· OAO AVTOVAZ OTU-2000 OTU-1-2000 General standards for equipment delivery 2 Volume contents:...

GENERAL TECHNICAL REQUIREMENTS

FOR EQUIPMENT DELIVERY TO OAO AVTOVAZ

OTU – 2000

Supersede OTU – 92

OAO AVTOVAZ OTU-2000

OTU-1-2000 General standards for equipment delivery 2

Volume contents:

OTU-1-2000 GENERAL STANDARDS FOR EQUIPMENT DELIVERY

OTU-2-2000 PURCHASED COMPONENTS

OTU-3-2000 WELDING EQUIPMENT

OTU-4-2000 ASSEMBLY EQUIPMENT

OTU-5-2000 CUTTING EQUIPMENT

OTU-6-2000 AUXILIARY TOOLS AND ATTACHMENTS

OTU-7-2000 MACHINE TOOLS

OTU-8-2000 FORGING MACHINES AND PRESSES

OTU-9-2000 DIES, CASTING TOOLS AND MOULDS

OTU-10-2000 SPECIAL PURPOSE PLANTS

OTU-11-2000 AUTOMATIC TRANSPORT SYSTEMS

OTU-12-2000 MEANS OF INSPECTIONS

OTU-13-2000 CONTROL SYSTEMS

OTU-14-2000 HANDLING DEVICES, MECHANIZED AND AUTOMATEDSTOREHOUSES

OTU-15-2000 EQUIPMENT FOR MAKING COMPONENTS FROM NON-METAL MATERIALS

OTU-16-2000 FOUNDRY EQUIPMENT

OTU-17-2000 POWERED TOOLS

OTU-18-2000 SOFTWARE & HARDWARE OF DATA PROCESSINGEQUIPMENT, TELECOMMUNICATIONS,COMMUNICATIONS, OFFICE EQUIPMENT



GENERAL TECHNICAL REQUIREMENTS

FOR EQUIPMENT DELIVERY TO OAO AVTOVAZ

OTU – 2000

GENERAL STANDARDS FOR EQUIPMENT DELIVERY

OTU – 1 – 2000

Supersede OTU – 1 – 92



Table of contents:

1. GENERAL PROVISIONS 8

1.1 Range of application 8

1.2 Applicability 8

1.3 Additional requirements 8

1.4 Deviations 8

1.5 Interpretation 8

1.6 Changes introduced to the equipment upon the request of the Customer 8

2. REQUIREMENTS ON DELIVERY 9

2.1 Customs clearance documents for imported equipment 9

2.2 Shipment 9

3. ACCEPTANCE AND TESTING 29

3.1 Equipment and tooling 29

3.2 Equipment without tooling 30

3.3 Testing of test equipment at the Customer's Works 31

4. TECHNICAL DOCUMENTATION 32

4.1 Technical documentation which is to be agreed upon with the Customer 32

4.2 Technical documentation subject to mandatory approval by the Customer 34

4.3 Technical documentation adjusted after the approval by AVTOVAZ. (Finaldocumentation) 34

4.4 Technical documentation adjusted based on equipment acceptance results 34

4.5 General requirement for technical documentation 35

4.6 Requirements set for individual types of technical documentation 35

5. TECHNICAL SPECIFICATIONS 52

5.1 General specifications 52

5.2 Production environment conditions 52

5.3 General safety requirements 57



5.4 Marking symbols – identification plates 59

5.5 Components 62

5.6 Manual controls 62

5.7 Pipelines and fittings 64

5.8 Removal of waste and chip 67

5.9 Foundation, levelling, fixtures 68

5.10 Painting 70

5.11 Requirements for metal-cutting machines 86

5.12 Requirements to machines with grinding wheels 86

5.13 Technical requirements for tooling 87

6. ELECTRICAL EQUIPMENT 89

6.1 Power supply 89

6.2 Protection 89

6.3 Control and alarm circuits 101

6.4 Design and location of electrical apparatus 108

6.5 Control devices 111

6.6 Wires and cables 119

6.7 Wiring 121

6.8 Electric motors and actuators 125

6.9 Connection of appliances and local lighting 126

6.10 Tests 127

7. HYDRAULIC EQUIPMENT 129

7.1 Fluids 129

7.2 Hydraulic systems 129

7.3 Hydraulic system embodiment 131

7.4 Fluid filtration 132

7.5 Valves 132

7.6 Cylinders 133

7.7 Rotary hydraulic motors 133



7.7 Pumps 134

7.9 Tanks 134

7.10 Accumulators 136

7.11 Heat exchangers 137

7.12 Connections 137

7.13 Identification plates 138

8. PNEUMATIC EQUIPMENT 139

8.1 Supply line 139

8.2 Systems 139

8.3 Arrangement of circuits 141

8.4 Cabinets and compartments 141

8.5 Connections 141

8.6 Filters, drying plants, lubrication units, pressure regulators 142

8.7 Gaskets 142

8.8 Cylinders 142

8.9 Compressors 143

8.10 Valves 143

8.11 Vessels working under pressure 144

9. OTHER EQUIPMENT 154

9.1 Lubrication 154

9.2 Cooling of tools 155

10. GENERAL REQUIREMENTS ON ERGONOMICS 158

10.1 Ergonomic requirements to the equipment for rational organization of theoperator's station 158

10.2 Ergonomic requirements to toggle-type switches 159

10.3 Ergonomic requirements to key-actuated and pushbutton switches 159

10.4 General ergonomic requirements for rotary switches 160

11. GENERAL SAFETY REQUIREMENTS TO EQUIPMENT 162

11.1 Requirements to basic structural elements 162



11.2 Requirements to controls 162

11.3 Requirements to protective means included in production equipment design 163

11.4 Special requirements to different machines 164

11.5 Requirements to working platforms and staircases 171

11.6 Safety requirements determined by peculiarities of installation and repair works,transportation and storage 171

11.7 General fire protection rules 172

APPENDIX 1 173

APPENDIX 2 177



1. GENERAL PROVISIONS

1.1. Range of applicationThe present general specifications for equipment delivery to AO AVTOVAZ constitute

executory documentation to be used in the development, manufacture and delivery of equipment,instruments, tooling, tools supplied to AO AVTOVAZ by AO AVTOVAZ's machine toolmanufacturing shops, CIS factories, foreign companies.

1.2. ApplicabilityThe present specifications are only applicable in the case when they are referred to in

contracts, agreements, protocols.

1.3. Additional requirementsAdditional and special requirements to the equipment are specified in the additional volumes

(OTU, Volumes 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17).

1.4. DeviationsAny deviations from the standards of the present technical requirements, any additions as

well as changes to the standards shall be considered valid subject to approval by the Customer inwriting.

The Customer's approval of any Supplier's document implying such deviations is effectivewhen supported with a special written permission for deviations, which is issued by the Customer atthe Supplier's request.

1.5 InterpretationWhen doubted both about the order contents and contents of these requirements as well as

their applicability or non-applicability the Supplier shall request instructions and/or necessaryexplanations in written form 30 days prior to expiration of validity of the request for the equipmentsupply offer.

1.6. Changes introduced to the equipment upon the request of the CustomerThe Customer is entitled to request the Supplier to make special technical decisions and/or

use certain materials. Any changes that can be possibly introduced to the equipment or appropriatetooling (electrics, hydraulics, pneumatics, lubrication system) shall always be approved by theCustomer in writing.



2. REQUIREMENTS TO DELIVERY

2.1. Customs clearance documents for imported equipmentWith a view to effect customs clearance at AO AVTOVAZ of the imported equipment,

instruments, tooling and tools the following documents are used:- waybill and railroad waybill or bill of lading- proforma invoice or invoice- packing list- shipping specification- freight insurance policy- certificate of conformity with GOST R- certificate of origin- customs export document (declaration) of the country that effects export- other documents required by customs bodies of Russia for customs clearance.In view of frequent changes in customs legislation taking place in the course of preparation

of documents used in customs clearance in Russian Federation, the foreign Supplier shall, apartfrom the Contract terms, follow instructions of AO AVTOVAZ's department responsible for customsclearance of import/export goods.

2.2. Shipment

2.2.1. Shipping instructionsWith respect to shipment and documentation necessary in performing equipment import

operations, the Supplier shall follow the instructions of AO AVTOVAZ transport departmentresponsible for transportation as per contract specifications.

A Safety Certificate of standard form is to be drawn up for all products shipped separately. If theequipment comes from abroad each shipment shall be accompanied with a part list and shippingspecification which shall be placed as follows: the part list to be put in the case that has a marking inRussian, "Содержит сопроводительные документы" (“Contains accompanying documents”), and a copy ofspecifications shall be put in each case of the shipment. The Supplier shall send, at the forwardingaddress of AO AVTOVAZ's department shown in the Contract, two copies of shipping specificationsin Russian and in the Supplier's language of the equipment and accessories, and also send blanks, toolsand materials received from the Customer or other customers for testing of the equipment and paidby the Customer.

2.2.2. Partial shipmentPartial shipments are only allowed as an exception and subject to approval by the Customer

in writing. Such partial shipments shall be accompanied with waybills and invoices which shall onlyspecify the cost of the dispatched material. Expenses incurred by the Customer due to non-observance ofthese requirements by the Supplier shall be charged against the Supplier.

2.2.3. Packing

2.2.3.1. General provisionsThe equipment shall be packed in export packaging in order to guarantee protection of all

controls against damages under most severe conditions of transportation and storage such as- transportation of the equipment by plane, sea or railway, etc.;- handling of the equipment by means of various lifting facilities;- long-term storage of the equipment outdoors under various climatic conditions;- storage of crates in several tiers;- storage for a period of 18 months between packing and unpacking with the ambient

temperature change from + 50 °C in summer to - 40 °C in winter.



The responsibility for calculation of the packing rests with the Supplier. The Customer andthe Supplier shall exchange necessary information concerning the correct packing.

Full description shall be given for inner and outer packing materials, specifying such data asmaterial consumption, type, chemical composition, hazard class, properties, etc.

2.2.3.2. Preparation of the goods to be packed Preparation of the equipment for thepacking includes

- partial disassembly of the equipment in order to reduce the packing volume and makethe load handling convenient

- extra protection of particularly fragile units;- clamping of the moving parts with wedges, braces or special padding.- When disassembled units are packed up together, they shall be fixed to the equipment to be

packed or fastened separately within the crate;- removal of auxiliary materials, production residues, corrosion or other impurities from the

equipment to be packed;- drainage of the equipment of liquid, water and aqueous solutions freezing at the temperature

below zero.

2.2.3.3. Preservation and protectionThe equipment must be contained in airtight packing to protect it against corrosion in the

transportation and storage.In deciding on the preservation type and when checking it account must be taken of the goods

nature and the maker's directions on preservation material properties and its appropriate handling.Full description of the conservation materials shall be presented (stress-strain properties,

quantity, chemical composition, hazard class).METHODS OF COSERVATION 1. Method with application of moisture absorbing material The

goods have to be welded up in a watertight film of high pressure polyethylene, 0.2 mm thick, or multi-layeraluminium foil. Refer to Table 1.



Approximate values for insulating layerTable 1

Material

Polyethylene TL8 135-0 19

Multilayer foil TL8135. Class 2

Polyethylene

Craft-paper

Multilayer foil TL8135-003 Class 1

Polyethylene

Aluminium foil

Plastic foilaccording to type

WeightG/m3

280

Thickness,mm

0,2

0,25

Used at T °C

From +70to - 40

From +70to - 40

From +70to - 40

Impermeability towater and steam

G/m2/24 hrs

0.4 at 20°C 85 %relative humidity



Russianequivalent

Polyethylene filmT half -tubing0.2x1400x2Grade I GOST10354



Measures to avoid the destruction of a polymeric hood are to be taken by covering sharp edges andcorners with special padding (polystyrene, etc.). Formation of water pockets in covers shall be preventedwith the help of appropriate measures. Special attention shall be paid to ensure proper weld seam qualityand tightening of goods fixing points in a crate (ref. fig. 1).

Example: tightening of the fixture in the water-and steam-proof packing.

Fig. 1Provision shall be made in the cover design for its multiple opening and closing in order to

replace the moisture absorbing material during long-term storage of goods. The required amount ofmoisture absorbing material shall be such as to permit the relative humidity of enveloped air to bebrought to no more than 50 %; as this takes place, account shall be taken of climatic conditions ofstorage at the place of destination. Moisture absorbing material is to be distributed evenly under thepolymeric cover and secured fast. Packets with moisture absorbing material shall not be in contact withthe goods to be packed.

Minimum amount of air is allowed inside the package so that the latter fits tightly against the goodsto be protected. Avoid contact of packing foil with the box lid and walls. After air evacuation check thepacking for tightness. To monitor the degree of saturation of watertight material during long-term storageof the equipment air moisture indicators can be placed within the crate. Peepholes made of polyethyleneor similar material complete with moisture indicators at the rear shall be welded up in a three-layerfoil insulating shells.

The above method is used for the goods intended not for contact preservation only.2. Method of application of protective coatingWhen using this method appropriate corrosion-resistant coating is applied to the surface

of the goods to be protected directly after the cleaning and drying.iAnticorrosive protection is not required when the surface is coated with chromium, silver, nickel

or other corrosion-resistant metals and alloys.Anticorrosive substance shall not be used for materials that may be damaged with this substance.

For example:- textile products, mica, rubber, paper, felt, leather and others;- electronic and electrical elements such as capacitors, distributors, breakers, fuses, switches,

resistance, rectifiers;- materials with glass, plastic, primer or paint coating.Irrespective of the way of application of the anticorrosive coat the protective layer shall be even

and unbroken.3. УС 1 Method (The application of volatile corrosion inhibitors)Even at low temperatures УС 1 active substance generates noticeable pressure and surrounds the

protected goods with the persistent and continuously operating protective gas.УС 1 substance can be applied to the surface to be protected as powder, spraying liquid, oil or

using УС 1 paper. In this case corrosive materials are not removed but neutralized by chemicaltransformation. For these purposes the outside air insulation is required. It is obtained by using thepolymeric hood where the protective gas remains much longer.

УС 1 substance is used for steel, iron, chromium, cast iron, aluminium, copper and its alloys.



2.1.3.4. Outside packing 1. Material used for packing crates1. As a rule, the export packing is to be made of good quality conifer wood having the following

specifications:- moisture content shall not exceed 20 % ;- cracks of no more than 1/5 deep across the width and 1/6 long throughout the length of the wooden

board or cross-piece are accepted only on one face;- knots as large as no more than 1/3 across the width of the wooden board and as few as 4 knots

per one running meter of board are accepted;- existing knot holes shall be stuffed with wooden blanks smeared with glue or special mastic.Minimum width of the wooden board shall be 100-200 mm. The thickness of a plank and a

cross-plank shall be as shown in Table 2 depending on the equipment type.

Table 2Weight of the equipment Plank Cross-plank

Up to 2 tons 22 mm 27mm

From 2 to 5 tons 27mm 32mm

From 5 to 10 tons 27mm 40mm

From 1 0 to 15 tons 32 mm 40mm

1 5 tons and over 40mm 40mm

Crates shall be made of planed boards set in groove and tongue.Bars can be used unplaned (rough).Veneer or other modern materials meeting the OTU-92 requirements for packing are

accepted.HPE Packing Guide Methods (Germany) shall be used in order to calculate the package

load.2. Crate dimensions guide

Inside dimensions are to be indicated in the following sequence: length (L), breadth (B),height (H).

Observe the following rules in determining inside dimensions of the package:- inside dimensions are measured between the elements of the crate: opposite walls or butt ends,

bottom and lid.When setting the inside slats measure between them (refer to figure 2).

Inside dimensions.Fig. 2

- Safety space (S) between goods to be packed and the packing material shall not be lessthan 30 mm (refer to figure 3)



Safety space Fig. 3

(except for the points where supports or gauge bars are placed).- Space "S" is to be 50 mm where specific care for transportation and storage is required;- separate elements of the crate are called (refer to figure 4):- bottom;- side wall;- butt end wall;-lid.

1.Bottom 2. Side wall 3. Butt end wall 4. LidFig. 4 . Types of package

3. Types of package. Regardless of the material to be packed there are two basic types of package (refer tofigure 5):

Carrying-type package



Gripping-type package Fig. 5

The most applicable type of package for supply of the equipment to VAZ is a carrying typeas it has the following advantages:

- it holds the goods to be packed made of separate parts, imparts rigidity and allows toincrease load in stacking;

- it maintains stability (directional stability and stability against rolling-over) especially in case ofoff-set center of gravity and for goods having small supporting surface area;

- it provides uniform load on the bottom and, if necessary, high contact load could bedecreased by increasing supporting surface area;

- it forms packages suitable for handling both by floor transportation and by lifting facilitiesas well as for piling;

- it protects the goods against mechanical damages.Carrying-type packages come in thefollowing varieties according to the design features based on the different requirements associated withthe goods which can easily suffer damages:

- casing;- crating;- partial packing.

Fig..6

The crate consists of six connected together elements completed in blind planking. Thedimensioning is made in accordance with the rated load (fig. 6). The crate can have cut-off edges (aprofile crate) in the case that maximum overall dimensions of the goods are oversized.



Fig. 7

The crate in the form of sheeting can be completed with partial planking; as this take place,blind planking is not excluded, (ref. Fig. 3). As a rule, planking makes up 40-60 % in relation to thetotal area of the wall, and in this case the board shall be 10 cm in width as a minimum.

Partial packing corner in various types.It covers: bar constructions, skid constructions, light planking and a bunch (ref.-fig.8-l 1).Examples of partial packing:

Bar constructionFig. 8

Skid constructionFig. 9



Light plankingFig. 10

Fig.11



2.1.3.5. Crate designCrates of following design are used in the equipment supply to AO AvtoVAZ (refer to

section 2.1.3.4.).They differ structurally as follows:1. Crates with bearing walls (refer to figures 12-13).

Crate with skids: horizontal board slat planking of sides and a lid on the inside, butt endtimber set made of bar on the outside. Applicable for the goods with the weight of less than 1000 kg.

