en 81-1/2+a3 - ucm application in germany

EN 81-1/2+A3 - UCMApplication in Germany

2013/04/06 Asansör Istanbul 04.-07. April 2013 1

Wolfgang AdldingerWITTURChairman – Components Committee European Lift Association ( ELA )


EN 81-1/2+A3 - UCM Application in Germany

Reason for (EN 81-1/2) Amendment 3

Number of accidents

The publication of the European Machinery Directive 2006/42/EC was one of the main reason for the immediate implementation of the Amendment 3 of EN 81-1/2:1998

Requirements in the Amendment 3 acc. to EN81-1/2‣Rated speed‣Fixing systems of guards‣Stopping and leveling accuracy‣Safety device against unintended car movement

UCM protection

> 0,15 m/s

± 10 mm± 20 mm

Need to remove ≤ 24 month

In Canada, USA, South Korea, Japan and Hong Kong the UCM requirements are already transposed into national standards‣ 1986 Canada‣ 2004 USA and South Korea‣ 2006 Japan‣ 2010 Hong Kong


Affected RegulationsEurope‣ Machinery Directive 2006/42/EC‣ Lift Directive 95/16/EC‣ EN 81-1/2:1998+A3:2009‣ EN 81-21:2009+A1:2012‣ EN 81-80:2003

In each country incidents have caused the fast implementation of UCM requirements into national standards.

ESR Annex I

Revision in process



The Definition of „unintended car movement“

“Unintended car movement” is to be understood as non-commanded (unintended)

car movement with open doors away from the landing position

down up

It is obligatory since 1st of January 2012‣ for new lifts ‣ for important changes at existing lifts

depending on country transposition of EN 81-80 (SNEL) or other country specific regulations



Protection against unintended car movement

Additional means have to protect unintended car movement (UCM)

down up

Detection / Activation stopping keep stopped

at any load and speed conditions



Protection against unintended car movement

dow

n

up

min1000mm

max 1200mm

min1000mm

max 1200mm

200mmmax

Required distances in EN 81-1/2+A3



ELA / CEN additional explanation papers (guides)

Interpretation CEN/TC10 [N1017]

‣ Guideline for a better understanding of the Amendment 3 requirements and application (Questions and Answers)

NB-L RECOMMENDATION FOR USE (04.03.2013)

‣ This document describes the proceeding of type examination and production control from Notified Bodies

A RECOMMENDATION FOR USE is obligatory for all Notified Bodies and shall unify the European test procedure



NB-L RECOMMENDATION FOR USE Proceeding with safety devices against UCM

‣ Proposed procedures of type examination, production control, conformity assessment procedure, risk assessment description and design prove according Annex F.8

‣ Procedure for components with existing EC- type examination certificate

‣ Procedure for installation and final inspection, periodical checks

‣ Maintenance, Changing units, Modernization, Dismantling

‣ Procedures for Lifts, sub systems and components



Placing on the market – responsibility of the installer

‣ provide the interfaces of the UCM means‣ responsible for the compliance with the legal /

normative requirements‣ provide the instruction for use‣ provide the manual for the test procedure

“TYPE TESTED SYSTEMS AND SUB SYSTEMS” Advantage for the installer



Affected components / solutions

Safety device

Lift controller

Door zone

monitoring

ELECTRONIC INTERFACE

Others!

Others!


History and experience with the application of the UCM requirements in Germany


Application in Germany



Lift Market in Germany (2012)

ca. 700.000 existing Lifts ca. 16.000 new Lifts

50%

30%

10%10% Residential

Commercial / Office Buildings

social Insti-tutions

Industry

93%

7%

electric Lifts

hydraulic Lifts

Value of Modernisation in 2012: ca. 250 Mio. €



Lift Market in Germany (2012)

most frequent causes of accident

38%

21%

21%14%

3%3%

Technical defects (incl. UCM cases)

opening / closing doors

no stopping accuracy

human failure

missing car door

Vandalism


The introduction of the European Standard EN 81-1/2:1998+A3:2009 on 1st. January 2012 provide a new definition for „State of the Art“ for the lift technology.


