AS 4024.

2801—2008
AS 4024.2801—2008

Australian Standard®

Safety of machinery

Part 2801: Safety distances and safety

gaps—Positioning of protective
equipment with respect to the approach
speed of parts of the human body
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 This Australian Standard® was prepared by Committee SF-041, General Principles for the
Guarding of Machinery. It was approved on behalf of the Council of Standards Australia on 27
May 2008.
This Standard was published on 25 June 2008.

The following are represented on Committee SF-041:

• Australian Chamber of Commerce and Industry

• Australian Electrical and Electronic Manufacturers Association
• Department for Administration and Information Services, SA
• Department of Consumer and Employment Protection, WorkSafe Division, WA
• Department of Industrial Relations, Qld
• Department of Primary Industries, Mine Safety, NSW
• Engineers Australia
• Federal Chamber of Automotive Industries
• Human Factors and Ergonomics Society of Australia
• Institute of Instrumentation, Control and Automation Australia
• National Electrical and Communications Association
• National Safety Council of Australia
• Office of the Australian Safety and Compensation Council
• Safety Institute of Australia
• The University of Melbourne
• Tractor and Machinery Association of Australia
• Victorian WorkCover Authority

This Standard was issued in draft form for comment as DR 07271.

Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through the public comment period.

Keeping Standards up-to-date

Australian Standards® are living documents that reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and new editions
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are published. Between editions, amendments may be issued.

Standards may also be withdrawn. It is important that readers assure themselves they are
using a current Standard, which should include any amendments that may have been
published since the Standard was published.

Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au

Standards Australia welcomes suggestions for improvements, and encourages readers to

notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at
mail@standards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.
 AS 4024.2801—2008

Australian Standard®

Safety of machinery

Part 2801: Safety distances and safety

gaps—Positioning of protective
equipment with respect to the approach
speed of parts of the human body

Originated as part of AS 4024.2(Int)—1992.

Previous edition part of AS 4024.2—1998.
Revised in part and redesignated as AS 4024.2801—2008.
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COPYRIGHT
© Standards Australia
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Published by Standards Australia GPO Box 476, Sydney, NSW 2001, Australia
ISBN 0 7337 8767 3
 AS 4024.2801—2008 2

PREFACE
This Standard was prepared by the Standards Australia Committee SF-041, General
Principles for the Guarding of Machinery to supersede, (in part), AS 4024.2—1998,
Safeguarding of machinery, Part 2: Installation and commissioning requirements for
electro-sensitive systems—Optoelectronic devices.
In common with other Parts of AS 4024, this Standard is based upon documents originating
within the European Community in the field of safety of machinery. Many of these
European Standards are being adopted virtually unchanged as International Standards by the
International Organization for Standardization (ISO) and the committee has agreed to
continue to use material emanating from both CEN and ISO.
The Standard is based upon but not equivalent to ISO 13855:2002 Safety of machinery—
Positioning of protective equipment with respect to the approach of parts of the human
body.
The term ‘informative’ has been used in this Standard to define the application of the
appendix to which it applies. An ‘informative’ appendix is only for information and
guidance.
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 3 AS 4024.2801—2008

CONTENTS

Page

FOREWORD.............................................................................................................................. 4
1 SCOPE ........................................................................................................................ 5
2 OBJECTIVE................................................................................................................ 5
3 REFERENCED DOCUMENTS .................................................................................. 5
4 DEFINITIONS ............................................................................................................ 6
5 METHOD .................................................................................................................... 7
6 GENERAL EQUATIONS FOR THE CALCULATION OF
MINIMUM DISTANCES............................................................................................ 9
7 CALCULATION OF MINIMUM DISTANCE FOR ELECTRO-SENSITIVE
PROTECTIVE EQUIPMENT EMPLOYING ACTIVE OPTO-ELECTRONIC
PROTECTIVE DEVICES ........................................................................................... 9
8 METHOD OF CALCULATING THE MINIMUM DISTANCES
FOR GROUND LEVEL TRIP DEVICES ................................................................. 16

APPENDICES
A WALKING SPEEDS AND STRIDE LENGTHS ...................................................... 18
B WORKED EXAMPLES ............................................................................................ 19
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 AS 4024.2801—2008 4