Fig. 12

Fig. 13 Crate with skids: vertical board slat planking on the inside



Crates of a frame design (ref. fig. 14) with plane planking. Bottom and frame of a crate are servingas carriers and they impart strength. The advantage of these crates is in their good stability.

Fig. 14

CONSTRUCTION ELEMENTS

1. Crate bottomThe crate bottom of any design represents the most important carrying element. Longitudinal slats

and transverse beams as well as bottom boards intended for carrying the load shall be designed to absorbthe resulting forces. HPE Packing Guide Methods (Germany), section B, Load Rating). Therefore thefollowing principles shall be observed:

- crate bottom is to be provided for the facilities for lifting the goods with crane or palletizerwith consideration of the center of gravity of the goods to be packed (fig. 16-18);

- the goods to be packed shall be fixed to the crate bottom by means of through-bolt connections.In the event that carrying beams are used the goods shall also be secured through the beams (fig. 19-21);

- if there is no way to use the through-bolt connection, horizontal displacement loads shall be takenby the frame made of longitudinal and transverse beams and also with special pads which are screwed all theway through the crate bottom (fig. 21);

- the load of the goods to be packed has to be distributed evenly throughout the crate bottom.If bearing area of the goods is less than the maximum size in the length and the width, appropriatesupports shall be built in (fig. 22) to transmit the forces through to the crate bottom (fig. 23);

- in case of packing heavy-weight goods the bottom of the crate on the inside along its edgesshall be reinforced with transverse beams screwed all the way through to longitudinal beams (fig. 24).

At least two bearing longitudinal beams are to be provided on the bottom of the crate. The distancebetween these bearing beams shall not exceed 80 cm.

If the provisions made for securing the goods are insufficient the number of carrying beamsshould be selected from Table 3



Table 3

Minimum width of the crate bottom (cm) 100 200 275 325

Number of carrying longitudinal beams, no less than 2 3 4 5

Additional transversal planks (ref. fig. 12-13) or longitudinal planks (ref. fig. 14) shall beprovided to lift a crate with crane or palletizer except for those cases when special conditions oftransportation require sliding of goods. For this purpose the carrying longitudinal beams shall have 45° bevelto the middle of the face end and be used as skids (ref. fig. 14). To ensure convenient lifting by slings theadditional planks under the skids shall be shortened along the carrying longitudinal beams to matchthe center of gravity of the goods and also the bearing area of the goods resting on the bottom of thecrate. In case of even loading at the bottom of the crate and if the center of gravity is in the middle, theplanks shall be shortened by 1/5 of the length of the carrying longitudinal beams at both ends (ref. fig.14).

Skids fitted with planks shall be used in the following cases:when the width of the crate bottom is less than 200 cm - they shall be 80 mm thick; when the width

of the crate bottom is more than 200 cm - they shall be 120 mm thick.

The recesses in the skid boards meant for palletizer shall correspond to fig. 15.

Fig. 15

Fig. 16 The bottom of the slatted crate, A3-A6 design, fitted with plank toprotect the edge against deflection by action of rope and having the recess intended for lifting byfork lift truck. A -maximum distance between slats is 80 cm. E - the depth of the recess in case when thewidth of the bottom is less than 200 cm shall be 80 mm, and when the width of the bottom is more than 200cm the recess depth shall be 120 mm.

Fig. 16a The bottom of the crate with skids, design B1-B3, with transversalplanks to protect the edge against deflection by action of rope.



Fig. 17 The bottom of the crate with skids, design B1-B3, withlongitudinal planks to protect the edge against deflection by action of rope having the recessintended for lifting by fork lift truck; the center of gravity is in the middle (C.G.).

Fig. 18 The bottom of the crate with skids, design B1-B3, 200cm inlength with displaced center of gravity (C.G.).

Fig. 19 Fixture of the goods to be packed on the crate bottom, A3-A6 designs.

Fig. 20 Fixture of the goods to be packed on the crate bottom, B1-B3 designs.

Fig. 21 Fixture of the goods to be packed on the crate bottom, B1-B3 designs.



Fig. 22 Fixture of the goods to be packed on the crate bottom withoutdirect bolt connection.

Fig. 23 Goods support for even distribution of the load on the crate bottom.

Fig. 24 Load transfer on the outside skids.

Fig.25 Butt end bar in the crate meant for heavy goods.

2. SIDE AND END WALLS

Side and end walls of a crate of any design make up an integral unit when assembled.Besides, the following forces are involved there:

- dynamic forces in transportation;- static forces in storage (pile compressive pressure).Total reliability of a package decreases if main units do not meet the calculation as per the

above indications. Therefore, connect lateral walls with butt end ones in the crate corners. The boards



intended for jointing side and end walls at the corners of the crate shall be carefully selected to thefollowing specifications:

- the width of the board on the edges shall not be less than 120 mm, and the width of the rest ofthe boards shall not be less than 100 mm;

- the thickness of the transversal slats is to be selected to the rated loads;- diagonal boards of the side and end walls shall be placed in the crates at a height no less than:- 600 mm (fig. 26)- 1500 mm (fig. 27, criss-cross)- 1800 mm (fig. 28, with additional horizontal force).

Fig. 26 Fig. 27

Fig.-28

To improve reliability of the wall jointing at the corners the slats at the edges shall be fixedto wall ends directly (ref. fig. 29-30).

In the case that the boards for wall planking are too short their joints shall be displaced so asto run across transversal slat (ref. fig. 31).The longitudinal slat is so placed with step that it can serve as a support for carrying bars of a lid andtransversal load beams (ref. fig. 32).



Fig. 29 Side slat-Crate height is up to 1,5 m Fig. 30 Side slat Crate height is more than 1,5 m

Fig. 31 Displaced board joints at wall planking

Fig. 32

3. CRATE LID

The crate lid overlaps the goods on the top thus making up flat surface which can accept uniformload. The lid of the crate rests on the slats of the side and end walls, on the framework or on theadditional bearing beams.

Wide lid of large area requires the use of special supports for stacking crates in many layers(ref. fig. 33).

Fig. 33



The edges of the crate lid shall be about 3 mm less than the outside overall dimensions of thecrate to protect against breakage and opening at handling by crane (ref. fig. 32-33).

The forces transfer through the lower beams of the lid on the side walls shall not be owing to thenails. The lower beams of a lid shall be laid on the framework of the sides. Pile compressive load shall notbe transmitted to the goods.

To avoid weakening of the wood profile the lower beams of the lid shall be free from incuts.The distance between the lower beams of the lid can be possibly reduced in the area where the rope

may run along when handling by crane.The lid shall be covered with polyethylene film over the whole area on the inside for

insulation and veneer or plastic shall be nailed to prevent from developing of water pockets.The crate lid shall be bound with zinc-plated metal sheets or other type of protective material

in case of prolonged exposure to the atmosphere at storage (ref. fig. 14).In case the weight of goods exceeds 3 tons the edges of the longitudinal skids and the top edges of

a crate shall be protected with steel strip.Corners of crates are to be bound with steel strips having 0,9 x 30 mm cross section. The

length of a strip from the wall edge of a crate shall not be less than 180 mm (ref. fig. 14).Note: Corners of the crate walls assembly shall be right and the walls shall be parallel. Non-

parallelism of walls shall not exceed 5 mm.If necessary, the crates shall have ventilation and water drain openings. They shall be covered

from the inside by metal net with 1 mm mesh size maximum.The equipment shall be reliably secured in the crates to maintain integrity and to prevent it from

breaking and mechanical damages. If necessary, plastic pads (made of polystyrene, etc.) should be usedto provide cushion against shocks.

The responsibility for any damage of goods caused by unsound protection or packing rests with theSupplier.

The equipment which is delivered without packing upon the Customer's approval shall havelifting rings or angle pieces intended for handling with a crane or fork lift truck.

Overall dimensions of packing shall not exceed the standards established in Russia and shown infig. 34.

The goods are considered to be oversize when exceeding overall dimensions specified for loading.Exceeding of size in vertical plane is acceptable at the top, side and lower areas (ref. fig. 34).Side oversize area is located 1230-4000 mm above the upper part of the rail.Top oversize area is located 4000-5300 mm above the rail head.Lower oversize area is located 0-1230 mm above the upper part of the rail.



Fig. 34

2.1.3.6. MarkingMarking of the packing cases containing the equipment shall be made on three sides: on two

opposite lateral walls and on a lid of the case. The Seller shall apply the marking of the name andthe address of the manufacturer on the two remaining walls of the case. The marking shall bemade clear using indelible light-fast paint in the Supplier's language and in the Russian languageand shall include the following:

Russia - Togliatti - AO AVTOVAZ - Upravlenie Oborudovaniya (in red paint only inRussian).

Lettering height is 6,0-7,0 cmSupplier (in black paint, e.g. RAL 9005, lettering height is no less than 20 mm)Contract number Trans numberNet weight, kg



Gross weight, kgCrate overall dimensions, cm (width, length, height)Nl Case number (numerator - for case number,N denominator - total number of cases).

The surface of the area meant for marking shall be of a property to maintain good quality lettering.Marking with contour templates is preferable.Marking symbols (ref. fig. 35) used to indicate safe, dangerous goods and symbols of commonunderstanding shall correspond to the World standards.

Standardized symbols:A-topB - glassC - protect from moistureD - protect from the sunE - hand hook usage is forbiddenF - center of gravityG - slingH - gripping is not at this pointI - clamp in wall directionK - applicable pile compressive loadL - compact packingM - applicable temperature rangeN - lift truck is not at this place

Fig.35



In places requiring special attention legible inscriptions shall be applied such as "Handlewith care", "Top", "Do not turn over", etc. depending on the cargo content.

Spare parts to the equipment, machine-tool attachments, measuring tools shall be packed inindividual cases and they shall have the following marking in colours specified below:

- spare parts - black stripe- machine-tool attachments - green stripe- cutting tools - red stripe- measuring tools - yellow stripe.The stripe is applied horizontally across the marking on two opposite sides and to the lid of

the case. The stripe shall be 5 cm wide and no less than 50 cm long.In case when both spare parts, tooling and measuring tools are packed in one case the stripes

have to be applied to the case in the colour that corresponds to the contents.If the equipment is packed in several packing cases each of them shall be numbered

irrespective of the packing type. The packing case is marked with a fraction where the numeratorindicates the case ordinal number and the denominator indicates total number of cases containing theequipment.

Packing of equipment components belonging to different trans numbers (or codes) in onecase is not allowed. In the event of packing of the equipment belonging to different trans numbers(different codes) in one case all code numbers shall be included in the main marking under "Trans №..."

Oversize and/or overweight cases weighing more than 50 kg shall be marked with indeliblepaint indicating the center of gravity with "+" symbol and C.G. letters showing the points of top cordarrangements in slinging.

Additional marking is to be applied according to the Customer's and Supplier'sinstructions and located on the machines with the Supplier's address on it. Marking shall be identicalwith shipping documents.

A watertight envelope containing the copy of shipping specification shall be fastened to eachcase on the outside. The envelope shall be hidden behind a metal plate nailed to the case or fixeddirectly on metal parts of the equipment.

The second copy of the shipping specification enclosed in a watertight envelope shall be putinside the case and secured in similar manner.

If the equipment is distributed in several packing cases the following supporting documentsshall be contained in the first case:

1. shipping specification of all the rest parts of the equipment including a complete list of theequipment broken down by packing case;

2. technical documentation for the equipment as an assembly.



3. ACCEPTANCE AND TESTING

3.1. Equipment and tooling

3.1.1. GuaranteesThe Supplier shall ensure conformity of the production means with the conditions

mentioned in the Contract or Agreement and execution of the specified operation meeting therequirements of production and consumption rates, tolerances for dimensions and shape of theworkpiece, surface finish and other requirements specified in the Contract, Agreement (Protocol),Orders and drawings attached.

The Customer has the right to send his representatives to the Supplier's and subcontractors'factories at any time of their working hours in order to check quality of the equipment andworkmanship of the materials employed in its manufacture. The Customer shall undertake toparticipate in the equipment tests at the Supplier's factory.

The Supplier shall guarantee that the equipment provides all the features, performance dataand specifications stipulated in the Contract, Agreement (Protocol), and/or catalogue presenting thismeans of production within 12 months upon putting it into operation or within 18 months from thedate of its delivery to the Customer.

The Supplier shall, 3 months prior to the equipment despatch, turn over to the Customer aset of initial data for the construction of the process equipment (construction assignment fordesigning the foundation, connection to utilities system (mains), local exhaust ventilation etc.).

3.1.2. Test at the Supplier's factoryThe Supplier shall test the function of the equipment, its capacity and process accuracy as

per the requirements of OTU-2000, GOST, OST and TU standards and specifications for equipmentto be manufactured.

The equipment shall be tested at the Customer's premises in line with jointly adoptedprogram and procedure of tests in the event that

- overall dimensions of the equipment make it impossible to carry out tests at theSupplier's (manufacturer's) premises;

- the equipment is to be modernised without its dismantling;- the Supplier lacks the required utilities.The tests shall be carried out at the Supplier's expense during 14 hours in idle mode and at

least one hour under load when machining a batch of workpieces.The Supplier shall carry out the quality control of the parts produced during load testing of

the equipment using his own measuring instruments.The Supplier notifies the Customer, at least 3 month before the contracted time of delivery,

that the equipment is ready for testing. If the Supplier does not receive any notification from theCustomer, the tests shall be carried out at a specified date. In this case the Supplier shall prepare thetest protocol stating conformity of the equipment to the Contract requirements and to the presenttechnical requirements.

The acceptance and testing of the equipment at the Supplier's factory shall be carried out inaccordance with a schedule worked out by the Supplier and approved by the Customer.

The Supplier has the right to use no more than 15 % of the blanks obtained from theCustomer for set-up operations. All the parts manufactured during the test are to be suppliedtogether with the equipment to the Customer with record in the packing list. Machined and acceptedparts shall be properly preserved and packed. The Supplier shall inform the Customer by fax of thecase number where the blanks to be returned are packed.

The procedure for testing of the process equipment that is manufactured by machine toolbuilding workshops of AO AVTOVAZ is specified by engineering regulation I37.101.1020-96,"Preliminary and acceptance tests of process, check-out and testing equipment manufactured atproduction facilities of VAZ "



3.1.3. Tests at the Customer's factoryThe Customer has the right to carry out final test of the equipment installed at the factory

and insist on participation of his representative and, if necessary, technical specialists of theSupplier in order to check that the following is provided:

1) hourly capacity and efficiency of the equipment;2) production accuracy as per requirements of the Customer and for metal-cutting

equipment as per requirements of item 3.3.4., OTU-7-2000; dispersion field should notexceed 75% of the tolerance band of parameters to be checked;

3) general operational capability of the equipment with the use of materials, tools, toolingand fluids agreed upon with the Customer;

4) meeting the requirements of the present OTU;5) consumption;6) other requirements stipulated in the contract (agreement).Meeting of the above requirements shall be guaranteed at any temperature of the equipment,

both when starting up the equipment at ambient temperature and when reaching the temperaturewhile in operation mode.

Test duration for the following equipment, depending on its complexity:1) transfer lines, rotary-type machines, grinding, gear-cutting, boring, and milling machines,

welding lines, welding equipment with robots, presses:- idle mode – 14 hours- under load – no less than 1 hour, for presses – 7 hours.2) assembly benches, broaching drilling and balancing machines, welding equipment not

mentioned in item 1, etc.:- idle mode – 7 hours- - under load – 1 hour.

3.14. Installation and set-up of the equipmentIf the Supplier sends his technical personnel for installation and/or commissioning of the

equipment too late, or the personnel is too slow with installation and set-up work because ofshortage of personnel or their insufficient special engineering competence, or negligence, theSupplier shall be held responsible for all damage relating to the above in accordance with supplyagreement.

If the Supplier effects any changes to the equipment in the course of installation, thesechanges shall always be officially protocoled3.1.5. in writing.

3.1.5. Negative results of the tests performed at the Customer's worksIn case of lack or insufficiency of initial data or quality of the production equipment, or in

case of its failure provisions of the Contract. Agreement (protocol) and/or attachments shall beadhered to.

3.2. Equipment without tooling

3.2.1. GuaranteesThe Supplier shall guarantee that the equipment provides all the features, performance data

and specifications stipulated in the Contract, Agreement (Protocol), and/or catalogue offering thismeans of production within 12 months upon putting it into operation or within 18 months from thedate of its delivery to the Customer.

3.2.2. Tests at the Supplier's WorksThe Customer is entitled to send his representatives to the Supplier's factories to check

quality of the equipment manufacture. The Supplier shall perform tests at his factory notifying theCustomer of the tests 20 days before the scheduled test date. The Customer is entitled to send hisrepresentatives to the company plants to take part in the tests. If the Customer advises the Supplier



that the Customer's inspector can not be present at the tests, the Supplier shall be entitled to carryout the tests subject to conditions of the Contract, the agreement and the present OTU beingobserved. The above tests shall be carried out at the Supplier's expense.

3.2.3. Tests at the Customer's WorksThe Customer has the right to carry out final test of the machine installed at his factory and

demand for the presence of the representative and, if necessary, technical specialists of the Supplierin order to check that the following is provided:

1) data of the test protocol, prepared at the Supplier's Company (refer to item 3.2.2.);2) fulfilment of requirements of item 3.1.3.;3) production process accuracy check shall be made according to the recommendations

attached to OTU-7-2000.

3.2.4. Negative results of the tests carried out at the Customer's worksIn case of negative results, the Supplier shall improve the equipment to meet the precision,

operating capability requirements in accordance with the Contract within the time-limits agreedwith the Customer.

If the above time period is not acceptable for the Customer, sanctions of the Contract oragreement shall be applied.

3.3. Testing of test equipment at the Customer's WorksAll the requirements of items 3.1.1.-3.1.5. are applicable to the testing equipment except for

those concerning duration of tests which is as follows:- idle mode – 7 hours;- under load – full cycle of workpiece testing according to specifications for the workpiece

under test.When testing the test equipment at the Customer's facilities primary validation of this

equipment is conducted following the program and procedure worked out by the Supplier andagreed upon with the Customer.

