Ansi B11.23-2002 (R2007)

ANSI B11.
23–2002 (R07)
American National Standard for Machine Tools –
Safety Requirements for Machining

Centers and Automatic, Numerically
Controlled Milling, Drilling and
Boring Machines
Secretariat and Accredited Standards Developer:
The Association For Manufacturing Technology

7901 Westpark Drive
McLean, VA 22102
Approved: June 14, 2002

Reaffirmed: August 28, 2007
by the American National Standards Institute, Inc.
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ii
AMERICAN NATIONAL STANDARDS
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Published by: AMT – The Association For Manufacturing Technology

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Copyright © 200X by the Association For Manufacturing Technology
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Table of Contents Page
FOREWORD..............................................................................................................................................................V
EXPLANATION OF THE FORMAT OF THIS STANDARD, AND ANSI B11 CONVENTIONS .............................VII
INTRODUCTION.....................................................................................................................................................VIII
1 SCOPE................................................................................................................................................................ 1
2 NORMATIVE REFERENCES............................................................................................................................. 1
3 DEFINITIONS ..................................................................................................................................................... 3
4 RESPONSIBILITY .............................................................................................................................................. 6
4.1 SUPPLIER'S RESPONSIBILITY ...................................................................................................................... 6
4.2 USER'S RESPONSIBILITY ............................................................................................................................. 7
4.3 PERSONNEL RESPONSIBILITY ..................................................................................................................... 9
5 HAZARD CONTROL ......................................................................................................................................... 10
5.1 TASK AND HAZARD IDENTIFICATION ......................................................................................................... 10
5.2 RISK ASSESSMENT / RISK REDUCTION ..................................................................................................... 11
6 DESIGN AND CONSTRUCTION ..................................................................................................................... 12
6.1 GENERAL ................................................................................................................................................... 12
6.2 COMPONENT SELECTION .......................................................................................................................... 12
6.3 MACHINE CONTROLS................................................................................................................................. 12
6.4 MODES OF OPERATION ............................................................................................................................. 12
6.5 ELECTRICAL EQUIPMENT .......................................................................................................................... 12
6.6 HYDRAULIC AND PNEUMATIC SYSTEMS ................................................................................................... 13
6.7 EXTERNAL POWER SOURCES ................................................................................................................... 14
6.8 STORED ENERGY ...................................................................................................................................... 15
6.9 EXTERNAL INTERFERENCES ..................................................................................................................... 15
6.10 PERFORMANCE OF SAFETY-RELATED FUNCTION(S)................................................................................ 15
6.11 MACHINE STARTING .................................................................................................................................. 15
6.12 STOP AND EMERGENCY STOP CONTROLS ............................................................................................... 16
6.13 OPERATOR CONTROL STATIONS .............................................................................................................. 17
6.14 MANUALLY OPERATED CONTROL DEVICES .............................................................................................. 17
6.15 INDICATORS ............................................................................................................................................... 19
6.16 ANTI-MOTION MECHANISMS OR COUNTER-BALANCE SYSTEMS........................................................... 19
6.17 POWER-OPERATED WORKHOLDING ......................................................................................................... 20
6.18 COOLANT SYSTEMS .................................................................................................................................. 20
6.19 TOOL HOLDER RETENTION........................................................................................................................ 22
6.20 ELIMINATION OF, OR PROTECTION FROM INHERENT HAZARDS ............................................................... 22
6.21 SAFEGUARDING ......................................................................................................................................... 23
6.22 ACCESS TO MACHINE PARTS .................................................................................................................... 27
6.23 EJECTED PARTS OR FLUIDS ...................................................................................................................... 27
6.24 VIEWING WINDOWS ................................................................................................................................... 27
6.25 STRUCTURAL INTEGRITY .......................................................................................................................... 27
6.26 NOISE......................................................................................................................................................... 27
6.27 MIST, FUMES, VAPORS AND DUST ............................................................................................................ 28
6.28 ERGONOMIC CONSIDERATIONS ................................................................................................................ 28
6.29 ENERGY SUPPLY FAILURES ...................................................................................................................... 28
6.30 ERRORS OF FITTING .................................................................................................................................. 28
6.31 LIFTING OF MACHINE COMPONENTS......................................................................................................... 28
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7 LAYOUT, INSTALLATION, TESTING AND START-UP................................................................................... 29
7.1 GENERAL ................................................................................................................................................... 29
7.2 LAYOUT AND INSTALLATION ...................................................................................................................... 29
7.3 TESTING AND START-UP ........................................................................................................................... 29
8 SAFEGUARDING............................................................................................................................................. 30
8.1 GENERAL ................................................................................................................................................... 30
8.2 GUARDS ..................................................................................................................................................... 30
8.3 SAFEGUARDING DEVICES ......................................................................................................................... 31
8.4 AWARENESS BARRIERS AND DEVICES ..................................................................................................... 32
8.5 SAFEGUARDING AGAINST SPECIFIC HAZARDS ......................................................................................... 32
8.6 SAFE WORK PROCEDURES ....................................................................................................................... 33
8.7 PERFORMANCE OF THE SAFETY–RELATED FUNCTION(S) ....................................................................... 33
9 SET-UP, OPERATION AND MAINTENANCE................................................................................................. 34
9.1 GENERAL ................................................................................................................................................... 34
9.2 MACHINE SET–UP PROCEDURES .............................................................................................................. 34
9.3 SAFEGUARDING......................................................................................................................................... 35
9.4 MAINTENANCE ........................................................................................................................................... 35
9.5 PERSONAL PROTECTIVE EQUIPMENT ....................................................................................................... 36
9.6 TRAINING ................................................................................................................................................... 37
9.7 SUPERVISION ............................................................................................................................................ 38
9.8 INITIATION OF NORMAL OPERATION ......................................................................................................... 38
ANNEX A – FIGURES (INFORMATIVE) .............................................................................................................. 39
ANNEX B -- LIST OF HAZARDS AND HAZARDOUS SITUATIONS (INFORMATIVE) ....................................... 42
ANNEX C – PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S) (INFORMATIVE)............................ 45
ANNEX D – SAFETY DISTANCE (INFORMATIVE)............................................................................................... 46
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Foreword (This Foreword is not part of the requirements of American National Standard B11.23-2002)
The primary objective of this standard is to eliminate or control hazards to personnel associated with machining
centers and automatic numerically controlled milling, drilling and boring machines by establishing requirements
for the construction, operation and maintenance of these machines. To accomplish this objective, responsibilities
have been assigned to the supplier (e.g., manufacturer, rebuilder, reconstructor, installer, integrator), the user,
and personnel in the working environment.
The words "safe" and "safety" are not absolutes. Safety begins with good design. While the goal of this standard
is to eliminate injuries, it is recognized that risk factors cannot be practically reduced to zero in any human
activity. This standard is not intended to replace good judgment and personal responsibility. Operator skill,
attitude, training, job monotony, fatigue and experience are safety factors that must be considered by the user.
Machining centers and automatic numerically controlled milling, drilling and boring machines, and associated
equipment technologies are continuously evolving. This standard reflects the most commonly used and time-
tested state of the art at the time of its approval. The inclusion or omission of language relative to any evolving
technology, either in the requirements or explanatory area of this standard, in no way infers acceptance or
rejection of such technologies.
Inquiries with respect to the application or the substantive requirements of this standard, and suggestions for its
improvement are welcomed, and should be sent to the AMT – The Association For Manufacturing Technology,
7901 Westpark Drive, McLean, Virginia 22102-4206, Attention: B11 Secretariat.
This standard was prepared by the B11.23 Subcommittee, processed and submitted for ANSI approval by the
B11 Accredited Standards Committee on Safety Standards for Machine Tools. Committee approval of this
standard does not necessarily imply that all committee members voted for its approval. At the time this standard
was approved as an American National Standard, the ANSI B11 Accredited Standards Committee was composed
of the following member organizations:
John W. Russell,PE, CSP Chairman

Gary D. Kopps, Vice-Chairman
David A. Felinski, Secretary
Organizations Represented Name of Representative(s)
Delegate Alternate
Aerospace Industries Association of America Willard Wood Robert Eaker
Alliance of American Insurers John Russell, PE, CSP Keith Lessner
Aluminum Extruders Council Jeff Dziki Martin Bidwell
American Insurance Service Group Henry S. Pankiw Paul Frenier
American Institute of Steel Construction Thomas Schlafly
American Society of Safety Engineers Bruce Main, PE, CSP George Karosas, PE, CSP
AMT – The Association For Manufacturing Russell Bensman
Technology
Can Manufacturers Institute Geoff Cullen
Deere and Company Gary D. Kopps Kent D. Johnson
Forging Industry Association John W. Commet Karen Taylor
General Motors Corporation Michael Taubitz
Graphic & Product Identification Mfgs. Assn. Donald Root
International Association of Machinists & Jim Soptic Ken Hass
Aerospace Workers, District Lodge 142
Intl. Union, United Automobile, Aerospace and Jim Howe, CSP Luiz Vazquez
Agricultural Implement Workers of America (UAW)
Machinery Dealers National Association John Stencel, III James Heppner, Jr.
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Metal Building Manufacturers Association Charles M. Stockinger Charles E. Praeger
Metal Powder Industries Federation Dennis Cloutier, CSP Donald White
National Electrical Manufacturers Association Vincent A. Baclawski Frank Kitzantides
National Fluid Power Association June VanPinsker
National Institute for Occupational Safety & Health John Etherton, PhD, PE
National Tooling and Machining Association Andy Levine Richard R. Walker
Precision Metalforming Association Christopher E. Howell Christie Carmigiano
Presence-sensing Device Manufacturers Jim Kirton Barry Stockton
Rubber Manufacturers Association Kim Weber Robert Walker
Sheet Metal and Air Conditioning Contractors' James T. Strother Tom J. Meighen
National Association
Tooling and Manufacturing Association Jeffery W. Hayes Bruce C. Braker
Unified Abrasives Manufacturers’ Association, Charles S. Conant
Bonded Division
U.S. Department of the Navy (NAVSEA) William Riley William Aberg
At the time this standard was approved, the ANSI B11 ASC B11.23 Subcommittee had the
following members who participated in the development of this standard:
Name Company Title

Miles Loretta Cincinnati-Milacron Chairman
John F. Bloodgood, PE JFB Enterprises Secretary
Anthony M. Bratkovich, PE AMT Administrator
Lance Chandler Boeing
Aaron Clark Lamb-Technicon
Shawn P. Creighton Monarch
David W. Demco General Motors
Robert Garcia Caterpillar
Kent Johnson Deere
Mark Perriello Westinghouse
Mark Reitzel Cellular Concepts
William E. Riley U.S. Navy
Mark Vetty Okuma
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This ANSI B11.23 – 2002 American National Standard is divided
Explanation of into parts formerly referred to as sections or chapters and now
the format of referred to as clauses in line with the current ANSI style manual.
Major divisions of clauses are referred to as subclauses and,
this standard, when referenced by other text in the standard, are denoted by the
and ANSI B11 subclause number (e.g., see 5.1).
conventions The standard uses a two-column format to provide supporting

information for requirements. The material in the left column is
confined to “Standard Requirements” only, and is so captioned.
The right column, captioned "Explanatory Information" contains
information that the writing Subcommittee believed would help
clarify the standard. This column should not be construed as
being a part of the requirements of this American National
Standard.
As in all American National Standards, the term “SHALL” denotes

a requirement that is to be strictly followed in order to conform to
this standard; no deviation is permitted. The term “SHOULD”
denotes a recommendation, a practice or condition among several
alternatives, or a preferred method or course of action.
Similarly, the term “CAN” denotes a possibility, ability or capability,

whether physical or causal, and the term “MAY” denotes a
permissible course of action within the limits of the standard.
B11 conventions: Operating rules (safe practices) are not

included in either column of this standard unless they are of such
nature as to be vital safety requirements, equal in weight to other
requirements, or guides to assist in compliance with the standard.
The B11 standards do not use the term “and/or” but instead, the
term “OR” is used as an inclusive disjunction, meaning one or the
other or both. A distinction between the terms “individual” and
“personnel” is drawn. Individual includes personnel (employees,
subcontractors, consultants, or other contract workers under the
indirect control of the supplier or user) but also encompasses
persons who are not under the direct or indirect control of the
supplier or user (e.g., visitors, vendors, etc.). Gauge refers to a
measuring or testing instrument; gage refers to limiting device
(e.g., backgage).
Suggestions for improvement of this standard will be welcome.

