Machine- and electrical safety

All machinery and lifting equipment must be CE marked and comply with applicable legislation, including the Machinery Directive and the Danish Working Environment Authority's guidelines. This means that the machinery must be designed and manufactured with built-in safety features such as emergency stops, guards and warning labels.

The emergency stop must be easily accessible and function tested regularly so that the machinery can be stopped immediately in an emergency.

Guards and shielding must always be in place and in working order, and in the case of automated machinery, light grids or other access controls should be used to prevent accidental access to hazardous areas. The machinery must never be modified or bypassed with regard to safety systems, as this can expose the operator to serious risk.

Machinery safety is also about proper maintenance – a machine that has not been serviced or cleaned can quickly become dangerous.

Risk assessment

Before a machine or lifting equipment is put into use, a thorough risk assessment must be carried out. This includes:

• Identification of all potential hazards (mechanical moving parts, electrical components, dust, noise, etc.).
• Assessment of the severity and likelihood of the risk.
• Implementation of preventive measures, such as guards, safety switches or correct positioning of the work area.
• Checking for valid approvals for slings, lifting chains and lifting eyes.

Training

Only trained and instructed personnel who have completed a minimum of one week's workshop course at IFA may operate machines. The training must include:

• Understanding the machine's functions and safety systems.
• Instruction in correct starting, operation, stopping and maintenance.
• Knowledge of emergency situations and emergency stop procedures.
• Information on personal protective equipment (PPE) and its correct use.

Continuous updating and refreshing of knowledge is important to avoid errors and accidents.

See also the sections on processing machines, lifting equipment and assembly work.

Machine tools pose several different types of risks, all of which require attention and prevention. One of the most obvious hazards is mechanical risks. Machines with rotating or moving parts can cause entrapment, drawing in, cutting or impact if you get too close. These accidents typically occur when guards are missing, working postures are inappropriate or the operator is not adequately trained. The consequences can be serious, including broken bones or amputations, which is why proper guarding, use of emergency stops and thorough instruction are essential.

Machine safety and working environment for processing machines

All machines must be CE marked and comply with applicable legislation, including the Machinery Directive and the Danish Working Environment Authority's guidelines. The machines must be designed with built-in safety features such as emergency stops, guards and warning labels. Emergency stops must be easily accessible and function tested regularly, and guards and guards must always be in place and functional. For automated machines, light grids or other access control should be used to prevent unintentional access to hazardous areas. The machine must never be modified or bypassed with regard to safety systems, as this can expose the operator to serious risk. Machine safety is also about proper maintenance - a machine that is not serviced or cleaned can quickly become dangerous.

Heavy lifting and ergonomics

According to the Danish Working Environment Act, an adult employee may lift a maximum of 25–30 kg manually and 20 kg when carrying under optimal conditions. In the case of repeated lifting, poor working postures or asymmetrical lifting, the weight must be reduced and aids such as cranes, lifting tools or teamwork must be used. The purpose is to prevent back injuries, muscle and joint pain and long-term strain injuries. See also the section on lifting equipment.

Noise and Vibration

Machinery can generate high sound levels and strong vibrations. Repeated exposure to noise above 80 dB(A) can lead to permanent hearing damage, tinnitus or other hearing problems. The Occupational Health and Safety Act limits exposure at 85 dB(A) to a maximum of 8 hours per day, and noise reduction measures are required above 87 dB(A). Long-term vibrations from handles or control panels can cause hand-arm vibration syndrome (HAVS), muscle and joint pain and reduced blood circulation. Prevention includes hearing protection, vibration-damping gloves, correct working posture, rotation schemes and breaks.

Risk assessment

Before a machine is put into use, a thorough risk assessment must be carried out. This includes identifying all potential hazards such as mechanical moving parts, electrical components, chips, dust and noise, assessing the severity and likelihood of the risk and implementing preventive measures, such as guards, safety switches and correct placement of the work area.

Training and instruction

Only trained and instructed personnel with a minimum of 1 week workshop course passed by IFA are allowed to operate machines. The training must include the machine's functions and safety systems, correct use of emergency stops, operation and maintenance, handling of emergency situations and correct use of PPE (personal protective equipment). Instruction must be repeated regularly so that employees are always updated on safe practices and correct machine operation. IFA holds workshop courses once a year. For further information, contact Torben Hyltoft Thomsen +45 23 38 24 67 / hyltoft@phys.au.dk 

When using machines outside normal working hours, this may only take place after prior agreement with the person responsible for the workshop, and when at least two people are present, of which at least one has a workshop certificate. When students use the workshops, they must have taken out liability insurance and possibly full-time accident insurance, as the State has not taken out insurance for students' work in laboratories and workshops.