In cases such as:- validation of test equipment used in the mandatory certification of the production,- product tests for conformance with the mandatory requirements of government

standards,- the manufacture of products supplied for the government needs measurement equipment

of approved types shall be employed in accordance with Regulations of metrologicaltesting, PR 50.2.009, with the specimens of measurement means being certified as perGOST R 8.563.

Special measurement means and gages required for certification shall be included in the listof the equipment supplied under the contract and delivered to the Customer complete with theequipment.



4. ENGINEERING DOCUMENTATION

4.1. Engineering documentation which is to be agreed upon with theCustomer

4.1.1. Mounting drawing with indication, in three coordinates, of connection points tomains, with chip and/or waste removal systems and also systems of lubrication and cooling.

General view drawing shall contain full data on initial reference point of the equipment: itslocation and relation to:

- overall dimensions and foundation of the machine (especially to coolant drain channel);- “transport-to-machine” interface point;- workpiece.The machine reference point shall be unambiguous and in the installation enabling to

measure the mounting dimensions of the machine with required accuracy. For turning machines, forexample, cross-section of chuck end and chuck centerline could serve as the reference point.

The drawing can be added with a text explaining, if necessary, the initial reference pointposition.4.1.2. Data on foundations and channels including all the necessary layout dimensions and loadvalues enabling to prepare foundation work drawings, drawings for insert parts for mounting of theequipment to the Supplier’s advise (making clear that transfer line foundation may be of beam-type); data on foundations and channels including drainage to sewer system with indication of wastepurification means. With respect to foundations for machines operating with dynamic loads theinitial data contents shall meet the requirements of SNiP 2.002.05.-87 standards and regulations.When the equipment is not in conformance with the SNiP 2.002.05.-87, recommendations arerequired on calculation of foundations and determination of loads on them.4.1.3. Electric, electronic, hydraulic, pneumatic circuit diagrams and also lubrication diagrams withspecifications attached to them.4.1.4. Properties and quantity of the employed coolants, oils, lubricants and working hydraulicfluids.4.1.5. Catalogue data of main apparatus and devices with specification of their performance andmanufacturing companies. 4.1.6. Assembly drawings of loading and unloading devices and of intra-line and inter-operationaltransport4.1.7. Сyclograms of operations4.1.8. Work drawings of cutting tools, auxiliary tools (tool holders), assembly tools, gauges,electrodes, electrode holders, cams for drives of slides and copying tools.4.1.9. Work drawing of attachments, dies of hot, half-hot and cold stamping, casting tooling andmolds. 4.1.10. Lists of sets of cutting tools, tool holders, electrodes, electrode holders; these shall includespecifications of cutting tool and electrode sets for 1000 hours of operation broken down by items(including disposable inserts) indicating grades of alloys and diamond-abrasive tools and theirrespective performance data.4.1.10.1. Lists of sets of shape-forming mold components, dies of hot, half-hot and cold stampingfor 1000 hours of operation indicating quantity by item, steel grades and properties.4.1.11. Lists of purchased items (bearings, chains, belts, seals, hydraulic and pneumatic lubricationdevices, ball-and-screw pairs etc.) indicating design types, names of manufacturing companies,their fitting locations on machine units and also catalogue data.4.1.12. Tool setup charts showing operating data (working travel length, stroke, RPM, cutting andfeed speed and machining parameters controlled as per OTU-7) broken down by item.Tool setup charts shall indicate movement cyclogram of abrasive and dressing diamond tools,grinding and dressing modes by grinding cycles.4.1.13. Lists of sets of rapidly wearing parts including performance data and names ofmanufacturers.



4.1.14. Lists of sets of spare parts required for trouble free operation during 10000 hours uponexpiration of the warranty period.4.1.15. Directions on safety rules including requirements for arrangement of the operator’s stationand requirements for premises and sites where the equipment is to be installed.4.1.16. When delivering forging and press equipment the following additional documentation shallbe presented:

1. movement charts of working members (movable operating elements) and forces actingon them;

2. tables containing stress values of tightening studs;3. performance data of flywheel, coupling and brake.

4.1.17. Information on all factors of effects on natural environment: emissions to the atmosphere,discharges to sewer system etc. with the respective qualitative and quantitative characteristics.4.1.18. Lists of sets of tools and tooling necessary for repair and maintenance of the equipment.4.1.19. When supplying testing equipment, processing equipment and instrumentation with themeans of on-board measurements the following additional documentation shall be provided:

1) a list, with metrological and performance specifications, of gages, reference standardsand special means of measuring for equipment validation, calibration and set-up of themeasurement means and measurement channels incorporated into the equipment;

2) drawings of gages and special standards of geometric and mechanical measuresspecified in the subitem 1 (rules, levers, plates, templates, gages, check weights etc);

3) diagrams of connection of the measurement means listed in the above subitem 1 tothe equipment and the installed measurement facilities and measurement channels.4.1.20. Schedule and procedure of primary validation4.1.21. Procedure for regular validation of testing equipment in the course of its use unless it isspecified in maintenance documents.4.1.22. Documents for special means of measurements and gages being employed as part of testingequipment and also necessary for its validation (drawing, chart, passport (certificate) certificate oftype approval or calibration certificate of the measurement means).4.1.23. Contents of engineering documentation supplied with the equipment.

Documents as per items 4.1.1. - 4.1.22. shall be part of engineering documentation suppliedwith the equipment.

In addition, the following papers are to be supplied:1) equipment certificate;2) instructions, with slinging charts, on machine transportation, unpacking and erection;3) machine maintenance and repair manual including a “Safety Rules” section;4) user guides for instruments and gages being part of the supplied equipment (metrological

and performance data, operation manuals, set-up and adjustment guides, procedures for calibrationof built-in measurement means and measuring channels).

5) catalogues of special spare parts;6) equipment units arrangement chart;7) directions on observance of safety rules and industrial sanitary standards indicating

measures of personal hygiene in working with process and lubricating fluids;8) protocol of equipment acceptance at the Supplier’s facilitiescertificates for vessels operating under pressure;10) album of drawings of rapidly wearing out parts and main units of the equipment

(including all types of gearing);11) catalogues of purchased items (bearings, electric apparatus, seals, chains etc.);12) packing list in two languages;13) technical passport (certificate) on industrial wastes including those from abrasive tools

(if they are formed) identifying intervals and specific standard limits of waste buildup, chemicalcomposition, class of hazard and measures of disposal/reclamation;

14) qualitative and quantitative characteristics of emissions into the atmosphere andconditions of meeting standard requirements for protection of the atmosphere;



15) qualitative and quantitative characteristics of industrial waste discharge into the sewersystem and conditions to ensure the required degree of their purification determined by theCustomer;

16) operation manuals for measuring devices and instruments used for control of buildupand purification of atmospheric emissions and industrial waste discharges;

17) list of chemical substances and materials that have properties approved by natureprotection authorities of Russian federation (Roskomsanepidemnadzor, Minprirody - RF Committeefor Sanitary and Epidemic Inspection, Ministry of Nature);

18) operation manuals, procedures for calibration checks (calibration) of special gages,reference standards and portable means of measurement designed to conduct the certification ofequipment, calibration and setup of measurement means and channels that form part of theequipment.4.1.24. Documents as per items 4.1.1. - 4.1.18. shall be part of drawings prepared on reproduciblepaper or 3.5’’ floppy disks or compact disks (CD-ROMs).

4.2. Engineering documentation subject to mandatory approval by theCustomer

4.2.1. Engineering documentation as per item 4.1. is subject to mandatory approval by theCustomer.4.2.2. Engineering documentation shall be sent to the Customer’s production division within twomonths from the date of a contract as concerns items 4.1.1., 4.1.2. and 4.1.4. and within 4 months asconcerns the rest of the items; as this takes place the documentation shall include:

- two copies in Russian and one in the language of the Supplier’s country, as concerns items4.1.1., 4.1.2. and 4.1.4.;

- one copy in Russian and one in the language of the Supplier’s country, as concerns the restof the items.4.2.3. A “C” character shall be put on the documentation, which means “To be considered”.4..2.3.1. A stamp, “Approved by AVTOVAZ”, shall be put on the engineering documentationagreed upon. Upon the approval, the Customer shall return to the Supplier, within two months fromthe receipt, one copy of the approved (considered) technical documentation in the Supplier’slanguage.4.2.3.2. Sending of just assembly drawings with parts lists and work drawings of rapidly wearingparts (as per OTU-6, item 3.2.) is sufficient for the Customer to approve work drawings of toolholders, gages and attachments.4.2.3.3. Approval of work drawings of slides drive cams is not required.

4.3. Engineering documentation adjusted after the approval by AVTOVAZ.(Final documentation)4.3.1. One copy in Russian of the final engineering documentation as per item 4.2.1. is subject tomandatory sending by airmail at the address of the Customer’s production division.4.3.2. Sending of the final engineering documentation shall be effected within two months from thedate of mailing to the Supplier of the engineering documentation approved by the Customer.4.3.3. The documentation shall be marked with an “O” character meaning “Finally approved”.

4.4. Engineering documentation adjusted based on equipment acceptanceresults4.4.1. Engineering documentation as per item 4.1 shall form part of the equipment supply.4.4.2. The complete package of equipment supply shall include engineering documentation inquadruplicate (three copies being in Russian and one in the Supplier’s language) or three copies intwo languages (in the Supplier’s language with Russian translation); in addition, a set of drawingson reproducible paper or 3.5’’ floppy disks or compact disks (CD-ROMs) in initial format of theSupplier and at the same time in DXF and JGES format reproduction of the technical documents inthe Customer’s PC. The engineering documentation shall be put in case № 1 of each machine.



4.4.3. Final list of necessary engineering documentation supplied together with the equipment shallbe agreed upon with the Customer.4.4.4. In case of purchasing of complex process equipment such as molded casting lines, automatedsystems of joined casting machinery for production of castings from nonferrous alloys and alsocasting furnaces provision shall be made in contracts for joint engineering in the arrangement of thesupplied equipment taking account of the conditions of the Customer’s existing production.

Engineering documentation for working out installation drawings (foundations, platforms,metalwork) shall be supplied in electronic as well as in paper version. The software type is to beagreed upon with the Customer.

4.5. General requirement for engineering documentation4.5.1. Work drawings (including drawings of all parts) shall contain all the data needed for themanufacture of tools, process tooling, spare parts to the equipment.4.5.2. The supplier shall make all the required amendments to the engineering documentation basedon results of equipment testing and acceptance at the Supplier’s facilities and also, if necessary,based on the erection supervision at AVTOVAZ.4.5.3. Each page of the engineering documentation shall have the following specified: contractnumber, part number of the workpiece, transport facilities number.4.5.3.1. Documentation format

Formats A4, A3, A2, A1 and A0 are allowable in the preparation of engineeringdocumentation. Those documents that are supposed to be used in the equipment repair shall be ofsuch format as to ensure convenient work at the equipment area. It is preferable, when making outdocuments of one type, to use one format. The pages within each type of engineering documentsshall be arranged in order of increasing starting the numbering of pages from 1 and indicating thetotal number of pages. In case of broken numbering (missing pages) each preceding page shall havethe number of the following page. The height of alphanumeric characters shall be at least 4 mm.4.5.3.1.1. Format A3 is more preferable for electric, hydraulic and pneumatic diagrams. Otherformats may be used, if it is caused by any necessity. Formats A3 and A4 should be used for textdocuments. 4.5.3.1.2. Large format documents shall be folded into format A4. It is allowable to keep thedocuments in A3 format sewing them together into an album with hard covers. The documentationprepared on reproducible paper shall be delivered rolled-up in a cylindrical tube.4.5.4. The documentation shall be supplied stitched in folders grouped by sections:

- general documents for all the equipment (initial data table, certificate, cyclograms, outlineand installation drawings, foundation drawings, instructions etc.);

- tool setup charts, drawings of cutting and auxiliary tools, process tooling drawings, list ofcutting tools for 1000 hours of equipment operation etc.;

- lists of spare parts sets for warranty period and for 10000 hours of operation, drawing ofequipment mechanical units, charging devices, inter-stage and line transport etc.;

- electrical equipment drawings, charts of hydraulics, pneumatics and of lubrication andcooling systems, etc.

Language used in documentationUnless otherwise stipulated in the contract, the documentation mentioned in item 4 shall be

issued in Russian language and in the language of the Supplier (applicable to foreign suppliers).4.5.6. Units of measurementUnits of measurements used in technical documentation shall be those of International System ofUnits.

4.6. Requirements set for individual types of technical documentation

4.6.1. Initial data as per Appendix № 2 to the contractThe documents shall contain all the initial data required for the design of the workshop and

inter-stage transport.



4.6.2. Machine diagram and certificateCinematic and functional flow diagram of the machine shall include the following:1) reduced and simplified chart showing sequence of operations, possible automatic control

and workpiece loading/unloading positions;2) machine operation conditions with relevant details on functioning, operating time and

rated capacity;3) diagrams of individual operation cycles.Certificate of the machine shall include1) purpose of the machine;2) performance data;3) structure of the unit and complete set of the supply;4) design and principle of operation;5) operation procedure;6) maintenance7) general view of the machine with designation of controls and control panels;8) cinematic diagram of the machine;9) certificate of acceptance;10) overall dimensions in the plan;11) drawings of machine units with cross-sections (made at bearing units as a must);12) roller bearings arrangement chart;13) machine weight;14) safety precautions.

4.6.3. Equipment operating cyclograms (cycle charts)Description of equipment functioning and operating cycle (or cycles) chart is required for

the whole equipment with large number of interrelated movements or the possibility of performinglarge number of cycles.

The cycle chart shall describe the machine movement; present all initial data on theapparatus employed in the cycle; moreover, specify time ratings for the cycle. If possible, suchcycle chart should go with electrical schematics diagram.

In case of preparing a cycle chart on several pages clear indication shall be made to the partof the cycle chart that refers to a part of the installation shown on the viewed page.

Description of functioning shall include:1) basic cycles of the equipment;2) possible cycles and conditions for the preparation of each one;3) control procedure upon emergency shutdown, with premature return and when setting up

for a machining operation.

4.6.4. Diagram of arrangement of instruments on the panelsIt is necessary and required for complex apparatus. It shall show relative position of each of

the components on each panel. Each component shall be designated in the same manner as in thecharts. The diagram may not be employed if the above requirements are provided for in paneldrawings.

4.6.5. Outline and installation drawings. Foundation drawingsInstallation drawing shall contain all the necessary information for carrying out preliminary

works prior to the equipment installation including foundation drawings and also contract number,workpiece part number and equipment trans. All the legend shall be translated into Russian.

Overall dimensions shall be indicated in the plan in front view:1) position and weight of different parts and weight distribution on individual support

plates;2) dynamic loads, if any, both in vertical and horizontal direction;3) position of probable means of access;4) arrangement of cables and pipelines laid in the installation area.



To arrange hoists weights shall be specified of parts to be removed for resetting andchanging tools. If necessary, information shall be given on dimensions, purpose and arrangement ofsupply and headway pipelines to be provided for by the Customer.

Perspective or orthogonal view drawing shall be presented indicating three coordinates anddiameters of all supply and leadaway pipelines including those of ventilation system and alsodrawing of covering built into the equipment for exhaust of all atmospheric emissions.

If it is required to provide for additional free space to use for equipment repair or change, anarea to be used for this purpose shall be indicated in the installation drawing.

Based on the above drawing and data, the Customer shall prepare final drawing offoundations and, if necessary, send it to the Supplier for further adjustment showing relationbetween foundation and equipment.

The drawings that show this relation shall1) be sent to the Customer together with final documentation;2) have precisely defined leveling and securing points. If the Customer intends to place

cabinets and auxiliary equipment on entresol, he shall inform the Supplier about this by sendinghim entresol arrangement chart relative to foundations of the equipment.

Moreover, if the Customer envisages that some system parts such as presses or systems ofleadaway pipelines from the equipment are to be located outside the building, he shall inform theSupplier of this and at the same time submit the building layout with indication of possible outsideoverall dimensions. If it is necessary to provide for an exhaust plant assembly the following datashall be turned over to the Customer:

1) pollutant type and its mass before and after purification;2) exhaust outlet position; flange dimensions;3) flow rate and pressure at the exhaust outlet.If provision is made for exhaust areas only, the Customer shall be informed of1) their location and dimensions of the connecting flange;2) passage capacity of exhausts: flow rate, resistance;3) type of pollutant.

4.6.6. Instructions and manuals for installation, operation and maintenanceOperation and maintenance manuals shall include:1) equipment operation manuals;2) preventive repair schedule3) instructions and explanation of probable peculiarities concerning the repair and

replacement of apparatus or its parts;4) instructions on set-up and start-up;5) list of rapidly wearing out parts and units;6) replacement intervals for rapidly wearing parts;7) inspection intervals;8) location of filler necks, outside lubrication points and type of lubrication to be required;9) location of fluid level indicators, feed points, drain points, filters, magnetic devices etc.

which require constant inspection or maintenance;10) repair manual for electric, hydraulic and pneumatic circuits;11) maintenance, repair, adjustment manual for adjustable elements of the machine with

required free-hand drawings;12) recommendations on special repair;13) list of special tooling for repair and maintenance;14) maintenance instructions for quick-detachable devices to be used to install tooling in

operation position;15) safety precautions.In addition, instructions for diagnostics of major potential failures shall be provided.Instructions shall enable quick troubleshooting as well as facilitate repair works.It is necessary to indicate those safety devices that are usually passive and require regular

checking of their function.



Maintenance manuals for electronic apparatus shall contain all information necessary forinstallation, adjustment and set-up of all devices and units. If protection conditions change duringrepair works, special indications shall be given concerning potential hazard. Repair chart shall bedrawn-up including all necessary instructions.

