GUDEL ZP 3-5 V4 Operating Manual Download Page 323

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nor

Moderate

Often

requent

The following should be
prevented:

1.1

x x x x x x x x x x x x x x

Processing of hazardous
materials. Fire and danger of
explosion.
Thermal factors

All

Non-compliance with the intended
use

Someone is injured or killed

x x

10 3/d Someone is injured or killed

Intended use: Güdel devices are only used to bring objects to a specific position,
hold them there or move them simultaneously with other machine movements.
No hazardous (e.g. poisonous or explosive) objects must be moved. Güdel devices
must not be operated in potentially explosive areas. The ambient temperature during
operation must be between 5° and 40 °C.

If the intended use is modified, this can result in hazards that are
not covered by the safety concept.

x Y

1.2

x x x

x x x x

Suspended load

Technician,

forwarding

agent,

commissioning

technician

Faulty lashing of slings, improper
use, defective or insufficient hoists

Injuring or killing of persons due to
components falling down

x x

10 3/d Persons are injured or killed by

falling parts.

Use appropriate lifting equipment. Wear protective clothing. Keep a safe distance.
Observe the operating manual. Never step below suspended loads

None

x Y

1.3

x x x

x x x x

Heavy load

Technician,

forwarding agent

Lifting without auxiliary agents,
falling

Physical injuries

x x

10 3/d Persons are injured

Use suitable lifting units. Use trained personnel as well as protective clothing

None

x Y

1.4

Movement of the axes

Setters

Unexpected start

Someone is surprised by the
unexpected situation and injured as a
result

x x

10 3/d When the enable button is

pressed, the operator is
exposed to a hazard due to an
automatic movement triggered
by a third party.

Axes can only be moved individually by a two-hand operating device in jog mode. In
the event of several carriages on a single gantry, the individual carriages have to be
selected using a key switch. The enable button is a "shock button".
For the enable button to be activated, only one safety door may be open and the
others must be closed and confirmed. Safety-relevant parts of the control are
inspected at appropriate time intervals by the machine control system.

In confirmation mode, the operator must pay great attention and
have a high level of individual responsibility. Only perform
movements if no other person is in the danger area and none of
your own body parts are in the line of danger of the corresponding
axis.

x Y

1.5

Movement of the axes,
suspended loads
(vertical axes and
workpieces)

Operator,

maintenance

personnel,

commissioning

technician

Gripper problems
Defective motor brake
General problems in the drive train

Someone is surprised by vertical
movement and injured as a result.

20 3/d That neither operating

personnel nor third parties can
reach or walk into the
hazardous locations where
automatic movements are
performed. The areas of
movement must be secured
accordingly.

The areas of movement are enclosed by light grids, light curtains as well as
mechanical safety fences so that it is impossible to enter this area from any
direction.
There are door elements or light barriers that allow access to the danger area or to
a portion of the danger area.
The height of the safety fences is described in EN ISO 13857.
Safety shutdown situation:
The vacuum system remains active in a de-energized state.

Door elements: When opening the danger area, a safety shutdown is performed for
at least those drives that pose a hazard in this area.
The door elements are also locked electromechanically.

Light barriers: These are monitored so that when contact is broken, at least those
drives that pose a hazard in this area are shutdown. The distance between the source
of the danger and the light barriers is described in EN ISO 13855.

In normal operation, all protective hoods must be closed.
Removable protective hoods must be screwed securely.

Required behavior:
Inspect the protective hoods before starting normal operation.

Safety shutdown situation: Never step into the area below
suspended workpieces and vertical axes.

x Y

1.6

x x

Movement of the axes,
suspended loads
(vertical axes and
workpieces)

Technician,

forwarding agent

Removal of transport securing
device without supporting
suspended loads and axes.

Someone is surprised by the
unexpected movement and injured as
a result

x x

10 3/d Suspended loads fall.

Before removing the transport securing device, support the suspended loads or axis.
If motors or gearboxes are removed, vertical axes must always be secured or
supported.