FOREWORD
The effectiveness of certain types of protective equipment described in this Standard to
minimize risk relies, in part, on the relevant parts of that equipment being correctly
positioned in relation to the danger zone. In deciding on these positions, a number of
aspects are to be taken into account, such as—
(a) the need to identify hazards and to assess risks;
(b) the practical experiences of users, including accident statistics;
(c) the state of the art and possible future technical developments;
(d) the type of equipment to be used;
(e) the response times of protective equipment used;
(f) the time taken to ensure the safe condition of the machine following operation of the
protective equipment, for example to stop the machine;
(g) the bio-mechanical and anthropometric data of body parts;
(h) the path taken by the body part when moving from the sensing or actuating means
towards the danger zone;
(i) the possible presence of a person between the device and the danger zone; and
(j) the possibility of undetected access to the danger zone.
If these aspects are further developed, the current state of the art, reflected in this Standard,
will be updated.
This Standard gives guidance based on the assumption that the correct device has been
chosen either by reference to the appropriate machine specific standard or by carrying out a
risk assessment.
The calculated distances, when implemented, will provide sufficient protection for persons
against the risks caused by approaching a danger zone which generate any of the following
mechanical hazards, such as: crushing, shearing, cuffing or severing, entanglement,
drawing-in or trapping, friction or abrasion, stabbing or puncture and impact.
Protection against the risks from mechanical hazards arising from the ejection of solid or
fluid materials and non-mechanical hazards, such as toxic emissions, electricity, radiation
etc., are not covered by this Standard.
The distances are derived from data that take into account population groups likely to be
found in European countries and are consequently applicable to those groups.
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NOTES:
1 If this Standard is to be used for non-industrial purposes, then the designer should take into
account that this data is based on industrial experience.
2 Until specific data is available for approach speeds for children, this Standard uses adult
speeds and lower detection factors, where relevant, to calculate the distances that could be
within the reach of children.
 5 AS 4024.2801—2008

STANDARDS AUSTRALIA

Australian Standard
Safety of machinery

Part 2801: Safety distances and safety gaps—Positioning of protective

equipment with respect to the approach speed of parts of the human body

1 SCOPE
This Standard provides the means to determine the minimum distances from the sensing or
actuating devices of protective equipment to a danger zone. The safety distances are based
upon values for hand or arm approach speeds and the response time for the machine.
These specific devices are—
(a) trip devices as defined in AS 4024.1201 (specifically electro-sensitive protective
equipment, pressure sensitive mats), including those used additionally to initiate
operation; and
(b) two-hand control devices as defined in AS 4024.1201.
NOTES:
1 For the purposes of this Standard, hold-to-run controls, which are designed to be actuated
with one hand, are not considered to be protective equipment.
2 Electro-sensitive protective equipment is a forms a family of trip devices which includes
active opti-electronic protective devices (AOPD).
This Standard does not apply to protective equipment which is intended to be moved,
without tools, nearer to the danger zone than the calculated distance, e.g. pendant two-hand
control devices.
The minimum distances derived from this Standard do not apply to protective equipment
used to detect the presence of persons within an area already protected by a guard or
electro-sensitive protective equipment.

2 OBJECTIVE
The objective of this Standard is to provide designers, manufacturers, suppliers, installers
and users of electro-sensitive protective equipment with the means of determining the
minimum distance from a danger zone the equipment must be located in order to minimize
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the risk to health and safety of those working with or otherwise near machinery at which the
equipment is installed.

3 REFERENCED DOCUMENTS
The following documents are referred to in this Standard.
AS
4024 Safety machinery
4024.1201 Part 1201: General principles—Basic terminology and methodology
4024.1202 Part 1202: General principles—Technical principles
4024.1301 Part 1301: Risk assessment—Principles of risk assessment
4024.1801 Part 1801: Safety distances and gaps—Safety distances to prevent danger
zones being reached by the upper limbs
4024.2601 Part 2601: Design of controls, interlocks and guarding—Two-hand control
devices—Functional aspects and design principles

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 AS 4024.2801—2008 6

IEC
61496 Safety of machinery—Electrosensitive protective equipment
61496-1 Part 1: General requirements and tests