Key risks of machine tools

Machines present several types of risks:

• Mechanical risks: Crushing, entrapment, shearing and impact. Cutting tools can cause serious wounds or amputations, while heavy components can cause crushing injuries. Prevention includes proper guarding, emergency stops, safety distances and PPE.
• Electrical risks: Shock, short circuits and fires can occur from faults, damaged cables or moisture. Prevention includes regular checks of cables and installations, proper earthing and the use of residual current devices (RCDs).
• Noise and vibration: Long-term exposure can lead to hearing damage and HAVS. Prevention includes ear protection, vibration-damping gloves, limited working hours and rotation schemes.
• Shavings and particles: Flying metal shavings, wood dust or plastic particles can cause eye injuries and skin lesions. The use of safety glasses, visors, gloves and proper shielding is essential.
• Fire and Explosion: Sparks from milling, welding or hot machining processes can ignite oil, lubricants or dust. Prevention includes good ventilation, cleaning, fireproof storage of flammable liquids and spark protection.

Personal Protective Equipment (PPE)

• Eye Protection: Safety glasses or visor.
• Hearing Protection
• Gloves

Gloves, hearing protection and eye protection are provided from 1523-210 and 1523-110

Safety when using lifting equipment

The use of lifting equipment is a central part of many work processes where heavy objects must be handled safely. Lifting equipment includes, among others, cranes, hoists, slings, chains, lifting eyes, lashing straps and forklifts. To prevent accidents and injuries, legislation requires correct use, regular inspection and trained personnel.

General rules for lifting equipment

All lifting devices must comply with the requirements of the Danish Working Environment Authority and the manufacturer's instructions. Lifting equipment may only be used for the purpose for which it is approved, and the load must never exceed the maximum working load (WLL), which must be clearly marked on the equipment. Lifting equipment must be visually inspected before each use for damage, wear, deformation, cracks or corrosion.

When using cranes and hoists, the operator must ensure that the load is correctly secured and balanced, and that lifting equipment such as slings or chains are not twisted, damaged or overloaded. CE-marked lifting eyes, hooks and carabiners must be correctly fitted and locked, and it must never be possible for the load to slip or fall during the lift.

Straps and lashing equipment

Straps, chains and hoists must be in good condition without damage or wear. Textile straps must not have sharp edges that could damage the fibres, and metal parts must be checked for deformation. Always use correct lifting technique, e.g. avoiding angles below 45°, which can reduce the load-bearing capacity of the straps.

Forklifts and mobile lifting equipment

Forklifts must only be operated by trained persons. The load capacity must never be exceeded, and the load must be placed stably on the forks. When transporting heavy or unbalanced items, the driving speed must be adjusted, and sharp turns and uneven floors must be avoided to prevent tipping. The load must be clearly secured, and people must never stay under raised forks. Mobile cranes and lifting trolleys must only be used by trained and instructed persons.

Lift trucks and mobile cranes are available for loan by contacting the precision mechanics workshop 1523-110

A compact, foldable mobile crane, suitable for use in difficult-to-reach areas, is available for loan from the area at ASTRID 1526-145

Inspection and control

Legislation requires systematic inspection and inspection of lifting equipment:

• Daily visual inspection: The operator checks that the equipment has no visible damage, wear, corrosion or deformation.
• Periodic inspection: Equipment such as cranes, hoists, slings and chains must be inspected at least once a year by a qualified person, or more frequently if the equipment is used intensively. At IFA, Fyns Kran uses  Fyns Kran Udstyr A/S - løftegrej, kraner, stålwire for certification of lifting equipment.
• Documentation: All inspections, repairs and checks must be documented digitally so that it can be presented during inspections.

Example of approval marking, crane in precision mechanical workshop 1523-100

Approved straps and other lifting equipment are available for loan from 1526-113

Work procedures

Before starting a lift, the operator must ensure that the work area is clear, that no persons are under or near the load, and that communication between team members is clear, e.g. by hand signals. The load must be lifted smoothly without sudden jerks, and all safety distances must be observed.

