EN 81-1/2+A3 - UCM
Application in Germany
Wolfgang Adldinger
WITTUR
Chairman – Components Committee
European Lift Association ( ELA )
2013/04/06
Asansör Istanbul 04.-07. April 2013
1
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
> 0,15 m/s
Need to
remove
≤ 24 month
± 10 mm
± 20 mm
UCM
protection
2013/04/06
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
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2
EN 81-1/2+A3 - UCM
Application in Germany
Affected Regulations
Europe
‣ Machinery Directive 2006/42/EC ESR Annex I
Revision in process
‣ Lift Directive 95/16/EC
‣ EN 81-1/2:1998+A3:2009
‣ EN 81-21:2009+A1:2012
‣ EN 81-80:2003
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
In each country incidents have caused the fast implementation of UCM requirements
into national standards.
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EN 81-1/2+A3 - UCM
Application in Germany
It is obligatory since 1st of January 2012
‣ for new lifts
‣ for important changes at existing lifts
down
“Unintended car movement”
is to be understood as non-commanded
(unintended) car movement with open doors away
from the landing position
up
The Definition of „unintended car movement“
 depending on country transposition of EN 81-80 (SNEL) or
other country specific regulations
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EN 81-1/2+A3 - UCM
Application in Germany
Additional means have to protect
unintended car movement (UCM)
stopping
keep stopped
down
Detection /
Activation
up
Protection against unintended car movement
at any load and speed conditions
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EN 81-1/2+A3 - UCM
Application in Germany
Protection against unintended car movement
down
Required distances in EN 81-1/2+A3
min1000mm
min1000mm
200mm
max
2013/04/06
up
max 1200mm
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max 1200mm
6
EN 81-1/2+A3 - UCM
Application in Germany
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
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EN 81-1/2+A3 - UCM
Application in Germany
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
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EN 81-1/2+A3 - UCM
Application in Germany
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
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EN 81-1/2+A3 - UCM
Application in Germany
Affected components / solutions
Door zone
monitoring
Lift
controller
ELECTRONIC
INTERFACE
Others!
Others!
Safety device
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EN 81-1/2+A3 - UCM
Application in Germany
History and experience with the application of the
UCM requirements in Germany
Application in Germany
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EN 81-1/2+A3 - UCM
Application in Germany
Lift Market in Germany (2012)
ca. 700.000 existing Lifts
10%
10%
ca. 16.000 new Lifts
Residential
50%
30%
93%
electric Lifts
Commercial /
Office Buildings
social
Institutions
hydraulic Lifts
7%
Industry
Value of Modernisation in 2012:
ca. 250 Mio. €
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EN 81-1/2+A3 - UCM
Application in Germany
Lift Market in Germany (2012)
most frequent causes of accident
Technical defects
(incl. UCM cases)
opening / closing doors
3% 3%
14%
21%
38%
21%
no stopping accuracy
human failure
missing car door
Vandalism
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EN 81-1/2+A3 - UCM
Application in Germany
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.
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)
Safety device against
= „State of the Art“
for new installation
unintended car movement
UCM
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EN 81-1/2+A3 - UCM
Application in Germany
Directive
89/655/EEC
„Ordinance on
Industrial Safety
and Health“
(Arbeitsmittelbenutzungsrichtlinie)
concerning the minimum
safety and health
requirements for the use
of work equipment by
workers at work
was replaced by
(Betriebssicherheitsverordnung)
transposed into
National Law
in Germany as
Directive
2009/104/EC
(Arbeitsmittelbenutzungsrichtlinie)
concerning the minimum
safety and health
requirements for the use
of work equipment by
workers at work
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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
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EN 81-1/2+A3 - UCM
Application in Germany
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
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EN 81-1/2+A3 - UCM
Application in Germany
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.
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EN 81-1/2+A3 - UCM
Application in Germany
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.
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EN 81-1/2+A3 - UCM
Application in Germany
Modification of Lifts
?