4 DEFINITIONS
For the purposes of this Standard, the definitions given in AS 4024.1201, AS 4024.1202
and the following apply.
4.1 Active opto-electronic protective device
A device whose sensing function is performed by opto-electronic emitting and receiving
elements detecting the interruption of optical radiations generated within the device by an
opaque object present in the specified detection zone or for a light beam device, on the axis
of the beam.
4.2 Actuation (of protective equipment)
Physical initiation of the protective equipment when it detects movement of the body or a
part of the body.
4.3 Detection capability (d)
Sensing function parameter limit specified by the supplier that will cause actuation of the
electro-sensitive protective equipment (ESPE).
4.4 Electro-sensitive protective equipment (ESPE)
Assembly of devices and/or components working together for protective tripping or
presence-sensing purposes and comprising as a minimum a sensing device,
controlling/monitoring devices and output signal switching devices.
4.5 Overall system stopping performance (T)
Time or travel occurring from the actuation of the sensing function to the cessation of
hazardous motion, or to the machine assuming a safe condition, comprising a minimum of
two phases.
T = t1 + t2 . . . (1)
where
T = overall system stopping performance, in seconds
t 1 = the maximum time between the actuation of the sensing function and the output
signal switching devices being in the off state, in seconds
t 2 = the maximum response time of the machine, i.e. the time required to stop the
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machine or remove the risks after receiving the output signal from the
protective equipment. t 2 is influenced by various factors, e.g. temperature,
switching time of valves, ageing of components, in seconds
NOTE: The relationship between t1 and t 2 is given in Figure 1. t 1 and t2 are functions of the
protective equipment and the machine respectively and are determined by design and
measurement.

© Standards Australia www.standards.org.au

 7 AS 4024.2801—2008

FIGURE 1 RELATIONSHIP BETWEEN t 1 AND t 2

5 METHOD
Figure 2 provides a schematic representation of the method for determining the correct
location of sensing or actuating devices of protective equipment.
The method is as follows:
(a) Identify the hazards and assess the risks (see AS 4024.1201 and AS 4024.1301).
(b) If a machine-specific Standard exist, select one of the specified types of protective
equipment from that machine-specific Standard, and then use the safety distance
specified in that Standard.
(c) If there is no machine-specific Standard or if the machine-specific Standard does not
specify any minimum safety distances, then use the formulae in this Standard to
calculate the minimum safety distance for the protective equipment selected. The
selection of the appropriate type of protective equipment should be made in
accordance with the relevant standards.
(d) Incorporate the distance in the machine design.
(e) Ensure that the device has been installed in such a manner that access to the danger
zone will not be possible without detection by the device.
(f) Check if the determined position will allow persons to be between the sensing devices
of the protective equipment and the danger zone without being detected. In this case,
supplementary measures may be required depending on the risk.
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 AS 4024.2801—2008 8
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FIGURE 2 SCHEMATIC OF METHOD

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 9 AS 4024.2801—2008

6 GENERAL EQUATIONS FOR THE CALCULATION OF MINIMUM DISTANCES

The minimum distance, in millimetres, from the danger zone to the detection point, line,
plane or zone shall be calculated by using the following general equations:
S = (K × T) + C . . . (2)
where
S = the minimum distance from the danger zone to the detection zone, in
millimetres
K = a parameter derived from data on approach speeds of the body or parts of the
body, in millimetres per second
T = the overall system stopping performance, in seconds (see Clause 4.4)
C = an additional distance based on intrusion towards the danger zone prior to
actuation of the protective equipment, in millimetres
NOTES:
1 For information on walking speed and stride length, see Appendix A.
2 For worked examples see Appendix B.