Safety device against unintended car movement

„State of the Art“ for new installation

=

Definition „State of the Art“: "the level of knowledge and development achieved in a

technique…“

“the development of new techniques and procedures by expert people in a particular field”

(www.wikipedia.com)

UCM



Directive 89/655/EEC(Arbeitsmittelbenutzungsrichtlinie)concerning the minimum safety and health requirements for the use of work equipment by workers at work

Directive 2009/104/EC (Arbeitsmittelbenutzungsrichtlinie)

concerning the minimum safety and health requirements for the use of work equipment by workers at work

was replaced bytransposed into National Law in Germany as

„Ordinance on Industrial Safety

and Health“ (Betriebssicherheitsverordnung)

Ordinance concerning the protection of safety

and health in the provision of work equipment and its use at work,

safety when operating installations subject to monitoring and

the organization of industrial safety and health at work



German Law: „Ordinance on Industrial Safety and Health“ (Betriebssicherheitsverordnung)

protection of safety and health in the provision of work equipment and its

use at work,

concerning safety when operating installations subject to monitoring

organization of industrial safety and health at work

required „State of the Art“ for new installation and modification of existing lifts



German law „Ordinance on Industrial Safety and Health” (Betriebssicherheitsverordnung -BetrSichV-):

Installations subject to monitoring shall only be put into service for the first time or after fundamental modifications:

if they comply with the other legal provisions, but at least with the state of the art, where the aforementioned legal provisions are not applicable.

Installations subject to monitoring shall not be put into service after a modification unless the parts of the installations that are affected by the modification comply with the state of the art.



German law „Ordinance on Industrial Safety and Health” (Betriebssicherheitsverordnung -BetrSichV-):

A fundamental modification of an installation subject to monitoring means any modification which influences the safety of the installation subject to monitoring to the extent that its safety features correspond to those of a new installation.

A modification of an installation subject to monitoring means any activity which influences the safety of an installation. Any service, maintenance or repair work influencing the safety of the installation shall also be considered a modification.



TRBS 1121: “Modification and fundamental modification of Lifts”‣ Described in detail which kind of work on the Lift is a

“modification” or a “fundamental modification” to fulfill “State of the Art”.

‣ The “German Committee for lifts (DAfA)” has worked on the further development of this Technical Rule:

-Lift Manufacturer-Component Manufacturer-Lift Consultants-Owner of Lifts-Notified Bodies and-Experts from the German Government

Modification of Lifts Fundamental Modification of Lifts

TRBS 1121

Technical Rule for Application of the Ordinance on Industrial Safety and Health

?

DAfA has also provide a Guide to application the Technical Rule 1121 for safe use in Lift modification


Federal Ministry of Labour and Social Affairs


New Lifts (subject to monitoring) Existing Lifts (subject to monitoring)

Modification Fundamental Modification

before putting into service: Lift must comply with „State of the Art“

TRBS 1121 „Technical Rule: Modification and fundamental modification of existing lifts“

Described in detail the „State of the Art“ for „modification“ and „fundamental modification“

TRBSTechnical Rules for Application of the „Ordinance on Industrial Safety and Health“

„State of the Art“ for new lifts is defined in EN 81-1/2:1998+A3:2009

(including UCM)

„State of the Art“ mandatory

DAfA has worked for the implementation of the EN 81-1/2+A3-Requirement into the German Technical Rules to fulfill the “State of the Art” Requirement: Lift Manufacturer Components Manufacturer Lift Consultants Owner of Lifts Notified Bodies Experts from the Government



Federal Ministry of Labour and Social Affairs


New Lifts (subject to monitoring) Existing Lifts (subject to monitoring)

modification Fundamental modification

before putting into service: Lift must comply with „State of the Art“

TRBS 1121 „Technical Rule: Modification and fundamental modification of lifts“

Described in detail the „State of the Art“ for „modification“ and „fundamental modification“

TRBSTechnical Rules for Application of the „Ordinance on Industrial Safety and Health“

„State of the Art“ for new lifts is defined in EN 81-1/2:1998+A3:2009

(including UCM)

„State of the Art“ mandatory

DAfA has worked for the implementation of the EN 81-1/2+A3-Requirement into the German Technical Rules to fulfill the “State of the Art” Requirement: Lift Manufacturer Components Manufacturer Lift Consultants Owner of Lifts Notified Bodies Experts from the Government

Under certain condition UCM is also mandatory for the „Modification“ and „Fundamental modification“ of

existing lifts in Germany(Decision in Germany with involving of the DAfA in November 2011)



for existing lifts a retrofit of safety device against unintended car movement must be considered by:

- Change of the complete Drive,- Modification of the drum drive

completely,- Renewal / modification of the protective

device against ascending car overspeed,- Change of controller completely,- Renewal / modification of safety gear,- Change of the rated speed of the lift

system,- Change of gear,- Modification of the hydraulic drive

completely,

- Shifting of complete lift system- Changing of complete well- Additional floor of lift system,- New lift with exception of guide rails

and fixings

Modification Fundamental Modification

Inspection of notified body necessary provided that the operation or type of the installation is affected by the modification

New conformity assessment procedure acc. LD 95/16/EC mandatory



Experience with the application of the UCM Requirement for Modification of Lifts


How does it work in the reality?



