOT DE-ENERGIZED BY ENCLOSURE DISCONNECT SWITCH" (ref. WD_TAGS)

16.4.3.37

Electrical equipment shall only be used when the manufacturer's name, trademark, or other means of identification of the manufacturer is permanently affixed to the equipment.

16.4.3.38

Each service, branch circuit, feeder, and disconnect shall be marked to indicate its purpose.

16.4.3.39

Equipment of the heat producing type shall be marked to indicate its purpose, class, group and operating temperature for which it is approved. The temperature rating shall not exceed the ignition temperature of the specific gas or vapor where such might exist. Markings shall be provided on electrical equipment giving voltage, current, wattage, or other ratings as necessary.

16.4.3.40

All non-current carrying parts of electrical equipment, including their associated fences, housing, enclosures and supporting structures shall be grounded, with the exception of equipment that is guarded by location and isolated from ground.

16.4.3.41

An A.C. system having a ground connection anywhere in the system shall have all equipment supplied by the system grounded and the grounding conductor routed with the phase conductors.

16.4.3.42

Portable and mobile equipment rated over 600 volts shall be supplied from a system having its neutral grounded. Exposed non-current carrying metal parts of portable and mobile equipment shall be connected by an equipment-grounding conductor to the point at which the system neutral is grounded.

16.4.4

Electrical Circuitry Hardware

16.4.4.1

All Emergency Stop and Cycle Stop circuits shall be hard wired.

16.4.4.2

All station level stop circuits shall be separately interlocked through dry relay contacts to effect system level stops.

16.4.4.3

Supplie r shall provide cycle stop circuitry for each fixture in a multi-station line, to accomplish the following:

A. De-energize automatic mode.

B. Remove power from shuttle drive actuators.

C. Place robots in safe hold (removing actuator drive power).

16.4.4.4

A software driven relay, "Software Cycle Stop" (SCSCR), shall be added into the hardwired Cycle Enable (CECR) circuit of all multi-station systems. This relay will provide a cycle stop feature.

16.4.4.5

All robot applications shall include a "Local Auto Enable" interlock.

16.4.4.6

Hardwired devices wired in a series string (i.e. Safety Gates, Safety Pins, Emergency Stops and Cycle Stop buttons) shall be independently monitored by PLC inputs to facilitate ease of maintenance. All devices in the string will be monitored by inputs including a contact of the relay. Logic will be written to validate their operation and if faulted disable the hardwired circuitry and display the appropriate fault message(s).

16.4.4.7

All auxiliary disconnects shall include a normally open contact which shall be wired to a PLC input. This input shall be used in the PLC logic to insure that NO motion will occur upon closure of a disconnect.

16.4.4.8

Lexan covers shall be provided over all exposed 480-volt connections to guard against accidental contact between personnel and high voltage. Such shields shall have the following characteristics:

A. Hinged shields secured by non-conductive wing nuts.

B. Mounted on stand off rods.

C. Appropriately sized access holes to facilitate testing.

16.4.5

Electrical Circuitry Software

16.4.5.1

When Multiple HMI’s (Human Machine Interface) are capable of having Manual control of the same tool/device the PLC logic shall conform to the following:

Initiation of Manual control of a station/tool from a HMI at one location shall prohibit control of that station/tool from any other location.

If the capability of Manual control of more than one station/tool resides in multiple HMI’s, initiation of Manual control of a specific station/tool from a HMI at one location shall not, under normal conditions, prohibit another HMI from controlling a different station/tool.

Release of Manual control from a HMI shall only be allowed at the location that originally acquired the Manual control of that tooling.

16.4.5.2

In applications where operators interface with robots, circuitry should be included to validate the operation of the robot base limit switches that indicate the robot is clear of the operator’s Work Zone.

16.4.6

Grounded Controls

16.4.6.1

Grounded control systems, when approved for use, shall be designed to:

Insure that the integrity of the grounded conductor (white, Neutral) is maintained at all times.

Monitor for faulted output devices.

Remove control power to actuator control circuits if a fault is detected.

Annunciate the faulted condition.

16.5. Light Screen Application Guidelines

Light Screen hardwired references (WD_REF01) and standard PLC logic is available from an AZ Controls Coordinator.

16.5.1.

This applies to tooling applications in assembly plants and assembly areas of stamping plants. To Outline the application criteria for the utilization of light screens in the guarding of all tooling, and establish guidelines to maximize a failsafe approach to the design and installation of light screens in hardwired and software circuits.

16.5.2.

Applications:

A. Work Zone guarding - Conditioning access to a work zone for the performance of an operation.

B. Perimeter guarding - Restrict access to open areas of automation that may be difficult to guard with physical barriers.

Violation of either application would neutralize any hazards and allow safe entry into an area or zone.

16.5.3.

Application Hardwired:

A. The light screen output which is low when the light screen is powered up and the light beam is not interrupted shall be wired directly to a PLC input.

B. The light screen output which is high when the light screen is powered up and the light beam is not interrupted shall be wired to a Light Screen Safe relay (LSSCR) and a contact of that relay will be wired to a PLC input.

C. On tooling without Cycle Stop circuitry both light screen outputs shall be wired directly to PLC inputs.

D. A Work Zone Safe relay is required to condition the circuit containing the Light Screen Safe contact to allow entry into a work zone.

E. A Perimeter light screen controlled relay shall be provided with adequate circuitry to restrict access into an area or zone.

F. Work Zone, and Perimeter light screen applications shall have a hardwired reset feature.

16.5.4.

Application Software:

A. The following logic circuits are required for ALL light screen applications.

1. Light Screen Violated

2. Light Screen Fault

3. Power Up/Rack Fault Safety Check

The following logic circuits are also required for Work Zone guarding applications.

1. Clear To Enter Set Up

2. Clear To Enter Globe Light

For systems that have Cycle Stop circuitry, light screen outputs shall be wired to I/O whose power is controlled solely by the disconnect.

16.5.5.

Additional Safety

Where a light screen is applied in a work zone guarding application, and the installation of physical guarding is not possible or practical to prevent access to adjacent hazardous areas, a perimeter ("Secondary Presence Sensing") device shall be applied to guard against intrusion beyond the work area. This device may be a light screen or safety mat and if violated will have the same effect as the Perimeter guarding described within this document.

Where exceptional hazard exists the light screen circuits shall condition the Manual operation of the hazardous element, as well as, the Automatic mode. This requirement will be determined on an individual basis.

16.5.6.

Effects of Work Zone Light Screen Violations

A. If a violation occurs during normal station sequence (i.e. clamping) the sequence will be stopped resulting in the following:

1. Stop all motion.

2. Remove closing pressure on clamps.

Reset of this circuit will only require the operator to depress the cycle initiate palm button.

B. If a violation occurs when the robot and the operator are in the same work envelope the sequence of the work zone will be stopped. Functions that are outside of the work zone and do not present a hazard may continue to sequence. This violation will result in the following:

1. Stop all motion.

2. Remove closing pressure on clamps.

3. Remove drive power of the robot.

Reset of this circuit will only require the operator to depress the cycle initiate palm button.

C. If a violation occurs on a multi-station line while the transfer is in motion the transfer sequence will be stopped. Functions outside of the work zone that do not present a hazard may continue to sequence. This violation will result in the following:

1. Stop all motion

2. Remove driving force of the transfer.

Reset of this circuit will only require the operator to depress the cycle initiate palm button.

16.5.7

Perimeter Light Screen Violation

A. If a violation occurs, at any time, the entire system wills Cycle Stop.

Reset of this circuit will require the operator to reset the perimeter light screen circuit re-establish Cycle Enable, and re-establish mode.

16.5.8

Light Screen Safe Relay

A. Light screens have two contacts available for use, a normally open and a normally closed. The light screen contact that is held closed when the light beam is not interrupted is used to control the Light Screen Safe relay. This relay is required when the device used does not have adequate signals available to provide a positive signal to the hardwired circuitry and to the logic (via a "Hot Input"). The second contact shall also be wired to a "Hot Input". This input is used in the logic to verify the integrity of the circuit between the light screen and the panel to which it is wired.