7 CALCULATION OF MINIMUM DISTANCE FOR ELECTRO-SENSITIVE

PROTECTIVE EQUIPMENT EMPLOYING ACTIVE OPTO-ELECTRONIC
PROTECTIVE DEVICES
7.1 General
Where a machine-specific Standard exists, the protective equipment shall be selected from
the specified types of protective equipment given in that Standard. The safety distance shall
be determined in accordance with that Standard. If no machine-specific standard exists, a
risk assessment according to AS 4024.1301 shall be undertaken.
This clause considers three main applications based on the direction of approach to the
detection zone as follows:
(a) Normal approach (see Figure 3).
(b) Parallel approach (see Figure 4).
(c) Angled approach (see Figure 5).
Where it is foreseeable that any gaps adjacent to or within the detection zone of the electro-
sensitive protective equipment will allow access to the danger zone, this should be taken
into account in the correct positioning of the protective equipment and additional
safeguards considered.
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Access to the danger zone by reaching over or around the electro-sensitive protective
equipment, together with any other protective equipment and additional safeguards, shall be
prevented.

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 AS 4024.2801—2008 10

LEGEND:
S = minimum safety distance
1 = danger zone
2 = detection zone
3 = direction of approach
4 = fixed guard
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FIGURE 3 THREE EXAMPLES OF NORMAL APPROACH

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 11 AS 4024.2801—2008

7.2 Direction of approach normal to the detection zone

7.2.1 Electro-sensitive protective equipment employing active opto-electronic protective
devices
The minimum distance from the detection zone to the danger zone shall be not less than that
calculated using Equation 2 as follows:
S = (K × T) + C
where
K = 2000 mm/s
C = 8(d − 14), but not less than 0
then
S = (2000 × T) + 8(d – 14) . . . (3)
Equation 3 applies to all minimum distances of S up to and including 500 mm. the minimum
value of S shall not be less than 100 mm.
If S is found to be greater than 500 mm using Equation 3, then Equation 4 may be used as
follows:
S = (K × T) + C
where
K = 1600 mm/s
C = 8(d − 14), but not less than 0
then
S = (1600 × T) + 8(d – 14) . . . (4)
In this case, the minimum value of S shall not be less than 500 mm.
Where it is foreseeable that electro-sensitive protective equipment employing active opto-
electronic protective devices will be used in non-industrial applications, for example in the
presence of children, the minimum distance S calculated with Equation 3 shall be increased
by at least 75 mm. It shall be noted that in such cases Equation 4 is not applicable.
Where it is foreseeable that the work will consist of rapid repetitive motions, e.g. where the
operation is sitting close to the machine during work, the workplace are small, of low
weight, easy to grip and handle with one hand and the cycle time is short, then the
minimum distance shall be calculated as follows:
S = (K × T) + C
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where
K = 2500 mm/s
C = 8(d − 14), but not less than 0
then
S = (2500 × T) + 8(d – 14) . . . (5)
7.2.2 Electro-sensitive protective equipment employing active opto-electronic protective
devices used for reinitiation of machine operation
Electro-sensitive protective equipment employing active opto-electronic protective devices
used for reinitiation of machine operation shall have a detection capability equal to or less
than 30 mm, Equation 3 (see Clause 7.2.1) shall apply and the minimum distance S shall be
greater than 150 mm.

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 AS 4024.2801—2008 12

If the detection capability is equal to or less than 14 mm, Equation 3 shall apply and the
minimum distance S shall be greater than 100 mm.
NOTES:
1 Conditions for using electro-sensitive protective equipment in the reinitiation of machine
operation are given in AS 4024.1201 and AS 4024.1202 and relevant machine-specific
standards.
2 Additional requirements for electro-sensitive protective equipment are given in IEC 61496-1.
7.2.3 Electro-sensitive protective equipment employing active opto-electronic protective
devices with detection capability greater than 40 mm and less than or equal to 70 mm
Such pieces of equipment will not detect intrusion of the hands and therefore shall only be
used where the risk assessment indicates that detection of intrusion of the hands is not
necessary.
This equipment shall be installed in accordance with the following parameters:
(a) The minimum distance from the detection zone to the danger zone is in part
dependent on the part of the body to be detected and shall be calculated using
Equation 2 as follows:
S = (K × T) + C
where
K = 1600 mm/s
C = 850 mm
then
S = (1600 × T) + 850 mm . . . (6)
(b) The risk of inadvertent access shall be taken into account during the risk assessment
stage but, in all cases, the height of the uppermost beam shall be greater than or equal
to 900 mm and the height of the lowest beam shall be less than or equal to 300 mm.
(c) Where it is foreseeable that electro-sensitive protective equipment will be used in
non-industrial applications, for example in the presence of children, the height of the
lowest beam shall be less than or equal to 200 mm.
7.2.4 Multiple separate beams
Multiple separate beams, for example a combination of 2, 3 or 4 separate beams, are often
used to detect intrusion of the whole body rather than parts of the body.
If the risk assessment indicates that separate beams are appropriate, they shall be positioned
at a minimum distance from the danger zone calculated in accordance with Equation 6, see
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Clause 7.2.3.
During risk assessment, methods which can possibly be used to bypass such equipment
shall be taken into account. These methods may include—
(a) crawling below the lowest beam;
(b) reaching over the top beam;
(c) reaching through between two of the beams; or
(d) bodily access by passing between two beams.
The heights for 2, 3 and 4 beams given in Table 1 have been found to be the most practical
in application.