After the lift, slings, chains and other equipment must be unloaded correctly and stored in a way that protects against damage and wear. In the event of faults or damage to lifting equipment, it must be taken out of use immediately and the responsible manager must be contacted.

Instruction and training

Only trained and instructed personnel may use lifting equipment. Training must include the correct use of cranes, slings, lifting eyes, hoists and forklifts as well as safety aspects such as maximum load, load placement, communication during lifting and emergency procedures. The instruction must be repeated regularly and documented.

If assistance with a forklift is needed, the following persons with forklift certificates can be contacted:

• Jens Jacob Iversen +87156617, +4551940211 E-mail jji@phys.au.dk
• Torben Hyltoft Thomsen +4523382467 E-mail hyltoft@phys.au.dk
• René Warthoe Davids +4523382101 E-mail rwa@phys.au.dk

Personal protective equipment (PPE)

• Helmet: Protects against falling objects.
• Safety shoes: With safety toe cap and non-slip sole.
• Gloves.

Gloves are issued from 1523-210 and 1523-110

Safety helmets available for loan at the entrance to Technical Room 1526-120

Emergency procedures

All employees must be familiar with emergency procedures for lifting work. This includes placing emergency stops on cranes, evacuation in the event of a fall or load slippage, and first aid in the event of personal injury. In the event of an accidental load fall, the area must be cordoned off immediately and only trained personnel may handle the situation.

Safety in assembly work

Assembly work often involves handling heavy components, using tools and machines, working at height and close cooperation between several employees. To ensure a safe working environment, assembly work must be planned carefully, risks assessed and all safety measures implemented consistently.

Heavy lifting and ergonomics

According to the Working Environment Act, an adult employee may lift a maximum of 25–30 kg manually and 20 kg when carrying under optimal conditions. In the case of repeated lifting, asymmetrical lifting or poor working postures, the weight must be reduced and aids such as cranes, lifting tools, pallet trucks or teamwork must be used. Correct lifting technique, planning of work processes and rotation schemes are important to prevent back injuries, muscle and joint pain and long-term strain injuries.

Noise and vibration

Assembly work can generate noise from tools, drilling and screwing machines and electrical machines. Noise levels above 80 dB(A) require hearing protection, and if exposure exceeds 85 dB(A), working hours must be limited to a maximum of 8 hours per day. Vibrations from hand tools can cause hand-arm vibration syndrome (HAVS) and muscle or joint pain. Prevention includes the use of hearing protection, vibration-damping gloves, correct working posture, rotation schemes and breaks.

Risk assessment

Before assembly work begins, a thorough risk assessment must be carried out. This includes the identification of potential hazards such as heavy lifting, falls from heights, electrical installations, sharp edges, falling objects, noise, vibrations and chemical risks from the use of solvents. The severity and likelihood of the risk are assessed, and preventive measures are implemented, e.g. the use of assistive devices, correct tools, barriers and planning of the work area.

Important risks in assembly work

• Mechanical and physical risks: Heavy components can cause crushing injuries, pinching or breakage. Working at height involves the risk of falling, while the use of sharp tools can lead to cutting injuries. If possible, scaffolding should be used when working at height or a temporary guardrail should be established.

Mobile scaffolding available for loan is located to the right of the gate at the entrance to 1522-016

• Electrical risks: Shock, short circuit and fire can occur when working with live installations. Prevention includes properly disconnecting power, checking cables, grounding and using residual current devices.
• Noise and vibration: Prolonged use of power tools can cause hearing damage and HAVS. Prevention includes wearing hearing protection, vibration-damping gloves and proper work planning.
• Fire and chemical risks: Assembly work may involve solvents such as alcohol, acetone or other organic liquids, which are flammable and can give off strong fumes. These chemicals must be handled with great care. Work should be carried out in well-ventilated areas, and solvents must be stored in a fume hood or approved, closed containers. Gloves, safety glasses and possibly a respirator must be used when using solvents, and spills must be cleaned up immediately. No open flames, sparks or hot surfaces should be nearby.
• Falling objects: Poorly secured items, tools or components can fall and cause serious injury. Prevention includes proper securing, fencing and wearing a work helmet.