4.6.7. Tool set-up chartsTool set-up chart shall contain all information by position and by element as to machining

parameters (cutting speed, feed, stroke length, tool operation cyclogram, adjusting dimensions, toolfailure monitoring, dimensions and roughness of the machined surface, base elements and surfacesfor each passage), amount and type of coolant to be used to allow the Customer to carry out quickand accurate evaluation of means to be used.

Each chart can represent one or two working places or positions. The chart shall clearlyindicate type and shape of a tool including fixing system suitable for appropriate tooling.Consequently, each chart shall include the following:

1) cutting tool to be used, auxiliary tool (including cutter inserts and grinding wheel arbors),diamonds, all types of abrasive and other tools such as electrodes (with appropriate holders), exactname of the Supplier, tool drawing number or Supplier’s catalogue number for the standard tool.The Supplier shall adhere to the uniform dimensions indicated in OTU-5-2000, OTU-6-2000;

2) data as to the machining of certain cutting tools and equipment units;3) schematic designation of monitoring and clamping tooling for the workpiece to be

machined; conventional signs recommended in OTU-5-2000, OTU-6-2000 shall be used for thispurpose.

All the required data shall be put in tables as shown in Fig. 36, 37, 38.



Operating data MachineDescription of functions Time, min

available used

Part movementPilot time of positionMachining time

EfficiencyParts per cycle100% %

offeredHourly outputrequired

Operation data | HeadType of head In position Outside

Time, minCycle of head Strokemm

Feed mm/minavailable used

Rapid advanceOperation

Sparking outRapid return

Total time of head

Fig. 36



Cutting tool or insert DrawingTableReferenceTool denominationOperation to be performedN° of axis to be machinedMax diameter to be machined mmRPMCutting speed m/minNumber of cutting edges nAdvance mm/revFeed mm/minTotal stroke mmCutting depth mmCoolantWheel DrawingTableReferenceSpecificationWheel denominationMachining to be performedMax diameter to be machined mmWheel dimensions mmWheel RPM mm/secCutting speed m/secAdvance m/revWorkpiece RPMRemoval mCoolant

Fig. 37

DrawingTable

Dressing tool of grinding wheel

ReferenceWheel denominationSpecificationDressing typeDressing modesDepth of the removed defective abrasive layer per dressing cyclemmNumber of runs (cycles) while dressing nDressing depth per each run mmValue of longitudinal feed, by dressing cycle , mm/min or m/secDressing tool RPM rev/min

Fig. 38



4.6.8. Drawings of tools and process tooling4.6.8.1. All tools except for those for which special written deviations approved by AVTOVAZ areapplicable, shall meet the requirements shown in OTU-5-2000, OTU-6-2000. In any case theCustomer shall receive working drawings for all standard and special tools including drawings oftools not indicated in OTU-5-2000, OTU-6-2000.4.6.8.2. Every change of a purchased item is to be supported with reworked drawings which shallbe submitted by the Supplier. During the agreement the Customer shall advise the Supplier hisregistration numbers for all the tools; The Supplier shall use these numbers in the final technicaldocumentation. The tool shall be marked by the Supplier with this number.

4.6.9. Specifications on sets of spare parts for warranty period and 10000hours of operation

4.6.9.1. List of spare partsList of spare parts shall be prepared in two packages, the first one specifying parts needed

for operation during the warranty period. These spare parts shall be delivered by the Supplierwithout additional payment. List of spare parts for 10000 hours of operation after the warrantyperiod is prepared separately. This list shall contain the following information: part name, type,brief performance characteristic, the manufacturer name, order number, the quantity mounted on theequipment, quantity offered for the purchase, unit weight and columns for the ordered quantity andits cost.

4.6.9.2. Spare partsThe Supplier shall indicate on the drawings rapidly wearing components. The following

shall be specified for these parts:1) part name2) quantity of such parts mounted on the equipment3) first set4) spare parts for 10000 hours of operationAs an example there is a list of parts subject to wear most:1) pneumatic and electric screwdrivers2) mechanical screwdrivers3) chains4) belts5) elements of tooling6) roller bearings7) electromagnetic couplings and brakes8) mechanical couplings and brakes9) ropes10) hinged joints11) differential gears12) gaskets13) gears14) toothings15) grinding spindles16) boring spindles17) reducers18) overruning clutches19) cloth, rubber bellows20) rotary tables21) speed regulators. The Customer has the right to request working drawings of any other component whether it

is included or not in the list of rapidly wearing parts.



4.6.9.2.1. The spare parts for maintaining of the equipment serviceability during 10000 hours afterthe warranty period are supplied for extra charge.The amount of spare parts shall tentatively make 5 % of total expenses for the equipment ordered.4.6.9.2.2. Tools providing the equipment operation for 1000 working hours shall be supplied uponagreement with the Customer. The amount of tools to be supplied shall approximately constitute 2% of total expenses for the equipment purchased.

4.6.10. Lists of purchased itemsThe list of purchased items shall cover all purchased items of the equipment including

possible tools and tooling with indication of their quantity by unit of equipment.All sufficient and relevant data shall be included in this list for probable ordering of the

specified items from the manufacturer, indicating the supply document.

4.6.11. List of tools and special tooling sets for maintenance and repair of theequipment

Rapidly wearing spare parts for warranty period and also special tools and tooling sets formaintenance and repair of the equipment by the Supplier shall be supplied without extra charge.

1) The set of special tools and tooling sets for maintenance and repair of the equipmentshall consist of the following:

1) special fitter’s and mounting toolsimplements for equipment disassembly and assembly2) special oil filling equipment3) special measuring instruments4) special devices, instruments and tooling needed to carry out maintenance and repair of

the equipment including electronic control systems.

4.6.12. Drawings of mechanical units of equipment4.6.12.1. Final drawings and diagrams of the equipment and drawings of movable parts of

the equipmentFinal diagrams shall include:1) working drawings (assembling and detailed drawings) of standard and special tooling,

including multispindle heads;2) drawings of units and parts of all moving equipment sections open to wear heads;Each component of such sections shall be numbered. Purchased parts shall be indicated inthe assembling drawings (original parts and those modified by the Supplier);3) general schematic drawing for complex equipment indicating assembling positions as per

items 1) and 2).

4.6.13. Documentation for electrical equipmentDocumentation for the electrical part of the equipment shall be compiled with consideration

of IEC-204 standards of the International Electrotechnical Commission or GOST 27487-.4.6.13.1. List of the documents to be supplied with the equipment and also at the stage of

engineering project agreement shall contain the following:1) principle electric diagram (diagrams of current-carrying circuits)2) list of electric elements3) diagram of external connections4) diagram of electric equipment arrangement in control cabinets, panels; general view of

the machine5) cable assignment record6) cyclogram7) when programmable controllers are used:- printout of the user program with comments;- input, output and marker list indicating functional designation;- list of cross references;



- printout of diagnostic program with comments;- description of special subprograms and functional blocks8) printout of the user program with comments - for special microprocessor units

9) contents of cell memory with comments - for all devices containing elements of read-onlymemory.

10) diagrams for additional built-in electric and electronic devices with individual functions11) documentation to be required for repair of electric modules and systems including

principle electric diagrams (internal diagrams of current-carrying circuits), mounting electricdiagrams, component specifications, service and set-up description and instructions.

12) catalogue data as to electric and electronic components13) documentation on service equipment14) list of spare parts for 10000 working hours15) diagrams of instruments and measurement channels (Fr imported instruments)16) documentation for set-up and repair of instruments (manuals)17) descriptions and instructions on maintenance, setting up and adjustment of instruments.Documentation specified in items 1, 2, 3, 4, 5, 6, 14 shall be presented at the stage of

engineering project agreement; however, only samples of documents can be sent instead of some ofthese documents subject to the Customer’s consent.

4.6.13.2. Principle electric diagramPrinciple electric diagram is the basic document on electric part of the equipment and it shall

cover all current-carrying circuits in full. This diagram shall be uniform for all the equipment andindicate all principle (active) elements. Principle electrical diagram shall be made withconsideration of IEC-113 requirements of the International Electrotechnical Commission.

The information and elements of the diagram shall be arranged in the following order:- brief contents on the arrangement of diagram individual elements indicating process or

design denomination of the equipment section and sheet number;- general information on the diagram make-up, explanation of accepted conventions and

brief performance specifications of the electric equipment;- power section including the input (main) switch, locking circuits, illumination, sockets,

transformers, protection circuits, power supplies, built-in electronic modules supply, electricmotors, power section of drives;

- individual large electronic modules (frequency converters, drive control units, CNC units,central microprocessor devices, complex measuring and amplifying devices and others);

- relay control circuits;- control circuits made with employment of programmable controllers including I/O

modules and monitoring and controlling elements connectable to them;- CNC I/O modules, if CNC is used;- additional information, for example, configuration of the programmable controller, CNC or

other complex device with indication of inter-modular communications.Small electronic blocks (rotation, voltage checking, temperature checking, braking units,

different special-type amplifiers and others) can be located in places where they are to be used.The arrangement order of diagram elements can differ from the above in the event that it is

more convenient for arrangement and understanding of the electric diagram.The diagram shall be outlined at the beginning of a normal automatic cycle with

disconnected main and auxiliary switches. Relay circuits of control shall be sketched in compliancewith the process operations. Signalling system shall be shown individually. When programmablecontroller is used, elements connected to inputs/outputs shall be grouped according to the principleof operation sequence of the equipment units. At first, general control circuits should be outlined(operating mode control, auxiliary system start, interlocking system effect, etc.), then elements ofcontrol over individual units or stations in the process order and followed by signalling elements.

With combined diagnostics available, a complete list of diagnostic messages must bepresented.



Diagnostic part of the program can be shown in any form. However, it shall not influencethe managing program.

1) Conventional graphic displays in diagramsConventional graphic displays of elements in electric diagrams shall be made with the help

of symbols as recommended by IEC-117 standards. It is allowable to use the Supplier’s nationalstandards developed on the basis of IEC recommendations. Explanation of symbols to be used shallbe attached to the electric diagram.

2) Conventional designations of elementsEach element shown on the principle electric diagram shall have a conventional designation

symbol. Conventional designations of elements shall correspond to IEC-113 standards or GOST2.710-.Generally the element designation consists of the main || 3 || and additional alphanumericblocks || 1 ||, || 2 ||, || 4 ||.

Structure of the conventional designation of an element for the general case.

= 1 + 2 − 3A 3B 3C : 4

Mandatory section additional Additional blocks ---------------------------------------- block

main block

On the left of the main block there is a designation of the device section (first goes the largersection || 1 ||, then goes the smaller section || 2 ||), which contains the given element, for example,number of a station or position, number of a head or unit. On the right of the main block there is anaddress for switching of the given element || 4 ||. The main block is a combination of element typedesignation || 3A ||, index (order) number || 3B || and function to be performed || 3C||. The additionalblocks || 1 ||, || 2 ||, || 4 || and function block || 3C || are not mandatory parts in the structure of theconventional designation. Element type designation || 3A || may consist of one or two letters as perTable 4. One-letter designation can be used when two-letter designation is not provided in Table 4for the given element. Index number of an element || 3B || within the limits of the device section ||2||shall increase with the increase of ordinal number of the technical documentation sheet; and withinthe sheet limits it shall increase from left to right and from the top down. In the absence of theadditional blocks || 1 || and || 2 || the index (order) number || 3B || shall be through for all equipment,i.e. have uniform ordinal numeration. It is recommended to use the appropriate I/O designation asan index number for elements to be connected to I/Os of the programmable controller. Table 5shows letter codes for designation of element functions || 3C ||. When break-down of thealphanumeric block into groups is required, the dot can be used.

If necessary, different designations other than those covered by Tables 4 and 5 are allowableto use. In this case they must be explained in the documentation for the installation (for example, onthe diagram field).



Table 4Conventional designation of the element type

One-letterdesignaton

Two-letterdesignaton

1 2 3 4A

B

CD

E

F

G

H

Device (general designation); amplifiers,controllers; units and blocks forming aconstructive device but having no otherletter designation in this table

Converters of non-electric values toelectric values and vice-versa (except forgenerators and power supplies)

CapacitorsIntegral circuits, binary cells, delay andmemory elements

Other devices: heater devices, lightingunits, photo-barriers, conditioners

Safety devices: fuses, dischargers,adjusting protection switches, Bimetaland magnetic disconnectors

Generators, power supplies

Indication and signalling devices, opticaland acoustic information instruments

LoudspeakerMagnetostrictorIonizing radiator detectorSelsyn-receiverTelephone (capsule)Synchro-transmitterHeat sensorPhotocellMcrophonePressure indicatorPiezoelementRotation frequency sensor(tacho-generator)Sound pick-upVelocity-type transducer

Analog ICDigital ICLogic elementMemory element

Delay elementHeater elementBulb

Explosive cartridgeCurrent protectionelement, inertialessCurrent protection inertialelementFuseVoltage protectionelement, discharger

Battery

Sonic signallinginstrumentSymbol indicatorLight signalling instrument

BABB

BBEBFBCBKBLBMBPBQBRBSBY

DADDDSDT

EKETFA

FPFA

FP

FUFV

GB

HAHGHL



Table 4 cont'd 1 2 3 4

K

L

M

P

Q

R

S

T

Relay, contactors, starters

Inductance coils, throttles

Motors

Measuring and testing, analog and digital,indicating and recording instruments anddevices, clocks, oscillographs

Heavy-current disconnectors: power andseparating switches, protection switchesin main current circuits, sectionalizingswitches

Resistors, fixed and adjustable set-upresistors, potentiometers, measurementresistors and shunts, starting and brakingresistors

Switching devices in control circuits,signalling and instrument circuits;switches and selectors, numbered,decadic and coded switches; push, rotaryand light buttons; limit switches, mastercontrollers; proximity switches,contacting and contactless non-analogpressure, temperature, level pick-ups

Transformers; current and voltagetransformers; autotransformers

Current relayIndicating relayElectric thermal relayContactor, magnetic starterTime relayVoltage relay

AmmeterPulse counterFrequency meterActive energy meterReactive energy meterOhmmeterRecording instrumentClock, time meterVoltmeterWattmeter

Automatic circuit breakerwith electromagnetic andthermal protectionShort-circuiting switchDisconnector

Thermal resistorPotentiometerInstrument shuntVaristor

SwitchButton switchNon-power switchindicating the protectionconditionSwitch to be actuated by:- level-pressure-position (limit switch)- rotation frequency- temperature

Current transformersElectromagnetic balancerVoltage transformer

KAKHKKKMKTKY

PAPCPFPIPKPRPSPTPYPW

QF

QKQS

RKRPRSRU

SASBSF

SLSPSQSRSK

TATSTV



Table 4 cont'd

1 2 3 4U

W

X

Y

Z

Communication systems, modulators,converters of electric values into electric,analog-digital and D/A converters,coding and decoding converters,optoelectronic switches

VHF lines and elements, aerials, doubletsof parabolic-reflector aerials,USW-regulators, light guides

Contacting connections, terminals, plugs,sockets, terminal strips

Mechanical devices with electromagneticdrive

Terminals: PC & IC active frequencyfilters; tone controls; dampers;limiters, capacitors

ModulatorDemodulatorDiscriminatorCurrent-frequency,voltage-frequencyconverter and vice-versa;inverter

CouplerShort-circuiting switchDoubletPhase shifter, transformer,non-uniformityAttenuatorAerial

Current collector,Sliding contactPinSocketDismountableterminal connectionHigh-frequency connector

ElectromagnetBrake withelectromagnetic driveCoupling withelectromagnetic driveMagnetic chuck or plate

LimiterCrystal filter

UBURUIUZ

WEWKWSWT

WUWA

XA

XPXSXT

XW

YAYB

YC

YH

ZLZQ



Conventional designation of the element functionTable 5

Letter designation FunctionalityA Auxiliary functionD Movement direction (forward, backward, lifting, lowering,

clockwise, counter-clockwise)C CountD Differentiation

F ProtectionG TestingH Signalling, communicationI IntegrationK Pulse modeM Main functionN MeasuringP ProportionalityQ Condition (start, stop, limit)R Return, erasure, resetS Memory, recordingT Time function, delay, synchronizationU Speed, acceleration, brakingW AdditionX MultiplicationY Analog functionZ Digital function

3) Marking of electrical connection linesAl line of electrical connections shall have digital or digital-letter marking. Conductors and

terminals connecting them and having equal potential shall have uniform marking.Through marking shall be used for all the equipment, with the digital designation numbers

increasing as lines of new potential appear on the subsequent sections of the diagram. Forconductors connected to inputs/outputs of the programmable controllers it is allowed to use markingidentical to that of the input/output. Addressing shall be indicated on all broken sections of theelectrical connection lines.

4) The way of indication of electrical devicesAll electronic units or electronic control systems shall be completely shown in principle

electric diagram. In doing this it is necessary to be guided by the following.The electronic block shall be outlined in the form of a rectangular with indication of all

external electrical connections through designated joints or terminal blocks. Internal connectionsbetween boards and elements shown in combination are not to be indicated.

When using complex electronic systems including microprocessors with a large number ofexternal connections the spread indication method shall be employed. In this case boards or I/Omodules are to be arbitrarily outlined separately in the form of a rectangular in order of increasingchannel numbers with each board being shown on one sheet. When the display on one sheet is notpossible, partial display of one board or module is allowable on several sheets.Communication with the central microprocessing device and internal power circuits conventionallyare not shown. The central microprocessing device shall be depicted in a certain place completely orin combination with the power supply. If the central unit has additional communications with otherinternal devices, all these communications shall be shown.

Each electronic element displayed on the diagram in the form of a rectangular shall haveposition designation.

Circuit diagrams of the internal device shall be outlined individually according to item4.3.3.1., subitem 11.