They should be sent to AMT-The Association For Manufacturing
Technology, 7901 Westpark Drive, McLean, VA 22102 - Attention:
B11 Secretariat.
vii
Introduction
The primary purpose of every machine tool is to process parts. This is accomplished by the machine imparting
process energy onto the workpiece. Inadvertent interference with, or accidental misdirection of the released
energy during production, maintenance, commissioning and de-commissioning may result in injury.
The purpose of the ANSI B11 series of machine tool safety standards is to devise and propose ways to minimize
risks of the potential hazards. This can be accomplished by an appropriate machine design, by restricting
personnel or other individuals’ access to hazard areas, and by devising work procedures to minimize personnel
exposure to hazardous situations. This is the essence of the ANSI B11 series of safety standards.
The responsibility for the alleviation of these risks is divided between the equipment supplier, its user and its
operating personnel, as follows (numbers in parentheses refer to the clause numbers in these standards which
address that responsibility):
SUPPLIER USER PERSONNEL

Responsible for:
Instruction manual Overall workplace safety Comply with

Operation manual Maintenance and inspection procedures instructions
Maintenance manual Training (4.3)
(4.1) (4.2)
Task and hazard

identification (5.1)
Risk assessment/risk
reduction (5.2)
For task/hazard combinations
for which the standard does not
provide protective measures,
Design and construction (6)
apply the principles of B11.TR3
Layout, installation, testing

NFPA 79 and start-up (7)
Safeguarding (8)
B11.19 Set-up, operation and

maintenance (9)
viii
American National Standard B11.23–2002 (R07)
American National Standard for Machine Tools –

Safety Requirements for Machining Centers and Automatic,
Numerically Controlled Milling, Drilling and Boring Machines
STANDARD REQUIREMENTS EXPLANATORY INFORMATION
(This column is not part of the requirements of this
American National Standard for Machine Tools – Safety
Requirements for Machining Centers and Automatic,
Numerically Controlled Milling, Drilling and Boring
Machines, ANSI B11.23-2002).
1 Scope E1
This standard specifies the safety requirements for the This standard is not intended to cover safety
design, construction, operation and maintenance (including requirements of manufacturing systems/cells (see
installation, dismantling, and transport) of machining B11.20).
centers and automatic numerically controlled milling,
drilling and boring machines (see 3.1).
This standard is applicable to machines where the axes of Larger machines may comply with this standard or
travel is not greater than 1x1x1 m (39x39x39 in.). use other effective means to reduce the risks
associated with the identified hazards.
1.1 Machining center E1.1

A machining center is a numerically controlled machine A machining center can also include, but is not
tool with automatic tool changing capability and work limited to, functions such as gaging, burnishing,
support means capable of multiple functions of drilling, grinding and machining operations that are not
milling, boring or any combination of these operations covered in this standard. A machining center may
normally utilizing a rotating tool. This machine operates in have one or more spindles, work stations and may
a continuous sequence of movements under numerical include an automatic work changing means.
control (NC).
NOTE - The terms machine and machinery as used throughout

this standard mean machining center.
2 Normative references E2 Informative references

The following normative documents contain provisions All normative documents are subject to revision and
that, through reference in this text, constitute provisions of users of this standard are encouraged to
this American National Standard. At the time of investigate applying the most recent revisions of the
publication, the editions indicated were valid. normative references listed in clause 2.
The following documents (this column, below) are

listed for information only, and are not essential for
the completion of the requirements of this standard:
ANSI Z 244.1-1982, Safety Requirements for the Lock ANSI B11.TR1 – 1994 Ergonomic Guidelines for
Out/Tag Out of Energy Sources the Design and Installation of Machine Tools
ANSI B93.114M, Pneumatic Fluid Power – Systems ANSI B11.TR2 – 1997 Mist Control Considerations
Standard for Industrial Machinery for the Design, Installation and Use of Machine
Tools Using Metalworking Fluids
1
Standard Requirements Explanatory Information
NFPA/T2.24.1 R1-2000, Hydraulic Fluid Power – Systems ANSI B11.TR3 – 2000 Risk Assessment and Risk
Standard for Stationary Industrial Machinery- Supplement Reduction – A Guide to Estimate, Evaluate and
to ISO 4413: 1998, Hydraulic fluid power – General rules Reduce Risks Associated with Machine Tools
relating to systems
ANSI B11.19-1990, Performance criteria for the design,

construction, care and operation of safeguarding when
referenced by other B11 machine tool safety standards
ANSI A14.3-1984, Safety requirements for fixed ladders
ANSI / ASME-2001 Boiler and Pressure Vessel Code;

Division 1, Section VIII
ANSI / ASME B15.1-1992, Mechanical Power

Transmission Apparatus
ANSI / NFPA 70-2002, National Electrical Code
ANSI / NPFA-70E-1994, Electrical Safety Requirements

for Employee Workplaces
ANSI / NFPA 79-2002, Electrical Standard for Industrial

Machinery
ANSI / IEEE Std. 518: 1982, IEEE Guide for the Installation
of Electrical Equipment to Minimize Electrical Noise Inputs
to Controllers from External Sources
ANSI / IES-RP-7-1991, Industrial Lighting
NMTBA (AMT) Noise Measurement Techniques (1976) Organization Resources Counselors (ORC)
Management of the Metal Removal Fluid
Environment: A Guide to the Safe and Efficient Use
of Metal Removal Fluids (www.orc-dc.org)
Metalworking Fluids: Safety and Health Best

Practices Manual (OSHA) (www.osha-
slc.gov/SLTC/metalworkingfluids).
2
3 Definitions
For the purposes of this standard, the following definitions
apply.
3.1 automatic operation: continuous sequence of

movements of a machine in accordance with the control
data until stopped by the program or the operator.
3.2 awareness device: An attachment that by

physical contact warns personnel of an approaching or
present hazard.
3.3 awareness signal: A signal that, by means of

audible sound or visible light, warns of a present or
approaching hazard.
3.4 control reliability: The capability of the machine

control system, the safeguarding, other control
components and related interfacing to achieve a safe state
in the event of a failure within their safety-related functions.
See also, 3.23.
3.5 fixture: A means used to locate or support E3.5 Examples of fixtures are universal tables,
material or workpieces or tools [tooling] during operation. angle plates, trunnions, rotating tables, and other
removable workholding equipment.
3.6 guard: A barrier, which prevents entry into the

work zone or other hazard area [zone].
3.7 hazard: A condition or set of circumstances that

can cause physical harm to exposed personnel
3.8 helper: An individual who assists another in the

operation, maintenance or repair of the machine.
3.9 hold-to-run control device: Control device, which

initiates and maintains operation of machine elements only
as long as the manual control (actuator) is actuated.
3.10 immediate stop command: A command that

initiates an action(s) to stop hazardous motion [situation] at
any point in the machine cycle.
3.11 installer: An individual, partnership or corporation

responsible for placement and preparation for use of a
machine.
3.12 integrator: Any supplier that designs, provides, E3.12 The machine referred to here means that
manufactures or assembles a machine, its associated which is within the scope of this standard.
machines or equipment, the safeguarding, control
interfaces, interconnections or the control system into a
machine production system. See also supplier.
3.13 jog: To impart motion by momentary manual

operation of the jog control device.
3
3.14 manufacturer: Any supplier that designs, E3.14 The machine referred to here means that
manufactures or assembles machines or systems. See which is within the scope of this standard.
also supplier.
3.15 monitoring: The checking of system components

to detect a failure of a component, subassembly or module
that affects the performance of the safety-related functions.
3.16 normal stop command: A command that initiates

an action(s) to stop motion(s) or situation(s) at the end of a
machine cycle or at other points required by the machine
functions.
3.17 numerical control (computer numerical control)

(NC, CNC): Automatic control of a process performed by a
device that makes use of numeric data introduced while
the operation is in progress.
3.18 operator: An individual who performs production

work and who controls the machine.
3.19 operator's control station: The complement of

controls used by the operator to operate the machine.
3.20 pinch point: An area, excluding the work zone or E3.20 The term "pinch point," as used in this
trapping space that poses a hazard by exposure to moving standard, refers only to hazards that may exist as a
parts of the machine, its related machines or equipment or part of the machine or its associated parts. The
the material or workpieces. expression is not used to describe hazards caused
by the tooling at the trapping space, since these
hazards are a different problem and require
different treatment.
3.21 programmable electronic system (PES): An

electronic system that performs logical, decision-making or
arithmetic functions by executing instructions in a specific
manner. A PES usually includes input and output
elements (ports) and is usually re-programmable.
3.22 redundancy: The use of multiple means to

perform the same function.
3.23 safety-related function: That portion of the

control system or safeguarding device that eliminates
exposure to a hazardous situation or reduces exposure to
a tolerable level.
3.24 safeguarding: methods for protection of

personnel from hazards using guards, safety devices or
safe work procedures.
3.25 set-up: The process of adjusting the machine and

the installation and adjustment of workholding devices or
tooling and appropriate safeguarding to ensure proper and
safe operation of the machine.
4
3.26 shield:
1) A barrier used to keep chips or coolant(s) within the
machine.
2) A barrier used to reduce the potential of tooling parts or
workpieces from being ejected from the machine.
3.27 stop: immediate or controlled cessation of

machine motion.
3.28 stop command: An action to cause cessation of

press motion either automatically or through human
intervention.
3.29 stop control: An operator control used to initiate a

machine stop.
3.30 supplier: An individual, corporation, partnership or E3.30 For the purpose of this standard, a supplier
other legal entity or form of business that provides or provides or makes available for use all or part of the
makes available for use all or part of the machine. machine.
NOTE – When the user provides any of the above services, the Besides the manufacturer, the supplier can include
user is considered to be the supplier within the scope of that work the manufacturer’s agent, representative, or
activity. distributor, reseller, installer, modifier, rebuilder or
integrator who provides equipment or services
associated with the machine.
3.31 tool [tooling]: Instrument [instrumentation] used
in a machine tool to cut or shape material.
3.32 tool trapping space: The space where it is

possible to trap body parts between the tooling or its
mounting and the workpiece or workholding equipment.
3.33 user: An entity that utilizes machines and related

equipment.
3.34 warning [warning device/signal]: A means used

to call attention to a hazard or unsafe work practice.
3.35 work zone: The space within the machine where

the metal cutting process takes place.
5
4 Responsibility
4.1 Supplier's responsibility E4.1
It shall be the responsibility of the supplier (e.g., The supplier should refer to clause 2 for applicable
standards relative to the product or service
manufacturer, reconstructor, modifier, installer, integrator)
to design and construct the machine in accordance with provided by that supplier. When safety standards
clauses 5, 6 and 8 of this standard. are not provided, safeguarding techniques used on
similar equipment should be applied to this type of
The supplier shall identify the sources of hazards (see equipment, where applicable.
5.1).
The supplier shall eliminate or provide the means for

controlling the identified hazards by implementing a hazard
control strategy (see 5.2).
The supplier shall provide instructional material for The machine documentation should contain the
installation, testing, start-up, operation, safeguarding, and following:
maintenance.
a) a clear, comprehensive description of the
machine and its installation including:
• foundation requirements (e.g., space
allocation, dynamic loading);
• power consumption requirements;
• equipment layout;
• major component weights;
• work area safeguarding;
• preparation prior to start-up;
• energy sources;
• procedures for transporting and lifting,
erection, commissioning and
decommissioning;
• the system performance specifications;
• physical environment requirements
(e.g., lighting, vibration, noise levels,
airborne contaminants);
b) information on the:
• programming;
• operation;
• frequency of inspection;
• frequency and method of functional
testing;
• guidance on the repair and
maintenance of the machine and its
safeguards.
6
The supplier shall provide an operator’s manual and a These manuals should include the following
maintenance manual with each machine. information:
• function and location of all controls;

• spindle speeds; horsepower; table speeds;
length of travel of the slide, spindle, etc.;
• lubrication specification, including
recommended lubricants, frequency of
lubrication, and locations to be lubricated;
• electrical, hydraulic, lubrication, and
pneumatic diagrams;
• periodic maintenance instructions;
• safety instructions for operators, helpers, set–
up and maintenance personnel.
Due to the wide variety of machines covered in this

standard, specific machines may require additional
information.
The supplier shall equip each machine with safeguards

(e.g. guards, safeguarding (protective) devices) as
appropriate.
The supplier shall be responsible for providing means of

isolating or dissipating stored energy associated with the
machine.
The supplier shall furnish, in writing or by diagram, the

clearances needed by personnel for lubrication,
adjustment, chip removal, coolant reservoir cleaning and
similar routine maintenance activities.
4.2 User's responsibility E4.2

The user shall be responsible for the overall workplace The user should provide, or require others to
safety of personnel. The user shall review the machine provide the necessary safeguarding.
and its associated equipment including installation and set-
up and any modifications as provided by the supplier(s) to
ensure their compliance with clauses 5, 7, 8 and 9 of this
standard.
The user shall ensure that:

a) The recognized hazards for the tasks to be One method that may be used to identify hazards
implemented on the machine are identified (see 5.1); and establish a hazard control strategy is to form a
b) The protective measures required for the tasks team of individuals from the various disciplines
identified in 4.2 a) are provided and used in involved with the design, construction, care and use
accordance with clause 8 (see 5.2); of the machine.
7
c) The safeguarding required to eliminate or control the

identified hazards as provided by the supplier is
used and maintained in accordance with clause 8 of
this standard (see 5.2);
d) A procedure for the inspection and maintenance of User should consult the supplier's instructional
the machine is established to ensure that its parts, material regarding the unpacking, handling,
safeguarding, and other safeguarding (protective) installation and operation including safeguarding
devices are in safe operating condition and and maintenance of the machine.
adjustment;
e) Correct and safe working procedures are being
followed.
The user shall ensure that the machine operator, helper, or

set-up person follows the instructions and directions set
forth by the user to meet the requirements of this standard.
The user shall ensure that all set–up and maintenance

personnel and operators are trained to perform the
functions for which they are responsible. The training shall
include making the employees familiar with the portions of
this standard related to their work. (See also, clause 9).
The following shall be considered as minimum and shall be

expanded as it applies to a particular condition:
a) the function, location and use of all controls;
b) a safe method for installing, removing, and adjusting
tooling;
c) the location and method for installation and
adjustment of all safeguarding (protective) devices
and guards, and the use of safe working procedures;
d) the control strategy designed to eliminate or reduce
the identified hazards.
The user shall designate, provide, and ensure the use of at

least one of the following methods of safeguarding that
affords protection for the operator consistent with the
requirements of the task:
1) guard(s) (see also, 8.2);
2) safeguarding device(s) (see also, 8.3);
3) awareness barrier(s) or an awareness device(s)
(see also, 8.4);
4) safe working procedure(s) (see also, 8.6).
The user shall be responsible for:

• availability and use of tools suited to the particular
operation being performed;
• availability and use of the proper tool holder or
adapter for the machine and operation being
performed;
• ensuring that tool holders or adapters are securely
held by the machine and securely hold the tool;
• providing a safe method of handling tools (e.g.,
safe working procedure – see 8.6);
• ensuring that the workholding device is properly
set.
8
The user shall determine what personal protective

equipment is required and shall train personnel and
enforce the use of the equipment.
The user shall establish and follow a lockout/tagout

procedure that will limit personnel to exposure from
unintended machine motion that can cause injury during
repair, servicing, set–up, or adjustment of machines (see
ANSI Z 244.1).
4.3 Personnel responsibility E4.3