Personal protective equipment (PPE)

• Helmet: Protects against falling objects.
• Safety shoes: With safety toe cap and non-slip sole.
• Gloves: For handling sharp, hot or heavy objects; nitrile or chemical-resistant gloves are recommended for solvents.
• Hearing protection: For noise above 80 dB(A).
• Eye protection: When working with flying particles, chemicals or solvents.
• Fall protection equipment: When working at height, e.g. harness and safety lines.
• Work clothes: Tight-fitting without loose parts, no jewelry, robust materials.

Gloves, hearing and eye protection are provided from 1523-210 and 1523-110

Nitrile and chemical resistant gloves are issued from 1522-423

Safety helmets available for loan are located at the entrance to Technical Room 1526-120.

Work procedures

Before starting assembly work, all safety precautions and tools must be checked. The work area must be kept tidy and materials must be placed securely. When using solvents, work must be carried out in a fume hood or well-ventilated area, and containers must be properly closed after use. Spills must be removed immediately, and gloves and eye protection must be worn. When maintaining or adjusting machines or tools, the power must be disconnected. Work must be stopped immediately in the event of errors, dangerous situations or unexpected events. Proper planning and adherence to work procedures contribute to both safety and efficiency.

Instruction and training

All new employees must receive thorough training in assembly work, safety procedures, the correct use of tools, lifting equipment and solvents, and emergency procedures. Training creates a culture where safety is a priority and employees are well equipped to perform safe assembly work.

Emergency procedures

All employees must be familiar with emergency procedures, including the location of emergency stops, fire extinguishing equipment, first aid equipment, and the company's emergency response plan. In the event of accidental spillage of solvents, fire, or chemical accidents, the area must be immediately cordoned off and only trained personnel may handle the situation. Regular drills ensure correct action under stress and emergencies.

Low current (Extra-low voltage)

AC voltages below 25 V and DC voltages below 60 V are characterised as extra-low voltage (low current) and are not covered by the directives for low or high voltage; they are considered as quite harmless for normal skin contact. AC voltage is typically used in, for example, an AC adaptor used as a charger for a mobile phone.

Low voltage

AC voltages between 25 and 1000 VAC and DC voltages between 75 and 1500 V are covered by the European low voltage directive, for a wide range of electrical equipment, which applies for both consumer and professional usage, for items such as household appliances, cables, power supply units, laser equipment and other components such as fuses. A number of security measures apply to working in this area.

High voltage

High voltage is used, for example, at IFA/ISA for accelerators and as a bias for detectors in the voltage range 500 VDC to 60 kVDC. High-voltage cables are available and are made as coaxial cables with a grounded sheath. Free-standing high-voltage installations are surrounded by wire fences with safety cut-off switches at the access points.

Electric current can directly affect the human body. If a person is healthy, short-term currents must exceed 30 mA in order to be life-threatening (HPFI relays usually switch off if the residual current exceeds 30 mA).
Electrical currents can directly affect the human body in several ways:

A shock can cause muscle spasms - An alternating current can stimulate muscles and nerves. The effect of the stimulation varies from a weak tingling to violent seizures and can be life threatening if the current passes through the chest. An electric shock can cause a sustained contraction of muscles. The victim may be unable to let go of the source of the current, making the duration of the contact longer and increasing the severity of the shock.

A shock can cause cardiac arrest - If a current from outside the body passes through the heart, it can mask natural electrical impulses and disturb the heart’s rhythm. This irregular heartbeat is called arrhythmia and can even manifest as a total disorganization of the rhythm, known as ventricular fibrillation. When ventricular fibrillation occurs, the heart stops pumping and the blood stops circulating. The victim rapidly loses consciousness and dies if a healthy heartbeat is not restored with a device called a defibrillator. The arrhythmia can occur at the time of the shock or in the hours following the electric shock.

A shock can cause burns to tissues and organs - A direct or alternating current can, depending on the size, frequency and duration of the current, cause burns of varying degrees. When a current above 100 mA passes through the body, it leaves marks at the points of contact with the skin. Electrical burns often affect internal organs. They are caused by the heat generated from the body’s resistance to the current passing through it. Internal damage may be much more serious than the external injuries suggest.

The effect of current

The table below shows the effect on the human body at different current levels (with contact on unbroken skin). These apply for a healthy grown-up weighing over 50 kg and an AC frequency of 50 Hz of the electricity.