5) Information to be contained in principle electric diagrams :- each element performing monitoring, control, signalling, influencing the operation of

power devices and performing other functions shall have an inscription explaining the elementfunction. Such elements are: limit switches, various transducers, buttons, electric, hydraulic andpneumatic elements, electric motors, electric and electronic blocks and modules, time relay startersand other elements;

- voltage value, frequency; power circuit polarity for direct current shall be indicated inevery sheet where they are present;

- short specifications shall be given for individual elements, namely: voltage, power andRPM for electric motors; power and voltage for transformers; voltage and current for powersupplies; power rating of the tripper for circuit breakers; rated parameters for separately placedelectronic components (capacitors, resistors, potentiometers etc.);

- for elements depicted by the spread method, such as relay coils and their contacts,automatic circuit breakers and their block-contacts etc., direct and return address shall be shown;

- each power supply unit or transformer and also each supply line shall have indications ofcircuits they feed;

- it is recommended to divide the drawing field into digital-latter areas for convenience inusing the diagram and more exact address indication.

4.6.13.3. List of electric elementsThe list of electric element shall include all elements shown in the principle electric diagram

and contain all data necessary for ordering spare parts.The list of elements shall be made in the form of a table and contain the following

information:- conventional designation as per the principle electric diagram;- element denomination;- -type;- brief specifications;- manufacturer’s name and number for ordering;- quantity of elements mounted on the equipment.Elements shall be listed in alphabetic order as per conventional designation.The list shall cover all elements including those arranged on the equipment board (motors,

limit switches). Motors complete specification and design shall be indicated. For hydraulic andpneumatic equipment designation as per diagram shall be given and also element denomination,electrical characteristics; and reference shall be made to the documentation (specification)containing other data of an element.

4.6.13.4. Diagram of external terminal connectionsThe Diagram of external terminal connections shall cover all links between electric cabinets

and on-board electric elements of the equipment through terminals and connectors that connectelements by means of cables and wires.

At first, a simplified diagram must be presented showing the arrangement of all terminalboxes, terminal blocks and joints on the equipment and in electric cabinets. Then all terminals andjoints of electric cabinets must be shown with indication of the address of external communication(terminal block or connector number), cable number or wire harness number, cable core number,connector marking and contact number. It is allowable not to show the internal address of anelement located in the electric cabinet. Then connections between intermediate distributingterminals and connectors are to be shown. Finally, links are shown between terminals andconnectors on the equipment and on-board elements of control and signalling, which shall also bedisplayed graphically. Cables and wire harness are to be shown with a thickened line whichbranches at the terminal block of a connector or electric element.

The diagram shall indicate specifications of cables and wires (number of cores, wire gauge,brand).



4.6.13.5. Drawings showing arrangement of electric equipment in control cabinets,on panels, and on general view of the machine

The arrangement drawings shall display the electric equipment arrangement with indicationof conventional designations of elements as per the electrical schematic diagram.

All onboard electric elements, terminal boxes (terminal blocks), control panels, separatelylocated control units etc. shall be displayed in the form of simple geometrical figures on thesimplified general view of the machine.

Control panels shown in the drawing shall have an outline of the control devices andinstruments mounted on it, with inscriptions indicating function and colour. Panel overalldimensions shall be indicated.

For electric cabinets it is necessary to indicate arrangement of electric apparatus on panels,arrangement of terminal blocks, connectors, coolers and other elements and also overalldimensions.

4. 6.13.6. Cable connections tableCable connections table shall contain all data as to cables and wires connecting terminal

blocks and connectors of electric cabinets with terminal blocks and connectors on board theequipment and onboard apparatus. Cable connections shall be presented in the form of a tablecontaining the following information:

- cable (wire) designation (number);- outgoing address;- incoming address;- number and cross-section area of cores;- length;- cable type, design.

4.6.13.7. Cyclogram represents a time diagram indicating starting sequence of power units(actuators) and control elements.

The cyclogram shall show states of electric and electric-hydraulic-pneumatic power unitsoperating in a cycle and also states of limit switches, transducers, pressure relays and other elementspredetermining the machine movements. The cyclogram shall indicate movements or operations tobe performed by mechanisms and designation of positions of power and control elements accordingto the principle electric diagram.

4.6.14. Diagrams of pneumatic, hydraulic systems and of lubrication, coolingand fuel gas supply, etc.

ISO R 1219 table symbols shall be used in these diagrams. Alongside the conventionaldesignation, symbols as per item 5.4.3. shall be indicated.

All pipelines shall be assigned with an ordinal number; communicating pipes shall bemarked with a common symbol if there is no device inserted between them.

These symbols shall be different from those marked by the manufacturer on connectingholes of devices. Parameters to be measured shall be indicated in points of measurement.

Diagrams shall display the apparatus in a position when the equipment does not operate atthe beginning of a cycle and with the system under pressure.

Electric limit switches with a hydraulic or pneumatic drive shall be shown using letter-digital designations specified for electric diagrams.

Inner circuits of multiple connectors shall also be shown in graphical diagrams. Thesecircuits shall be separated with dividing lines.

Besides, diagrams shall contain the following information:1) pipe dimensions (outer diameter and thickness)2) pipe material3) diameter of pistons and rods, stroke length and the required operating force4) output per minute or per revolution; required torque of each hydraulic or pneumatic

motor



5) capacity in litres or kg/min and rotation direction of pumps or compressors6) power, in kW, RPM and drive type of each pump and compressor7) adjustment pressure (including working pressure) of pumps and compressors8) set-up values of various instruments and cntrol equipment (pressure relay, termometers

etc.)9) type and degree of cleaning of filters to be used10) tank capacity11) type and viscosity of recommended fluids12) fluid flow rating (only for lubrication circuits)13) heat exchanger specifications14) drain flow rate, pressure, type, temperature and contamination15) pressure of accumulator precharge16) characteristics of lubrication points and their arrangement on the equipment17) description of power unit specific functions and indication of appropriate direction of the

displacement during the working cycle.



5. TECHNICAL SPECIFICATIONS

5.1. General specificationsThe Supplier shall guarantee that multipurpose and special equipment, transfer lines, etc.

provide specified accuracy and roughness of the machined parts and have process accuracy margin.Utilities consumption rates of process equipment shall correspond to state-of-the art level

achieved by leading foreign and domestic companies developing similar equipment.Manufacturing methods and processes and the equipment shall meet the requirements of ISO 9001-

91 GOST 12.3.047-98.

5.1.1. Units of measurementUnits of measurement shall be as per GOST 8.417-. The standard binds to use units of

measurement as per International System (SI) and allows the application of units which are notincluded in SI system but which are necessary.

5.1.2. Structure of equipmentThe equipment structure shall meet the requirements as to rigidity, resistance against

deformation in order to allow the dynamical stability to guarantee the production of parts.5.1.2.1. Belts and chains Refer to OTU-2-2000, item 5.3.5.1.2.2. Sealing elements and anti-friction bearingsRef. OTU-2-2000, items 5.1., 5.2.

5.1.3. Dismembering and transportationThe equipment bed shall be provided with eyes or holes appropriately arranged for even weight

distribution to perform lifting and transportation. If the equipment dimensions do not allow forhandling it as one unit a machine design shall provide the possibility for easy dismembering as wellas easy mounting.

5.1.4. RepairAll units of the equipment shall be designed and manufactured with consideration of their

subsequent repair and replacement which is to be performed without complicated disassembly.Particular attention shall be paid to mounting of bearings, couplings, belts, chains, gaskets, electrical,hydraulic and pneumatic equipment, etc. With the Customer's written consent appropriate workingplatforms shall be provided for performing works at height.

Circular grinding machines shall have maintenance platforms to facilitate wheelreplacement.

Transfer lines as well as welding presses shall be equipped with detachable selector keyswitches with an automatic spring return in order to exclude the devices interlocking guards as well as limitswitches of movable platform latches to provide the return of drives to their original position and theexecution of movements in manual cycle.

These selector key switches shall:- be located on both sides of the plant in places which ensure maximum visibility;- operate only with movable platform latches in fixed position.

5.2. Production environment conditions

5.2.1. Environmental conditions and the operation limitationsIf the Customer does not put forward additional instructions the equipment shall be designed

for normal operation under the environmental conditions as per GOST 12.1.005, sanitary requirementsfor microclimate of production areas, SanPin 2.2.4.548-96:

1) Temperature.Stipulated environmental temperature varies within the range of 0°C to +40°C. Successful

performance of the equipment shall be provided at the temperature ranging from +5°C to +40°C, theaverage temperature within 24 hours being less than +35°C.



2) Height above sea levelThe height above sea level shall be less than 1000 m.3) Atmospheric conditionsAir shall not contain inadmissible amount of dust, acids, corrosive gases, salts.If there is an environmental requirement on the part of the Supplier, the Supplier shall specify

precisely the environment parameters and set the deviations.If there is no special requirement the latter is determined as per GOST 12.1.005-88, with the

temperature ranging from +5°C to +40°C and humidity from 0 to 90 % at t = +20°C.The equipment shall show successful performance at relative humidity of 90% at 20°C. It is

always necessary, with the view of control, to bear in mind possible formation of condensate with thetemperature change.

5.2.2. Conditions of installationIf all the equipment tooling or a part of tooling should be installed by the Customer's personnel

and if it is to be installed in specific conditions (in inclined position, when vibrated), these specialrequirements shall be specified while ordering.

5.2.3. Violation of conditions of production environmentIn the event the equipment affects the conditions of environment where it is to be installed

(heat, humidity, etc.) the Customer shall be provided with all necessary information for possibleinstallation of a conditioning system there.

In any case the equipment shall meet the following requirements:1) contamination of air in the working areaConcentration of harmful substances in the working area shall not exceed the limits specified in

GOST 12.1.005 and industrial hygiene standards, GN 2.2.5.686-98.To comply with these requirements, emissions per unit of equipment shall not exceed the

amount of similar existing equipment or a value determined by formula:M max = 5 MPC (maximum permissible concentration), (mg/s)In case of exceeding of the specified emission limits provision shall be made for the

following:- maximum possible sealing of the equipment and contaminated air exhaust system;- maximum possible confinement of material (metal) processing/machining area; in the

enclosure area there shall be a container for scrap collection;- as an exception, an open type exhaust is allowed in the form of a panel or funnel; local

exhaust flange have to be shown beyond the machining bounds, with its coordinates and dimensions,amount of exhausted air, exhaust efficiency, resistance to air passing, exhaust temperature, coordinates anddimensions of the connector branch pipe, head (pressure) loss value;

- in-building materials-handling transport shall be of electric type. As an exception, gasolinecombustion engines may be used, fitted with catalyst converters.

The equipment where coolants and process lubrications are used has to be provided with localexhaust devices such as covers to be ventilated in the metal machining area (hoods, uniform suction panels,etc.);

2) Soil contaminationSpecial collector bins shall be installed where waste spillage is possible.If the wastes are of hazard category 1 and 2, then the collectors shall be sealed.In case of the waste causing air contamination the requirements of item 1 shall be met.3) The equipment surface temperature shall not exceed + 45°C;4) Non-ionizing electromagnetic fields (EF), emanation and radiation shall not exceed

maximum admissible levels, as follows:- heat radiation intensity in compliance with GOST 12.1.005;- maximum permissible Coulomb force at the working place is 21,2 kV/m;- maximum permissible 50 Hz Coulomb force in the working area is no more than 5 kV/m;- permissible irradiation dose for the human body: category A - 2.9 Mrem/h, category B - 0.24

Mrem/h.



5) Contamination of waterThe composition of drain water shall be described in technical documentation to be

submitted for the Customer's approval. Absolutely innocuous product for draining shall beguaranteed as a mandatory standard.

6) NoiseNoise pollution shall be confined within material and part machining area, noise intensity to be in

compliance with the requirements of Table 7 (GOST 12.1.003, GOST 12.1.035, GOST 12.1.045).Limits of exposure to noise generated by arc and contact welding to be in compliance with GOST

12.1.035.7) VibrationMaximum levels of vibration generated by machines in operation and transferred to the

operator's hands are shown in Table 6.

Table 6Permissible value of rated parameter

Vibrational velocityVibroaccelerationM/sec 10 -2 dB

Geometric mean frequencyvalues of octave bands

Hz

Xp Zp Yp Xp Zp Yp Xp Zp Yp8 1.4 1.4 11516 1.4 1.4 10931,5 2.7 1.4 10963 5.4 1.4 109125 10.7 1.4 109250 -21.3 1.4 109500 42.5 1.4 1091000 85.0 1.4 109

Table 7Purpose of a production area

or territoryGeometric average frequencies

63 125 50 500 1000 2000 4000 8000Noise pressure level, dB

Noiselevel

dB, A

2 3 4 5 6 7 8 9 10

Workstations in production areas 94 87 81 78 75 73 71 69 80

8) Maximum level of electrostatic fields Electric element, V/M50 - for frequency band from 60 kHz to 3 MHz 20 - for frequency band from 3 MHz to 30 MHz 10-

for frequency band from 30 MHz to 50 MHz5- for frequency band from 60 MHz to 300 MHz Magnetic element, A/M5 - for frequency band from 50 kHz to 1.5 MHz0.3- for frequency band from 60 kHz to 50 MHz Infra-sound level at working areas shall not exceed

values shown in Table 8



Table 8Sound pressure level in dB in octave bands with geometrical average frequencies in Hz

2 4 8 16 31.5

Total soundpressure level in

dB, Linear

105 105 105 105 102 110

Maximum permissible levels of vibration generated by machines in operation and transmitted to theworking area are shown in Table 9.

Table 9Geometric average frequencies

of frequency response intervals in HzVibration speed level dB

2 1084 998 9316 9231.5 9263 92

Table 10Average geometrical frequencies of the third

octave band, kHzSound pressure levels dB

12,50016,00020,000

7585

110

Maximum levels of energy flow density are shown in Table 11

Table 11Energy flow density

W/2 MW/cm2

Duration of theworking day

Notes

0.10.1 to 1.01.0 to 10

1010 to 100

100 to 1000

FullNo more than 2 hoursNo more than 20 min

Energy flow density throughoutthe remaining working hours

shall not be over 0. 1 W/m2

9) Possible supply of protective meansAll safety devices used to bring the environment to the above specified levels are the

Supplier's competence even though their assessment required separately from the equipment.Material-handling transport with electric traction only shall be accepted. Combustion engine

transport shall be fitted with catalyst converters, the efficiency with respect to the main fumes (CO, NO2,soot) being no more than 90 %.



5.2.4. Environmental requirementsThe supplied equipment shall meet environmental requirements as per normative documents ofRussia, OTU specifications and subject to agreement with the Customer.

Requirements specification for offer request shall be agreed with AO AVTOVAZ'senvironmental control department.

Project documentation for equipment and process engineering shall have positive opinion ofenvironmental impact assessment by the State Environmental Control authorities.

Process engineering documents shall comprise full set of project documentation for theequipment including the equipment for purification, treatment, disposal and neutralization of allharmful and hazardous discharges into the air, reservoirs and soil.

The following shall be specified in technical documents for the supplied equipment:- quantitative and qualitative description of the composition of the emitted harmful substances

calculation per one unit of products;- degree of purification of treating plants supplied with the equipment.The equipment operation and maintenance manual shall include a section, "Environmental

Control". No ozone-destroying substances shall be employed or supplied with the equipment. The list

of ozone-destroying substances (Appendix 1) is determined by "Procedure for importation to andexportation from Russian Federation of ozone-destroying substances and products containing suchsubstances" adopted by Regulation of the Government of Russian Federation, № 563, of May 8,1996.

The equipment shall meet the following environmental requirements:- minimum environmental effect;- low-waste technology;- maximum elimination of harmful and hazardous substances and materials from the

processes;- utilization of main and auxiliary materials and substances with recycling of their wastes.The equipment that might become the source of harmful emissions (discharges) shall be fitted

with devices preventing emergency emissions (discharges) of hazardous pollutants and with devicesalarming in the event of failure in the confinement of harmful emissions (discharges).

Waste disposal plants/treatment works shall be state-of-the-art and ensure the amount ofharmful emissions (discharges) not exceeding 80 % of similar existing equipment.

Treating plants and equipment shall be fitted with automatic process control system and theinstrumentation to check process operation effectiveness.

All the purchased equipment is subject to agreement with and approval by industrialbuilding design department with respect to its compliance with requirements of productionenvironmental safety, environmental control and construction of process covers and installation oflocal exhaust systems and noise confinement.

5.2.4.1. Atmospheric air protectionIn the event the equipment is the source of atmospheric contaminant emission over 80 % of

maximum concentration limits specified in Section 7 of SNiP 2.04.05-91 the following measuresshall be provided:

Provision shall be made for confinement of contaminants and their withdrawal through thedust-cleaning and gas-cleaning equipment that ensures the required purification.

If the required treating facility is not produced in Russia it shall be ordered and suppliedcomplete with the equipment purchased outside Russia.Dust- and gas-cleaning equipment shall be fitted with the instrumentation incorporated in theprocess automation system.The equipment shall be ordered complete with automatic control and monitoring system.Combustion engines of the process transport and intrashop vehicles shall be fitted with catalystconverters ensuring maximum possible emission control, at least up to the maximum concentration



limit. Procedure to check the effective performance of the catalyst converters shall be specified inthe operation and maintenance manual, as well as replacement interval and methods.The equipment that is fitted with the local exhaust as per item 5.2.3. shall be provided with cleaningmachines ensuring proper cleaning and neutralisation of harmful emissions up to the valuesspecified by the Customer.

The delivery of cleaning machines for these purposes shall be part of the contract. Type andspecifications of cleaning machines is subject to agreement with the Customer. Procedure to checkthe effective performance of the catalyst converters shall be specified in the operation andmaintenance manual, as well as replacement interval and methods.

5.2.4.2. Protection of reservoirsProvision shall be made for employment of recirculating water in water consuming

equipment. When it is impossible to employ recirculating water, the amount and type of water shallbe specified with advance approval by the Customer.

Polluted water shall be cleaned to the maximum on local purification plants before thedrainage to the sewage system, up to the level specified by the Customer.