The operator shall comply with the instructions of the user Examples of the machine operator's, helper's, or
concerning safe methods of operation of the machine. set-up person's responsibilities:
• Follow all safety practices and procedures
given in this standard that apply to his/her
actions and conduct;
• Notify their supervisor when they observe
an unsafe practice or condition;
• Properly use all personal protective
equipment as specified by the user;
• Install, position, or adjust safety devices as
instructed by the user under the provisions
of this standard;
• Do not alter, remove, or disable any safety
equipment without the approval of the user;
• Make a visual safety check of the set-up
during each shift. Severe operating
conditions should require more frequent
checking;
• Do not wear clothing or jewelry that will
present a hazard to their personal safety;
• Maintain an orderly work area. Particular
attention should be given to the storage of
tools or parts that could be dislodged and
fall or roll;
• Never slow or stop the spindle or workpiece
by hand-gripping. Never use improvised
braking devices (e.g., pry bar);
• Keep work areas clean of oil and coolant to
prevent slipping hazards.
9
5 Hazard Control
5.1 Task and hazard identification E5.1
Reasonably foreseeable tasks and associated hazards Task identification should take into account, but not
shall be identified throughout the life cycle (design, be limited to the following task categories:
installation, set-up, operation and maintenance) of the • packing and transportation;
machine. • unloading/unpacking;
• systems installation;
• startup/commissioning;
• set-up and tryout (debug);
• operation (all modes);
• tool change;
• planned maintenance;
• unplanned maintenance;
• major repair;
• recovery from control failure;
• recovery from jam;
• troubleshooting;
• housekeeping;
• decommissioning;
• disposal.
For each of the task categories there may be many

tasks. Tasks are specific activities that relate to the
task category. Each task category may have
numerous tasks associated with it, such as:
• changing a mill cutter;
• replacing a drive belt on motor #2;
• replacing an oil filter on HPU # 1;
• troubleshooting ram repeatability;
• clearing chips from the machine table.
For each of the above tasks, there may be

numerous hazards. Examples of hazards and
hazardous situations addressed within this standard
(design/construction, installation, set-up, operation
and maintenance) are contained in Annex B.
In addition, reasonably foreseeable hazards not directly Following are some examples of reasonably
related to tasks shall be identified. foreseeable hazards not related to tasks:
• power failure;
• failure of a high-pressure hydraulic line;
• bearing failure or bearing seizure;
• failure of the structural components of the
machine.
Tasks and associated hazards shall be identified and Each time a machine is modified or its use is
reassessed when necessary or whenever the machine is changed, the tasks/hazards associated with the
modified or its typical use is changed (see 5.2). modification or change should be identified and re-
assessed. For a more detailed discussion on
task/hazard combination identification, refer to ANSI
B11.TR3.
10
5.2 Risk assessment / risk reduction E5.2

Risks associated with the task/hazard combinations Where possible and when necessary, the user, in
identified in 5.1, including reasonably foreseeable hazards conjunction with the supplier, should ensure that
not directly related to tasks, shall be assessed and the task/hazard combinations and reasonably
reduced to a tolerable level by incorporating one or more foreseeable hazards not directly related to tasks
of the following protective measures, in hierarchical order: identified in this standard, and their associated
protective measures are appropriate for the specific
machine to which this standard is being applied.
For further information on risk assessment, see
ANSI B11.TR3.
a) eliminate or control hazard(s) by design;

b) control exposure to hazards by the use of guards or
safeguarding devices;
c) provide other safeguarding (e.g., awareness barriers,
awareness signals and safeguarding methods);
d) implement administrative controls or other protective
measures (including safe work procedures,
preventive maintenance, training, re-training,
personal protective equipment and warning signs).
When performing risk reduction for task/hazard For performing risk reduction on task/hazard
combinations identified in 5.1, including reasonably combinations and reasonably foreseeable
foreseeable hazards not directly related to tasks, the hazards not directly related to tasks not resolved
requirements of clauses 6, 7, 8 and 9 shall be by applying clauses 6, 7, 8 and 9, see B11.TR3.
implemented.
Tolerable risk shall be determined by evaluating the Zero risk does not exist and cannot be attained.
application of the protective measures against the However, a good faith approach to risk
following factors: assessment and risk reduction should reduce risk
to a tolerable level. For further information on
tolerable risk, see ANSI B11.TR3.
• risk-reduction benefit; Risk-reduction benefit is determined by estimating

the potential reduction in severity of harm or
probability of occurrence of harm. The type of
protective measure is determined by the nature of
the task and associated hazard(s) for the
machine under consideration. Protective
measures should be selected to provide the
desired degree of risk reduction.
• technological feasibility;
• economic feasibility;
• ergonomic impact;
• productivity;
• durability and maintainability;
• usability.
Risk reduction is complete when the protective

measures, consistent with this standard, are applied and
tolerable risk has been achieved for the identified
task/hazard combinations and the machine as a whole.
11
6 Design and construction

6.1 General
This clause describes the design and construction
requirements for the component elements of a machine.
6.2 Component selection

All components shall be selected to have specification
limits, established by their manufacturer, equal to or
greater than any adjustable setting of the system.
6.3 Machine controls

The controls may be electrical, mechanical, hydraulic,
pneumatic, or in combination. The control system shall
be designed with a stopping operation that requires a
separate manual action to restart the machine.
6.4 Modes of operation

6.4.1 General
The selection of a mode of operation shall be either by
key–switch, access code or equally secure means and
shall only be permitted from outside the work zone.
Selection of a mode shall not initiate a hazardous
situation.
Each machine shall have at least two modes of operation

with a visual indication of which mode is active. These
modes are as follows:
6.4.2 Automatic mode E6.4.2

This mode allows the use of a machine under numerical See also, 6.21.1.2
control to achieve programmed sequential operation with
the guard closed and safeguarding (protective) devices
active (e.g., guard lock, pressure sensitive protective
device, electro-sensitive protective equipment).
6.4.3 Set–up mode E6.4.3

This mode allows machine movement under restricted See also, 6.21.1.3
speeds and feeds with the work zone guard open and the
safeguarding (protective) devices disabled.
6.5 Electrical equipment E6.5

The electrical equipment shall meet the requirements of ANSI / NFPA 79 specifies the requirements for the
ANSI / NFPA 79. system or components, which are provided to
operate the machine.
6.5.1 Voltage
All ac operator control circuits shall be powered by not
more than a nominal 120-volt ac supply obtained from a
transformer with an isolated secondary.
12
Higher voltage that may be necessary for operation of

machine or control mechanisms shall be isolated from
any control mechanism handled by the operator, but
motor starters with integral start-stop buttons may utilize
line voltage control. All dc operator control circuits shall
be powered by not more than a nominal 24-volt dc supply
isolated from any higher voltages.
When a part-sensing device is used in which the

workpiece is a conductor, the voltage shall not exceed a
nominal 24 volts.
6.5.2 Grounding and shielding E6.5.2

The machine control system shall be protected against The grounding and shielding recommendations of
false operation due to improper or accidental grounding the electrical equipment suppliers should be
or improper shielding. considered when interconnecting various parts of
the electrical equipment.
6.6 Hydraulic and pneumatic systems

The hydraulic and pneumatic equipment shall meet the
requirements of NFPA/T2.24.1 and ANSI B93.114M
respectively.
6.6.1 Control pressure
6.6.1.1 Rating of control pressure E6.6.1.1
The maximum anticipated working pressure in any The service manual should state the maximum
hydraulic or pneumatic system shall not exceed the safe pneumatic/hydraulic system pressure setting.
working pressure (as specified by the component
supplier) of any component used in that system.
6.6.1.2 Variation of control pressure E6.6.1.2

Circuits shall be designed and components applied so Pressure variations caused by valve closures or
that pressure variations shall not create a hazard. similar action should not cause a high-pressure
transient, which in turn can cause failure of other
components, creating a hazard from flying parts,
hot hydraulic fluids, or uncontrolled motion.
6.6.1.3 Loss of control pressure E6.6.1.3

Circuits shall be designed and components selected, Examples of hazards due to loss of control
applied, and adjusted so that loss of control pressure will pressure are parts coming loose from fixtures,
not create a hazard. tools flying out, and heads dropping due to loss of
clamping.
6.6.2 Circuits with maintained pressure E6.6.2

Whenever pressure is maintained after power is off, a An example would be in counterbalance or
warning sign shall be used and procedures for accumulator circuits. See also, 7.2.5
depressurizing the circuit shall be described in the
maintenance manual.
6.6.3 Stopping machine operations

Where proper safe machine operation requires that
supply pressure be controlled within specific limits, an
automatic means for stopping and preventing machine
operation when the supply pressure falls below or goes
above the specified limits shall be provided.
13
6.6.4 Interruption of pneumatic supply pressure

A means of interrupting the supply pressure and safely
venting stored pressure in machine operation shall be
provided. The valve or other means provided for this
function shall be equipped with a lockout provision (see
ANSI Z 244.1).
6.6.5 Accumulators E6.6.5

Hydro-pneumatic accumulators and air receivers shall A pressure vessel is a storage tank or container
conform to the ANSI / ASME Boiler and Pressure Vessel for a fluid (gas or liquid) under pressure above
Code, Division 1, Section VIII. 100 kPa (15 psig) gauge pressure, intended as a
means of energy storage or control, and has a
cross section larger than the system tubing or
piping. In most cases, the supplier will not
actually manufacture the pressure vessel,
however, the supplier should procure a pressure
vessel that has been manufactured according to
that Code.
6.6.5.1 Isolation or venting
Means shall be provided to vent or isolate accumulator
pressure from causing unintended motion.
6.6.5.2 Non-vented accumulators E6.6.5.2

Non-vented accumulators shall not actuate machine Properly identified non-vented accumulators are
motion and shall be identified with a sign that says intended to remind the maintenance personnel to
"Warning: Pressurized Vessel". Charging and discharge fluid before servicing them.
discharging information for proper servicing of non-
vented accumulators shall be given on or near the
accumulator in a visible location, and in the maintenance
manual.
6.6.6 Filtering and separating E6.6.6

When safe operation of hydraulic or pneumatic See also NFPA/T2.24.1 and ANSI B93.114M.
components or systems require control or elimination of
contaminants in the pressure-supply system, a means of
filtering or separating these contaminants shall be
provided.
6.6.7 Compatibility
Working fluids or gases shall be compatible with systems
components to provide reliable and safe operation.
6.7 External power sources

6.7.1 Fluctuation in or interruption of power E6.7.1
sources
Fluctuations or interruptions, which exceed the machine Power source monitors that initiate the stopping
design specifications of the external power sources, shall action may be required. See also ANSI / NFPA
immediately initiate stopping action of hazardous 79, NFPA/T2.24.1 and ANSI B93.114M.
conditions.
Machine components and controls shall be designed so

that any fluctuation, loss, or restoration of power shall not
create a risk or initiate hazardous conditions.
Restoration of normal power conditions shall not in itself

initiate operation of the machine.
14
Resumption of normal operation shall require restoring

normal power conditions and the operator restarting the
machine.
6.7.2 Isolation of power sources E6.7.2

Means for isolating power sources shall be provided, See also, 7.2.5.
shall be marked or labeled to identify the power
source(s), and shall have lockout/tagout capability (see
ANSI Z 244.1).
6.8 Stored energy E6.8

Loss of power shall not result in a hazardous condition Some examples of stored energy are air or
due to the release of stored energy. hydraulic pressure, gravity, springs, counter-
balances, flywheels, capacitors, and un-
interruptable power supplies.
Means shall be provided for the isolation, containment or Examples of isolation, containment or controlled
controlled release of stored energy that can create a release of stored energy are:
hazardous condition. • blocking;
• pinning;
• chaining;
• locking;
• controlled bleeding;
• check valves;
• discharging;
• dynamic braking;
• mechanical braking;
• powerdown procedures.
6.9 External interferences E6.9

The supplier shall design and construct the control or Some sources of external interferences are:
power systems so that external interferences do not • electromagnetic interference (EMI);
adversely affect the safe operation of the machine and its • electrostatic discharge (ESD);
associated equipment. • radio frequency interference (RFI);
• shock/vibration.
These are normally associated with the operation

of air conditioners; electric welders; electric
furnaces; elevators; high energy power lines; radio
frequency (RF), radar, or microwave equipment;
cellular phones; two–way radios; electrostatic
equipment; large brush type motors; and heavy
machinery or similar equipment (see ANSI / IEEE
518).
6.10 Performance of safety-related function(s)

The control system shall meet the requirements of 8.7.
6.11 Machine starting

Machine starting shall require that actuation be from a
control station(s) located outside the associated hazard
zone(s).
15
All machine controls shall incorporate a type of drive-

motor starter that will disconnect the drive motor from the
power source in the event of control voltage or power-
system failure. A separate starting operation shall be
performed to restart the motor when power conditions are
restored to normal.
6.12 Stop and emergency stop controls

6.12.1 General E6.12.1
Stop and emergency stop controls shall be provided and The category O stop required by ANSI/NFPA 79
shall be designed and constructed to meet the may be satisfied by the use of the electrical
requirements of ANSI / NFPA 79. disconnecting means.
The components of the stop circuit shall be designed, Considerations should be given to:
selected, constructed and interconnected in a manner to • frequency of operation;
withstand the expected operational and environmental • need for periodic testing (especially
operating conditions and to ensure reliable stopping where operation is infrequent);
functions. • vibration, shock, temperature, dust,
foreign or corrosive materials, fluids, etc.
NOTE - Where the stop function utilizes electronic

devices or is generated by the programmable electronic
system (PES) the reliability of the stop function should
be considered.
6.12.2 Normal Stop

Normal stop shall cause a controlled stopping action by
the normal stopping means associated with the machine
and related equipment. Normal stop shall override the
associated starting functions. Each manually operated
starting device shall have an associated manually
operated stopping device. Manually operated stopping
devices shall meet the requirements of ANSI / NFPA 79.
The normal stop control(s) shall be either hardware or

program based and shall signal the system PES that a
normal stop condition exists.
6.12.3 Emergency stop E6.12.3