Steps for Implementation of UCM in existing lifts

Evaluation of current situation

Search for possible technical UCM solutions / Feasibility study

Type examination of non certified components (if necessary)

Under consideration of the requirements in the German Technical Rule TRBS 1121 and the „Guide for application the TRBS 1121“

Inspection through notified body



1. Step for Implementation of UCM in existing lifts

Evaluation of current situation

‣ rated load,‣ rated speed,‣ traction drive (with gear or gearless)‣ controller type,

Operation and type of lift

‣ „modification“ or a „fundamental modification“?

‣ renewal without effect to the safety operation and type of lift?

‣ is a retrofit of UCM due to planned modernisation necessary?

Planned modernisation of Lift system





‣ existing components can be used?‣ type examination regarding UCM for existing components available?‣ use of other certified components for „detection - stopping - keep stopped“?‣ use of certified complete system against UCM possible?‣ Combination of certified and non-certified components possible / necessary?

Detection stopping keep stopped

1 braking element start a reduction of speed2 speed3 response time of UCM detection4 response time of braking elements5 time





‣ several individual components for “detection, stopping and keep stopped”

‣ Calculation of the complete system necessary,

‣ several description of interfaces, connection to controller,

‣ Installer has to describe the instruction for use for the complete system,

‣ Installer has to describe the test instructions for the complete system,

‣ certified component‣ Distance of the

component in the UCM case known,

‣ Instruction for use from owner of certificate,

‣ Test procedure from owner of certificate

a) use of certified components

Advantage Disadvantage





‣ Type examination (EN81-1/2+A3; Annex F.8) for complete system necessary (not only for component)

‣ Calculation of the complete system necessary,‣ Installer has to describe the instruction for use for

the complete system,‣ Installer has to describe the test instructions for the

complete system,

‣ No change of component

‣ …

b) use of non certified components






‣ Certified system for “detection, stopping and keep stopped”

‣ Calculation of the complete system done by owner of certificate,

‣ Instruction for use for the complete system done by owner of certificate,

‣ test instructions for the complete system done by owner of certificate,

‣ one interface to controller

‣ …

c) use of certified complete system against UCM





‣ Technical implementation‣ Replacement of components‣ possibly certification of used components

with proof of the stopping distance in accordance with EN 81-1/2 + A3, section F. 8 with calculation

Description of whole UCM System Operating instructions Test instruction

‣ Costs‣ Time


Decision:




2. Modernisation

Experience with Modernisation

1. Modernisation 3. Modernisation

certified UCM System:‣ Gearless Brake,‣ Overspeed Governor,‣ Electronic Interface

certified UCM System:‣ Safety Gear,‣ Overspeed Governor,‣ Electronic Interface

UCM certified:‣ Overspeed Governor,‣ Electronic Interface

‣ Non certified gearless brake

Results ?




Experience with 1. Modernisation

certified UCM System:‣ Safety Gear,‣ Overspeed Governor,‣ Electronic Interface

UCM calculation and distance given in instruction for use

Inspection by notified body

Practical check of the calculated UCM stopping distances.

measured Values under calculated values





certified UCM System:‣ Gearless Brake,‣ Overspeed Governor,‣ Electronic Interface

UCM distances calculated

Inspection by notified body

Practical check of the calculated UCM stopping distances.

measured Values under calculated values

Stopping distance:0,557m





certified UCM System:‣ Overspeed Governor,‣ Electronic Interface‣ + non certified

gearless brake

UCM distances calculatedfrom owner of certificate

Type examination of complete UCM System for these

specific liftby notified body

Test procedure acc. EN 81-1/2+A3; F.8

measured Values within allowed

empty up

Full down

0,62m



Example for Implementation of UCM in existing lifts

Inspection through Notified Body



Summary and Future Prospects

Revision of Lift Directive 95/16/EC‣ Expected changes

New safety devices for UCM protection in Annex III (previous IV)In the existing draft is no difference between “with opened doors or with closed doors”!

New EU-type examinations also for safety devices against UCM?

EU-

‣ Publication by EU → second half of 2013

‣ Withdrawal of LD 95/16/EC → second half of 2015

‣ Transition period: → 2 Years



Summary and Future Prospects

Revision of EN 81-1/2 New EN 81-20/50‣ Requirement acc. safety devices against UCM,

chapter 5.6.7 of EN 81-20 and 5.8 of EN 81-50‣ Type examination for UCM protection necessary

‣ Final version publication → Jun. 2014

‣ Harmonisation under Lift Directive → Oct. 2014

‣ Transition period 3 years → Jun. 2017



Thank you for your time and attention

EN 81-1/2+A3 - UCMApplication in Germany

Wolfgang AdldingerWITTURChairman – Components Committee European Lift Association ( ELA )

en 81-1/2+a3 - ucm application in germany

Documents

a3 ucm application

components en

country transposition

a3 ucmapplication

european test procedure

speed conditions en

application questions

proceeding of type examination