5.2.4.3. Soil protection. Generation, storage, recycling of industrial wastes.- the amount of accumulated toxic wastes and its collecting shall not exceed maximum

accumulation limits;- collecting of wastes shall be carried out separately (by type, class of hazard, aggregative

state and other characteristics) into special containers to provide for further recycling and disposal;- wastes shall be accumulated in special containers designed for specific types of wastes,

and at specially arranged places.Equipment operation conditions shall provide for minimum possible waste build-up and

recycling after regeneration.Provision shall be made on waste generating equipment for devices (slides, transporters) to

withdraw wastes into places where they are piled and stored or recycled for their further return tothe process cycle.

Detailed description of properties and neutralisation technique or disposal specificationsshall be available for wastes generated in the production and not utilised in the production cycle.

5.3. General safety requirementsEquipment shall be manufactured to existing safety requirements in order to prevent any

possible danger of an accident.

5.3.1. Spontaneous movement of the equipment unitsIt shall be guarantied that no irrelevant factor should cause spontaneous movement of the

equipment units. The following factors are considered irrelevant:- power supply failure;- external magnetic fields;- working pressure deviations;- damage of overground cables and consequent short-circuiting between two conductors.Besides, it is necessary to exclude the possibility of a machine start and restart resulting

from acting on or shifting of any operating controls not designed for starting of the machine.

5.3.2. Self-protective systemsAll instruments which directly or indirectly involved in protection shall have self-protective

means. These devices shall prevent the occurrence of conditions and situations dangerous forpersonnel in the case of possible fault caused by any component of the equipment or peripheralapparatus.

Any fault in the electronic equipment designed to ensure the operator's safety shall stop theoperation in the event the safety is not guaranteed.



If it is an important operating control and absolute safety conditions are to be observed it isimperative that machines have dual-control circuits. This is important and therefore mandatory onthose presses where two remote-controlled breakers installed in parallel should be provided for thecontrol of bake-clutch systems.

5.3.3. Devices and pipes working under pressureIf necessary, the equipment shall be fitted with the systems, devices, vessels and pipes

designed to work under fluid, gas or steam pressure, meeting the safety standards effective at andstipulated by special regulations of the Customer.

5.3.4. Fire and explosion safetyIn case of fire or explosion hazard caused by flammable or explosive vapours or dust

(aluminium, magnesium, solvents) the following shall be provided:- employment of non-flammable materials;- installation of screens to prevent contact between flammable materials and heat sources

in case of emergency;- employment of sealed or explosion-proof electric equipment;- explosion-proof valves both on the equipment and exhaust units when the machining

causes danger of explosion. When coming into action, these valves shall by no meansendanger personnel.

5.3.5. Harmful and hazardous substancesIt is necessary to prevent the inhalation, contacting or taking inward harmful substances. It is

forbidden to use fluids containing polychlorobiphenyl and polychlorotriphenyl on any plant orapparatus including electrical devices (capacitors, resistors, transformers, inductance) and in closedcycle heat-exchangers. If this is impracticable, appropriate safety measures shall be taken.Appropriate instructions and identification marks shall clearly explain the nature of materials andthe hazard they might present.

5.3.6. Interlocking system of the equipment mechanismsWhen the operations of part loading or unloading, adjustment, part change, cleaning repair

and maintenance require that the operator should be inside the equipment or part of his bodybetween the equipment units that might be operated and set in motion, provision shall be made fordevices reliably insuring stationary condition of the machine and providing electromechanical unitinterlock, a safety rope. Besides, appropriate facilities shall be provided to prevent setting theequipment in motion by unauthorised persons.

5.3.7. Protection

5.3.7.1. Protection of units executing any type of movementThe following members shall be completely protected:- transmission of motion (crank mechanisms, pulleys, belts, chains, gears, couplings, etc.);- protruding parts of shafts as well as components projecting from rotating units. Any part

accessible from the operator's place shall be guarded. All members and parts leaving a space lessthan 500 mm beyond stroke limits during movement shall be enclosed.

All members of the equipment which serve for machining shall be isolated or protected tothe extent limited by the machining process. Wherever technically impossible or only partiallypracticable, emergency stop devices shall be installed in accessible places. Where more than onestarting control device is provided they shall operate simultaneously. If machining members mightcause flattening, dragging or have considerable inertia, an effective braking system shall beprovided to ensure their stop at the soonest possible time. Holes of the counterweights for verticaldevices shall be covered to prevent from being used.

Spoke flywheels or those with projecting grips are prohibited to use if these members areactuated automatically. Any member involved in machining and presenting possible injury hazard



shall be isolated with detachable guards incorporating devices interlocked with controls putting theequipment in to operation as well as in the case of motion of heavy masses directly connected to thedangerous movement.

5.3.7.2. Protection of loading/unloading and handling areasEquipment loading and unloading areas shall be protected with appropriate guards (parapets,

grids, hoppers, covers).Loading/unloading or transportation device members which can cause collisions (gripping

and flattening) with stationary parts shall have appropriate protection. Those operators carrying outloading/unloading or those who work in this area shall be protected by means of:

- dual controls;- guards with interlocks;- permanent guards;- platforms (bridges) with interlocks;- photocells.Such guards shall always be approved by the Customer.

5.3.7.3. Spillage and splashesShields and, if necessary, transparent screens shall be provided to protect the operator from

splashes of various fluids or vapours.It is not allowed to use such materials as aluminium or cast iron.

5.3.7.4. Characteristics of safety guardsThe guards shall conform to the equipment specifications. They shall meet the following

requirements:- be rigid in structure (with minimum sheet thickness of 1.5 mm);- have no excessive weight;- be reliably secured;- allow easy installation;- ensure quick repair and adjustment.If these guards are to have openings for adjustment or some other kind of work they shall be

covered by means of hinged doors. The removal of guards and opening of doors equipped withelectrical interlock system shall be performed using hand-tool (screw-driver-key). In the cases ofhigh risk of serious injury an automatic mechanical interlocking system shall be provided in orderto prevent the movement of guard while in operation.

In the case that transparent guards or guards with transparent inserts are required then theemployed material shall have such properties as to maintain transparency over a long period.

Glass guards are not acceptable.The transparent inserts are to be arranged in such a way that would enable their replacement.Netted guards shall have such a mesh size as to rule out any part of human body getting to

dangerous areas or in contact with dangerous machine parts.

5.3.7.5. Supply of guardsThe Supplier shall provide all guards.

5.4. Marking – conventions - identification plates

5.4.1. DefinitionsMarking means indications to be used for identification of the equipment or the equipment

elements to distinguish them.Conventions (distinctive sign) mean indications to be used for identification of apparatus

and elements mounted on the same equipment.Marking can be applied by stamping or on identification plates.Both marking and identification symbols shall be in Russian and in the Supplier's language.



5.4.2. Marking

5.4.2.1. Marking of the equipmentAll the equipment shall have clear marking made in plain view and also remain intact after

the installation of the equipment, the marking containing at least the following data:- manufacturer's name or factory trade mark;- power supply voltage and frequency rating (if several voltages and frequencies are used

it is necessary to indicate each of them individually);- rated value of current consumed per each power source;- manufacturer's serial number or any other initial reference enabling to identify the

equipment;- weight of individual machine.

5.4.2.2. Marking of componentsEach component shall have marking including the following data:1) manufacturer's name or a factory trade mark;2) manufacturer's serial number.Note: Parts to which AvtoVAZ assigned the identification number during final confirmation

shall have this identification number. The marking shall also apply to spare parts.3) electrical parts shall have the following designations:- type and value of operating voltage;- maximum value of current.It should be kept in mind that if an element has a replaceable coil then the marking as per

items 1), 2), 3) shall also be on the coil and item 3) data shall be designated on the fitted coil.

5.4.3. Identification marksThe following components shall always have the identification mark:according to the diagrams:parts;terminals;conductors;pipelines;openings;measuring points on the electrical equipment.The identification mark of the component shall be inscribed on the identification plates to be

permanently affixed near but not on the component except for plates intended for pushbuttons andlights as well as for pipelines and conductors.

2) near openings:- devices with inserted elements;- such devices as throttle valves, metering valves located inside manifolds, mounting plates,

joints. These devices shall have the identification plates. If the opening is not visible the plate shallbe placed as close to it as possible and have the word "hidden" inscribed on it.

3) apparatus using fluids exclusively in its operation shall be marked by ordinal number. Asthis takes place, even apparatus units of the same type shall have different numbers. No marking isrequired on the electric elements which shall have designation of their function written in words(e.g. manual controls, light signalling controls).

On the contrary, marking on all elements connected with the fluids is mandatory even whentheir function designation in words is required.

5.4.4. Identification platesBeside the identification plates with indication of marking and symbols plates specified in

special requirements shall also be attached.



5.4.4.1. Language to be usedAll identification plates shall be in Russian and in the Supplier's language.

5.4.4.2. Material and the way of fasteningIdentification plates shall be made of metal and shall be attached with rivets or screws.

Aluminium identification plates shall be 0,5 mm thick unless otherwise specified or agreed uponand have lettering colour contrasting with the background.

Identification plates used for buttons and signal lamps can be fixed to the clamping ring ofthese elements.

5.4.5. Warning signThe warning sign shall be applied on the outside of the cabinet containing electrical

elements. The sign represents black or red lightning with black border. The lightning is located inthe middle of a yellow field and takes no less than 50% of the total sign surface area. The drawingsof the sign and the lightning are given below. Lightning dimensions: height is l,26 a, width is 0,5a.



Fig. 39

5.5. Components

5.5.1. General requirementsElectrical components shall comply with IEC standards (edition 204 and further revisions)

or with the RF standards and this correspondence shall be apparent from the marking and from thecertificate of the component.

All components shall be manufactured from materials with consideration of theirapplicability in the industrial premises.

They shall be protected from external media existing and having the influence in suchpremises.

It should be noted that the number of component types, including printed circuit boards,ought to be reduced to minimum.

5.5.2. Limitations on applicationAll components shall be used within the limits specified by the manufacturer under normaloperating conditions as well as under the most unfavourable circumstances.

5.5.3. Recommended componentsThe Customer reserves the right to request the Supplier adopt special engineering solutions

or employ certain materials.

5.6. Manual controlsManual controls for the locally produced equipment shall be made according to GOST

12.2.009- item 1.3.

5.6.1. Arrangement of controlsExcept for the selectors of the main breaker disconnection circuit no other manual control

shall be mounted inside the cabinets containing electrical apparatus. All controls that require routineadjustment (performed by the operator) shall be placed on the outside of the electric cabinets or atleast be accessible for adjustment from outside.

It is imperative to observe the following requirements as to the arrangement of the controls:1) they shall be within the operator's reach at his (her) normal working place;2) they shall be actuated by the operator without the need to hang over rotating or moving

parts as well as over the blank that is being machined;3) they shall not impede the operator's usual movements;4) they shall be protected against damages from the outside;5) inadvertent operation shall be excluded;6) they shall have easy access for repair;



7) they shall not rest upon the pipelines unless otherwise specified.In addition:1) the direction of the movement of manual control levers shall be the same as the direction

of the equipment movement which is actuated with these levers;2) pedal control (acceptable only in exceptional cases and when it is indispensable) shall

always be protected from above and on both sides.

5.6.2. Two-hand controlThe type of control that is always subject to approval by the Customer or to be installed at

his request shall meet the following requirements: 1) the equipment shall only come into action through simultaneous actuation of all

pushbuttons and interlock its start in case of time difference between the pushing being over 0,5sec;

2) throughout the cycle or a part of the cycle when a risk of injury is present these controlsare always to be actuated with both hands of each operator;

3) the equipment shall not come into action unless all controls are released in the periodbetween successive cycles.

5.6.3. Requirements for pushbuttons1) start pushbuttons shall not project over the protective casing, their push rods are to be

recessed 2-4 mm below protective casing level; as this takes place, at the Customer'sdemand the operator shall have the possibility to press buttons with the hands in gloves;

2) "stop" pushbuttons shall be outward-projecting;3) emergency stop pushbuttons shall be outward-projecting and have the shape of a

mushroom;4) two-hand operated controls shall be made in accordance with item 1) and spaced at least

300 mm apart from each other; they shall operate with two hands only;5) it is recommended that the controls be mounted on vertical surfaces;6) the lower row of electric control panel pushbuttons is to be located at the height of no

less than 600 mm and the upper row - no higher than 1700 mm from the lower surface ofmachine or platform base. Control panels with the lower row of pushbuttons located atthe height no less than 900 mm shall have at least 30° inclination in relation to thevertical plane;

7) painting requirements are described in item 6.5.2.3.2.;8) pneumatic pushbuttons for cycle start shall always be black.

5.6.4. Control panels1) separate machines: panel shall always be mounted on the machine on the right from the

operator;2) transfer lines: the control panel shall always be mounted on the cabinet body in the most

convenient place to provide the wide field of view of the equipment;3) plants: refer to item 1);4) galvanic plants: dual redundancy should be provided for main measuring instruments

and adjustment pushbuttons on the appropriate panel located in the loading/unloadingarea;

5) control panels for each separate spindle head shall be provided on transfer lines or unit-type machines;

6) These panels should be arranged in the most convenient way for the operator and shallbe directly connected to the main control panel.



5.6.5. Identification plates for the controlsEach manual control shall be provided with an identification plate. In the event that the

direction of operation is not quite evident it shall be specified on the identification plate along withany position the control can be set to. The inscription shall be done in Russian.

5.6.6. Protection from inadvertent actionsAll controls related to working cycle selection, adjustment, setting-up, change of the

direction of the main motor rotation, welding parameter regulation, motor speed adjustment or anyother control which requires attendance of a highly qualified operator shall be separately actuatedwith keys or placed in grouped cabinets and covered with a transparent door to be locked with akey.

It should be noted that in the first case the keys shall be detachable at any position of theselector switch; it is recommended also to have the common key for all devices.

5.6.7. Protection1) Electric shockAll manual controls shall be made of insulating material. If they are made of metal they

shall be by no means under the voltage neither under normal conditions nor when in failure.It is imperative to observe this requirement. None of the following causes such as- metal part deformation;- wire breakdown;- screw loosening;- inner insulation damage;- shall bring these controls under the voltage. In the event the insulated levers are mounted

on metal shafts the latter shall never be under the voltage over 1000 V (peak), they shallbe reliably connected to the grounding circuit which in its turn is to be connected toearth.

2) Elevated temperatures and corrosive liquidsIn the event the controls are to be used to exert control over liquids at elevated temperatures

or over corrosive liquids their handles shall be properly protected to prevent any possible injury tothe operator.

5.6.8. Painting of handles All handles shall be:- black if made of plastic;- chrome-plated if made of metal.

5.7. Pipelines and fittingsGeneral standards are applicable.

5.7.1. Selection of pipesAll pipes shall be made of steel and withstand the working pressure and the temperature of

liquids.Non-welded low-carbon steel pipes are to be used for the following media:

1) superheated water2) industrial water3) compressed air4) nitrogen5) methane6) propane7) liquid fuel



8) diesel fuel9) petrol10) solvents11) paints12) oils or other hydraulic liquids13) emulsions for tool cooling.

Material for pipelines is to be agreed upon with the Customer if they are used to convey:1) steam2) demineralised water3) oxygen4) acetylene5) ammonia6) carbon dioxide7) superheated water8) natural gas9) hydrogen10) hydraulic systems11) Process pipelines as per "Rules of arrangement and safe operation of process pipelines", PB 03-

108-96.Fire and explosion safety requirements in the selection of process pipelines (fuel, solvents,

lacquers, paints) are the following:- pipelines shall be made of steel seamless pipes and meet the requirements of "Rules of

arrangement and safe operation of process pipelines", PB 03-108-96;- pipelines shall be connected by welding except for connections with fixtures and

equipment;- employment of segment branches on pressure pipelines and expansion glands is

prohibited;- mandatory strength test by applying pressure of 1.5 working pressure, but no less than

0.5 MPa.Flexible pipes are only allowed for connection of movable parts and in exceptional cases.

The length of a flexible part of a pipe shall be minimized as required. Employment of plastic pipesis subject to the Customer's prior consent in writing. Pipe cross-section shall prevent:

1) excessive losses of hydraulic energy;2) excessive heat build-up;3) occurrence of cavitation.Standard and improved accuracy pipes shall be used, of the following diameter range: 6, 8,

10, 12, 15, 16, 18, 22, 28, 34, 35, 38, 42 mm.

5.7.2. Installation of flexible pipelinesObserve the following standards while installing flexible pipelines:1) pipeline end mounting brackets shall be arranged vertically; if it is impossible to install

them in the vertical position special supports are to be used;2) the length shall not be over such value that to avoid stretching and squeezing;3) the mounting shall be carried out in such a way that to prevent twisting;4) the arrangement shall be such that to prevent the abrasive wear.In the connection of reciprocating movable parts with a very long stroke (horizontal) by

means of a flexible pipeline, a safety rope and supporting chains protecting pipelines in theirmovement are to be provided.



5.7.3. Pipeline route1) 1) Connections between the equipment units to be dismounted for transportation or

maintenance shall be made on the intermediate fittings and have several offsets. '2) Connections (joints) can only be used in the cases when necessary due to3) pipeline length;4) engineering requirements.5) The dismantling of any pipeline section shall not involve the dismounting of parts,

assembly units or equipment.6) Replacement of a flexible pipeline shall meet the requirements stated in item 3).7) The guards shall be provided to prevent damage by transport.8) Pipelines shall be mounted so as to enable the adjustment, repair or component and

tooling replacement.9) No wear or damage are allowed in operation or repair.10) Pipes crossing the passage-way shall be mounted 2 meters above the floor and have an

easy access. Besides, they shall rest upon solid supports and be protected againstdamages from outside.

11) Connections on the floor level, even under the platform, are not allowed.12) Pipelines within the machine bed are prohibited unless otherwise specified by technical

requirements.

5.7.4. Pipeline supporting bracketsThe pipes shall be properly fixed in order to reduce vibration. The supporting brackets shall

not be welded to the pipes and cause their damage. Maximum distance between two successivesupporting brackets shall not exceed the distance specified in the following diagram (ref. fig. 40).