16.5.9

Work Zone Safe Relay

A contact of "Work Zone Safe" (WZSCR) will be used to remove drive power from the transfer(s), or robot(s) that presents the hazard within a zone.

Recovery from a violation will require the operator to exit the light screen and depress the cycle initiate palm button. Reset of this circuit will clear the faults, allow the system to re-enable the drive power, and provide for the resumption of the cycle.

*This contact will condition the light screen contact to allow entry into the work zone at a predetermined time during the cycle. Entry at another time will drop this circuit and generate a fault, which will halt the process.

B. The signal is from a hardwired relay, limit switch, or output driven relay (hardwired is preferred). The device used for the signal would depend on complexity of the conditioning that is required to determine when it is safe to enter the zone through the light screen (i.e. position of a transfer, press or robot).

**REES palm button is the only device on the approved source list that has two (2) normally open and two (2) normally closed contacts.

16.5.10

Entry/Exit Light Screens - #1 Entry/Exit Zone Safe

This circuit is utilized when blanking of the light screen is not required.

Violation of an EZSCR circuit will result in stopping of all motion and loss of mode.

Recovery from this violation will require the reset of this circuit. The reset push button should be located at the point of entry into the zone.

Entry/Exit Light Screens - #2 Entry/Exit Zone Safe

A. This circuit is used when blanking of the light screen is required for entry or exit type applications. This circuit will determine if a carrier is passing through an Entry/Exit Zone and will blank out the light screen signal. This circuit is used in conjunction with safety mats that monitor the zone at all times.

Violation of an EZSCR circuit will result in stopping of all motion and loss of mode.

B. Recovery from this violation will require the reset of the circuit. The reset push button should be located at the point of entry into the zone.

*This contact will allow the light screen to be blanked out when a carrier is entering or leaving a system. Entry or exit at another time will drop this circuit, generate a fault, and loss of mode.

C. This signal is from a hardwired relay, or limit switch which monitors a conveyor mounted device.

16.5.12

Entry/Exit Light Screens - Known Position

A. This circuit is used to establish a known position for a carrier when two (2) conveyor mounted limit or proximity switches are used. The conveyor-mounted switches are each mechanically actuated by the same carrier. A contact of KPCR would be used in the Entry/Exit Safe circuit.

16.5.13

Perimeter Light Screens

A. When light screens are used as Perimeter guarding or Secondary Presence Sensing the Light Screen Safe contact is used in the Cycle Enable circuit. Recovery from this violation will require the reset of the Cycle Enable circuit.

B. Violation of this light screen will result in stopping of all motion and loss of mode.

16.6. Piping

16.6.1.

Piping Construction/Installation

16.6.1.1

All devices (shut-offs, valves, pressure switches, regulators, lube points etc.) shall be accessible from the floor without the use of a ladder or assist platform and, where practical devices requiring access during operation should be accessible outside of the safety gated area. Final location at build shall be approved by an AZ Launch Technician.

16.6.2

Piping Pneumatic

16.6.2.1

Supplier shall provide pneumatic safety lock out valve for each fixture containing pneumatic motions.

16.6.2.2

All long-stroke pneumatic devices shall be provided with adequate controls to insure position is maintained when source actuating or control power is lost. Long-stroke shall be considered any motion in which the actuator or any portion of the driven member moves six (6) inches or more.

16.6.2.3

Pneumatic clamping applications at manual load stations shall use a 4-way, two position, double solenoid, detented valve for directional control, in conjunction with, a 4-way, single solenoid, spring return valve installed in series between the cylinder and the directional valve in the extend circuit.

16.6.2.4

Pneumatic weld gun applications at manual load stations shall use a 4-way single solenoid spring return valve for directional control, in conjunction with a 4-way single solenoid spring return valve installed in series between the weld gun cylinder and the directional valve in the extend circuit. This shall apply to all applications where the operator's hands come within 2 inches of the pinch point caused by the weld gun tips during load or unload. It is not required on applications where devices have been applied to effectively reposition guns to eliminate these pinch hazards; such as, straight guns mounted on a retracting unit.

16.6.2.5

Manually attended operations that have traditionally employed mechanical safety latches on weld guns for operator safety (i.e. PW2, PW4, PW6, etc.) shall apply a "safety" valve instead. This "safety" valve is a redundant single solenoid directional valve piped in series with the extend circuit of the primary single solenoid directional control valve. See controls Design Coordinator for application requirements.

16.6.2.6

All air logic controls shall be designed to include pinch point protection and all required safety circuitry.

16.6.3

Piping Hydraulic

16.6.3.1

Hydraulic lifters shall use three (3) position spring centered valves with "A" and "B" metered to tank and pilot operated blocking checks. All other hydraulic cylinders with strokes (6) inches or greater shall use three (3) position spring centered, blocked center valves. Control circuits must stop the cylinder in position when the signal is removed.

16.7. Weld Guns - Robot and Portable

16.7.1.

All initiating switches, including retraction and dual schedule switches, located on portable welding guns shall be equipped with suitable guards capable of preventing accidental initiation through contact with fixturing, operators clothing, etc. The movable holder, where it enters the gun frame, shall have sufficient clearance to prevent pinch points. Where pinch points may not be eliminated by design, suitable guards shall be provided.

16.8. Robots

16.8.1.

Robot Design

16.8.1.1

The robot controls shall be placed to reflect the layout of the robots in the station. This placement shall provide a clear view of the robot while utilizing the controller.

16.8.1.2

The design Supplier shall provide installation drawings for each robot workstation. The drawings shall be 1/8" scale. The drawings shall provide the necessary views, sections and dimensions to install the robot and its associated equipment in the workstation. Any and all details, supports, units, transfer rails, etc., that are located within the robot's work envelope shall be shown. The installation drawings shall be submitted for review and approval as early in the design phase as possible.

16.8.1.3

All hard-stops must be shown in the design layout.

16.8.2

Robot Identification

16.8.2.1

The integrator shall provide "Hard Stop" indicators on the robot's base. These indicators must be clearly visible and indicate the reduced work range of the robot (i.e. Tiger striping).

16.8.3

Robot Construction/Installation

16.8.3.1

Prior to the 20-hour run the robot's operation and safety must be approved and verified by an AZ Launch Technician in accordance with the programming check list.

16.8.3.2

Programming practices to achieve line cycle rates that create unsafe machine operation is not permitted.

16.8.3.3

The Integrator shall provide, and is responsible for, the installation and adjustment of all limit switches and hard-stops required to meet AZ and O.S.H.A. standards.

16.8.3.4

When manual back-up capabilities are used in the process, the integrator shall provide and install a limit switch to indicate when the robot is in the stored position. This position shall be clear of any back-up personnel required to perform manual back-up procedures. An interface shall be provided to the applicable conveyor systems and transfers.

16.8.3.5

Robot pinch point safety distance between robot restricted space and any obstacle shall be a minimum of 18 inches, except where the pinch point occurs more than 7' above the work surface.

16.8.3.6

The system and its robots shall be in accordance with O.S.H.A. and A.N.S.I./R.I.A. R15.06 standards on robot safety.

16.8.3.7

Robot installations shall be provided with safety circuitry to hold the program count, while de-energizing robot actuator drive power.

16.8.3.8

The integrator shall provide manual back-up capability for all automatic load/unload stations. This shall include all safety related items required to manually back-up the robots assignment.

16.8.3.9

Supplier shall provide a pneumatic lockable type ball valve, with a safety exhaust feature, for service air to each tip dresser and robot.

16.8.3.10

The integrator shall provide pressure sensitive safety mats in areas defined by AZ Safety Department and AZ Launch Technicians. The safety mats will be wired back to the power source in their area.

A. Safety mats shall be installed in an approved manner.

B. Provide all platforms required for safety mat installation.

C. Install no more than four (4) mats per control box.

16.8.3.11

Construction Group and Plant Manufacturing/Builder shall ensure that the robot manufacturer designs and constructs industrial robots in accordance with 16.8.3.14 through 16.8.3.23 of this instruction.