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 13 AS 4024.2801—2008

TABLE 1
HEIGHTS FOR BEAMS
Heights above reference plane,
Number of beams
for example the floor, mm
4 300, 600, 900, 1200
3 300, 700, 1100
2 300, 800

7.2.5 Single height beams

These beams have only been considered when they are used parallel to the ground or
reference plane and the beam is broken by a person’s body in the upright position.
S = (K × T) + C
where
K = 1600 mm/s
C = 1200 mm
then
S = (1600 × T) + 1200 . . . (7)
Where the risk assessment allows a single height beam to be used alone then the minimum
distance shall be calculated using Equation 2 as follows:
A height of 750 mm from the ground or reference plane (see AS 4024.1801) has been found
in industry to be a practical solution to the problems of inadvertent access from stepping
over or bending under the beam.
7.3 Direction of approach parallel to the detection zone
This minimum distance shall be calculated using the following equation:
S = (K × T) + (C − 0.4H) . . . (8)
where
S = the minimum distance from the danger zone to the detection zone, in
millimetres
K = the approach speed of the body or part of the body, in millimetres per second
= 1600 mm/s
T = the overall system stopping performance, in seconds
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C = the intrusion distance of the body, or part of the body, towards the danger zone
before actuation of the protective equipment, in millimetres
= 1200 mm
H = the height of the detection zone above the reference plane, for example, the
floor, in millimetres
≤ 1000 mm
The parameter C − 0.4H shall be not less than 850 mm.
For this form of protective equipment, the height H of the detection zone shall be not
greater than 1000 mm. However, if H is greater than 300 mm (200 mm for non-industrial
applications, for example in the presence of children) there is a risk of inadvertent
undetected access beneath the detection zone. This shall be taken into account in the risk
assessment.

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 AS 4024.2801—2008 14

The lowest allowable height of the detection zone shall be calculated using the following
equation:
H = 15 (d − 50) . . . (9)
Thus, for a given height of the detection zone, the corresponding detection capability d
shall be calculated using the following equation:
H
d = + 50 . . . (10)
15
That means, where the height of the detection zone is known or fixed, a maximum detection
capability can be calculated, for example when calculating the horizontal section of
L-shaped electro-sensitive protective equipment, or if a detection capability is known or
fixed, a minimum height can be calculated, up to the allowable maximum of 1000 mm.

LEGEND:
H = height of detection zone above reference plane
S = minimum safety distance
1 = danger zone
2 = detection zone
3 = direction of approach
4 = fixed guard
5 = start of detection zone
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FIGURE 4 PARALLEL APPROACH TO THE DETECTION ZONE

7.4 Detection zone angled to the direction or approach

If the detection zone has been installed so that it is angled greater than ±30° to the direction
of approach, then it shall be treated as a normal approach (see Clause 7.2 and Figures 5a
and 5c).
If the detection zone has been installed so that it is angled less than ±30° to the direction of
approach, then it shall be treated as a parallel approach (see Clause 7.3 and Figures 5b
and 5c).
NOTE: A tolerance of ±5° should be used for these angles.