Fig. 40

5.7.5. Protection of disconnected pipelinesIf the equipment is supplied in disassembled condition pipelines shall be properly protected

by means of plugs and caps. To avoid spillage the liquid shall be drained.

5.7.6. Points of measurementSuch points, if any, shall be clearly marked using symbols related to the pipeline.

5.7.7. Pipeline conventionsPipelines shall have marks used on the diagrams. These marks are to be applied to the

pipeline edges as well as on the appropriate supporting manifolds.When different liquids are in use the dangerous liquid delivery pipe shall be singled out.Standard size of distribution lines (cables and pipes) is indicated in fig. 41.



Fig 41

The mark indicating the pipes less than 1 inch in diameter and the cable less than 35 mm indiameter is applied to an identification plate having 20 mm in height and the length = a variablevalue depending on the denomination of the goods to be pipelined. If the pipe has two diameters themark is applied to the pipeline part with the bigger diameter.

5.7.8. Selection of connectionsPipe-to-apparatus welded connections are not allowed. Welded construction of manifolds is

applicable. If operating pressure in hydraulic units exceeds 17 MPa (170 kgf/cm2) pipe-to-fittingswelding may take place (spherical connections along the inside cone). It is allowed to weld thepipelines more than 2" in diameter located outside of the technological equipment.

The following types of connections are recommended:- for industrial and recirculated water pipe connections " " to be made as per GOST 6357 -

(ISO R49);- for compressed air, nitrogen, methane, propane threaded pipe connections to be made as

per GOST 15763 -(ISO R49);- for oil, diesel fuel, petrol, solvents, paints flange connections to be made as per GOST

19535 -(ISO R49);- for oil, coolant threaded pipe connections to be made as per GOST 15763 - (ISO R49);- for steam and superheated water flange connections to be made as per GOST 19535 -

(ISO, UNI or ANSI);- for all types of pipelines more than 3" in diameter flange connections to. be made as per

GOST 19535 - (ISO,UNI or ANSI);- for pipelines meant for other types of operating mediums the type of connections is to be

agreed upon with the Customer.Hose connections as per Du and connective dimensions shall comply with rigid pipe

connection. requirements. Sufficient space between connections is required in order to tighten them with ordinary

tools.It is not allowed to reduce the conventional passage in connections without technical

justification and approval by the Customer.

5.8. Waste and chip removal

5.8.1. Waste removalIf in the operation cycle the waste is produced it is necessary to prevent it against becoming

trapped between the equipment units. For this purpose it is essential to supply the equipment withchutes or other devices removing the waste to one or several places.



In the event the waste is produced in negligible quantities a door used for regular cleaning isto be provided by the Customer's prior consent.

5.9. Foundation, levelling, fixtures

5.9.1. Supply of fixing elementsLevelling elements, fixing screws and bearing supports shall be included into the volume of

the equipment supply.

5.9.2. Machines with line transportMachines equipped with line transport and intended for machining with coolants shall be

arranged according to the standard diagram as shown in figure 42.The height of bearing supports shall be specified on the final drawing of the foundation. The

height varies in accordance with the distance of the machine axis. All bearing supports which restupon the common beam longitudinally shall be of the same height.

The bearing supports are to be marked with symbols. Identical bearing supports shall havesimilar marking. Symbols applied on the bearing supports shall comply with foundation drawingsymbols.



Installation parts

Fig. 42



5.10. PaintingGeneral standards on acceptance of import equipment

5.10.1. The present "General standards of equipment painting" are applicable to all types of theequipment supplied by foreign companies.

5.10.2. The standards lay down:1) painting colours of outside and inside equipment surfaces as well as signal colours which meet

the safety precaution requirements;2) painting colours of communications (pipelines) according to their function;3) general recommendations for selection of colours for the painting of different types of the

equipment and tooling.5.10.3. Process of painting shall be in conformity with standard techniques of painting of the

equipment used in the importers' countries.5.10.4. The equipment is to be painted with high-quality varnish-and-paint materials.The main painted surfaces shall have gloss not exceeding 55%, having been measured with

photoelectric gloss-metering instrument.5.10.5. The following colours indicated in table 13 are selected as per table IVI "Italian Paint

Industry".

Table 13

Muster - № Farbe Nach RAL - Tabelle

1. 01.131 Egyptian-green RAL 60112. 1277 Canary-yellowRAL RAL I02I3. 01.122 Orange RAL 20004. 2114 Red RAL 30005. 881 Smoke-grey RAL 70386. — White RAL 90167. 1402 Blue RAL 50178. 2233 "Positano"-dark blue RAL 50059. 841 Sakhara sand-cream RAL 101410. - Black RAL 901711. - Silvery RAL 9006

General standards on acceptance of CIS-made equipment5.10.6. The present "General standards on equipment painting" cover all types of the equipment

supplied by CIS enterprises.5.10.7. The standards lay down:- painting colours of outside and inside equipment surfaces as well as signal colours which meet

the safety precaution requirements;- painting colours of communications (pipelines) according to their function;- general recommendations for selection of colours for the painting of different types of the

equipment and tooling.5.10.8. Process of painting shall be in conformity with standard techniques specified in OST

2N06-2-77 "Painting. Colours. Technical requirements", OMTEM 7312-010-78 "Painting of metalsurfaces", OTU 37-002-0001-76 "Development and manufacturing of special production equipment",STP 37.101.7009-78 "Painting of equipment. Colours. Technical requirements".



5.10.9. The equipment is to be painted with high-quality the least fire hazardous varnish-and-paintmaterials.

5.10.10. The main painted surfaces shall have gloss not exceeding 55Z, having been measuredwith FB-2 photoelectric gloss-metering instrument.

5.10.11. Colours for the painting of equipment surfaces and shade numbers are selected from thefile of standards "Colours of GIPI LKP varnish-and-paint materials" and STP 37.101.7009-78.

When painting the equipment and selecting the enamels tables 13, 14 of the present technicalrequirements are to be followed.

It is allowed, by agreement with the Customer, to apply other types of enamels having qualitativeparameters as good as those recommended in Table 15.



Table 14

Equipment and tooling groups Description of unitsOrdinal number

as per VAZ ShadeTable.Colour

Note

1 2 3 41. Cabinets with electric apparatus, control panels,terminal boxes, electric motors

No 5Light grey

2. Inner surfaces of electric cabinets and controlpanels, terminal and junction boxes

No 6White

3. Inner surfaces of electric cabinet doors, innersurfaces of tanks

No 4Red

4. Handrails, guards, parapets of repair and mountingplatforms of high machines

No 2 yellowNo 10 black

In alternate strips inclined at45-60° angle or straight lines(vertical or horizontal) ofequal width.

1. All the equipment andtooling

In some cases it is admissibleto substitute black for darkblue No 9



Table 14 cont'd1 2 3 4

1. All parts of machines, plants, presses (beds,frameworks, bases, spindle stocks, panels, bodyparts, servicing platforms) except for those indicatedbelow

No 1Pistachio

2. Guards of abrasive wheels, mills, gears, drivingbelts, circular saw chains, etc., moving parts of theequipment dangerous for personnel (slides, rotatingchucks, etc.).

No 2Yellow

3. Movable parts of a machine, which protrudebeyond the machine overall sizes during themovement, guards for dangerous areas.

No 2YellowNo 3Orange-yellow

2. Metal-cutting, plating,welding, washing machines,forge-and-press equipment,plants

4. Inner surfaces of feed boxes, speed-change boxes,electric cabinet doors, etc., background for high-speed parts and mechanisms (recesses for detachablegears, lead screws, etc.); inner surfaces of body parts,hydraulic and lubrication system tanks, filler caps.

No 4Red




Table 14 cont'd1 2 3 43. Heat-treatment equipment Surfaces of parts, units, frames, sheeting exposed to

heating and rapid oxidation.Moving parts dangerous for personnel.

No 11 SilveryNo 2 Yellow

1. Frame, outer panel sheeting, air-ducts (to besupplied with primer applied).Ladders, platforms for maintenance of the installation

No 11 SilveryNo 5 light-grey

Zinc-plated surfaces are notpainted

4. Painting, bonderizing,drying plants

2. Pumps, valves, electric motors, which requireindication of their functional application on specialplants.

No 8 deep-blue

5. Arrangement of paintpreparation areas

1. Mixers, tanks No 5 light-grey

6. Test benches All surfaces No 12 cream

7. Assembly lines 1. Steel-works of units and parts of movabletransporters.2. Moving parts, carriages, attachments, rails, edges,projected parts.

No 1 pistachio

No 2 yellow

8. Power-and-free and load-carrying overhead conveyors

1. Surfaces of steel-works, units and parts, drivestations 2. Process load hangers (except for platinginstallations)3. Chain link and carriage assemblies

No 5 light-greyNo 3 golden yellowNo 10 black

9. Drying chambers throughconveyors

All assembly units except chains No 11 silvery

10. Chip removal conveyors,sheet scrap transporters

Surfaces of steel-works, assembly units and parts No 11 silvery

11. Gauges, portable controlapparatus and tools

1.Gauges and portable control apparatus.2. Tools

No 8 deep-blueNo 10 black

Mass-produced apparatusmay be painted the colourused by the manufacturer.

12. Dies for presses Non-operating surfaces No 7 blue



13. Crane equipment 1. Surfaces of carrying steel-works, bridge cranetracks, jibs, steelwork of mechanised warehouses2. Bridges of travelling cranes, jibs, palletizers, etc.3. Crane movement mechanisms, pulley block liftingmechanismsNo 5 light greyNo 3 golden yellow

No 2 yellowNo 2 yellow

No 10 blackIn alternate strips inclined at45-60° angle or straight lines(vertical or horizontal) ofequal width.

14. Floor transport facilities(automotive and electric cars,bogies, etc.)

1. All surfaces2. Bumpers, side surfaces of truck forks

No 3 goldenyellowNo 10 black


15. Racks All surfaces No 5 light grey

16. Containers, tare, trays All surfaces No 3 goldenyellow

17.Individual lockers, toolboxes, shelves

All surfaces No 5 light grey

18. Laboratory accessories All surfaces No 12 cream19. Staircases, bridges,ladders

All surfaces except for the handrails (for handrailpainting refer to item 1)

No 5 light grey

20. Fire equipment 1. Fire extinguishers, fire cocks, sand boxes,components of fire equipment2. Main surfaces of panels used to keep fireequipment, doors, tanks where such equipment isstored.

No 4 redNo 6 white

Note: Zinc-plated, plastic, rubber and decorative surfaces are not to be painted.



Table 15Standard

No.Colour Enamel employed Note

1 2 3 41. 369, 370 Pistachio НЦ-П, pistachio,

GOST 9198-83

2. 235, 236 Yellow НЦ-П, yellowGOST 9198-83

3. 121, 128 Golden-yellow НЦ-П, golden-yellowGOST 9198-83

4. 7, 62 11, 9

Red НЦ-П, redGOST 9198-83XB-16, red, TU 6-10-1301-83

5. 555 Light-grey НЦ-246, light-grey, TU 6-10-609-79НЦ-П, light-greyGOST 9198-83

6.-- White НЦ-П, white, GOST 9198-83ХВ-16, white, TU 6-10-1301-83

7. 463, 464 423, 424

Blue НЦ-132, blue, GOST 6631-74ПФ-133, blue, GOST 926-82

8. 446 Deep-blue ХВ-124, deep-blue, GOST 10144-89

9. 436, 437 426

Dark-blueDark-blue

Щ-П, dark-blue, GOST 9198-83ХВ-16, dark-blue, TU 6-10-1301-83

10. Black НЦ-11, black, GOST 9198-83НЦ-132K, black, GOST 6631-74

11. Silvery KO-813, silveryGOST 11066-74

XB-125, silveryGOST 10144-89

For the painting ofsurfaces of parts, units,sheeting, frames ofheat-treatmentequipment whichoperate at temperaturesup to 500 °C andsubject to oxidation.

For the painting ofinner surfaces of partsand parts located insidethe machines (exceptfor the surfaces to bepainted in red) installedin metallurgical andforging shops; frames,outer panel sheeting ofpainting plants,



12. 270 Cream ПФ-837, aluminiumT2 6-10-1309-82

Lacquer ПФ-170,GOST 15907-70 with addition ofaluminium powder,GOST 5494-71

НЦ-246, cream,TU 10-609-79

НЦ-246K, creamTU 10-609-79

bonderizing plants,drying chambers aswell as metalworksurfaces of units andparts, air-ducts of chipremoval conveyers,sheet scrap transporters.

For the painting of unitsand parts of conveyerspassing through dryingchambers attemperatures as high as150 – 350 °C as well assurfaces which aresubject to temperatureheating and requirefrequent painting(pouring ladle, ovenvalves of heat-treatmentequipment).



PAINTING EXAMPLES

Fig. 43



Fig. 44



Fig. 45



Fig. 47



Fig. 48



Fig. 49



Fig. 50



Fig. 51



5.11. Requirements for metal-cutting machines

5.11.1. Cutting tool speed changeExcept for those cases when the optimum cutting speed is precisely determined, the

possibility is to be provided for changing this speed by means of belts and pulleys or with the helpof a gearbox In order to set optimum cutting speed.

5.11.2. Milling headsAll milling machines including those designed to perform specific operations shall have

adjustable head or heads.

5.11.3. Spindle stock shut-downIn the event the operator is standing in the immediate vicinity of tools performing loading

operation an automatic lock of a tool shall be provided at the end of every operating cycle.Attention shall be paid to the fact that in such cases countercurrent type of braking is not allowed.

In exceptional cases and only with the Customer's consent it is allowed to use self-brakingmotors if they are in compliance with the technical requirements.

5.11.4. Safety requirementsThe equipment to be produced shall meet general operating safety requirements.

5.11.5. Automatic workheadOn machines with an automatically actuating workhead the return of the latter shall be

possible only in the event when the tool is in the "fully retracted" position.

5.12. Requirements to machines with grinding wheelsWheel dimensions and types of protection shall be in conformity with F.E.P.A. standards

(Federal Europeenne de Fabricante de Produits Abrasifs).

5.12.1. GuardsGrinding wheels are to be protected with robust metal guards and appropriate detachable

covers which encircle most of the part of wheel circumference leaving open only the sectionrequired for machining.

The guard shall also extend over the two side surfaces of the wheel and fit as close to itssurface as possible.

Thickness of the guard depending on the material applied for its manufacturing andmounting to stationary parts of the machine shall be adequate to withstand the impacts of wheelfragments in the case of wheel breaking.

Guards made of regular cast iron or aluminium are excluded. Upon fixing covers shall haveprecisely the same strength properties as the guards.

The guard shall have a dust exhaust branch pipe with diameter of no less than0.65 √ dwheel

5.12.2. Multispeed rough-grindersVariable-speed rough-grinders shall have a device preventing operation start at the speeds

exceeding the one specified based upon the diameter of the installed wheel.In the case of error in wheel-speed combination the wheel motor shall not start.Completely mechanical interlocks are allowed.



5.12.3. Fixed-head grindersSuch grinders are to be equipped with appropriate part holders.Those adjustable holders shall have plain supporting surface with their inner side being at

the distance of no more than 2 mm from the wheel.For machining of laminating material and in accordance with the safety rules this distance

may be larger.All machines of this type shall have adjustable screens that are to be transparent and break-

proof.

5.12.4 Workhead stopIt is imperative that on circular grinding machines with manual loading the workhead keeps

rotating until the wheel reaches the most rearward position.If when loading manually maximum safety Is not guaranteed, it is imperative to provide the

wheel with a removable screen properly interlocked with an operating cycle of the wheel.In such cases some form of protection shall be provided for the workhead as well.

5.12.5. Electromagnetic platesWhen the part is clamped by means of magnetization it is necessary that all machines

equipped with similar magnetization device have safety system to withdraw the grinding wheelfrom the part every time the power supply fails or the current intensity level drops below specifiedcontrol value ensuring efficiency of magnetic plates.

5.12.6. Automatic tailstocksOn such machines tailstock return shall only occur with the wheel in the "fully retracted"

position.

5.13. Technical requirements for tooling

5.13.1. Withdrawal of unfinished partsOn automatic systems with the work piece moving by means of gripping devices or along

the tunnel, provision shall be made for the withdrawal of the work piece in case of failure orbreakdown without the necessity in completing the movement cycle.

5.13.2. Manual clamping of partsIn part manual clamping the following requirements shall be fulfilled:1) the force applied by the operator shall be no more than 20 N2) the height of the clamping handles arrangement relative to the floor the operator stands

on shall be within 1100 to 1400 mm3) the handles shall be so arranged that to enable their operation by the right hand.

5.13.3. Chip removalIn case that long chips are formed, appropriate chip breakers shall be used. The installation

shall be made in such a way that ensures the possibility of inspection of different units. The toolingdesign and that of the machine itself shall prevent chip settling. Chip transporter outlet shall be atleast 1100 mm high over the floor when containers are used, and 350 mm if discharging by hand isprovided.

In the machining with employment of coolant, in the event that a lot of chips is formedprovision shall be made for automatic chip discharge into containers.

As to small amount of chips, it may be discharged by hand from the pan, its edges in thiscase being at 350 mm from the floor.

When coolant is employed in the machining, with chip accumulation taking place in largeamount, provision shall be made for automatic chip discharge into containers.



As to small amount of chips, discharging from the pan by hand is acceptable. In this case thepan edges shall be at 350 mm from the floor.

Machines with chip transporters that are not seen from the operator's work place shall have asafety device ensuring the machine shut-down at the end of the machining cycle when thetransporter breaks down. The chip transporter shall have a selector switch with a key to prevent thehazard of inadvertent starting during repair operations.

5.13.4. The paint coloursThe paint colours on outer surfaces of clamping devices (golden yellow), gauges and monitoringequipment (blue) shall correspond to Table 14 of the present General Standards.

5.13.5. Change of toolIt is necessary to group the tools in such a way that would enable carrying out simultaneous

change of several tools during the machine stop. For this purpose appropriate tables shall beprovided to lay the sharpened and adjusted tools.