16.8.3.12

Reconstruction and Modification. Anyone reconstructing/modifying an industrial robot shall do so in accordance with 16.8.3.14 through 18.8.3.23 of this instruction.

16.8.3.13

Hazards to Personnel

A. Moving Parts Hazards shall be eliminated by design or protection shall be provided against the hazards.

B. Component Malfunction Robot components shall be designed, constructed, secured or contained so hazards caused by breaking or loosening, or released stored energy are minimized.

C. Sources of Energy A means of isolating all sources of energy to the robot with lockout/tagout capability shall be provided. (Reference ANSI Standard Z-244-1982 and M.T.I. SMI-107)

D. Hazards From Stored Energy Means shall be provided to release stored energy. This energy may be in the form of air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. An appropriate label shall be affixed to each stored energy source.

E. Electromagnetic Interference and Radio Frequency Interference. The design and construction of the robot shall incorporate good engineering practices of shielding, filtering, suppression and grounding to eliminate the effects of Electromagnetic Interferences (EMI) and Radio Frequency Interference (RFI).

16.8.3.14

Actuating Controls

A. Protection from Unintended Operation Actuating controls that initiate power or motion shall be constructed or mounted so as to prevent inadvertent operation. For example, a guarded pushbutton, key selector switch.

B. Labeling Actuating controls shall be labeled to clearly indicate their function.

C. Remotely Located Controls - Each robot that can be controlled from a remote location, shall be provided with an effective means, that when used, will prevent that robot's motion from being initiated from any location other than at the individual robot.

16.8.3.15

Emergency Stop Device

A. Every robot shall have an emergency stop device using hardware-based components. The emergency stop device shall override all other robot controls, remove drive power from the robot actuators, and cause all moving parts of the robot to stop.

B. Each operator control station, including pendants capable of initiating robot motion, shall have an emergency stop device.

C. Pushbuttons that activate an emergency stop device shall be red, unguarded, and unobstructed. In addition, except for those on pendants, they shall be palm or mushroom head type.

D. Provision shall be made within the emergency stop circuit to include additional stop devices.

E. Following the use of the emergency stop device, restarting the robot shall require a deliberate action by the operator to initiate a prescribed start-up procedure. In multiple robot installations, such deliberate action may be accomplished by resetting the individual robot control panels, or resetting the single emergency stop push button (maintained contact lockable type only) which was operated, in addition to resetting a process control panel.

16.8.3.16

Pendant

A. It shall not be possible to place the robot into automatic mode using the pendant.

B. All buttons and other devices on the pendant that cause robot motion shall stop motion when the button or device is released. (Deadman type control.)

C. The pendant shall have an emergency stop device.

D. The pendant shall be designed so that when the robot is under pendant control, all robot motion shall be initiated only from the pendant.

E. All motion of the robot that is initiated in teach mode shall be at slow speed.

16.8.3.17

All robots capable of hazardous motion shall have a controlled slow speed. The maximum slow speed of any part on the robot shall not exceed 250 millimeters (10 inches) per second due to the action of any individual axis. The robot shall be designed and constructed so that in the case of any single reasonable foreseeable malfunction, the slow Speed shall not be exceeded when the slow speed is intended.

16.8.3.18

Mechanical stops shall be capable of stopping the motion of the robot under rated load and maximum speed conditions. Mechanical stops are required when the robot must be stopped short of the designed capacity in order to avoid contact with obstacles such as, but not limited to: Columns, Posts, Barrier Fencing. Adjacent Robots (when rear or side swing causes pinch points). A minimum clearance of eighteen inches (18") must be maintained between the potential reach of the end effector (with suspended part on material handling applications) and non-point of operation structures.

16.8.3.19

Required Information

A. Function and location of all controls

B. Robot specifications including range and load capacity

C. Precautionary information

D. Operating instructions

E. Maintenance information

F. Information required for installation

G. Special environmental requirements - including EMI and RFI

16.8.3.20

All electrical connectors used on robots which could cause hazardous motion if mismated, shall be keyed to prevent mismating. Electrical connectors, which could cause hazardous motion of the robot if they are separated or if they break away, shall be designed and constructed so as to guard against unintended separation.

16.8.3.21

Power Loss or Change

A. Robots shall be designed and constructed so that loss of electrical power or voltage surges or changes in oil or air pressure will not result in hazardous motion-of the robot.

B. End Effector Design

C. End effectors shall be designed and constructed so that loss of electrical power or oil or air pressure shall not result in a hazardous condition. Clamping mechanisms shall have locking characteristics.

16.8.3.22

Robots shall be designed and constructed so that any single failure shall not cause hazardous motion of the robot.

16.8.3.23

Group and Plant Manufacturing/Production Engineering shall ensure that the robot system is installed in accordance with the following instructions:

A. The robots or robot systems shall be installed in accordance with manufacturers specifications.

B. Electrical ground shall be provided in accordance with robot manufacturers specifications and/or applicable codes.

C. Electrical power provided shall meet the robot manufacturers specifications.

D. Robot and associated controls requiring access during automatic operation shall be located outside the barrier enclosure.

E. The robot control console shall be positioned so that the robot is in full view. Placement of consoles in positions that reduce visibility of the unit and its restricted space must be avoided. Consoles must not be used as barriers in place of barrier guard panels.

F. The robot system shall be installed to avoid interference with buildings, structures, utilities, other machines, and equipment.

G. Each installation shall have a means to shut off power to the robot located outside the barrier guard or enclosure. There shall be a lockout/tagout capability.

H. Hard stops shall be positioned to establish restricted workspaces to restrain the motion of the robots.

I. All environmental conditions, including but not limited to explosive mixtures, corrosive conditions, humidity, dust, temperature, EMI and RFI, shall be evaluated to ensure compatibility of the robot with the anticipated operational conditions.

J. Robot systems shall be installed so that shut down of associated equipment will not result in hazardous motion of the robot.

K. The restricted workspace shall be conspicuously identified by line markings on the robot base.

L. Each industrial robot system operator station shall be provided with an emergency stop device.

16.8.3.24

Automatic Tip Dress installation shall comply with the following:

A. Floor mounted shall be equal to or less than 24 inches from the floor.

B. Fixture mounted shall be equal to or less than the height of the product in the work position.

C. Shall be located within the robot’s work space (in front).

D. Shall be located in such a manner so as not to protrude beyond the fixture base.

E. Mounted to overhead structure shall be equal to or greater than 7 feet above the floor.

16.8.4

Robot Teach (Pinch Point) Protection

16.8.4.1

Mat Circuitry will be active in any mode.

16.8.4.2

The circuitry will effect only the robot or robots associated with the sensed area (Robot Pinch Point). The circuitry will not effect other automation.

16.8.4.3

With the System in Automatic mode the circuitry will cause the effected robot(s) to be put in a safe hold condition when the device is violated.

16.8.4.4

With the robot in Robot Teach Mode the circuitry will cause the effected robot(s) drive power to be removed when device is violated. Drive power will be restored by stepping out of the sensed area.

16.8.4.5

Teach permissive circuitry is required when the robot’s maximum restricted space overlaps or they work on a common fixture.

16.8.5

Safeguarding

16.8.5.1

Group and Plant Manufacturing/Production Engineering/Builder shall ensure that safeguards are provided and used in accordance with Sections 16.8.5 and 16.13 of this instruction. The means and degree of safeguarding including any redundancies shall correspond directly to the type and level of hazard presented by the robot system consistent with the robot application.

16.8.5.2

One or more of the following shall prevent intrusion by personnel into the restricted workspace or enclosure:

A. Presence Sensing Devices

1. Presence sensing devices are safeguarding devices that use a sensing field and may include but are not limited to light curtains, mats, proximity detectors or vision safety systems. A failure of the presence sensing devices shall interrupt the operation of the robot system.

2. The presence-sensing device shall be designed and constructed so that its proper operation is not adversely affected by ambient factors.

3. The presence sensing device shall be designed and installed so that operation of the robot ceases or is inhibited when the sensing field is violated by entry or reaching into the restricted workspace.

4. Resumption of robot motion shall require removal of the sensing field violation.

5. Where entry to the restricted workspace does not cause a continuous violation of the sensing field, the deliberate activation of the controls shall be required to resume robot motion.