Fundamental Modification of Lifts
Technical Rule for Application of the Ordinance on Industrial Safety and Health
TRBS 1121
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
DAfA has also provide a Guide to application the Technical Rule 1121 for safe use in Lift modification
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EN 81-1/2+A3 - UCM
Application in Germany
Federal Ministry of Labour and Social Affairs
German Law: „Ordinance on Industrial Safety and Health“ (Betriebssicherheitsverordnung)
New Lifts (subject to monitoring)
TRBS
Technical Rules for Application
of the „Ordinance on Industrial
Safety and Health“
Existing Lifts (subject to monitoring)
Modification
Fundamental Modification
before putting into service:
Lift must comply with „State of the Art“
„State of the Art“ mandatory
„State of the Art“
for new lifts is defined in
EN 81-1/2:1998+A3:2009
(including UCM)
TRBS 1121
„Technical Rule: Modification and fundamental modification of existing lifts“
Described in detail the „State of the Art“
for „modification“ and „fundamental modification“
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:






2013/04/06
Lift Manufacturer
Components Manufacturer
Lift Consultants
Owner of Lifts
Notified Bodies
Experts from the Government
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EN 81-1/2+A3 - UCM
Application in Germany
Federal Ministry of Labour and Social Affairs
German Law: „Ordinance on Industrial Safety and Health“ (Betriebssicherheitsverordnung)
New Lifts (subject to monitoring)
Existing Lifts (subject to monitoring)
TRBS
Technical Rules for Application
of the „Ordinance on Industrial
Safety and Health“
modification
Fundamental
modification
Under certain condition UCM is also
mandatory
for
the
„Modification“ and „Fundamental modification“
before putting into service: of
„State of the Art“ mandatory
Lift must comply with „State of the Art“
existing lifts in Germany
„State of the Art“in Germany with involving ofTRBS
(Decision
the1121
DAfA in November
for new lifts is defined in
„Technical Rule: Modification and fundamental modification of lifts“
EN 81-1/2:1998+A3:2009
2011)
Described in detail the „State of the Art“
(including UCM)
for „modification“ and „fundamental modification“
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:






2013/04/06
Lift Manufacturer
Components Manufacturer
Lift Consultants
Owner of Lifts
Notified Bodies
Experts from the Government
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EN 81-1/2+A3 - UCM
Application in Germany
for existing lifts a retrofit of safety device against
unintended car movement must be considered by:
Modification
Fundamental Modification
-
Change of the complete Drive,
-
Shifting of complete lift system
-
Modification of the drum drive
completely,
-
Changing of complete well
-
Additional floor of lift system,
-
Renewal / modification of the
protective device against ascending car
overspeed,
-
New lift with exception of guide rails
and fixings
-
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,
 Inspection of notified body
necessary
provided that the operation or type of
the installation is affected by the
modification
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 New conformity
assessment procedure acc.
LD 95/16/EC mandatory
22
EN 81-1/2+A3 - UCM
Application in Germany
Experience with the application of the
UCM Requirement for Modification of Lifts
How does it work in the reality?
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EN 81-1/2+A3 - UCM
Application in Germany
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)
Inspection through notified body
Under consideration of the requirements in the German Technical Rule
TRBS 1121 and the „Guide for application the TRBS 1121“
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EN 81-1/2+A3 - UCM
Application in Germany
1. Step for Implementation of UCM in existing lifts
Evaluation of current situation
Operation and type of lift
‣
‣
‣
‣
rated load,
rated speed,
traction drive (with gear or gearless)
controller type,
Planned modernisation of Lift system
‣ „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?
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EN 81-1/2+A3 - UCM
Application in Germany
2. Step for Implementation of UCM in existing lifts
Search for possible technical UCM solutions / Feasibility study
Detection
stopping
1
2
3
4
5
‣
‣
‣
‣
‣
2013/04/06
keep stopped
braking element start a reduction of speed
speed
response time of UCM detection
response time of braking elements
time
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?