Each machine shall be provided with one or more Retention of power on certain portions of the
emergency stop devices. system may be necessary to prevent hazardous
motion, to maintain program logic, or to provide
braking during emergency stopping. See ANSI /
NFPA 79.
The emergency stop function shall be operational at all
times and in all operating modes.
Once activated, the emergency stop function shall remain A push–pull operator with positive opening action
active. Resetting of the emergency stop function shall be is an example of a suitable device.
by an appropriate and deliberate action.
The emergency stop function shall not impair any The emergency stop function may include the
facilities designed to release trapped individuals. initiation of such facilities.
16
6.13 Operator control stations

Operator control stations shall be located so as to be
readily accessible to the operator from his/her normal
work position.
When more than one control station is provided, only one

shall be operative at a time except for the emergency
stop control. Switching from one control station to another
shall not create a hazard.
6.14 Manually operated control devices

6.14.1 General E6.14.1
Manually operated control devices shall be:
a) readily identifiable and appropriately marked or
labeled as to their function;
b) designed and installed to accommodate human b) Human capabilities and limitations addressed
capabilities and limitations; can include:
• work heights;
• reaching distance;
• strength;
• visibility;
• posture.
(See also, B11.TR 1)
c) readily accessible to the machine operator and c) The machine should be designed so that the
be placed to avoid reaching past moving parts machine operator is not required to reach over or
that are likely to cause injury; past moving parts that may be inadvertently
contacted and likely to cause injury while attention
is focused on operating the controls.
d) protected from unintentional operation by normal d) This is particularly applicable where such
movement of the machine operator or flow of unintentional operation can result in unexpected
workpieces, material, or tooling. hazardous conditions.
6.14.2 Means for limiting access to control devices E6.14.2

Means for limiting access to control devices used for the Means for limiting access can include:
initiation of motion or other hazardous conditions and • location;
selection of the mode of operation of the machine shall • design;
be provided. • key lock switch;
• access codes;
EXCEPTION - This requirement does not apply to controls such
as "Emergency Stop," where ease of access is of primary • interlocks.
importance.
6.14.3 Control designation E6.14.3

A control shall not initiate any motion unrelated to its The intent is to avoid startling the operator by
designation. having an unexpected action occur when
actuating a control device.
17
6.14.4 Stop devices

Stop devices shall be located where they can be easily
reached by the operator from the normal operating
position and shall not require reaching into hazardous
areas. They shall be clearly marked and shall require
only momentary actuation to deactivate the source of
power.
6.14.5 Emergency stop devices E6.14.5

Emergency stop device(s) shall be in accordance with Types of devices include, but are not limited to:
ANSI / NFPA 79 except that they shall be of the self– • mushroom type push buttons;
latching type. • cables, ropes or bars;
• handles;
• in some specific applications, foot pedals
without protective covers.
6.14.6 Hold–to–run control devices E6.14.6

Hold–to–run (e.g., jog) control devices, when provided, Hold–to–run control devices should be readily
shall be designed to prevent accidental or continuous identifiable from run or automatic operation
operation. controls by design such as:
• location;
• color;
• touch;
• sight.
6.14.7 Run control devices E6.14.7

Run control devices shall be used to start continuous Examples of meeting this requirement are the use
machine operations and shall be guarded to prevent the of shielded or recessed run buttons.
accidental starting of the machine.
6.14.8 Foot control devices

Foot-operated control devices, when provided, shall be
protected to prevent accidental operation from falling or
moving objects or from someone accidentally stepping on
them.
6.14.9 Rotary control devices E6.14.9

Rotary control devices turned in clockwise rotation shall A handwheel is an example of a rotary control
cause the controlled component to move clockwise or device.
linear to the right, upward or away from the operator and
vice versa.
6.14.10 Enabling device E6.14.10

When an enabling device is provided as a part of a An enabling device is an additional manually
system, it shall be designed to allow motion when operated control device used in conjunction with a
actuated in one position only. In any other position motion start control and which, when continuously
shall be stopped. actuated, allows a machine to function.
18
It shall have the following features:

• be connected to a category 0 stop or to a
category 1 stop (see ANSI / NFPA 79);
• be designed in consideration of ergonomic
principles;
• for a two-position type:
position 1: off-function of the switch (actuator
is not operated);
position 2: enabling function (actuator is
operated);
• for a three-position type:
position 1: off-function of the switch (actuator
is not operated);
position 2: enabling function (actuator is
operated in its mid position);
position 3: off-function (actuator is operated
past its mid position);
when returning from position 3 to position 2,
the function shall not be enabled.
6.15 Indicators E6.15

Indicators when provided shall meet the following
requirements:
a) Indicators, displays, and monitors required for
safety shall be designed, constructed and
located such that they provide a recognizable
signal, either visible or audible to the operator.
b) All indicators shall be clearly identified as to
their meaning.
c) Visual indicators required for safety shall be A possible color scheme for lights used as status
located such that they can be seen by the indicators, is found in ANSI / NFPA 79.
operator when facing the hazard zone or when
the operator is in the normal operating To safeguard those who are color-blind, additional
location. measures such as unambiguous positioning,
patterning, labeling or flashing of the indicators
should be used.
d) Audible indicators shall have a distinctive
sound and intensity such that it will be
distinguishable from other audible sounds.
6.16 Anti-motion mechanisms or counter- E6.16

balance systems
Anti–motion mechanisms or counterbalance systems shall Instructions necessary for safe disassembly and
be provided to prevent or retard unintended motion where reassembly should be included in the maintenance
the motion will create a hazard. A warning sign shall be manual.
provided if improper disassembly can create a hazard.
6.16.1 Counterweights
Counterweights shall be designed and located so they do
not, of themselves, present a hazard to personnel in the
area.
19
6.16.2 Spring counterbalance systems E6.16.2

Spring counterbalance systems, when used, shall Spring counterbalance systems, when used for
incorporate a safe means for disassembly. anti-motion purposes, should include a self-
energizing locking or retarding mechanism.
6.16.3 Hydraulic or pneumatic counter–balance E6.16.3

systems
Hydraulic or pneumatic counterbalance systems shall Sudden release or loss of hydraulic fluid should not
include a self-actuating locking or retarding mechanism if eliminate the counterbalancing capabilities of a
the motion can create a hazard. weight-balancing system. Mechanisms such as
orifices, check valves, or spring-loaded stops may
be used to fulfill this requirement.
6.16.4 Brakes and locking devices E6.16.4

Where brakes or locking mechanisms are used for anti- Mechanisms such as spring-set brakes may be
motion devices, they shall be of the self-actuating type. used to fulfill this requirement.
6.16.5 Counterbalance support chains or cables

Safeguarding shall be provided to prevent a hazard from
whipping counterweight support chains or cables in case
of failure.
6.17 Power-operated workholding E6.17

Power-operated workholding shall prevent the workpiece This may be accomplished by the use of toggles,
from falling or being thrown from the machine or fixture wedges, cam lock arrangements, accumulator
after a power failure or the initiation of an emergency stop. tanks with check valves, or by other equivalent
means.
6.18 Coolant systems E6.18

Coolant tanks and return lines shall have access openings Coolants (metal removal fluids) are primarily used
or a means to permit cleaning. to cool or lubricate the workpiece/tool interface as
well as to remove chips from the cutting area.
Comprehensive and informative guidance on the
total management of metal removal fluid systems
can be downloaded (at no cost) from Organization
Resources Counselors (see clause E2).
6.18.1 Containment of fluids E6.18.1

Where a fluid application system is provided, it shall be The use of fixed or movable guards is one
designed to minimize splash, spray, and mist. means to minimize splashing during operation.
See also, ANSI B11.19 and B11.TR2.
Where applicable, means for containment of mist, fumes,
vapors or dust shall be provided and provisions made for
the addition of exhaust ventilation equipment, if needed.
When operators must place their hands into the work zone
(e.g., during load/unload operations, during setting),
coolant flow should be automatically stopped or diverted.
20
6.18.2 Fluid reservoirs E6.18.2

Fluid reservoirs and other system components shall be Where sediment buildup occurs, cleaning should be
made of suitable materials to ensure the continued integrity made easier by design (e.g., rounded corners in
of the system. containers) and cleaning should not require
drainage of the whole system.
Fluid tanks shall be fitted with:
• lifting points where appropriate;
• identified fluid level indication which is easily
legible;
• identified filling point.
6.18.3 Fluid contamination E6.18.3

The total content of the coolant system shall circulate in Coolant systems can be contaminated by a variety of
normal use so that no stationary volumes (‘dead’ zones) sources, including but not limited to:
exist except where settlement is required by design. • Microorganisms;
• Trash or other waste;
• Tramp oils (way lubes, gear oils, etc.).
Good design should incorporate considerations to

eliminate or minimize these potential contaminants.
Materials that are exposed to coolant (e.g., sound

absorbing products used inside splash guards), shall be
either non–porous or sealed to avoid being saturated by
coolant.
6.18.4 Filtering and separating

When safe operation of coolant components or systems
require control or elimination of contaminants in the
pressure-supply system, a means of filtering or separating
these contaminants shall be provided.
6.18.5 Coolant pressure

6.18.5.1 Rating of coolant pressure E6.18.5.1
The maximum anticipated working pressure in any coolant The service manual should state the maximum
system shall not exceed the safe working pressure (as coolant system pressure setting.
specified by the component supplier) of any component
used in that system.
6.18.5.2 Variation of coolant pressure E6.18.5.2

Circuits shall be designed and components applied so that Pressure variations caused by valve closures or
pressure variations shall not create a hazard. similar action should not cause a transient that in
turn can cause failure of other components,
creating a hazard from flying parts, hot coolants, or
uncontrolled motion.
6.18.5.3 Interruption of coolant supply pressure

A means of interrupting the supply pressure and safely
venting stored pressure in machine operation shall be
provided. The valve or other means provided for this
function shall be equipped with a lockout provision (see
ANSI Z 244.1).
21
6.18.5.4 Stopping machine operations

Where proper safe machine operation requires that
coolant pressure be controlled within specific limits, an
automatic means for stopping and preventing machine
operation when the coolant pressure falls below or goes
above the specified limits shall be provided.
6.19 Tool holder retention

6.19.1 General E6.19.1
Tool holder retention mechanisms shall prevent the This applies to machines with automatic tool
uncontrolled release of the tool holder. changers and matrixes.
6.19.2 Monitoring
The tool holder retention mechanism shall be monitored
so that a failure to achieve correct registration or clamping
of the tool holder shall:
• inhibit starting spindle rotation;
• stop spindle rotation if running.
6.19.3 Unclamping/ungripping
Unclamping of the tool holder by releasing of the tool
holder retention mechanism shall be inhibited during
spindle rotation.
6.20 Elimination of, or protection from inherent

hazards
6.20.1 Power transmission components E6.20.1
Where practicable, the supplier shall eliminate the hazard Some of the hazards that might exist are the
by design or provide protection against the hazard in following:
accordance with ANSI / ASME B15.1. • Rotating components, such as gears,
sheaves, and shafts in close proximity to
personnel;
• Pinch points, such as meshing gears, belts,
and chains.
6.20.2 Powered moving parts E6.20.2

A powered moving part that constitutes a hazard to Some of the hazards associated with powered
personnel shall be safeguarded where possible in moving parts (other than rotating tools, trapping
accordance with 5.2, or identified with appropriate space or other work zone hazards) are:
accident prevention instructions. • pinch points between moving and stationary
components of the machine;
• moving pallets;
• work table moving past a stationary
structure.
6.20.3 Broken or falling machine components or E6.20.3

accessories
Machine components or accessories shall be designed, Some of the hazards that may exist are those due
secured, or covered to minimize the possibility of injury to to the following:
personnel in the event that the component or accessory • breaking of shafts, causing falling motor
breaks, falls, or releases its mechanical energy. sheaves, flywheels, clutches, gears, or
other moving parts;
• loosening of mounting bolts, causing falling
of motors, protective covers, or other
stationary parts.
22
6.20.4 Machine mounting E6.20.4

The machine shall be designed, where necessary, with The machine installation is to be performed in
provision to secure the machine to the floor, a bench or accordance with recommendations of the supplier
machine stand. The bench or stand, where necessary, to prevent unintended tipping of the machine from
shall be provided with a means to secure it to the floor or its mounting, or movement of the machine from its
foundation. The manufacturer shall indicate in the mounting location. The use of isolation mounts or
installation instructions the conditions under which the vibration damping pads is an acceptable means of
machine should be secured to the floor or foundation. mounting provided unintended tipping and
movement of the machine from its mounting
location are prevented.
6.20.5 Ladders, work platforms, and walkways E6.20.5

When provided, ladders, work platforms, and walkways See also, 29 CFR 1910 subpart D standards
are to be in accordance with ANSI A14.3. (1910.21-.30).
Means of access on machines (e.g., ladders, platforms,

walkways) shall be designed to minimize the likelihood of
slips, trips, and falls by provision of adequate hand holds,
foot holds, and, where necessary, by slip resistant
surfaces.
6.20.6 Operating platforms

Where provided as an integral part of the machine, an
operating platform(s) shall provide:
• a protected position for the operator;
• sufficient space for the operator;
• sufficient lighting and ventilation;
• means for easy exit off the platform.
6.20.7 Contact with high-temperature components E6.20.7

The supplier shall provide protection for machine Inadvertent contact with a surface temperature in
operators in the normal work area from coming into excess of 60°C (140°F) can result in injury to the
contact with machine components whose surface operator due to reflexive reaction causing falls or
temperature is in excess of 70°C (160°F). The supplier unintended movement into some other hazard.
shall also provide protection for the operator(s) in normal
work area so that he/she will not contact machine
components at temperatures in excess of 60°C (140°F)
where reaction from contact may result in an injury.
EXCEPTION - Cutting tools are excluded from this requirement.
6.20.8 Contact with sharp edges, corners, and E6.20.8

projections
The supplier shall design and construct the machine Edges or corners with less than 0.25 mm (0.010
components without exterior sharp edges, corners, and in.) radius are considered sharp.
projections.
6.21 Safeguarding E6.21