B. Barrier Guard

1. A barrier shall prevent personnel from reaching over, under, around or through the barrier into the restricted workspace. It shall be necessary to use tools to remove the barrier or its section in order to gain entrance to the restricted workspace. A barrier shall be eight (8) inches from the floor at the bottom edge and 68 inches from the floor at the top edge.

C. Interlocked Barrier Guard

1. An interlocked Barrier guard shall prevent access to the restricted workspace except by opening an interlocked gate. Opening of the interlocked gate shall:

a) Stop the robot and remove drive power to the robot actuators.

b) Prevent automatic operation of the robot and any other associated equipment that may cause a hazard. Returning to automatic operation shall require both closing the interlocked gate and deliberately activating the controls used to restart the automatic operation.

D. Awareness Barrier

1) An awareness barrier shall be constructed and installed so that a person cannot approach the restricted workspace of an industrial robot without sensing the presence of the barrier. The awareness barrier shall be located so as to prevent inadvertent entry into the restricted workspace. Use of such a method will require additional safeguarding be used.

2) Use of such a method will require additional safeguarding be used.

E. Awareness Signal

1) An awareness signal device shall be constructed and located such that it will provide a recognizable audible or visual signal to individuals of an approaching or present hazard. When awareness signals in the form of lights are used to warn of hazards in a work envelope, sufficient devices shall be used and located so that the light will be seen by an individual facing in any direction in the proximity of the work envelope.

2) Audible awareness devices shall have a distinctive sound of greater intensity than the ambient noise level.

3) Use of such a method will require additional safeguarding be used.

16.8.5.3

Operators of industrial robots are personnel who initiate the intended production operation of a robot system. The users of a robot system shall insure that safeguards are established for each operation associated with the robot system. Safeguards shall prevent the operator from being in the restricted space during robot motion or prevent motion when any part of an operator’s body is within the restricted workspace.

16.8.5.4

Operators of robot systems shall be trained to recognize known hazards associated with each assigned task involving the robot system. Operators shall be instructed in the proper operation of the control actuators for the robot system and shall be instructed in how to respond to recognized hazardous conditions.

16.8.6

Manual Back-up of Robots in Automated Processes

16.8.6.1

In line replacement of disabled robots by personnel in the robot restricted space can be acceptable only if the necessary manual workstation have been planned and installed in a manner consistent with maximum operator safety.

16.8.6.2

The following measures or their equivalents must be taken in the establishment of in line manual back-up workstations:

A. The operator must have full control of each cycle of the machinery from the backup workstation.

B. Drive power must be interrupted to the robot.

C. The robot boom, end effector and any suspended part must be moved to a predetermined position that does not interfere with the manual operation.

D. Work stations must be bordered with frontal and side barriers sufficient to prevent the operator from inadvertently becoming exposed to machine movements or adjacent operating robots.

E. Care must be taken during design to assure that manual back-up stations are free of unnecessary obstacles that could impede operator movement in the workstation. Protruding junction boxes, transformers, drive mechanism, hoses, electrical cables, etc. are examples of such potential obstacles.

1. Presence sensing devices shall be incorporated with manual controls unless the task can be accomplished safely without placing any part of the body in the movement path of the machinery or parts in process.

2. Secondary presence sensing shall be added to prevent personnel entry beyond the manual back up workstation.

16.8.7

Simflex Robotic Systems

16.8.7.1

Simflex robotic systems shall be in accordance with all sections of this instruction, in addition to the following.

(See Illustration 16-3.0)

A. Automatic Loading/Unloading. When feasible, loading or unloading devices shall be designed and installed to allow the completion of necessary manual functions, from a point entirely outside the restricted workspace of any robot or robots in a Simflex system.

B. Manual Loading/Unloading. When loading or unloading must be accomplished in the restricted workspace of a robot, the following conditions must be met:

1. The operator shall have full control of each robot cycle.

2. Work stations shall be bordered with frontal and side barriers sufficient to prevent an operator from inadvertently becoming exposed to machine movement.

3. Presence sensing devices shall be utilized in conjunction with cycle controls. These devices shall be installed in work stations in a manner that will prevent access to the interior of a system through a work station, without crossing the barriers indicated in item (2) and activating the presence sensing devices.

Such devices must be positioned to assure that presence sensing occurs before any part of the body enters the restricted workspace.

4. A combination of hard wire circuitry and presence sensing devices must be provided in order to prevent any robot that services more than one work station from entering an occupied station.

16.8.8

Safeguarding the Teacher

16.8.8.1

The teacher shall be trained on the particular model of robot and shall be familiar with the recommended "teach" procedures.

16.8.8.2

Before teaching a robot, the teacher shall visually check the robot and operating workspace to assure that extraneous conditions that may cause hazards do not exist. The teach controls of the pendant shall be function tested to ensure proper operation. Any damage or malfunction shall be repaired prior to commencing the teaching operation.

16.8.8.3

When the teach mode is selected, the following conditions shall be met.

A. The robot shall be under sole control of the teacher.

B. The robot shall operate at slow speed only.

C. The robot shall not respond to any remote interlocks or signals that would cause motion.

D. Automatic movement of the other equipment in the restricted workspace shall be under the sole control of the teacher if such movement would present a hazard.

E. All robot system emergency stops shall remain functional.

F. The teacher shall be required to leave the barrier guard enclosure prior to initiating the automatic mode.

16.8.9

Safeguarding Maintenance Personnel

16.8.9.1

Personnel who perform maintenance on robots or robot systems shall be trained for the procedures necessary to safely perform the required tasks.

16.8.9.2

Personnel who repair and maintain robot systems shall be safeguarded from injury due to unexpected or unintended motion. The means and degree of safeguarding, including any redundancies, shall correspond directly to the type and level of hazards presented by robots and robot systems.

16.8.9.3

The most effective means of safeguarding is to shut the robot off. A procedure shall be followed that includes lockout/energy control of sources of power and releasing or blocking of stored energy.

16.8.9.4

When it is not feasible to follow a lockout/energy control procedure, alternate safeguarding methods shall be established as required to prevent injury.

16.8.9.5

Personnel performing maintenance tasks within the restricted workspace when drive power is available shall have total control of the robot or robot system. This shall be accomplished by the following:

A. The control of the robot shall be removed from the automatic operations.

B. Robot control shall be isolated from any remote signals that could initiate robot motion.

C. Movement of other equipment in a robot system shall be under the control of the person in the workspace if such movement would present a hazard.

D. All robot systems emergency stop devices shall remain functional.

E. The robot system shall only be reset for automatic operation after the person leaves the restricted workspace.

16.8.10

Robotic End-of-Arm Tooling Guidelines

16.8.10.1

Fail-safe designs shall be utilized in clamping and holding operations to guarantee safe operation, and minimize part and equipment damage.

16.9. Balcony

16.9.1.

Design/Construction/Installation

16.9.1.1

Balcony floor shall be made of grip strut material. Exceptions see Canadian Safety regulations for 480V power.

16.9.1.2

Balcony safety rails shall be 42" in height and constructed of 1-1/2" square tubing with 0.140 minimum wall thicknesses.

16.9.1.3

6" Toe Board shall be provided around perimeter of the balcony except in stairway locations.

16.9.1.4

Provide a minimum of (2) access stairways per assembly line, (1) on each side of the balcony.

16.9.1.5

Stairways shall include safety rails and must conform to Occupation Safety and Health Administration (OSHA) and Canadian Ministry of Labour (MOL) requirements.

16.9.1.6

Balcony legs shall be positioned relative to fixture so as not to restrict the functional access to fixtures and robots and provide 18" clearance to robot maximum hard stopped path and part transfer envelopes.

16.10. Transfers/Shuttles/Lifters

16.10.1.

General

16.10.1.1

Safety pins and plugs with receptacles shall be mounted on both sides of the line and at intervals of not more than sixty (60) feet.