None

x Y

1.7

x x x x

Movement of the axes.
Parts are flung out

Operator,

maintenance

personnel,

cleaning

personnel

Unexpected start

Someone is surprised by the
unexpected situation and injured as a
result

x x

10 3/d A person is injured by the

unexpected start-up of moving
parts.

The start-up of the plant without the enable button being pressed or available must
be prevented.
With the permission device pressed, moving plant parts can be moved in a controlled
manner, even if the plant is unsecured.
When the enable button is pressed, it must not be possible for the operator to be
endangered by an automatic movement triggered by a third party.

The lockable main plant switch breaks all main and control circuits.

Never step into the area below suspended workpieces and vertical
axes.

In confirmation mode, the operator must pay great attention and
have a high level of individual responsibility.

If motors or gearboxes are removed, vertical axes must always be
secured or supported.

x Y

1.8

Parts flung out

Setter,

third parties

Gripper problems, defective motor
brake, torn belt (telescopic axis),
pressure drop (load balancing),
general problems in the drive train

Someone is surprised by parts flying
off and injured as a result.

x x

10 3/d Parts are flung out.

The axes can only be moved with reduced speed.
Rotating parts must be shut down securely.

Work in this mode requires great attention and a high level of
individual responsibility from the operator. Only perform
movements if no other person is in the danger area and none of
your own body parts are in the line of danger of the corresponding
axis.

x Y

1.9

Parts flung out

Operator,

third parties

Parts clamped improperly
Breakage of rotating tools

Someone is surprised by parts flying
off and injured as a result.

x x

10 3/d Operating personnel or third

parties are injured by parts that
become loose and fly away.

Mechanical guards must be placed in the possible flight path of parts that could fly
away.
Safety devices are inspected by means of calculation and trial.

In normal operation, all protective hoods must be closed,
removable protective hoods must be screwed securely.
Required conduct: Inspect the protective hoods before starting
normal operation.

x Y

1.10 x

x x x x

Parts flung out

Operator,

third parties

Carrier hits mech. buffer unit.
Moving parts are torn out of their
holder and hurled away due to the
delay which occurs.

Someone is surprised by parts flying
away and injured as a result.

x x

10 3/d Operating personnel or third

parties are injured by parts that
become loose and fly away.

Attachments to moved masses (vertical and horizontal axes) must be fastened in such
a manner to prevent them from being separated or sheared off due to the delay. The
max. delay must be calculated. The calculation of the fastening and loading of the
attachments must also be taken into account in the construction.

Workplaces and operating devices in the direction of travel should
be avoided as far as possible.

x Y

1.11

Suspended loads
(vertical axes, telescope
axes, counter balance
cylinders, and workpieces)

Setters

Gripper problems, defective motor
brake, torn belt (telescopic axis),
pressure drop (load balancing),
general problems in the drive train

Person is surprised by unexpected
situation and injured as a result.

x x

10 3/d It must be ensured that when

the enable button is not
pressed, no persons can be
endangered by falling vertical
axes, telescope axes or
workpieces.

Grippers must remain in the de-energized state in clamping position.
To minimize risk, vertical axes can be redundantly equipped with an additional
brake.
Telescope axes and counter balances: Special attention is required here. The axis
(for a telescope axis, the 2nd stage) is to be secured with a mechanism. Operation in
setup mode only when the restricted area is closed off.

Do not walk under suspended workpieces or vertical axes. Take
special care with telescope axes. Inspect belts visually for cracks
and tears before every setup procedure.

x Y

1.12

Suspended loads
(vertical axes, telescope
axes, counter balance
cylinders, and workpieces)

Setters

Inattention and/or careless
operation by operator

Someone is surprised by the
unexpected situation and injured as a
result

x x

10 3/d Workpieces are dropped

accidentally

Grippers can only be operated in the storage position.

Do not walk under suspended workpieces or vertical axes. Take
special care with telescope axes. Inspect belts visually for cracks
and tears before every setup procedure.

x Y

Safety goal

(negation of the event)

robability of

occurrence

isk assessment (<

; 4-8; 9-20; >

Internal assembly

Special operating modes

rmal

operati

zard no.