See also Wikipedia page “Electrical injury” - en.wikipedia.org/wiki/Electrical_injury

Grounding

Electrical equipment that is encapsulated by a conductive material can, in the event of a fault in the appliance, send current from the enclosure (cabinet) and through a person who touches the conductive surface. To divert this leakage current, the conductive part is grounded.
Many appliances use safety capacitors from the mains to the ground connection to protect the appliance from noise from the mains. Since a capacitor conducts alternating voltage, there will be 115 VAC on ground on an appliance where the ground connection is missing.
It is not immediately dangerous as the current is limited to under 10 mA, but can result in unpleasant pain and muscle contractions. This can lead to dangerous situations.

Fuses

Fuses are installed to protect against excessive heat generation in an installation, or to secure appliances. Never change a fuse to one which has a higher current rating than that prescribed. There is always a reason why a fuse blows.

HPFI relay

An HPFI relay is usually placed before the standard fuses. Its purpose is to cut off the current if more than 30 mA of the current sent out finds other return paths (e.g. through a human to ground). If the conductive surface of a device is grounded through the ground pin in the wall outlet, any fault current will immediately activate the HPFI circuit breaker.
Remember that an HPFI relay must be tested at least once a year by pressing the test button, which artificially conducts a current of 30 mA around the relay. If it does not switch off, contact the electronics department.

Plugs

Equipment is often sold with the requirement that it must be properly grounded. However, they are often delivered with a 2 pin plug which does not allow connection to the earth connection in the sockets in Denmark. If it is required that a piece of equipment should be grounded, then a 3 pin plug (as pictured) must be used.
If a plug with only 2 pins is fitted, then it must be changed by the electronics department. It can be dangerous to use an appliance without a correct ground connection.

Distribution boards

In order to have sufficient 230VAC outlets, distribution boards are often used in the laboratories. Distribution boards without an earth connection through three-pin connectors must not be used. In IFA's laboratories, we prefer this model, which can be obtained by contacting the electronics department.

Distribution board used in laboratories at IFA

Test leads

Only use test leads where the pins cannot be touched.
Safety plugs with fixed sheaths should preferably be used. These connectors can only be inserted into a corresponding safety socket.

Safety sleeve/bushing and plug with a fixed shield

As these bushings are not yet mounted on all equipment, it may be necessary to use safety connectors with sliding cover during a transition phase.

Plug with a sliding cover                                                           Banana plug           

Test leads with uncovered banana plugs must not be used.

Coaxial cables

Coaxial cables with a standard BNC connector, or similar, where the pins may be touched can be used with voltages up to 25 V AC or 60 V DC.

BNC plug                                                          SHV plug

Coaxial cables for high voltage use must be fitted with connectors intended for high voltage . Contact the electronics department regarding purchase, installation and use of high voltage connectors

What can I do?

You may only work with or repair anything which comes after the electric socket (e.g. appliances). As a general rule, anything that has to do with the fixed installation may only be altered, installed or repaired by an authorised electrician.

Responsibility

Supply and security in delivering to the consumer: Electricity provider. The wiring and further installations: The consumer (yourself).
Everything after the socket is your own responsibility.

Law and rules

Directives:

2014/35/EU: EU Council directive of the 26th February 2014 on the harmonisation of the laws of the member states relating to electrical equipment designed for use within certain voltage limits. [https://eur-lex.europa.eu/legal-content/en/TXT/?uri=CELEX%3A32014L0035] 
The low voltage directive. The Danish legal basis is defined under executive order number 311 dated the 30th of March 2016 [In Danish: https://www.retsinformation.dk/eli/lta/2016/311] 

Standards: 

EN 61010-1: Safety requirements for electrical equipment for measurement, control and laboratory use.

IEC 364-4-41: Electrical installations of buildings, Protection for safety, Protection against electrical shock.

EN 60742: Safety transformers. Contains insulation and distance requirements for low current circuits

Protective equipment:

Personal protective equipment | Arbejdstilsynet

Protect yourselves with personal protective equipment

Protective footwear - Arbejdstilsynet

Protective helmets - Arbejdstilsynet

Eye protection - Arbejdstilsynet

Useful links:

Use of lifting equipment - Arbejdstilsynet

Rules and laws for cranes, lifting gear and lifting equipment →