Each machine shall be designed and safeguarded in General guidance for the design and construction of
accordance with the relevant requirements or measures in safeguards is given in ANSI B11.19.
this subclause, clause 8 and ANSI B11.19.
Machines shall be safeguarded by fixed or interlocked

movable guards.
23
Fixed guards shall be permitted where infrequent access is

required (e.g., for maintenance). Otherwise, interlocked
movable guards shall be used.
Safeguarding (protective) devices shall be permitted where

fixed and interlocked guards are not possible.
Means shall be provided for the movement of machine

axes for emergency purposes (e.g., release of trapped
persons).
6.21.1 Work zones

6.21.1.1 General
Work zones shall be guarded using fixed or interlocked
movable guards designed to contain processed materials,
fluids, parts and tooling.
Measures to minimize possible defeat of interlocking shall

be taken.
Where practicable, work zone guards shall be fixed to the

machine structure.
6.21.1.2 Automatic mode E6.21.1.2

Machine operation shall only be possible when the See also, 6.4.2
interlocked movable guards are closed and the
safeguarding (protective) devices are active. If it is
possible, in this mode, to open an interlocked movable
guard, the hazardous movements shall cease and be
inhibited.
If opening of the interlocked movable guard gives access to

hazards, guard locking shall be provided.
6.21.1.3 Set–up mode E6.21.1.3

When any interlocked movable guard is open or a See also, 6.4.3
protective device is suspended, powered machine
movements shall only be permitted under the following
conditions:
a) Axis movements at a maximum rate of 2 m/min (6.5

ft/min) or a maximum increment of 6 mm (0.25 in) at full
feed rate. These movements shall be selected one axis at
a time and may be initiated and maintained by one of the
following means:
• a hold–to–run control device;
• a rotary control device (e.g., electronic handwheel);
• manual data input (MDI) followed by cycle start
together with an enabling device.
24
b) Spindle speed shall be limited by its stopping

performance that shall not exceed 2 revolutions. Spindle
rotation shall only be initiated and maintained by one of the
following means:
• a hold–to–run control device;
• a spindle start control device together with an For a description of an enabling device, see 6.14.10.
enabling device. The 3 – position device is preferred.
c) The limits of speed or incremental distance [defined in An example of monitoring is servo (position) error
a) and b) above] shall be monitored and if exceeded, the detection (axis and spindle).
power to the drives shall be removed by a controlled stop
(Category 1 – see ANSI / NFPA 79).
d) Means shall be provided to prevent hazardous

movement of vertical or slant axes under gravity.
e) Unguarded swarf (chip) conveyor movements shall only

be initiated and maintained by a hold–to–run control device.
f) Where multiple hold–to–run control device locations are

provided (e.g. main control station, hand-held pendant),
only one shall be functional at a time.
6.21.1.4 Multiple work zones

Where more than one work zone is provided on a single
machine, access to hazardous machine movements shall
be prevented by fixed or interlocked movable guards.
Where there is access to a work zone for loading/unloading,
movement of the machine spindle into that work zone shall
be prevented. This measure shall not rely solely on
software.
The selection of the work zone for setting (set–up mode)

shall be either by a key switch, access code, or equally
lockable means and shall only be permitted from outside
the work zone.
6.21.2 Tool magazine

When the machine is equipped with an automatic tool
changer, access to hazardous movements of the tool
magazine shall be prevented by fixed and interlocked
movable guards.
Where the interlocked movable guard is open, the tool

magazine drive power supply shall be positively
disconnected by means of a category 1 stop (see ANSI /
NFPA 79).
It shall be possible to view the movement of the tool

magazine with the interlocked movable guard in the closed
position.
25
In order to prevent falls or ejections, tools shall be securely

held within the holders of the magazine. The design data
for tool holding (e.g., limits for maximum mass, moments of
inertia, and spatial envelope of tools) shall be made
available to the user.
6.21.3 Automatic Tool changer

Fixed or interlocked movable guards shall prevent access
to movable parts. When interlocked movable guards
providing access to the tool changer from the work zone,
tool magazine, or other directions are open, the movement
of the tool changer shall be inhibited.
No other hazardous machine movement shall arise from the

actuation of any sensor or feedback device. In order to
prevent falls or ejections, tools shall be securely held in the
tool changer under all operating conditions or loss of power.
It shall be possible to view the movement of the tool

changer with the interlocked movable guard in the closed
position.
6.21.4 Workpiece transfer devices

Load/unload positions for operators at workpiece transfer
devices shall be located outside the work zone and away
from other hazardous mechanisms (e.g., the tool changer).
Hazardous machine movement shall be inhibited or access

shall be prevented by means of fixed or interlocked
movable guards or safeguarding (protective) devices.
Where access is required to the workpiece transfer device

with the guards open and the safeguarding (protective)
devices suspended and powered motion is necessary for
adjustment or maintenance, such motion shall be initiated
by a hold–to–run device which permits only step–by–step
function.
No other hazardous machine movement shall arise from the

actuation of any sensor or feedback device.
6.21.5 Chip collection/removal

Access to hazardous machine parts in chip collection and
removal systems shall be prevented by fixed or interlocked
movable guards. When interlocked movable guards are
open, movement of the chip system shall be inhibited.
Where movement of the chip system is required with the
movable guard open to assist cleaning, this movement shall
be under the control of a hold–to–run device.
Fixed guards shall be permitted where infrequent access is

required (e.g., for maintenance). Otherwise, interlocked
movable guards shall be used.
26
6.22 Access to machine parts E6.22

One or more of the following protective measures shall be See also, 29 CFR 1910 subpart D standards
provided where parts of a machine which need to be (1910.21-.30).
accessed for maintenance or troubleshooting are at least 3
m (10 ft) above the machine mounting surface:
• fixed railings and toe boards;
• fixed means of access (e.g., stairways, ladders);
• fixed working platforms with safety railings against
falling hazard;
• supports for safety belt;
• means to attach movable ladders.
6.23 Ejected parts or fluids E6.23

Persons shall be protected against ejected parts by shields These could include such things as broken tools,
of sufficient strength (including means of fixing to the work material, machine parts, and coolant.
machine/floor) to contain these parts.
6.24 Viewing windows E6.24

When safety guards are equipped with viewing windows, Based on their recent research results, the German
which are also intended to contain ejected parts, machine tool association (VDW) recommends that
consideration shall be given to the selection of materials such windows that have been in service for 10 years
and the method of their installation. Window materials (e.g., or longer be replaced regardless of their
polycarbonates) that are subject to impact resistance appearance, and windows with cracks, coolant
deterioration over time (aging) due to contamination by penetration due to damage to edge seals, bulging,
lubricants, metalworking fluid, solvents, etc., shall be discoloration or damage to protective external layers,
protected by external sheathing layers (e.g., safety glass, be replaced immediately.
plastic coating) and sealed on the periphery.
6.25 Structural integrity

The machine shall be designed to maintain structural
integrity throughout the full range of functions and dynamic
motions taking into account the maximum workpiece size
and weight distribution.
6.26 Noise E6.26

The manufacturer shall state the value of the measured This value should be measured in accordance with
acoustical noise level while the machine is idling. NMTBA (AMT) Noise Measurement Techniques.
Acoustical noise emissions and resulting risks

should be considered when designing and operating
the machine. The noise generated during cutting will
be affected by many factors including blade type,
cutting speed, cutting fluid used and material
characteristics of the workpiece. The user is
ultimately responsible for determining a noise control
strategy for the particular application.
Examples of technical methods for reducing noise at

the main sound sources of the machine, and
possible means of reducing the noise are listed
below:
Sound Source Solution
transmission noise Gearbox damping
pneumatic exhaust Silencers
27
power generation source Damping or absorber
noise under cutting and Damping or absorber

cutting tool change inside the workzone
workpiece change Enclosing guard
6.27 Mist, fumes, vapors and dust E6.27

Where applicable, means for containment of mist, fumes, See also, ANSI B11.TR2.
vapors and dust shall be provided and provisions made for
the addition of exhaust ventilation equipment.
6.28 Ergonomic considerations E6.28

Provision shall be made to enable: See also, ANSI B11.TR1.
• workpieces, tools or fixtures to be loaded/unloaded
without excessive effort or adverse effects on health;
• the work zone to be accessed with/by lifting
equipment.
The control to release the tool holder retention mechanism See also, ANSI B11.TR1.
shall be close enough to avoid excessive reaching while
supporting the weight of the tool.
Means shall be provided to ensure safe operation by

making controls, observation and service points easily
reached.
Lighting shall be installed to ensure that personnel can The lighting should not create shadows, excessive
safely perform their tasks. glare, or stroboscopic effects. For lighting
requirements see ANSI / IES RP-7.
Screen display information shall be clear and unambiguous; Screen height should be designed for the range of
minimize reflections and glare. typical workers.
6.29 Energy supply failures

The machine shall be designed and constructed such that a
failure or interruption in any energy supply shall not result in
any hazard.
6.30 Errors of fitting E6.30

Positive means shall be embodied in the design of machine These could include the use of male/female
parts to minimize the probability of errors of fitting or the connections or asymmetrical location features.
machine parts shall be marked with instructions during
fitting.
6.31 Lifting of machine components E6.31

Components, assemblies, or subassemblies heavier than Lifting point identification can be eye–bolt
40 kg (88 lbs) shall be provided with lifting point attachment holes, permanent hook(s) or other
identification. suitable component features to which lifting
equipment can be attached.
Instructions including weights and eyebolt sizes shall be
provided for lifting equipment required to lift specific
components, assemblies or subassemblies.
28
7 Layout, installation, testing and start-up

7.1 General
This clause describes the requirements for the layout,
installation, testing and start-up of the machine and its
associated equipment.
7.2 Layout and installation E7.2

The layout and installation shall meet the following The user should consider the various suppliers'
requirements: recommendations for the layout and installation
plans. (See also, B11.TR1)
7.2.1 Evaluation of layout area

The installation layout area shall be compatible with the
expected machine operating and maintenance conditions.
7.2.2 Floor loading

The flooring supporting the machine and its associated
equipment shall be capable of bearing the dynamic load.
7.2.3 Space allocation E7.2.3

Equipment layout shall allow individuals access to and Examples of space allocation considerations for
egress from the machine for operation, material handling access and egress may include:
and maintenance. • positioning of equipment and workplace
physical features to provide for maintenance;
• arrangement of machinery and operator
interfaces to avoid blind corners;
• traffic guide markings;
• door swing.
Sufficient space shall be provided to properly access Where practical, maintenance elements (e.g., points
machines for maintenance. of lubrication, adjustment mechanisms) should be
located outside the hazard zone.
7.2.4 Electrical requirements for installation

The installation of the machine and its associated
equipment shall be in accordance with ANSI / NFPA 70,
ANSI / NFPA 70E, and the supplier’s instructions and
recommendations.
7.2.5 Lockout/tagout
Each installation shall have a means to disconnect and
isolate all energy sources in accordance with ANSI Z
244.1.
7.2.6 Lighting E7.2.6

Lighting shall be installed to ensure that personnel can The lighting should not create shadows, excessive
safely perform their tasks. glare, or stroboscopic effects. (For lighting
requirements see ANSI / IES RP-7).
7.3 Testing and start-up

Testing and start-up shall meet the requirements of 7.3.1
through 7.3.3 below.
29
7.3.1 Testing and start-up procedure E7.3.1

The user shall ensure that a testing and start-up procedure The user should use the supplier's recommendations
is provided and used. as a guideline in developing a testing and start-up
procedure.
7.3.2 Personnel restrictions

Only trained personnel shall be allowed to operate the
machine and its associated equipment during test and start-
up.
7.3.3 Safeguarding
If the operational safeguarding is not in place prior to testing
and start-up, other safeguarding shall be provided and
used. See also, clause 8.
8 Safeguarding
8.1 General
Where a hazard, either immediate or impending, exists, one
or more of the following shall be provided:
• guard(s);
• safeguarding device(s);
• awareness barriers and device(s);
• safe work procedures.
The selected means of safeguarding shall be consistent

with the identified hazards and their associated risks.
Specific safeguarding requirements are found in 8.5.
8.2 Guards
8.2.1 General E8.2.1
Guards shall be designed and constructed in accordance Guards may include fixed and interlocked movable
with ANSI B11.19. guards.
Guards shall meet the following design, construction,
application, and adjustment requirements so that they:
• prevent accidental entry of clothing or body parts
into the hazard area(s) that it is guarding;
• create no pinch points between the guard and
moving machine parts;
• be mounted to minimize the possibility of misuse or
unintentional removal;
• facilitate its inspection; and
• offer maximum visibility of the work zone consistent
with the above requirements.
30
8.2.2 Fixed guards E8.2.2

A fixed guard shall be kept in place (i.e., closed) by either A fixed guard is intended for situations that require
permanent means (e.g., welding,), or by means of infrequent access (e.g., repair, maintenance,
fasteners (e.g., screws, bolts), making removal/opening service).
virtually impossible without the use of tools.
Where practicable, work zone guards should be
fixed to the machine structure.
8.2.3 Movable guards E8.2.3

Movable guards shall provide access to hazard areas (e.g., Movable guards are intended for situations that
work zones) without the use of tools. require frequent access (e.g., during normal
production).
Movable guards shall be interlocked so that:
• The hazardous machine functions protected by the
guard cannot operate until the guard is closed;
• If the guard is opened while hazardous machine
functions are operating, a category 1 stop (see
NFPA 79) for those hazardous situations covered
by that guard shall be initiated.
The closing of the guard shall not, by itself, initiate the

operation of the hazardous functions covered by the guard
(i.e., manual initiation shall be required).
8.3 Safeguarding devices

8.3.1 General
Safeguarding devices shall protect personnel from the
hazards by one or more of the following methods:
• presence-sensing devices;
• two–hand control.
8.3.2 Presence-sensing devices E8.3.2