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 15 AS 4024.2801—2008

When angled approach detection zones are considered as parallel approach, then Equation 9
linking H and d in Clause 7.3 shall apply to the lowest beam or the beam closest to the
reference plane (see H in Figure 6). In the case of parallel approach, the equation to derive
the minimum distance S shall apply to the beam furthest from the danger zone. This beam
may be used up to a maximum height of the detection zone of 1000 mm.
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LEGEND:
S = minimum safety distance
1 = danger zone
2 = detection zone
3 = direction of approach
4 = fixed guard
5 = start of the detection zone
6 = parallel approach
7 = normal approach

FIGURE 5 ANGLED APPROACH TO THE DETECTION ZONE

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 AS 4024.2801—2008 16

7.5 Dual position equipment

When the detection zone can be readily converted to a position either normal or parallel to
the direction of approach, then the minimum distances for both directions of approach shall
be applied (see Example 3 in Appendix B).
The axis of rotation of the detection zone shall be at a point where both requirements can be
achieved. This need not necessarily be the last beam.
When in position normal to the direction of approach (vertical detection zone), the
minimum distance S shall be calculated using Equation 3 (see Clause 7.2.1) up to
S ≤500 mm.
If S is found to be greater than 500 mm using Equation 3, then Equation 4 (see
Clause 7.2.1) may be used, but with a minimum distance of 500 mm.
When in position parallel to the direction of approach (horizontal detection zone), the
minimum distance S shall be calculated using Equations 8, 9 and 10 (see Clause 7.3) up to a
maximum height of 1000 mm.

FIGURE 6 DUAL POSITION EQUIPMENT

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8 METHOD OF CALCULATING THE MINIMUM DISTANCES FOR GROUND

LEVEL TRIP DEVICES
8.1 General method
The selection and use of ground level trip devices actuated by the feet is dependent on the
appropriate machine-specific standard or a risk assessment in accordance with
AS 4024.1301 where no machine-specific standard exists.
Examples of ground level trip devices include pressure sensitive mats, pressure sensitive
floors and active opto-electronic protective devices.
The minimum distances derived in this clause for ground level trip devices assume that the
approach speed to the danger zone will be at walking speed. Regarding the risk of stepping
over the detection zone, see Appendix A.

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 17 AS 4024.2801—2008

The minimum distance shall be calculated using Equation 8 (see Clause 7.3).
8.2 Floor mounting
In most situations, the trip device will be fitted directly onto the floor, i.e. H is equal
to zero. Therefore the minimum distance for trip devices installed on the floor shall be
calculated using Equation 8 (see Clause 7.3) as follows:
S = (K × T) + (C − 0.4 H)
where
K = 1600 mm/s
C = 1200 mm
H = 0
then
S = (1600 × T) + 1200 . . . (11)
8.3 Step mounting
If the trip device is mounted onto a step or raised platform, then the minimum distance may
be reduced by 0.4H, where H is the height of the step in millimetres.
8.4 Two-hand control devices
The minimum distance from the nearest actuator to the danger zone shall be calculated
using the following equation 2 as follows:
S = (K × T) + C . . . (12)
where
K = 1600 mm/s
C = 250 mm
then
S = (1600 × T) + 250
If the risk of encroachment of the hands or part of the hands towards the danger zone is
eliminated while the actuator is being operated, for example by adequate shrouding,
then C may be zero, with a minimum allowable distance for S of 100 mm.
NOTE: AS 4024.2601 gives advice on shrouding to prevent defeating the intended operation of a
control. Measures described there are not adequate in all applications to prevent encroachment of
the hands or parts of the hands towards the danger zone.
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 AS 4024.2801—2008 18

APPENDIX A
WALKING SPEEDS AND STRIDE LENGTHS
(Informative)

A1 GENERAL
The positioning of equipment which is activated by a person walking into the detection
zone, for example by stepping onto a pressure sensitive mat, is affected by the speed of
approach and stride length.
The walking speed and stride length depend on the physical and anthropometric data of the
population.

A2 SPEED OF APPROACH
This Standard assumes that the approach of persons towards the danger zone will be at
walking speed.
Other types of approach, for example running or jumping, should be considered in the risk
assessment.