16.10.1.2

Transfer lifters that are held in the "raised" position during transfer shall be mechanically locked in that position. Designs not applying an over-center lock style of design shall include latch mechanisms that will sequence each machine cycle. In stations that may require operator attendance, a multi-position latch shall be provided for added safeguarding. This latch shall be capable of holding lifter position at multiple locations between end stops and shall be fail-safe engaged when the possibility exists of access to the lifter mechanism or parts-in-process.

16.10.2

Lift and Carry Shuttle

16.10.2.1

The Supplier shall provide and install blocking valves in counterbalance circuits to prevent "dropping" of the shuttle in case of inadequate air pressure.

16.10.2.2

All electric or electromechanical drive systems must have torque limiters. Torque limiters must be mechanically disengaged.

16.10.2.3

An air-operated spring set brake is required on both the Lift and Carry motions between the torque limiter and the load. The brake must stop the load in one half (0.5) seconds.

16.10.2.4

Lift motion of the shuttle design shall be over center locked or mechanical latch(es) must be used for safety lockout.

16.10.2.5

The lifter drive mechanism shall be safety pinned at the torque tube.

16.10.2.6

The transfer drive mechanism shall be safety pinned at the transfer drive.

16.10.3

Lifter Controls

16.10.3.1

Single station, lifters powered by individual drive mechanisms that are related to a common transfer shall be provided with independent manual control at each station and collective manual control at the System Control Panel. The circuitry shall preclude simultaneous operation from both locations. The collective control shall only be active when the system guarding is intact.

16.10.3.2

Manual control of individual lifters from a station control Panel shall be permissible without perimeter guarding intact. Where extreme hazard exists, the controls shall only be active when all perimeter guarding is intact. An example is Pit mounted and/or overhead gull-wing type lifters or obstructed line of sight.

16.10.3.3

Manual control of multi-station lifters powered by one common drive mechanism shall be provided with manual control at the Master Control panel, which shall only be active when all guarding is intact.

16.11. Induction Curing

16.11.1.

Design/Construction/Installation

16.11.1.1

The system installation shall comply with all applicable federal audio noise and safety standards. (See Section 12 for Design requirements)

16.11.1.2

Pacemaker warning signs shall be displayed on this equipment.

16.12. Automation

16.12.1.

Design Construction, Modification

16.12.1.2

The Manufacturing Engineering /Builder shall ensure that the design, construction and/or modification of automated systems and equipment, is in accordance with this instruction.

16.12.1.3

Automated equipment shall be designed, constructed, or contained so that hazards caused by moving parts are minimized. Remaining hazards associated with moving parts shall be eliminated by providing appropriate protection.

16.12.1.4

A means of isolating all sources of energy to the automated equipment, with lockout capability, shall be provided.

16.12.1.5

All machinery and equipment having long stroke movements (6" or greater vertical/horizontal) shall be provided with circuitry and devices sufficient to drop power to drive activators and to mechanically immobilize, in order to prevent potential hazardous movement.

16.12.1.6

17. Mechanical immobilization is most often achieved by pinning or blocking (i.e. Safety Pin or Die Block).

16.12.1.7

Interlocked pinning/blocking capability must be provided on both sides of major lines at regular intervals to allow convenient and efficient isolation of energy when access to the automation is required.

16.12.1.8

Machinery equipped with air balancing systems must utilize blocking valves, dynamic braking, and latching devices as prescribed in AZ Tool and Design Standards.

16.12.1.9

Sufficient clearance between moving parts and obstacles such as fences, barriers, columns, conduit pipes, and structural supports, shall be provided to reduce the likelihood of injury from pinch, shear, or trapping points. Minimum hand clearance at employee workstations shall be 4", between obstacles and the path of moving parts. Minimum pinch point clearance for obstacles less than 24" to the floor or work surface shall be 12". Minimum obstacle clearance in all other situations shall be 18", except where the pinch point occurs more than 7' above the work surface.

16.12.1.10

All major lines (multiple station) shall be provided with automatically functioning horns to signal initiation of the automatic mode. Such signals shall sound for four seconds. A minimum of seven seconds delay prior to the movement of machinery or system components is required after the sound stops.

16.12.1.11

A means shall be provided to release stored energy, except where this may cause a hazard. Stored energy may be present in hydraulic, pneumatic, electrical, or mechanical machinery and equipment. Appropriate labels shall be affixed at each energy retention source.

16.12.1.12

Electromagnetic interference and radio frequency interference. The design and construction of automated systems shall include effective engineering practices of shielding, filtering, suppression and grounding to eliminate the effects of electromagnetic interferences (EMI) and radio frequency (RFI).

16.12.1.13

Hazards associated with exposure to internal electrical components when maintaining, installing or inspecting electrical service or distribution (dist. panels, I/O panels, junction boxes, switch gear, motor control, main consoles, buss ducts/trays, etc.) must be minimized by providing sufficient system and machine disconnects to achieve total isolation of energy and effective lockout.

16.12.1.14

All automated systems shall have an emergency stop circuit. The emergency stop shall override all other controls, remove drive power from the equipment actuators, and cause all moving parts of the systems to stop.

16.12.1.15

Each operator control station shall have an emergency stop device.

16.12.1.16

Push buttons that activate a system emergency stop device shall be 2" in diameter, maintained contact, lockable, red, unguarded, and unobstructed. In addition, they shall be mushroom head type.

16.12.1.17

Provision shall be made within the emergency stop circuit to include additional stop devices in large or multiple station processes.

16.12.1.18

Following the use of the emergency stop device, restarting the system shall require a deliberate action by the operator to initiate a prescribed start-up procedure. In multiple unit installations, such deliberate action may be accomplished by resetting the single emergency stop push button (maintained contact type only) which was operated, in addition to resetting a process control panel.

16.12.1.19

All emergency stop devices shall have manual reset (push/pull) characteristics. Such devices located on station control panels and on main consoles shall be equipped with lockable hasps.

16.12.1.20

Emergency stop palm buttons shall be readily accessible and located on both sides of multi-station process lines.

16.12.1.21

Actuating controls that initiate power or motion shall be constructed or mounted so as to prevent inadvertent operation. For example, a guarded push button, key selector switch or two-hand controls could be used.

16.12.1.22

Actuating controls shall be labeled to clearly indicate their function.

16.12.1.23

Remotely Located Controls - Part/product transfer equipment shall not function in the auto or manual mode until all safety circuits, devices, or interlocked access faults are restored.

16.12.1.24

Electrical connectors shall be keyed to avoid mismatching if such mismatching would cause a hazard. Connectors shall be designed and constructed so as to guard against separation, if such separation could cause a hazard.

16.12.1.25

Cycle stop circuitry must be provided at each station (accessible on each side) in multi-station processes to accomplish the following:

A. De-energize the automatic mode

B. Remove power from all part transfer drives

C. Remove power from all robot drives

16.12.1.26

All cycle stop devices shall have manual reset (push/pull) characteristics and lockable hasps. Such devices may be used to disable moving equipment during periods of employee access, within the system.

16.12.1.27

All valves located in employee work stations that cause component movement, when activated (ex. opening/closing of clamps), shall have their controls designed to preclude delayed or unexpected movement.

16.12.1.28

The use of a Cycle Start (Slap) Button(s) and Presence Sensing Device(s) is required for the following reasons:

A. Whenever the hold down time of Dual Palm Buttons would exceed (4) four seconds.

B. When there is more than (1) one operator required to perform the process.

C. Whenever visual management of the fixture is in question.

16.12.1.29

Dual palm buttons shall be provided at manual (off line) operations when presence-sensing devices are not required. The operator must maintain button contact for the duration of all hazardous movement.

16.12.1.30

Automated systems shall be designed and constructed so that loss of electrical power, voltage surges, or changes in oil or air pressure, will not result in hazardous motion.

16.12.1.31

Fixtures that cannot be visually managed by the operator(s) must be guarded to protect against pinch/shear points. The maximum reasonable area that can be visually managed by an operator is about (3) three feet on each side of the operator’s centerline and (3) three feet in front of the operator. In addition, the proximity of the clamps or other such devices to walk paths or aisles and passageways used by other employees, must be considered when determining guarding requirements.