A presence-sensing device shall be designed and Presence-sensing devices may include:
constructed in accordance with ANSI B11.19. • safety mats;
• electro-optical;
A presence-sensing device shall be interlocked into the • radio frequency;
control circuit to initiate a category 1 stop (see ANSI / NFPA • capacitive;
79) for those hazardous situations covered by the device, or
• sonic;
prevent operation of the hazardous function(s) covered by
the device if a hand or other part of the body is detected in • inductive devices.
the sensing field. It shall not in itself create any hazard.
The removal of the object from the sensing field shall not
cause the hazardous functions covered by the device to
resume (i.e., manual initiation shall be required).
8.3.3 Two-hand control used as a protective device

A two–hand control device shall be designed, constructed,
selected and operated in accordance with ANSI B11.19.
8.3.4 Safety distance stopping monitor E8.3.4

When the effectiveness of the safeguarding (protective) See also, ANSI B11.TR1.
device is dependent on the safety distance, a stopping
performance monitor shall be provided. See ANSI B11.19.
31
8.4 Awareness barriers and devices E8.4

Awareness barriers and devices shall be designed, See also, ANSI B11.TR1.
constructed and located in accordance with ANSI B11.19.
8.5 Safeguarding against specific hazards

8.5.1 Power operated workholding hazard
When power operated workholding exposes the operator to
a pinch-point hazard, a protective device or guard shall be
provided. Where the clamp opening is 6 mm (0.25 in) or
less, or the distance between the clamp and clamp control
is greater than the operator's reach, a guard or protective
device is not required.
8.5.2 Chip or coolant hazard E8.5.2

Chips and coolant shall be controlled by the use of a shield When a shield or guard placed on a machine for the
or other means from being thrown or splashed onto an purpose of safeguarding against some other hazard
operator, an aisle, or an assigned work area. also effectively controls the chips and prevents
coolant or chips from being thrown onto the
operator, the work station, or other assigned work
areas, then further chip or coolant shielding is not
required.
The shields specified herein are not intended to

replace the use of, or need for eye or face
protection.
8.5.2.1 Portable chip or coolant shields E8.5.2.1

One or more portable chip or coolant shields, either Portable chip or coolant shields, because they are
transparent or nontransparent, may be used in lieu of movable, should not be used as the sole means of
permanent chip shields where they are so placed and protecting against a tool or trapping–space hazard.
consistently used as to effectively control the chips or
coolant.
8.5.2.2 Chip removal E8.5.2.2

Chips that are in the process of being generated shall not Removal means by itself should not create a hazard.
be handled by hand.
8.5.2.3 Slipping hazard E8.5.2.3

When it is necessary for the operator to step or walk on The design should not require the operator to step or
part of the machine that is wet with coolant or lubricating oil walk on parts of the machine that could be wet with
and as such presents a slipping hazard, a non-slip stepping coolant or lubricating oil.
surface shall be provided.
EXCEPTION - Where these surfaces are work–mounting or work–

bearing surfaces, the use of leak–proof and non-slip footwear is
acceptable.
8.5.3 Gauges E8.5.3

Gauges (gages) that are attached to machine components This is intended to avoid having the operator reach
to check machine functions, or fixture or part set-up, shall into a hazard area when attempting to retrieve a
be rigidly secured to the machine and located so that their gauge (gage) that is slipping or falling.
use will not create a hazard to the operator.
32
8.5.4 Powered head changer

The powered head changer shall be safeguarded if it
exposes the operator or others to trapping, nipping or
shearing points.
8.5.5 Workpiece loading device

Loading devices shall be safeguarded if they expose the
operator or others to trapping, nipping or shearing points.
The safeguarding may be a barrier, a protective railing, an
electric device, or other means.
8.6 Safe work procedures E8.6

The use of safe work procedures shall protect personnel Caution should be exercised to ensure that the
from the hazards associated with set-up, operation and procedure used is appropriate for the task and that
maintenance of the machine by reducing the exposure to a any changes in the work procedures or tasks do not
hazard(s). render them hazardous. The user should ensure
that the operator is properly trained in the use of the
procedure and aware of the hazards involved.
Factors to consider in determining whether safe

work procedures are required may include, but are
not limited to, the following:
• where tasks are complex;
• where tasks have high risk;
• where training, skill or work experience is
limited;
• where other safeguarding is removed or
bypassed;
• where required to augment other safeguarding.
Where determined to be necessary, safe work

procedures should be developed and used to ensure
that a safe work practice is implemented for the
task(s) performed.
Where practical, it is recommended that the user

consult with the machine or safeguard supplier(s) to
identify the tasks and associated hazards.
Safeguarding procedures should be written by the
user, with the assistance and recommendation of
those suppliers.
When developing the safe work procedure, the user

should consider the supplier’s performance
specifications, schematics, diagrams, installation,
operating and maintenance instructions, and
warnings.
8.7 Performance of the safety–related E8.7

function(s)
When a component, module, device or system failure Because some failures cannot be detected until
occurs, such that it or a subsequent failure of another the completion of a cycle or a portion of the cycle,
component, module, device or system would lead to the loss of the safety-related function(s) may occur for
inability of the safety-related function(s) to respond to a a portion of the machine cycle.
normal stop command or an immediate stop command, the
safety-related function shall:
33
a) prevent initiation of hazardous machine motion (or Other failures cannot be detected until a demand
situation) until the failure is corrected or until the is made on the safety-related function. An
control system is manually reset; or example of such a safety-related function may be
b) initiate an immediate stop command and prevent the use of an electro-optical device protecting a
re-initiation of hazardous machine motion (or hazardous area where individuals do not normally
situation) until the failure is corrected or until the enter the area during a normal machine cycle.
control system is manually reset; or
c) prevent re-initiation of hazardous machine motion When a failure is detected, the safety-related
(or situation) at the next normal stop command until function should meet the requirements of Annex
the failure is corrected or until the control system is C.
manually reset.
In the presence of a failure, the user shall be responsible to In the presence of a failure, it is recognized that
ensure that repetitive manual reset of the system or device some control systems or devices can be manually
is not used for production operation. reset or can be reset by cycling the power to the
system or device off and on.
The intention of a manual reset is to encourage

the diagnosis of a failed component, subassembly,
device or module. A second failure may occur
during the diagnostic or troubleshooting process,
negating the safety-related function(s). Additional
safeguarding should be used to protect individuals
during this process.
Control reliability:
• is one of the design strategies that may be
used to meet these requirements;
• cannot prevent a repeat cycle in the event of
a major mechanical failure or in the
presence of multiple simultaneous
component failures;
• is not provided by simple redundancy.
There must be monitoring to assure that
redundancy is maintained.
For further information on safety-related functions,

see ANSI B11.19.
9 Set-up, operation and maintenance

9.1 General
This clause describes the requirements for the operation
and maintenance of the machine and its associated
equipment.
9.2 Machine set–up procedures E9.2

The user shall establish machine set–up procedures in These procedures should also take into account:
accordance with the supplier's recommendations. • materials;
• fixtures/tooling;
The user shall establish proper machine component • coolants;
handling methods in accordance with 6.31. • processing.
34
9.3 Safeguarding
9.3.1 Guards
The user shall ensure that all guards are in place and
functioning such that:
• fixed guards are in place;
• movable guards are adjusted after each tooling
change or set-up;
• interlocked barrier guards are interfaced with the
machine control system such that no hazardous
motion can occur if the interlock is open.
9.3.2 Presence-sensing devices E9.3.2

The user shall ensure that presence-sensing devices: See also, ANSI B11.19 and ANSI B11.TR1.
• are installed, adjusted, and functioning properly;
• are located at a distance from the nearest hazard
such that the operator or others cannot reach the
hazard with a hand or other body part until
cessation of motion in the hazardous part of the
cycle.
9.3.3 Two-hand control E9.3.3

The user shall ensure that a two-hand control device when See also, ANSI B11.19 and ANSI B11.TR1.
provided:
• is installed, operated and maintained properly;
• is located at a distance from the nearest hazard
such that the operator cannot reach the hazard
area with a hand or other body part until cessation
of motion in the hazardous part of the cycle;
• shall require concurrent operation of both of the
hand controls or trips to initiate a machine cycle;
• shall incorporate an anti-tie down feature.
9.3.4 Awareness devices or signals E9.3.4

The user shall ensure that personnel are trained in the Examples of awareness devices are:
purpose of the awareness device(s) and the awareness • colored coded stack lights;
device(s) is functioning. • flashing beacons;
• audible noise devices which can be
distinguished from other sounds in the
immediate area of the machine;
• tactile devices.
Operators, set-up and maintenance personnel

should be made aware of the nature of the hazards
and the significance of the signals by instructions,
training and the use of signs the vicinity of the
hazardous area.
Audible awareness devices and signals should not

be used in conjunction with paging systems or for
start and stop work signals.
9.4 Maintenance E9.4

The user shall follow supplier’s instructions and
recommendations to establish procedures for the
maintenance of the machine.
35
The user shall ensure that instructions, procedures and Maintenance personnel should follow procedures set
recommendations for the maintenance of the machine are forth by the user. Examples of maintaining
provided, and used. equipment in a safe manner may include:
• following all recommended safety practices
and procedures that apply to their work;
• notifying their supervisor when they observe
an unsafe practice or condition;
• studying and understanding the material
related to their job;
• installing or adjusting safety equipment,
devices, guards, or shields, as set forth by the
user.
The user shall ensure that the machine and its associated The frequency of maintenance and inspections
equipment are inspected and maintained as required for varies depending on the use of the machine. The
continuing safe operation. user should consider the supplier's
recommendations when determining the period
between inspections.
Maintenance personnel shall not alter, remove, or disable When the machine or its associated equipment is
any safeguarding without authorization as established in the modified, the user should ensure that maintenance
user's maintenance procedure. instructions and procedures are updated and
maintenance personnel are trained in the revised
procedures.
When it is necessary to disable safeguarding so as to be
able to perform maintenance, the user shall provide
alternate means of safeguarding.
The machine shall not be returned to service until the

safeguarding is re-established.
The user shall establish a lockout/tagout program in

accordance with ANSI Z 244.1.
9.5 Personal protective equipment E9.5

The user shall determine what personal protective See also ANSI B11.TR3 and 29 CFR 1910 Subpart I
equipment is needed when operating or maintaining standards (1910.132 – 138 and appendices).
machines. The user shall enforce the proper use of this
equipment. (See clause 5).
36
9.6 Training E9.6

The user shall establish personnel training programs that The user should refer to the supplier’s
ensure the following: recommendations when establishing a training
program.
Training shall ensure that user personnel associated with Examples of training program elements include:
machining centers are properly trained in safe working • description of the assigned task;
procedures and are qualified to perform the functions to • function of operator controls to be
which they are assigned. encountered in performing the assigned
task;
• hazards associated with the assigned task;
• designated method of safeguarding;
• methods of function-testing or otherwise
assuring the proper function of
safeguarding means.
The user shall instruct all operators in the set–up and The user should place particular emphasis on the
operation of the machine. Instructions shall include the training, instruction, and supervision of workers
following requirements: who are inexperienced in the operation of the
machine or have difficulty communicating verbally.
a) Instruct the operator in the proper method of operation Instructions should include guidelines to ensure
for each production set–up before the machine is that:
placed into production; • all personnel are in a safe location before
operating the machine;
• operators know and understand the startup
and stopping procedures;
• operators know and understand the safe
working procedures established by the user;
• operators know the safeguarding required for
the operation and understand its function;
• operators know they should report to their
supervisor any apparent defect, damage,
malfunction or inconsistent or unpredictable
performance of the machine.
b) Require that all operators demonstrate their

knowledge of the proper operation of the machine.
The user shall instruct all set–up personnel in the proper

procedures for installing and utilizing fixtures/tooling.
Training shall include:
• following all recommended safety practices and

procedures listed in this standard that apply to their
work;
• proper safeguarding means and methods;
• removal, transport, and storage of fixtures/tools;
• system operation.
The user shall ensure that supervisors and maintenance The user should make supplier’s instructions and
personnel are trained in safe working procedures for recommendations readily available to maintenance
inspecting and maintaining the machine. personnel.
37
The user shall train personnel, as required by assigned

functions, in the safe working procedures for lockout/tagout
of hazardous energy sources in accordance with ANSI Z
244.1.
9.7 Supervision
The user shall ensure that the operation of the machine is
supervised by trained personnel.
The designated supervisor shall ensure that user's

operating and maintenance procedures are within the
guidelines as described in the supplier's operating manual.
9.8 Initiation of normal operation

The initiation of normal operation of the machine shall only
be allowed where all of the following conditions are
satisfied:
• operating personnel have been properly trained on
the use of the machine;
• the associated safeguards are in place and
functioning;
• no persons are present within the hazard zone(s);
and
• proper safe working procedures are followed.
38
American National Standard B11.23–2002
Annex A – Figures
(Informative)
1 – Column with feed drive, Y – axis 6 – Spindle head with main drive and 11 – Tool magazine
feed drive, Z–axis
2 – Cross slide with feed drive, X–axis 7 – Guard 12 – Central lubricating unit
3 – Work table 8 – Tool changer 13 – Control panel
4 – Pallet pool 9 – Pneumatic unit 14 – Electrical cabinet
5 – Coolant device with chip conveyer 10 – Hydraulic unit
Figure A.1: Machining center with horizontal spindle and pallet pool
Figure A.2: Total view of the machining center shown in figure A.1
39
1 – Tool changer 7 – Pneumatic unit 13 – NC–rotary table

2 – Tool magazine 8 – Hydraulic unit 14 – Pallet changer
3 – Spindle head with horizontal spindle 9 – Electric cabinet 15 – Setting station
4 – Column with feed drive, Y–axis 10 – Main drive 16 – Guard
5 – Mist separator 11 – Cross slide with feed drive, 17 – Chip conveyor with coolant
Z–axis device
6 – Central lubricating unit 12 – Bed with feed drive, X–axis 18 – Cooler for the motor spindle
Figure A.3: Machining center with horizontal spindle and pallet changer
1 – Setting station 6 – Crosshead for transportation of 10 – Control panel

the machine
2 – Rotable window of pallet changer 7 – Rear maintenance door 11 – Rotating view panel
(hydraulic, pneumatic, central
3 – Chip conveyer with coolant device lubricating unit, motor cooler) 12 – Sliding gate to work area
4 – Vision panel of tool changer 8 – Cabinet door 13 – Front folding door
5 – Vision panel of tool magazine 9 – Maintenance door
Figure A.4: Total view of the machining center shown in figure A.3
40
Figure A.5: Large machining center with perimeter safeguarding and two separate work zones
Figure A.6: Machining center with two separate work zones
41
Annex B -- List of hazards and hazardous situations