A3 STRIDE LENGTH
Available research data has shown that the 95th percentile of two steps (i.e. starting and
finishing with the same foot) measured from heel contact at walking speed is approximately
1900 mm. By dividing by two and subtracting the 5th percentile shoe length, a stride length
of 700 mm is obtained. If it is assumed that an allowance has to be made, for example,
between the detection zone and the stride length of for example 50 mm, this gives a
minimum width of 750 mm for the detection zone.
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 19 AS 4024.2801—2008

APPENDIX B
WORKED EXAMPLES
(Informative)

B1 GENERAL
This Appendix gives examples to show how this Standard can be used.
It is assumed in these examples that either the appropriate machine-specific Standard or the
risk assessment for the relevant machine will allow the use of the protective equipment
chosen for these examples.

B2 EXAMPLE 1
A machine has a stopping time of 60 ms (t 2). It is fitted with electro-sensitive protective
equipment employing a vertical active opto-electronic protective device having a detection
capability of 14 mm and a response time of 30 ms (t1 ).
Using Equation 3:
S = (2000 × T) + 8(d − 14)
where
S = the minimum distance from the danger zone to the detection zone in
millimetres
T = the overall response time of (60 + 30) = 90 ms
d = 14 mm
then
S = (2000 × 0.09) + 8(14 − 14)
S = 180 mm

B3 EXAMPLE 2
The same machine as in example 1 is used, but with a detection capability of 30 mm.
Using Equation 3:
S = (2000 × T) + 8(d − 14)
where
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T = is the overall response time of (60 + 30) = 90 ms

d = 30 mm
then
S = (2000 × 0.09) + 8(30 − 14)
S = 180 + 128
S = 308 mm

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 AS 4024.2801—2008 20

B4 EXAMPLE 3
B4.1 Introduction
A dual position detection zone is required for a machine with a table height of 1000 mm.
Overall system stopping performance T is 100 ms and the detection capability of the
curtain d is 40 mm.
B4.2 Vertical application
Using Equation 3:
S = (2000 × T) + 8(d − 14)
where
T = 100 ms
d = 40 mm
then
S = (2000 × 0.1) + 8(40 − 14)
S = 200 + 208
S = 408 mm
This is not greater than 500 mm, so the equation is valid.
B4.3 Horizontal application
Using Equation 8:
S = (1600 × T) + (1200 − 0.4 H)
where
(1200 − 0.4 H) is not less than 850 mm
then
S = (1600 × 0.1) + 850
S = 160 + 850
S = 1010 mm
The pivot point will therefore be at a horizontal distance of 408 mm from the danger zone.
The minimum length of the detection zone will be (1010 − 408) = 602 mm.
Risk assessment will indicate if additional safeguarding is required, in this example for the
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resulting gap of 408 mm between the pivot point and the danger zone.

B5 EXAMPLES COMPARING DIFFERENT DEVICES

B5.1 Example 4
Inadvertent access to the danger zone of an automated machine system is detected by an
active opto-electronic protective device.
The risk assessment indicates that a multiple separate individual beam device would be
appropriate and a three-beam device is selected.
The stopping time of the machine system is 300 ms and the response time of the protective
equipment is 35 ms.

© Standards Australia www.standards.org.au

 21 AS 4024.2801—2008

From Table 1, the beams should be set at 300 mm, 700 mm and 1100 mm from the floor.
The minimum distance is given by Equation 6:
S = (1600 × T) + 850
where
T = 335 ms
then
S = (1600 × 0.335) + 850
S = 536 + 850
S = 1386 mm
B5.2 Example 5
The same machine as in Example 4, but by installing a floor-mounted pressure sensitive mat
or a floor-mounted active opto-electronic protective device instead of a three-beam device:
S = (1600 × T) + 1200
then
S = (1600 × 0.335) + 1200
S = 536 + 1200
S = 1736 mm

B6 EXAMPLE 6
Risk assessment indicates that a two-hand control device is appropriate to prevent access to
a danger zone. The overall response time of the device and the machine is 90 ms.
Using Equation 12:
S = (1600 × T) + 250
then
S = (1600 × 0.09) + 250
S = 144 + 250
S = 394 mm
If adequate shrouding is used, S can be reduced to 144 mm (see Clause 8).
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www.standards.org.au © Standards Australia

Accessed by DEAKIN UNIVERSITY on 18 Nov 2011

AS 4024.2801—2008
22

NOTES
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23

NOTES
AS 4024.2801—2008
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AS 4024.2801—2008
24

NOTES
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