16.12.1.32

The following information shall be provided to the user, for all automated machines and equipment:

A. Function and location of all controls

B. Specifications

C. Precautionary information

D. Operating instructions

E. Maintenance information

F. Information required for installation

G. Special environmental requirements - including EMI and RFI

16.12.2

Installation

16.12.2.1

Group and Plant Manufacturing Engineering/Builder shall ensure that automated systems are installed in accordance with this instruction and manufacturer's specification.

16.12.2.2

Electrical ground shall be provided in accordance with manufacturers specification and/or applicable codes.

16.12.2.3

Electrical power provided shall meet the manufacturer's specifications and any applicable codes and standards.

16.12.2.4

Control stations shall be positioned so that the automated/manual function is in full view. Placement of control stations in positions that reduce visibility of the unit and its function must be avoided. Control stations shall not be used as barriers in place of barrier guard panels except when approved in design and permanently mounted.

16.12.2.5

When a component of an automated system is located in an area of reduced visibility, the Manual Control Station that is the sole manual manipulator of that component must be located in an area of good visibility.

16.12.2.6

The system shall be installed to avoid interference with buildings, structures, utilities, other machines, and equipment.

16.12.2.7

Each installation shall have a means to shut off power located outside the barrier guard or enclosure. This means shall have a lockout/energy control capability.

16.12.2.8

All environmental conditions, including but not limited to explosive mixtures, corrosive conditions, humidity, dust temperature, EMI and RFI, shall be evaluated to ensure compatibility of the automated system with the anticipated operating conditions.

16.12.2.9

All operator stations shall have an E-Stop and Cycle-Stop pushbutton located within an unobstructed forty-eight (48") inches of the cycle initiate palm button.

16.12.3

Safeguarding

16.12.3.1

Group and Plant Manufacturing/Builder shall ensure that safeguards are provided and used in accordance with Sections 16.12.3 and 16.13 of this instruction. The means and degree of safeguarding including and redundancies shall correspond directly to the type and level of hazard presented by the system consistent with the automated application.

16.12.3.2

Access by personnel to the automation while in automatic shall be prevented by one or more of the following:

A. Presence Sensing Devices

1. Presence sensing devices are safeguarding devices that use a sensing field and may include but are not limited to light curtains, mats, capacitance systems, proximity detectors or vision safety systems.

2. A failure of the presence sensing devices shall interrupt the operation of the system.

3. The presence-sensing device shall be designed and constructed so that its proper operation is not adversely affected by ambient factors.

4. The presence sensing device shall be designed and installed so that automatic operation and all hazardous motion of the system, ceases or is inhibited when the sensing field is violated.

5. Resumption of motion shall require removal of the sensing field violation.

6. Where entry does not cause a continuous violation of the sensing field, the deliberate activation of the controls shall be required to resume motion.

B. Barrier Guard

1. A barrier shall prevent personnel from reaching a hazardous position in the restricted area by reaching over, under, around or through the barrier. It shall be necessary to use tools to remove the barrier or its section in order to gain entrance to the restricted area. A barrier shall be a maximum of eight (8) inches from the floor at the bottom edge and a minimum of 68 inches from the floor at the top edge. (Refer to Website://www.a-sp.org)

C. Interlocked Barrier Guard

1. An interlocked barrier guard shall prevent access to the hazard zone except by opening an interlocked gate. Opening of the interlocked gate shall:

a) Stop motion and remove power to all drive actuators that could initiate hazardous motion.

b) Prevent automatic operating of the system.

c) Deny entry until all hazardous motion has stopped. Returning to automatic operation shall require both closing the interlocked gate and deliberately activating the controls used to restart the automatic operation.

2. Interlocks shall be mounted is such a manner as to prevent reconnection from the inside of the barrier.

D. Awareness Barrier

1. An awareness barrier shall be constructed and installed so that a person cannot approach a hazard or restricted area without sensing the presence of the barrier. The awareness barrier shall be located so as to prevent inadvertent entry to a hazard zone.

2. Use of such a method will require the installation of additional safeguarding.

E. Awareness Signal

1. An awareness signal device shall be constructed and located such that it will provide a recognizable audible or visual signal to individuals of an approaching or present hazard.

2. Audible awareness devices shall have a distinctive sound of greater intensity than the ambient noise level.

3. Use of such a method will require the installation of additional safeguarding.

F. Modular Guarding

1. When it becomes necessary to service a system component while adjacent equipment and process machinery continue to operate normally; access to the operating components of the system must be prevented. Modular guarding (isolation of individual or small groups of units) may be accomplished by combining interlocked barrier guarding and presence sensing devices.

2. Secondary presence sensing is required behind low barriers when there is other activity in the process cell i.e. Sealer Apply, Pedestal Welding, or other automatic functions. See Light Screen Application Guidelines in Section 16.5. (The application of secondary Presence Sensing provides the required safety, while facilitating maximum up time by eliminating unnecessary maintenance intervention due to nuisance tripping of the safeties.)

G. Safeguarding the Operator

1. Operators of automated systems are personnel who initiate the intended production operation. The users of automated systems shall ensure that safeguards are established for each operation associated with the system. Safeguards shall prevent the operator from being in a hazardous position during motion or prevent motion when any part of an operator's body is within the restricted area.

2. Operators shall be trained to recognized known hazards associated with each assigned task involving automated processes. Operators shall be instructed in the proper operation of the control actuators for the system and shall be instructed in how to respond to recognized hazardous conditions.

3. Operator Stations including Manual Back-Up of Loaders, Unloaders, Robots, Transfer Equipment in Automated Processes.

4. In line replacement of disabled equipment by personnel in or near the restricted area is acceptable only if the necessary manual workstations have been planned and installed in a manner consistent with maximum operator safety.

5. The following minimum requirements must be met in the establishment of workstations:

The operator must have full control of each cycle of the machinery from the workstation.

a. Workstations must be bordered with frontal and side barriers sufficient to prevent the operator from inadvertently becoming exposed to machine movements or adjacent operating machinery/ equipment. b.

b. Care must be taken during design to ensure that stations are free of unnecessary obstacles that could impede operator movement in the workstation. Protruding junction boxes, transformers, drive mechanism, hoses, electrical cables, etc. are examples of such potential obstacles.

c. A combination of hard wire circuitry and presence sensing devices, or other equally effective means, must be provided in order to prevent any automatic equipment that services more than one work station, from entering an occupied station.

16.12.3.3

Automatic Loading/Unloading - When feasible, loading or unloading devices shall be designed and installed to allow the completion of necessary manual functions, from a point entirely outside the restricted area.

16.12.3.4

Manual Loading/Unloading - When loading or unloading must be accomplished by reaching into the restricted area, the following conditions must be met:

A. The operator shall have full control of each cycle.

B. Work stations shall be bordered with frontal and side barriers sufficient to prevent an operator from inadvertently becoming exposed to machine movement.

C. Such low barriers shall be no higher than the adjacent tooling and shall not interfere with employee work activity (Load/Unload).

D. Presence sensing devices shall be utilized in conjunction with cycle controls. These devices shall be installed in workstations in a manner that will prevent access to the interior of a system through a workstation, without crossing the barriers indicated in item (16.12.3.2), and activating the presence sensing devices. Such devices must be positioned to ensure that presence sensing occurs before any part of the body enters a restricted area.

16.12.3.5

Light screen height for operator to robot workstations shall be a minimum seven (7) feet to the top beam of the light screen from the work platform.

16.12.3.6

Sensing plane of all vertical light screens shall be positioned a minimum of twelve (12) horizontal inches from the nearest pinch point.

16.12.3.7

When pressure sensitive mats are used in employee workstations, they shall be permanently mounted with anti-trip edging. Multiple mats shall be connected with an "Active Edge" or equivalent devices to prevent dead spots.

16.12.3.8

Presence sensing mats used for Secondary presence and/or product entrance/exit shall be a minimum of forty-eight (48) inches deep.