(Informative)
The following table is to be used as a means of verification of the hazard identification and safeguarding
required by this standard
List of significant hazards and major sources of these hazards associated with machining centers
• Description Example(s) of related Associated activity Related danger zone

hazardous situation(s)
1 Mechanical
1.1 Crushing workpiece clamping loading/reorienting/ between clamps and workpiece
unloading
automatic tool changing power–operated tool envelope of tool-changer motion
change between spindle and tool
1.2 Shearing moving axes manual operation/ tool between tool/spindle and table
change
1.3 Cutting or severing spindle or tool running or spindle running at spindle or tool
cutting
1.4 Entanglement automatic tool changing power–operated tool- at spindle or tool
change
removal of swarf power–operated swarf swarf collection and discharge
removal zones
1.5 Drawing–in or rapid travel of table or power–operated motion envelope of movement of workpiece
trapping spindle head of workpiece on table or on table axes; envelope of
tool in spindle movement of tool in spindle head
1.6 Impact moving/rotating tool spindle running at spindle or tool

automatic tool changing power–operated tool envelope of tool change motion
change
automatic workpiece power-operated envelope of motion of workpiece
transfer (e.g. pallet loading workpiece transfer and work-piece transfer
system) mechanisms
1.7 Stabbing or moving/rotating tool process control at tool in spindle
puncture (especially eccentric tools)
automatic tool changing power–operated tool envelope of tool changer motion
change (especially tool grippers)
handling tools during manual tool at sharp tool faces
change or replenishing
tool magazine
handling swarf during loading/ unloading at workpiece, table, and swarf
and cleaning collecting and discharge zones
1.8 Ejection of parts ejection of parts of work during cutting and near cutting and work material
material and swarf process control
1.9 Loss of stability unrestrained machine or during loading/ unloading at machine
machine part (maintained and process control at
in position by gravity), falls heavy/ unwieldy
or overturns workpieces during
maintenance
(disassembly/ relocation)
1.10 High pressure fluid ejection of parts of work during cutting and near cutting and work material
injection or ejection material and swarf process control
1.11 Slip, trip, fall ejection or spillage of during and after process floor area around machine and work
cutting fluid (coolant) and control material
lubricants (also hydraulic
fluid if used); swarf and after maintenance
detritus entrained in spilled
fluids; work at heights
42

2 Electrical
2.1 Electrical contact during maintenance
– direct or indirect
2.2 External influences potential for
on electrical equip- electromagnetic
ment interference either to or
from the machine unless
adequate provisions in
design of machine
3 Noise
3.1 Hearing loss; motion of power during operating cycle of near machine
psychological transmission elements, machine
disorders due to cutting processes
excessive noise
3.2 Interference with air blast used for cleaning
speech of tool or pallet locations
communication,
acoustical signals
4 Hazards generated by materials or substances processed, used or exhausted

4.1 Inhalation of fluids, conditions near machine during cutting near machine
mists, fumes, and caused by ejection of
dusts particles of work material,
fluid droplets or mist from
cutting fluids
4.2 Fire or explosion flammable work material, during cutting near machine
mist generation, loss of
cooling fluid supply to
cutting, during rupture by
flexure of electrical or
hydraulic power supply or
lubricant supply cables
4.3 Biological and contact with hydraulic or during operation, process near machine
micro–biological cutting fluid as liquid or control, and maintenance
mist containing detritus
and bacteria
5 Ergonomic hazards
5.1 Unhealthy postures lifting and reaching while during loading/ unloading, at load/unload and tool mounting
or excessive handling workpiece, tools, process control, and positions, maintenance action points
(repetitive strain) and machine parts maintenance
efforts
5.2 Inadequate local judgment and accuracy of during loading /unloading, at load/unload, tool mounting
lighting manual actions impaired process control, tool positions
during handling/ handling
positioning of work
materials and tools
5.3 Human errors inadvertent operation of during loading/ unloading, at load/unload, tool mounting
controls, incorrect work process control, tool positions
material and tool handling handling
and setting
43

6 Failures of the energy supply (ies), breakdown of machine parts, other functional disorders
6.1 Energy supply malfunctions of the control during operation, process at machine – machine elements
failures with consequence of control, maintenance retained in a safe condition by the
misapplication of stored application of power or fluid
energy or power. Power pressure.
workholding fails, motor
over-speed. Part breakage
causes machine elements
to move under residual
forces (inertia, gravity,
spring/ energy storage
means) causing external
elements to move
unexpectedly
6.2 Unexpected ejection Over-speeding of motors, during cutting near machine
of machine parts or tool breakages, hydraulic
fluids system ruptures –
breakage of part(s) causes
ejection of machine
elements by residual
forces
6.3 Failure, malfunction mechanical hazards during setting, cleaning, at machine
of control system associated with selected maintenance and repair
(unexpected start– machine movement activities
up, unexpected
overrun)
6.4 Errors of fitting machine elements fail or during process, tool at machine
move unexpectedly mounting, maintenance
7 Missing or incorrectly positioned safety–related measures/means
7.1 Guarding inadequate maintenance of during all aspects of at or near machine
the machine operation
• This list is derived from annex A of EN 1050: 1996, Safety of machinery – Principles for risk assessment.
44
Annex C – Performance of the safety-related function(s)

(Informative)
The purpose of the requirements of this standard is to prevent exposure to hazardous motion (or situations). The level of
performance of the safety-related function(s) depends on the level of risk associated with the hazard. See clause 5.
There are various design strategies that may be used to ensure that failures of components, modules, devices or systems
meet the level of performance required above. Some design strategies may allow an accumulation of single failure and yet
still stop (or prevent the re-initiation of) hazardous motion (or situations) when the next critical failure would cause loss of the
safety-related function. Other strategies include self-diagnosis to determine and respond to failures. Still other strategies
use tried and proven components and design principles to reduce the probability of a failure to a tolerable risk. Control
reliability is a design strategy, method or feature that separates the safety-related functions of a system into components,
modules, devices or systems that can be monitored or checked by other components, modules, devices or systems. It is
axiomatic that protection from the loss of safety-related functions due to multiple, simultaneous failures (common cause) of
components, sometimes referred to as “fail-safe”, is not practically achievable. Catastrophic failure of the machine actuator
(electrical, mechanical or fluidic) may result in the loss of the safety-related function. The use of redundant components,
modules, devices or systems (with or without monitoring or checking) is frequently used in process control systems where the
goal is to maintain the process in the event of a failure. Aircraft systems, chemical processing plants and electrical power
transmission systems are examples of applications where the process must continue in the presence of a failure. Control
reliability is not provided by simple redundancy. There must be monitoring to assure that redundancy is maintained. Control
reliability uses monitoring and checking to determine that a discernible component, module, device or system has failed and
that the hazardous motion (or situation) is stopped, or prevented from starting or restarting. Control reliability ensures that a
failure of the control system or device will not result in the loss of the safety-related function(s). NOTE - Because some failures
cannot be detected until the completion of a cycle or a portion of the cycle, loss of safety-related functions may occur for a portion of the
cycle.
Control reliability of electrical, electronic, pneumatic, or hydraulic systems or devices frequently consists of monitored,
multiple and independent parallel or series components, modules, devices or systems. Control reliability of machine control
systems or devices can be achieved by the use of, but not limited to, one or both of the following:
• The use of two or more dissimilar components, modules, devices or systems, with the proper operation of
each being verified (monitored) by the other(s) to ensure the performance of the safety function(s).
• The use of two or more identical components, modules, devices or systems, with the proper operation of
each being verified (monitored) by the other(s) to ensure the performance of the safety function(s).
These methods require that the safeguarding device, its interface to the control system (or directly to the actuator control)
and actuator control meet the above requirements.
Another control reliability strategy may be used when the machine motion is stopped and reinitiated at least once per cycle.
This strategy requires that the control system and the actuator control utilize the design methods above. The safeguarding
device and its interface may or may not be control reliable. To ensure that these elements cannot cause a loss of the safety-
related function(s), the control system must be designed to require that the device and its interface is exercised automatically
or by the operator (e.g., releasing hand controls or interrupting an electro-optical device) before a subsequent machine cycle
may be initiated. NOTE – The requirements of control reliability are not comparable to the requirements of ISO 13849-1, and exceed the
requirements of category 2.
The achievement of control reliability is dependent upon the selection and integration of components, modules, devices and
systems that have been specifically designed and intended for use in safety-related functions. A disciplined design
process, including design guidelines, peer review and other elements, is important for achieving completeness and
accuracy of the design, and should be implemented to ensure that control reliability is achieved.
45
Annex D – Safety Distance

(Informative)
The safeguarding devices listed below do not prevent an individual from reaching into a hazard area. In order for these
devices to be effective, they must either prevent the start of, or stop hazardous motion (or situation) when an individual is
exposed to the hazard. For the devices to accomplish this requirement, they must be located at a distance from the hazard
such that hazardous motion (or situation) is prevented, completed or stopped before the individual can be harmed.
Devices that require location at a safety distance include, but are not limited to:
1) interlocked barrier guards;

2) two hand control devices;
3) two hand trip devices;
4) single control safeguarding devices;
5) electro-optical presence-sensing devices;
6) RF presence-sensing devices;
7) safety mat devices;
8) safety edge devices.
The first four devices protect individuals by positioning the individual at or beyond the safety distance before hazardous
motion can be initiated, or by maintaining the individual’s position at the safety distance after hazardous motion has been
initiated. The remaining four devices protect individuals by detecting an individual entering (or their presence within) a
hazard area at or within the safety distance.
NOTE - Barrier guards and movable barrier devices with various openings are located at a position from the hazard area
based on the ability of the operator to reach through the opening. Figure D.10 (and Table D.1) is one method that may be
used to locate barrier guards.
The safety distance may be calculated using the following equation:
Ds = K (T ) Equation (1)
Where: Ds = the safety distance
K = the maximum speed that an individual can approach the hazard
T = the total time to stop hazardous motion which includes various factors as described below
The factor K is the speed constant and includes hand and body movements of an individual approaching a hazard area.
The following factors should be considered when determining K :
a) Hand and arm movement;

b) Twisting of the body or shoulder, or bending at the waist;
c) Walking or running.
One of the accepted values for K is the hand speed constant (it is usually considered as the horizontal motion of the hand
and arm while seated). Its common value is 1.6 m/s (63 in/s) although other values (typically greater) are also used. The
hand speed constant does not include other body movements, which can affect the actual approach speed. Consideration of
the above factors should be included when determining the speed constant for a given application.
The factor T is the total time that it takes for the hazardous motion to stop, or for the hazardous portion of the machine cycle
to be completed. A power press may present a hazard during the closing portion of its cycle or a machining center may
present a hazard during a tool change or while the tool is approaching the workpiece (trapping zone), but not present a
hazard during the balance of the machine cycle.
T includes portions of time that vary by machine type and by the safeguarding device applied. The following affect the total
stopping time:
a) Type of actuator;
i. Full revolution clutch, or machines that cannot be stopped during a machine cycle. See note 1.
ii. Part revolution friction clutch, or machines that can be stopped at any point in the machine cycle or
anywhere during the hazardous portion of the machine cycle. See note 2.
iii. Braking mechanism. See note 3.
iv. Stopping capability of the motors and drive. See note 4.
v. Reaction time of valves. See note 5.
b) Reaction time of the machine control system. See note 6.
c) Reaction time of the safeguarding device, including its interface. See note 7.
46
d) Additional time required by the use of braking performance monitor. See note 8.
Note 1: Full revolution (pin) clutches have one or more engaging points within a rotation of the flywheel where the clutch can
be engaged. Once engaged, the clutch completes a full revolution or cycle (stroke) before it is disengaged and brought to a
stop. After the machine is tripped by the control system or mechanical treadle, pedal, hand controls or levers, the clutch
typically engages after the flywheel rotates to the engaging position. Therefore, it is possible that the tripping device could
have tripped the clutch just after the flywheel engaging point has passed and will not engage the clutch until the flywheel has
rotated one full revolution. Assuming that the hazard exists during the closing portion of the cycle or stroke (provided that no
hazards are generated during the opening portion), the time to stop hazardous motion could take up to one and a half times
the time it takes the machine to complete one cycle (stroke). For clutches with only one engaging point the stopping time,
Ts , is:
Ts = 1.5(Tmc) Equation (2)

Where: Tmc = the time it takes to complete a machine cycle (stroke)
Some clutches have multiple engaging points on the flywheel. Therefore, the clutch has more than one position
where engagement can occur. The equation for calculation of this time, the stopping time Ts is:
Ts = (1 / 2 + 1 / N )(Tmc) Equation (3)

Where: N = the number of engaging points on the flywheel
For machines that are tripped (or sequenced) to initiate the machine cycle, which in turn initiates immediate motion
and which cannot be stopped until the completion of the machine cycle, the stopping time Ts is:
Ts = Thm Equation (4)