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EN 81-1/2+A3 - UCM
Application in Germany
2. Step for Implementation of UCM in existing lifts
Search for possible technical UCM solutions / Feasibility study
a) use of certified components
Advantage
‣
‣
‣
‣
2013/04/06
Disadvantage
certified component
Distance of the
component in the UCM
case known,
Instruction for use from
owner of certificate,
Test procedure from
owner of certificate
‣
‣
‣
‣
‣
Asansör Istanbul 04.-07. April 2013
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,
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EN 81-1/2+A3 - UCM
Application in Germany
2. Step for Implementation of UCM in existing lifts
Search for possible technical UCM solutions / Feasibility study
b) use of non certified components
Advantage
‣
‣
No change of
component
…
Disadvantage
‣
‣
‣
‣
2013/04/06
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,
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EN 81-1/2+A3 - UCM
Application in Germany
2. Step for Implementation of UCM in existing lifts
Search for possible technical UCM solutions / Feasibility study
c) use of certified complete system against UCM
Advantage
‣
‣
‣
‣
‣
2013/04/06
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
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Disadvantage
‣
…
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EN 81-1/2+A3 - UCM
Application in Germany
2. Step for Implementation of UCM in existing lifts
Search for possible technical UCM solutions / Feasibility study
Decision:
‣ 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
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EN 81-1/2+A3 - UCM
Application in Germany
3. Step for Implementation of UCM in existing lifts
Experience with Modernisation
1. Modernisation
2. Modernisation
3. Modernisation
certified UCM System:
certified UCM System:
UCM certified:
‣
‣
‣
‣
‣
‣
‣
‣
Overspeed Governor,
Electronic Interface
‣
Non certified
gearless brake
Safety Gear,
Overspeed Governor,
Electronic Interface
Gearless Brake,
Overspeed Governor,
Electronic Interface
Results ?
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EN 81-1/2+A3 - UCM
Application in Germany
3. Step for Implementation of UCM in existing lifts
Experience with 1. Modernisation
certified UCM System:
‣
‣
‣
Safety Gear,
Overspeed Governor,
Electronic Interface
Inspection by
notified body
measured Values under
calculated values
Practical check of
the calculated UCM
stopping distances.
UCM calculation and
distance given in
instruction for use
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EN 81-1/2+A3 - UCM
Application in Germany
3. Step for Implementation of UCM in existing lifts
Experience with 2. Modernisation
certified UCM System:
‣
‣
‣
Gearless Brake,
Overspeed Governor,
Electronic Interface
Inspection by
notified body
measured Values under
calculated values
Practical check of
the calculated UCM
stopping distances.
UCM distances calculated
Stopping distance:
0,557m
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EN 81-1/2+A3 - UCM
Application in Germany
3. Step for Implementation of UCM in existing lifts
Experience with 3. Modernisation
certified UCM System:
‣
‣
‣
Overspeed Governor,
Electronic Interface
+ non certified
gearless brake
Type examination
of complete UCM
System for these
specific lift
by notified body
measured Values
within allowed
Full down
0,62m
Test procedure acc.
EN 81-1/2+A3; F.8
empty up
UCM distances calculated
from owner of certificate
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EN 81-1/2+A3 - UCM
Application in Germany
Example for Implementation of UCM in existing lifts
Inspection through Notified Body
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EN 81-1/2+A3 - UCM
Application in Germany
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?
2013/04/06
‣
Publication by EU
→ second half of 2013
‣
Withdrawal of LD 95/16/EC
→ second half of 2015
‣
Transition period:
→ 2 Years
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EN 81-1/2+A3 - UCM
Application in Germany
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
2013/04/06
‣
Final version publication
‣
Harmonisation under Lift Directive → Oct. 2014
‣
Transition period 3 years
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→ Jun. 2014
→ Jun. 2017
37
EN 81-1/2+A3 - UCM
Application in Germany
Thank you for your
time and attention
Wolfgang Adldinger
WITTUR
Chairman – Components Committee
European Lift Association ( ELA )
2013/04/06
Asansör Istanbul 04.-07. April 2013
38