16.12.3.9

Light screen height for operator workstations shall be of a minimum height to insure that any hazard cannot be accessed

16.12.3.10

Single beams used for secondary presence sensing shall be horizontally spaced as follows:

Elevation Above The Work Surface	Maximum Horizontal Space Between Beams
0" - 6" Above	6" Apart
7" - 12" Above	10" Apart
13" - 24" Above	12" Apart
25" - 29" Above	15" Apart
30" and Higher	18" Apart

16.12.3.11

Safeguarding Maintenance Personnel

A. Personnel who perform maintenance on automatic machinery or automated systems shall be trained in the procedures necessary to safely perform the required tasks.

B. Personnel who repair and maintain automated systems shall be safeguarded from injury due to unexpected or unintended motion or both. The means and degree of safeguarding, including any redundancies, shall correspond directly to the type and level of hazards presented by automatically cycling machinery and automated systems.

C. Maintenance personnel shall have an effective line of sight to devices for which station control panels have manual control capability.

16.12.3.12

When it is not feasible to apply lockout/energy control, alternate equivalent safeguarding shall be provided to prevent injury. Personnel performing maintenance tasks within the restricted area when drive power is available shall have total control of the machine or system. This shall be accomplished by the following:

A. The control of the machinery and equipment shall be removed from the automatic mode.

B. Control shall be isolated from any remote signals that could initiate motion.

C. Automatic movement of other equipment in an automated system shall be under the control of the person in the workspace if such movement would present a hazard.

D. All emergency stop devices shall remain functional.

E. The automated system shall be reset for automatic operation only after personnel leave the restricted area enclosure, and all safety circuits and devices are restored.

16.12.3.13

If, during maintenance, it becomes necessary to bypass safeguards required for automatic mode operation, alternative safeguards shall be provided and written notification shall be posted at the bypassed device. The bypassed safeguards shall be returned to their original effectiveness when the maintenance task is completed.

16.12.3.14

OverHead Conveyor entrance/exit zones shall be protected by the installation of presence sensing devices a minimum of four (4) feet deep. Such devices shall overlap the entrance/exit by a minimum of two (2) feet. This overlap can also be accomplished by the use of additional fencing.

16.12.3.15

Inverted conveyor entrance/exit zones shall be protected by vertical and horizontal presence sensing. Controls shall include an approved hard-wired failsafe blanking circuit for the vertical presence-sensing device.

16.12.3.16

Mounting of equipment to fixtures/tools shall be accomplished so that:

A. Components do not extend above or beyond the tooling within the robot point of operation (in front).

B. Equipment does not create a pinch point to the rear or side of the robot.

16.12.3.17

Obstacles such as stanchion legs, junction boxes, valve stands, hydraulic reservoirs, tip dressers CMM pull-offs, positioners or stabilizers and part bins that exceed 24" in height require 18" clearance or presence sensing.

Note: Other robots and "Points Of Operation" such as part load, part weld, sealer apply, pedestal welders and part unload stations are not considered pinch points.

6.12.4

Care

16.12.4.1

Plant Manufacturing/Production Engineering shall establish a regular and periodic inspection and maintenance program to assure the continued safe operation of the automated system. The inspection and maintenance program shall be in accordance with the manufacturer's recommendations.

16.12.5

Initial Testing and Startup

16.12.5.1

This section defines the procedures that shall be followed during the testing of automated systems after installation or relocation. It also applies to automated systems after software-hardware changes and after maintenance or repairs which could affect their safe operation.

16.12.5.2

During this testing and startup, no personnel shall be allowed in the restricted area enclosure of the systems until safeguards and proper operations are verified.

16.12.5.3

The manufacturer's recommendations for testing and startup shall be followed.

16.12.5.4

An initial startup inspection shall include but not necessarily be limited to the following:

16.12.5.5

Before applying power, verify:

A. Mechanical mounting and stability

B. Electrical connections

C. Utility connections

D. Communications connections

E. Peripheral equipment and systems

16.12.5.6

After applying power, verify that:

A. Emergency stop devices are functional

B. Drive power disconnects are functional

C. Program executes as intended

D. Interlocks function

E. Safeguards are functional

16.12.5.7

An inspection prior to restart after hardware or program modification, repair, or maintenance shall include but not necessarily be limited to the following:

A. Check anything rewired or added to the hardware system prior to applying power.

B. Function test for proper operation.

16.12.6

Training

16.12.6.1

Manufacturing Engineering/Plant Manufacturing/Production Engineering, along with the Plant Safety function shall ensure that:

A. Training is provided before any personnel are assigned to program, maintain, or operate automated systems.

B. Training shall include applicable safety procedures and the safety recommendations of the manufacturers.

C. General safety precautions and specific safety procedures that are germane to the installation and application of the particular machines and equipment in use shall be integrated into every phase of the training.

16.13. Conveyors

16.13.1.

General

16.13.1.1

Conveyor systems are to adhere to the latest version of the specifications listed in sections 1.1.1 and 1.1.2 of the Do’s and Don’ts.

16.13.2.

Safety Training Program

16.13.2.1

See section 16.12.6 of the Do’s and Don’ts.

16.13.3.

Guarding

16.13.3.1

The following are special safety guarding applications in addition to general requirements:

A. All power rail is to be finger guarded for conveyor elevations 7'-0" and less from floor level, and production platforms and in all accessible areas on platforms.

B. All power only is to be finger guarded for conveyor elevations 7’-0" and less from floor level, and production platforms and in all accessible areas on platforms and on screen guard.

C. All sprockets and traction wheel turns elevations 7'-0" and less and in all accessible areas on platforms and on screen guard shall be guarded. All traction wheel guards to be easily removable. Traction wheels on elevated take-ups with ladder access do not require cover guards.

D. All traction wheels shall be supported from below or have safety support angles as part of a safety arrangement to prevent the wheel from falling in the event of failure. This arrangement shall be robust and include a drip pan.

E. Screen guard to be installed under all Power and Free carrier return conveyors.

F. All Power and Free stop blades are to be fully guarded with easily removable expanded metal type guarding.

G. All body transfers are to be fully enclosed with safety fencing or light screens. Access into transfer areas along carrier path will be protected with safety mats and light screens, with blanking limit switches. Pinch points that may exist when loading or unloading at screen guard level are included in this requirement.

H. All rotating head and tail shafts on floor or platform level shall be protected with expanded metal guarding.

16.13.4.

Safety Labeling

16.13.4.1

Safety and hazard signs for all pinch points, caution areas, low clearance areas, moving parts, etc., are to be installed by the Contractor in a visible area.

16.13.4.2

Safety tags shall be installed on all drives, take-ups and maintenance access areas which are potential safety hazards. Tags shall be engraved lamacoid nameplate with 2" high minimum black letters.

16.13.4.3

Safety lock-out/energy control graphics and location maps shall be installed on all conveyor drive panels with lockout tag on each device. Safety lockout graphics are to include location, method and checking procedure. Safety lockout graphics (color) shall be installed at all conveyor drive panels, sequence panels, transfer panels, fenced automation areas, drive fences and drive platforms. The graphics shall show plan layout of conveyor and automation equipment complete with all safety devices (safety mats, light screens, safety plugs, etc...). The graphics are to label all devices that disconnect/lock-out an energy source (electrical, hydraulic, pneumatic, etc.). Square vinyl stick on labels (4"x 4") with legends corresponding to each device on the sign shall be affixed to the permanent surface adjacent the device. The graphics are to be mounted in an approved plexi-glass frame. Safety lockout graphics are to include location, method and checking procedure.

16.13.4.4

Safety lock-out/energy control graphics shall be installed, as specified.

16.13.4.5

Conveyor contractor shall provide and install a conveyor stop sign at all conveyor run/stops push button stations. Signs shall be AZ approved.

16.13.5.

Pinch Points

16.13.5.1

All "carrier to field device" (stops, reducers, etc.) or platform and stairway pinch points shall be protected with angle iron guard. Angle shall be welded to units to serve as "funnel", to eliminate person from being trapped in area. Angle shall be painted safety yellow.

16.13.5.2

All Pinch points shall be identified by the Contractor and protected with safety devices (safety mat, light screen, pull cord) including in screen guard areas. Safety warning signs shall be installed at all Pinch points.