Where: Thm = the time, after initiation of motion, until hazardous motion is completed
Note 2: The stopping time, Ts , of part revolution clutch driven machines or machines that can be stopped at any point in
the machine cycle or stopped anywhere during the hazardous portion of the machine cycle is equal to the time it
takes to stop hazardous motion (see also, Note 3). If eddy current or other electro-magnetic clutches are used,
see Note 4.
Note 3: The stopping time, Ts , is the time it takes to disengage the clutch, the time it takes to apply the brake and the
time it takes the brake to stop motion.
Note 4: The stopping time, Ts , for direct drive, motor driven machines utilizing full voltage motors, servo systems, vector
systems or other variable speed systems, is equal to the time it takes to stop hazardous motion after a stop
command or signal is given to the motor contactor or drive system. This time should take into consideration both
uncontrolled stops (category 0) and controlled stops (categories 1 and 2) including dynamic braking. See ANSI /
NFPA 79.
Note 5: The stopping time, Ts , of machines actuated or controlled by pneumatic or hydraulic valves must include the
reaction time of the valve measured from the time that the valve is de-energized until motion is stopped. Stopping
time for systems using valves may be affected by high or low supply pressures, exhaust restrictions, sluggish
spools or poppets or performance of the pilot sections.
Note 6: Control systems inherently have a delay from the time its inputs or the system logic initiate a stop command, until
the system’s output de-energizes the actuator. This time, Tc , is the reaction time of the control system.
Note 7: Safeguarding devices also have a delay from the time that they sense the presence, or absence (for hand controls
and trips or hostage controls) of individuals. Additionally, there may be a delay caused by the interface between
the device and the control system. The interface may, as an example, include interposing relays. The interface
delay must be added to the total delay time. This time, Tr , is the reaction time of the device and its interface.
The reaction time of the device, without the interface, is stated by the device manufacturer.
Note 8: Stopping performance monitors are used to assure that a gradual increase in the stopping time caused by the
degradation of components does not exceed the stopping time used to calculate the safety distance for the
safeguarding device. Stopping time at the end of a machine cycle is usually different than the stopping time during
the hazardous portion(s) of the cycle, and since these times may vary due to such factors as machine temperature,
tool loading and energy transferred to the workpiece, a factor, Tspm , must be added to the total stopping time.
Tspm is a calculated factor. As an example, if the monitor is set to a point or time 5% greater than the normal
stopping position or time, then Tspm is equal to 5% of Ts ...
47
Therefore, the total stopping time is the sum of these factors and may be represented by the following equation:
T = Ts + Tc + Tr + Tspm Equation (5)
Stop time measuring devices are normally used to measure these times. When using these devices, Ts can be measured
from the output of the control system until motion is stopped. Likewise, Ts + Tc can be measured from the input to the
control system. Some stop time measuring devices include plungers and flags that are used to simulate operation by an
individual. When using this type of device, it is possible to measure Ts + Tc + Tr . (Use the manufacturer’s value for Tr,
when provided).
Substituting Ts + Tc + Tr + Tspm for T in Equation 1, the equation for calculating the safety distance becomes:
Ds = K (Ts + Tc + Tr + Tspm) Equation (6)
An additional distance needs to be added to the safety distance when using electro-optical devices, safety mats, single
control safety devices and RF devices.
Electro-optical and RF devices do not detect the presence of individuals at the plane or within the field of the device until an
amount of penetration into the plane or field occurs. This amount is known as the distance (depth) penetration factor. The
distance that must be added is called Dpf . See Figures D.1 -- D.6 and D.9.
When using safety mats and single control safety devices, it is possible for the individual to be reaching into the hazardous
area or stepping onto the mat beyond its edge. The amount of reach or stride should be added to the safety distance and
can be called Dpf . See Figures D.2, D.6 and D.8.
The equation for calculating the safety distance for these devices, therefore, is:
Ds = K (Ts + Tc + Tr + Tspm) + Dpf Equation (7)
Equation 7 can be used to calculate the safety distance for the eight safeguarding devices listed in paragraph 2 by
substituting the non-zero values or combination of values as determined above.
48
Figure D.1: Penetration factor, Dpf, for presence-sensing devices used in a

vertical application with object sensitivity less than 64 mm (2.5 inches)
Dpf, the distance added to the safety
64 (2.5)
distance due to the penetration factor
compensates for varying object
sensitivities of electro-optical presence-
51 (2.0)
sensing devices.
Minimum 38 (1.5) When blanking features are used and

Object when the blanked area is not completely
Sensitivity, filled by the workpiece or part, or by
S mechanical guarding, the minimum object
25 (1.0) sensitivity can be calculated as:
Object sensitivity = size of the blanked

13 (0.5) area plus minimum object sensitivity
without blanking.
0.0 Once this value is found, then determine

0.0 25 50 76 102 127 152 178 Dpf.
(1.0) (2.0) (3.0) (4.0) (5.0) (6.0) (7.0)
If the entire blanked area is filled with
Dpf = 3.4 (S – 7) mm
mechanical guarding or other fixed
(Dpf = 3.4 (S − 0.275) in) material or guards, use the device’s
object sensitivity to determine Dpf.
Figure D.2: Dpf for ground level devices that can be reached over (30° or less)
Examples include safety mats, area scanners, and horizontally mounted electro-optical devices.
Allowable Sensing Field Heights in mm. (in)

Objects Sensitivity (S) Mounting Height (h)
Minimum Maximum
< 50 (2) 0 990 (39)
64 (2.5) 190 (7.5) 990 (39)
76 (3.0) 380 (15) 990 (39)
89 (3.5) 570(22.5) 990 (39)
102 (4.0) 760 (30) 990 (39)
108 (4.25) 860 (33.75) 990 (39)
117 (4.6) 990 (39) 990 (39)
h
Minimum mounting height (h) can also be
REACH-OVER determined by the following,
Dpf = 1200 mm (48 in) for horizontal sensing h = 15 (S – 50) mm
field applications without vertical sensing. h = 15 (S – 2) in
where S is the object sensitivity.
NOTE - Minimum depth-of-field or sensing area must hinder an individual from stepping over the electro-
optical presence-sensing device or safety mat. This distance is 1.2 m (4 ft) if an individual can step over and
pass unrestricted; 900 mm (3 ft) if supplemental safeguarding or physical barriers are used such that an
individual must stand within the sensing area. For electro-optical presence-sensing devices inclined greater
than 30º from horizontal, and for which you can reach over without being detected, use Figure D.1.
49
Figure D.3: Dpf for object sensitivities greater than 64 mm (2.5 inches)
NOTE - For electro-optical presence-sensing devices using large blanked areas, or if an individual can otherwise reach
through or over the sensing field and not be detected, the distance between any two adjacent detection points shall not be
greater than 600 mm (24 in), i.e., from one active point to the next active point above.
The top of the sensing NOTE - Where

If the individual cannot field (“B”) is between 900 individuals can
reach over the top of and 1200 mm (3 and 4 ft) place themselves
the sensing field and above the floor. The between the
the bottom of the bottom of the sensing safeguarding
sensing field (“A”) is field (“A”) is no more than device and the
no more than 300 mm 300 mm (1 ft) above the B hazard zone and
(1 ft) above the floor. floor. remain
A A
undetected,
additional
REACH-THROUGH REACH-OVER measures must be
Dpf = 900 mm (3 ft) for reach through applications. Dpf = 1200 mm (4 ft) for reach over applications. taken.
Figure D.4: Example of guarding with object sensitivity less than 64 mm (2.5 inches)
Ds =
K (T total) + Dpf NOTE - Where
individuals can place
themselves between
the safeguarding
device and the
hazard zone and
remain undetected,
additional measures
must be taken.
Figure D.5: Example of guarding with various object sensitivities
Ds Safety Distance (Ds) for devices with a

larger value for object sensitivity must be
K (T total) Dpf placed farther from the hazard than a
device with a smaller value for object
sensitivity.
Hazard Zone
50
Figure D.6: Dpf for ground level devices that can be reached over (30° or less)
Ds
Allowable Sensing Field Heights in mm (in)
K (T total) Dpf Objects Sensitivity Mounting Height (h)
Minimum Maximum
< 50 (2) 0 990 (39)
64 (2.5)) 190 (7.5) 990 (39)
76 (3.0) 380 (15) 990 (39)
Hazard Zone 89 (3.5) 570 (22.5) 990 (39)
102 (4.0) 760 (30) 990 (39)
108 (4.25) 860 (33.75) 990 (39)
117 (4.6) 990 (39) 990 (39)
Minimum mounting height (h) can also be

h determined by the following,
h = 15 (S – 50) mm
h = 15 (S – 2) in
where S is the object sensitivity.
Area Scanner
Safety Light Minimum depth of field or sensing area must hinder an
Safety Mat individual from stepping over the presence-sensing device or
safety mat. This distance is 1.2 m (4 ft) if an individual can
step over and pass unrestricted, 900 mm (3 ft) if supplemental
safeguarding or physical barriers are used such that an
individual must stand within the sensing area.
Figure D.7: Single Control Device
Ds
K (T total) Dpf
Hazard Zone
Safety Distance (Ds) for a Single Control Device includes a large Dpf of 2 meters (6.5 feet) due to
the ability of the operator to stand between the device and reach towards the hazard.
51
Figure D.8: Two-hand Control & Two-Hand Trip Devices
Ds = K (T total) Ds = K (T total)
Hazard Zone
Safety Distance (Ds) for Two-Hand Control and Two-Hand Trip applications have a Dpf = 0. When used as
a safeguarding device, the position must be placed such that the safety distance is measured from the
closest hand control to the hazard.
Figure D.9: RF Presence-sensing Devices
Ds
K (T total) Variable detection
+ variance area
Hazard Zone
Antenna(e)
The point of detection must take into account fluctuations and variances in the field density and sensitivity
due to environmental conditions and physical changes in the work area. This amount must be added to K(T
total) to determine the total safety distance, Ds.
52
Table D.1: Maximum Guard openings vs. Distance from Hazard Zone in millimeters (inches)
As a function of gap size As a function of distance
Known Gap Minimum Distance Known Distance Minimum Gap
0 - 6 (0 - 0.250) ≥ 13 (0.5) 13 (< 0.5) 6 (0.250)
6.1 - 11 (0.251 - 0.375) ≥ 64 (2.5) 13 - 63.9 (0.5 - 2.49) 11 (0.375)
11.1 - 16 (0.376 - 0.625) ≥ 89 (3.5) 64 - 88.9 (2.5 - 3.49) 16 (0.630)
16.1 - 32 (0.626 - 1.250) ≥ 166 (6.5) 89 - 165.9 (3.5 - 6.49) 32 (1.250)
32.1 - 49 (1.251 - 1.875) ≥ 445 (17.5) 166 - 444.9 (6.5 - 17.49) 49 (1.875)
49.1 - 132 (1.876 - 5.000) ≥ 915 (36.0) 445 - 914.9 (17.5 – 35.99) 132 (5.000)
>132 (>5.0) Not permitted 925 (36.0)
The diagram below shows the recommended safe openings between the bottom edge of the guard and fixed
machine members at various distances from the nearest hazard. The various openings are such that neither
fingers, hands nor arms are permitted to reach the hazard even though they may contact the bottom of the guard.
A guard extending from the minimum guard line toward the guard opening will create a wedging of the fingers,
hand or forearm between the barrier and the permanent machine member, preventing movement of the fingers
toward the hazard.
When installing guards, careful test should be made by maintenance workers, set up people and operators to
make sure the guard is effective before the machine is run in production. The guard should be checked for
stability and rigidity of mounting. End and rear access to the point of operation should also be guarded.
53
Figure D.10: Location of Guards vs. Openings; Distance from hazard in millimeters (inches)
At distances over 915 mm (36 in), use 132 mm (5 in) as maximum opening.
54

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ANSI B11.

American National Standard for Machine Tools –

Safety Requirements for Machining

Secretariat and Accredited Standards Developer:

The Association For Manufacturing Technology

Approved: June 14, 2002

by the American National Standards Institute, Inc.

Published by: AMT – The Association For Manufacturing Technology

ANNEX B -- LIST OF HAZARDS AND HAZARDOUS SITUATIONS (INFORMATIVE) ....................................... 42

ANNEX C – PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S) (INFORMATIVE)............................ 45

ANNEX D – SAFETY DISTANCE (INFORMATIVE)............................................................................................... 46

John W. Russell,PE, CSP Chairman

Name Company Title

conventions The standard uses a two-column format to provide supporting

As in all American National Standards, the term “SHALL” denotes

Similarly, the term “CAN” denotes a possibility, ability or capability,

B11 conventions: Operating rules (safe practices) are not

Suggestions for improvement of this standard will be welcome.

SUPPLIER USER PERSONNEL

Instruction manual Overall workplace safety Comply with

Task and hazard

Layout, installation, testing

B11.19 Set-up, operation and

American National Standard for Machine Tools –

1.1 Machining center E1.1

NOTE - The terms machine and machinery as used throughout

2 Normative references E2 Informative references

The following documents (this column, below) are

Standard Requirements Explanatory Information

ANSI B11.19-1990, Performance criteria for the design,

ANSI A14.3-1984, Safety requirements for fixed ladders

ANSI / ASME-2001 Boiler and Pressure Vessel Code;

ANSI / ASME B15.1-1992, Mechanical Power

ANSI / NFPA 70-2002, National Electrical Code

ANSI / NPFA-70E-1994, Electrical Safety Requirements

ANSI / NFPA 79-2002, Electrical Standard for Industrial

ANSI / IES-RP-7-1991, Industrial Lighting

Metalworking Fluids: Safety and Health Best

Standard Requirements Explanatory Information

3.1 automatic operation: continuous sequence of

3.2 awareness device: An attachment that by

3.3 awareness signal: A signal that, by means of

3.4 control reliability: The capability of the machine

3.6 guard: A barrier, which prevents entry into the

3.7 hazard: A condition or set of circumstances that

3.8 helper: An individual who assists another in the

3.9 hold-to-run control device: Control device, which

3.10 immediate stop command: A command that

3.11 installer: An individual, partnership or corporation

3.13 jog: To impart motion by momentary manual

Standard Requirements Explanatory Information

3.15 monitoring: The checking of system components

3.16 normal stop command: A command that initiates

3.17 numerical control (computer numerical control)

3.18 operator: An individual who performs production

3.19 operator's control station: The complement of

3.21 programmable electronic system (PES): An

3.22 redundancy: The use of multiple means to

3.23 safety-related function: That portion of the

3.24 safeguarding: methods for protection of

3.25 set-up: The process of adjusting the machine and

Standard Requirements Explanatory Information

3.27 stop: immediate or controlled cessation of