16.13.5.3

Pressure sensitive mats or light screens required at all Pinch points where production/maintenance personnel may be subjected to safety hazard.

16.13.5.4

Whenever possible, pinch points should be eliminated.

16.13.6.

Incline/Decline Safety Devices

16.13.6.1

Chain anti-runaway or anti-backup devices will be installed on all conveyor inclines or declines with elevation changes 4'-0" or greater. Chain anti-runaway or anti-backup devices shall be spaced at a maximum of 4’-0" as measured along the elevation (vertical) change. When used, a minimum of two devices per vertical curve is required, with at least one device placed on the lowest section. Chain anti-backups and anti-runaways are not required on power only vertical curves. Chain anti-backups are not required on Inverted Power and Free.

16.13.6.2

Carrier anti-backup or anti-runaway devices shall be installed on conveyor elevation changes of 4'-0" or greater. These devices shall be spaced at a maximum of every 4’-0" as measured along the elevation (vertical) change. When used, a minimum of two devices per decline is required, with at least one device placed on the lowest section.

16.13.6.3

Conveyor inclines beginning within 30’-0" of a workstation shall be equipped with carrier anti-backup devices spaced every 2’-0" along the track, through the bottom half of the vertical curve and every 4’-0" along the track for the top half of the incline.

16.13.6.4

Conveyor declines ending within 30’-0" of a work station shall be equipped with carrier anti-runaway devices as follows:

A. Top half of decline equipped with devices spaced at maximum of 4’-0" as measured along the track.

B. Bottom half of decline, including bottom radius, equipped with devices spaced on 2’-0" centers as measured along the track.

C. Bottom half devices to continue through bottom radius until carrier is fully horizontal.

16.13.6.5

Conveyor declines within an oven enclosure above 110 deg. F shall be exempt from Section 16.13.6.1 and 16.13.6.2. However, as a decline enters a "cool" zone (below 110 deg. F), all anti-runaway devices are required as discussed above.

16.13.6.6

Decline safety devices shall be provided such that when the device is tripped, an electrical device shall be actuated which will shut off the conveyor drive(s) and signal a fault at the drive panel. These safety devices shall be capable of preventing the carrier, chain or load from injuring anyone at bottom of the vertical curve.

16.13.6.7

All devices associated with incline/decline safety conveyors shall be equipped with a tag indicating all adjustments and/or settings required for proper operation

16.13.6.8

Carrier anti-backup and anti-runaway requirements on the following systems must meet the requirements of this section unless AME and Corporate Safety grant deviations.

•4" overhead systems •3" overhead systems •Enclosed track systems (i.e. Unibuilt)

16.13.7.

Noise

16.13.7.1

Contractors are responsible for providing conveyor systems with noise levels that fall within O.S.H.A. noise abatement guidelines. Areas suspect to high noise levels shall be indicated during engineering and design. Areas which are known in advance or found at start-up to be above acceptable levels shall be protected with owner approved noise abatement material.

16.13.8.

Start-Up

16.13.8.1

Only authorized Conveyor Contractor personnel shall start/ restart systems during start-up and debug phases.

16.13.8.2

Conveyor Contractor shall alert all personnel, in area, of system running schedule during start-up/debug phase.

16.13.8.3

All safety devices and interlocks are to be verified as operational prior to start-up of conveyor system.

16.13.8.4

Proper jam clearing procedures as outlined by conveyor contractor, and submitted to AZ are to be followed during all start-up/debug phases.

16.13.8.5

During the start-up/debug phase, a procedure for starting all conveyors is to be submitted to AZ for approval.

16.13.9.

Miscellaneous

16.13.9.1

Proper troubleshooting procedures on all conveyor systems shall be strictly followed during all phases of the project.

16.13.9.2

All hazardous conditions (unprotected pits, sharp edges, etc.) should be protected and labeled during installation and start-up phases.

16.13.9.3

Carrier safety cables or chains are required on all Overhead carriers, one for each load trolley.

16.13.9.4

All platforms are to be installed with proper handrail, mid-rail and toe-plate (kick-plate). All handrail, etc., to be painted safety yellow.

16.13.9.5

Six-inch wide safety yellow stripe shall be painted on each side of all in-floor conveyors, except where protected by safety yellow track seal.

16.13.9.6

Proper housekeeping of installation areas required to prevent accidents.

16.13.9.7

Foot guarding with safety striping required on all conveyor floor penetrations (example: Flat Top Conveyor at head section).

16.13.9.8

All stabilized track to be in place prior to installing work platforms.

16.13.9.9

Pressure sensitive mats and light screens shall be installed at all body transfers and carrier pinch points whether on the floor, screen guard, etc. Safety device shall stop transfer and/or all related conveyors.

16.13.9.10

Light screens and/or safety mats shall be installed on work platforms where operators may violate carrier transit area after depressing transfer ready buttons. Safety device shall stop conveyor and only be reset by depressing ready buttons.

16.13.9.11

Multi-points shall be installed in banking areas where clearances of less than 18" exist between carriers and/or parts on carriers. Safety device shall stop conveyor and only be reset by depressing ready buttons.

16.13.9.12

Power and free systems shall include tools for the use of de-dogging carriers. De-dog tools shall be hung at each elevated merge/diverge area.

16.13.9.13

All inverted power and free conveyor crossovers with a height up to and including 36" shall be minimum 3’-0" in width. Crossovers at an elevation higher than 36" shall increase in width by 1’-0" for every 1’-0" of elevation change. Handrails are required for crossovers 2’-0" or higher and must not create a pinchpoint with passing carriers or product.

16.13.9.14

Conveyor floor openings are All power only is to be finger guarded for conveyor elevations 7’-0" and less from floor level, and production platforms and in all accessible areas on platforms and on screen guard. limited to 3" in width on straight transits. Expanded openings necessary to accommodate turns must be covered with material sufficient to support personnel. In addition any opening wider than 3" in any accessible area shall have handrail on each side of the conveyor to prevent personnel from crossing the conveyor.

16.13.9.15

Attachments to the conveyor housing, such as limit switches, light beams, proximity switches, etc., and their mounts must be installed with sufficient clearance to moving parts, assuring the absence of trapping points.

16.13.9.16

Powered and un-powered track switch sections must be painted yellow with diagonal black stripes and conspicuously labeled with safety signage. The track switch tongue itself will be painted safety orange. A conveyor run/stop station for each chain shall be located at the track switch for Overhead P&F systems and on each side of the conveyor for Inverted P&F systems.

16.13.9.17

All track switches that are in stabilized track areas (the switch is below floor or platform level) shall have diverter mechanisms on them. The diverter mechanism will restrict personnel from stepping into the track opening at the switch.

16.13.9.18

Provide minimum clearance of 18" between all empty and loaded carriers and walls, fences and other conveyor components.

16.13.9.19

All powered roll conveyor shall have fully enclosed chain drives and no protruding screws, bolt heads, etc.

16.13.9.20

Inverted conveyor in which the power and free track is above floor level to have side skirting in production and high traffic area.

16.13.9.21

All devices with vertical motion greater than 6" shall have a method of securing (pinning and/or chaining) the unit at each end of travel. Securing mechanism shall be lockable. The safety devices will have an interlock plug to E-Stop the device when removed from the storage position.

16.13.9.22

All devices with powered horizontal motion greater than 6" shall have a method of securing (pinning or chaining) the unit at both ends of travel. Securing mechanism shall be lockable. The safety devices will have an interlock plug to E-Stop the device when removed from the storage position.

16.13.9.23

All devices with vertical lift motion greater than 4' shall have an anti-drop mechanism that acts on the load (a brake on the drive motor doesn't qualify).

16.13.9.24

In addition, these lifts shall include interlocked safety lockout chains, which shall secure the carriage and load anywhere in its travel. The lockout chains will have an interlock plug to E-Stop the lift when removed from the storage position.

16.13.9.25

Carrier and product entering screen guard or platforms shall have a vertical clearance of at least 1’-0" at the entrance section, as measured from the lowest point of the carrier/product to any steel below the carrier. Exceptions shall require approval by AZ Manufacturing Engineering and AZ Corporate Safety.