5.13.6. Adapter tapers for tool change.In the tool changing it is mandatory to use quick-detachable bushings for tools.

5.13.7. Tool set-upCutting tool set-up shall normally be carried out outside the machine, for which purpose

checking facilities and gauges shall be provided.

5.13.8. Operation execution controlWhen roughing and finishing is carried out on the same machine, it is necessary to provide

checking of the following in every cycle:- roughing tool integrity;- execution of operation.

5.13.9. Flanges and other means of wheel mountingNormal disc-type wheels shall be fitted on the equipment by means of fixing flanges made

of non-breakable material with appropriate properties, of the same size which is at least 1/3 of thewheel diameter (refer to ISO R 666).

The flange and the wheel shall adjoin by the peripheral part along a circle of appropriatewidth with a gasket of elastic material inserted (leather, pressboard, felt).

Bowl- and plate-shaped wheels as well as wheels of special shape shall normally bemounted in the way to ensure maximum reliability and protection against displacement andbreaking of the moving wheel.

Grinding wheels without devices for dynamic automatic balancing shall have mountingmarks on the flanges, enabling to carry out checking by means of a stroboscope.

In case of need, the set of grinding machines shall be complete with.1. Load-lifting mechanism for the removal and mounting of the set up grinding wheel

assemblies.2. Support for mounting of the removed grinding wheel assembly set-ups.



6. ELECTRICAL EQUIPMENTDesign of electrical equipment shall comply with the requirements for production machinery

as per International Electrotechnical Commettee IEC-204 or GOST 27487-87.

6.1. Power supply

6.1.1. Voltage and frequency of power supplyElectrical equipment shall be designed to be operated from 3-phase supply circuit with rated

voltage of 380 V and rated frequency of 50 Hz and shall remain serviceable at loaded and unloadedcircuit with voltage variation of + 10%, -10% of rated value and frequency variation of +2%, -2%,of rated value.

6.1.2. Connection to the mainsElectric power supply of one unit of the equipment shall be connected to the factory mains

only in one point. Connection should be done to the 3-phase 4-wire circuit with the use of therequired number of phases and neutral protective wire. The employment of neutral wire asoperating is not accepted. When using 3-phase voltage, the load shall be evenly distributed betweenphases. The rest of the required operating voltages shall be provided with electric power supply of aunit of the equipment by transformers, rectifiers, converters, stabilizers, etc.

It is recommended to connect mains wire directly to the input switch terminals.6.1.2.1. Welding power circuits and control circuits shall be connected independently.

6.1.3. Power supply of electronic equipment6.1.3.1. Electronic equipment shall remain serviceable under the following conditions:- deenergizing for the time being less than or equal to 10 ms ( except for power electronic

equipment );- voltage drop not exceeding 15% of rated supply voltage for as long as 0.5 s or less;- occurrence of peak voltages with extreme values of no more than 200% of rated value for

up to 1.5 ms.6.1.3.2. If trouble-free and continuous operation depends on the functioning of electronic

equipment that can falsely come into action with momentary deenergizing, provision shall be madefor interlocks which interrupt execution of operations.

6.1.4. Batteries and galvanic cellsDevices and equipment being fed from built-in storage batteries or galvanic cells shall have

the possibility of employing several standard batteries or cells, or power supply from externalpower source.

6.2. Protection

6.2.1. Protection from electric shockElectric shock protection of maintenance personnel shall be provided both in normal

operation and in case of fault.Protection shall correspond to the requirements of item 6.2.1.1. and 6.2.1.2. or safe extra-

low voltages shall be applied as per item 6.2.1.3. If necessary, item 6.2.1.4. shall be furthergoverned for protection against residual voltages.

6.2.1.1. Protection from accidental touch 1) Protection by enclosuresAll live parts shall be located inside the enclosure that shall meet the requirements of item

6.4.Enclosures (doors, covers, protective shields) shall be provided with a special key with tree-

edged head, of 7 mm in size, with three-way lock, or a key with four-edged head with the side of 6-8 mm. Locking device with a secret shall be provided additionally for cabinet doors containing



electrical or electronic equipment, irrespective of the applied voltage. Skilled personnel only andwith special permission is allowed to have access for maintenance of electrical equipment.

Live parts inside the enclosure with doors being opened shall have proper protection againstaccidental touch.

It is necessary to provide special requirements for indoor areas being used as enclosures forelectrical equipment with an access only for the skilled personnel.

Protective guard or barrier for protection from accidental touching the live parts (or toprevent them from touching one another) shall not impede maintenance personnel to handle withthem.

2) Protection by insulating the current-conducting partsThis method implies the protection by complete covering of live parts with insulating

material that can only be removed by its destruction. Such type of insulation shall withstandpossible continuous mechanical, electrical or thermal effects it may be exposed to during operation.As a rule, varnish, enamel or similar materials are not considered to be sufficient to ensureprotection from electric shock in normal operation.

6.2.1.2. Indirect protectionIndirect protection or protection from indirect contact shall ensure protection of personnel in

case of insulation puncture and failure between current-conducting parts and parts of electricalequipment frame (breakdown to the frame).

6.2.1.2.1. Protection by automatic voltage shut-offAutomatic voltage shut-off shall serve for protection of personnel from electric shock in the

event of breakdown through a frame. This type of protection shall include the following:- proper connection of all frame current-carrying parts of equipment with earthed neutral

terminal of transformer (protective neutral earthing); .- selection of proper installation of protective facilities which provide automatic voltage

shut-off when insulation punctures.1) Arrangement of protective circuitProtective circuit shall consist of protective wires and current-carrying frame parts and

sections of equipment. It shall ensure proper connection of these structures with outside mainsprotective wire.

2) Permanency of protective circuit connectionPermanency of protective circuit connection shall be provided by proper connection with

protective wires and construction components of all sections of equipment to be protected(protective neutral earthing ):

- components to be used for connection of different metal parts are considered suitable toensure permanency of protective circuit connection if they offer adequate conductivity. However,components to be applied for protective wire connection shall not be used as fastening at the sametime. When employing aluminium or its alloys for components and conductors attention shall begiven to the danger of electrolytic corrosion;

- when a section of equipment is detached for repairing or for other reasons, the rest sectionsshall retain connection with protective circuit;

- metal conduits shall not be used as protective conductors, except for those cases when theyare specially intended for this purpose and after relevant checking. However, all metal conduits andwires metal sheaths (steel pipes, lead sheaths) shall always be connected to the protective circuit.

- moving parts of electrical equipment placed on the metal runways having sufficient contactpressure shall provide reliable connection with protective circuit. Proper measures should be takenwhen contact resistance is too high;

- when adjustment and maintenance are effected with inevitable touching the moving partsof electrical equipment being live, frames of these parts shall be connected to the protective circuitby means of protective wire;

- if electrical devices are fitted on doors, covers and enclosures, provisions shall be made toensure proper connection with protective circuit. It is recommended to use protective wire with thecross-section area dependent on the maximum gauge of supply circuit wires connected to the



devices. Any similar electrical connection specially designed for this purpose (sliding contact,hinges protected against corrosion) are also considered to be meeting these requirements. Ifelectrical devices are not fitted on doors, covers and enclosures or if they are fitted but with the useof low-voltage circuits as per item 6.2.1.2.3., then employment of standard metal hinges or similarfacilities is sufficient to provide permanency of protective circuit connection.

3) Restriction on protective circuit disconnectionProtective circuit shall not be disconnected by any switching or protective devices. Fuses,

shunts and other elements are not accepted to be included in protective circuit. Only jumpers can bemounted in protective wire circuit, which can be removed for maintenance and tests only by skilledpersonnel.

4) Employment of connectors in protective circuitWhen disconnection of power circuit is effected through the use of connector assembly, the

design of connector shall imply disconnection of live conductors at first, and then disconnection ofprotective wire; when connecting power circuit the reverse sequence of actions is presumed. Metalbodies of connectors shall be connected to the protective circuit, except for those of low-voltageconnectors.

5) Protective wires gaugesAll parts of protective circuit shall be designed so as to withstand the highest thermal and

mechanical effects of short-circuit current that may occur in this part of protective circuit. Ascommon practice, values listed in table 16 may be used without additional verification. If non-copper conductor is used, its resistance per unit length shall not increase the acceptable resistance ofcopper wire. Separate structure elements may be used as protective circuit, provided their gauge inelectrical sense is at least equivalent to the minimum gauge, indicated in table 16.

Tab1e 16Gauge of copper protective wire

Rated current of fuses or rated set-upcurrent of other devices for short-circuit

protection of associated circuit, A.Gauge of copper protective wire, mm2

up to and inclusive of

- 200- equal to the gauge of main wires but no less than16

- 315 - 25- 500 - 35- 800 - 50- 1000 - 70- 1250 - 95- 1600 - 120- 2500 - 185- 3200 - 240

6) Terminal for connection of outside protective wireThe entire protective circuit shall be connected to the terminal according to item 6.1.2., intended forconnection of outside main protective (neutral) wire. As a rule, the terminal shall be of proper sizesuitable for connection of outside protective wire with copper core (or as per the gauge indicated intable 17).Size of terminal determined from connection of outside protective wire



Tab1e 17Gauge of outside main phase leads, mm2. Gauge of outside protective wire to determine

the lead terminal size.

up to 16 mm2, inclusiveover 16 mm2

Equal to the gauge of main leads.No less than 50% of main lead gauge

but no less than 16 mm2.

Lead terminal for connection of outer protective wire shall have one of the followingdesignations:

symbol (_ _ ); (Grounding)letters ( PE );coloured green-yellow.7) Manual controlsManual controls of electrical units (buttons, handles, handwheels ) shall comply with the

following requirements:- shall be made of insulating material or coated with additional or strengthened insulating

material which provides insulation from other parts. This insulation shall be calculated based on themaximum voltage applied to that part of electrical equipment where control is mounted, or

- they shall have constant and reliable electrical connection to the protective circuit.The first requirement is preferable. However, metal parts having varnish or enamel coating

only can not be tolerated.8) Sections of equipment not connected to the protective circuitSections of equipment are not to be connected to the protective circuit if they are installed in

such a way that danger of electric shock is eliminated for the following reasons:- touching them is excluded;- they have small dimensions, up to 50X50 mm;- their arrangement eliminates touching the live parts even in case of insulation breakage.- they have metal contact with the grounded structure.These provisions refer to small elements like screws, rivets, plates, on the one hand, and on

the other hand, to the parts located inside the enclosure regardless of their dimensions, like starterand relay core, mechanical parts of equipment, etc.

6.2.1.2. Protection by employment of safety or double insulationThe purpose of these measures is to prevent the occurrence of dangerous voltages on easily

accessible parts when insulation is damaged.This protection is achieved with application of one of the following methods:- the use of additional protective insulation (2nd class protection);- the use of factory instruments, fully insulated;- the use of double or strengthened insulation.In order to comply with the requirements given in items 6.3.2.2. and 6.3.2.3., it is

recommended to connect current-conducting (but not live) parts, being under insulating enclosure,to the protective circuit.

6.2.1.2.3. Protection by operating low-voltageOperating low-voltage is used to prevent the occurrence of dangerous voltage for the

personnel on the equipment sections when isolation breaks. The highest voltage value in thusprotected circuits shall not exceed 42 V (RMS value) of alternating current or 110 V of directcurrent value at voltage oscillations being no more than 10%.

One of the following conditions shall be further met:- one of the outputs of power source terminals shall be connected to the protective circuit

considering the presence of higher voltages relative to the machine frame;



- power source and all current-conducting elements in this circuit being live shall be isolatedand insulated from circuits with higher voltages by insulating material designed for the voltagehigher than of this section of equipment. When using braids, shields and similar metal parts, thelatter shall be connected to the protective circuit.

Transformers to be used in these power sources shall be built in accordance with therequirements of safe design for isolation and protective transformers.

Connector assemblies to be used in such circuits shall comply with the followingrequirements:

- connectors plugs and sockets of these circuits shall not structurally mate those of circuitswhich do not match the requirements of the given item.

6.2.1.2.4. Protective breakdown of current circuitProtective breakdown of circuits into several current branches shall serve to diminish a

danger of electric shock when insulation breaks in one of the current branches.

6.2.1.3. Protection by extra-low voltages for special machine structures in case ofdirect and indirect touching

Sections of special machine structures with uncovered current-conducting elements beinglive at standard conditions and that may be possibly touched shall comply with the followingrequirements:

1) maximum voltage of current circuit shall not exceed 25 V (KMS value) of alternatingcurrent and 60 V of direct current at voltage fluctuations of no more than 10 %. The application ofextra-low voltage may turn out to be necessary under special conditions (for example, humidity);

2) the maximum current through the jumper connecting two current-conducting parts,unprotected from direct touching, shall not exceed 1 A of alternating current and 0,2 A of directcurrent;

3) current-conducting parts, unprotected from direct touching shall be rigidly fixed and shallbe of such configuration which makes it impossible to grip completely by hand;

4) power source as well as all current-conducting parts and wires of these circuits shall beisolated and insulated from circuits with higher voltages.

5) one of the terminals of power source shall be connected to the protective circuit, consider-ing the fact that higher voltages compared with the machine frame there are on the equipment;

6) equipment frames involving such circuits shall be isolated or insulated from circuits withhigher voltages or shall be connected to their protective circuit;

7) connectors plugs and sockets of these circuits shall not structurally mate those of circuitsnot being considered in this item;

8) similar circuits to be used as control and alarm circuits shall comply with therequirements of item 6.3. as well.

6.2.1.4. Protection against residual voltagesIf electrical equipment incorporates elements which can retain hazardous electric charge

after they have been de-energized (for example capacitors with energy reserve exceeding 0.1 J), it isrecommended to provide voltage drop up to no more than 120 V during 5 s with the use ofdischarge resistor.

If it is impossible, warning plate shall be provided on the door or on the barrier. But whenhazardous voltage exists outside the frame, measures shall be taken to reduce voltage below 120 Vduring 5 s.



6.2.2. Short circuit protection

6.2.2.1. General protectionManufacturer of electrical equipment shall provide general short-circuit protection at the

point of power input to the equipment. Electrical documentation shall contain the type specification,rated current of thermal set point and instantaneous operating setting of these protection devices.

General protection devices shall not operate at electric motor starting. With instantaneouscurrent interrupter, its setting shall be no less than 110% of peak current sum of all electric motorsand other loads which can be put into operation simultaneously.

6.2.2.2. Branch circuit protectionAll electric conductors shall be short-circuit protected by protection devices, chosen in

accordance with the requirements listed in item 6.2.2.3. All live conductors shall be controlled bydevices to detect and disable short circuits.

In the circuit of protective wire (PE) it is not allowed to use current cut-off devices.One protection device can prevent short circuits in several branches, the difference in their

electric loads being no more than 30 %.6.2.2.2.1. Protection by fuses and automatic circuit-breakersWhen using fuses, their type and protection characteristics shall be included in the technical

documentation. Fuses should be used only when it is well founded, if it is impossible to use otherprotection devices, for example to protect powered or electronic semiconductor devices.

Breaking capacity of circuit-breaker shall be rated for the expected short-circuit current ofthe circuit section to be protected. It is acceptable to use circuit-breaker with less breaking capacity,if the protection device (for example, common group protection) with the required breakingcapacity by power is provided. In this case, characteristics of such protection devices shall be ofthose, that current passing through these protection devices sequentially does not exceed thosevalues which can be withstood by components and wires protected by these devices withoutdamages.

6.2.2.2.2. Current relay protectionFor branch protection it is allowed to use instantaneous current overload relays for circuit-

breakers having sufficient breaking capacity. Such cut-off devices may serve for tripping of one orseveral circuits or branches, of for general protection purposes as well as for emergency stops.However, for protection one shall use chiefly automatic circuit-breakers.

6.2.2.3. Rated current and currents of settings of short-circuit protection devicesRated values of fuse currents or values of seating currents of other short-circuit protection

devices shall be set as low as possible, considering overload currents which may occur on motoroverload or when connecting to the transformer voltage.

Rated value of fuse current or setting current of short-circuit protection devices is limited bythe minimum gauge of the conductor protected by this device. As this takes place, it is necessary toconsider the following:

1) permissible current load on wires with respect to the insulation type.The given proposition spreads to single- and multicore unshielded wires with PVC

insulation for the permissible operating temperature of 70°C (the permissible temperature for long-run operation).

For all wires having another insulation type the permissible temperature shall correspond tothe one stated in the standards and technical requirements for the certain wire types;

2) consideration of permissible heating and ambient temperatures.For single- and multicore unshielded copper wires the permissible current loads, which are

given in the following table, correspond to the air temperature of 30° C. The correction factor usedfor reduction of load of aluminium wires is equal to 0.78. However, it is not desirable for theelectrical equipment to use aluminium wires, unless agreed with the Customer.



Table 18Load on wires run in the machine, A

of ordinary design for mass productionRated wire gauge,

mm2

in channels in the open air in channels in the open air1 2 3 4 5

0.96*0.283**

0.50.75

11.52.54610162535

50***7095120150185240

2.53.56912

15.5212836506889111134171207239275314369

2.73.86.510

13.517.52432415776101125151192232269309353415

235

7.5101318243143587694114145176203234267314

2.23.35.58.511.5152027344865806106128163197228262300353

* rated diameter = 0.5 mm** rated diameter = 0.6 mm*** net section = 47 mm2

- in columns 2 and 4 loads for wires run in the channels are specified; air temperature ismeasured outside the channels;

- in columns 3 and 5 loads for wires in the open air with determined temperatures arespecified (for example, inside the electrical cabinet or in the machine recess). Air temperature shallbe measured between wire and wall, partition restricting air circulation around wires;

- when working under rated load, the specified temperatures are considered to be set andthey are measured after the machine operation during the period required to reach them;

- when operation of the structural unit at high temperatures is not required, then the ambienttemperature for channels and wires in the machine and electrical equipment shall be based on thespecified environment temperature value of 30°C;

- if the air temperature around the channels and wires is higher than 30°C, it is necessary touse the load reduction factor according to Table 19.



Tab1e 19Air temperature, ° C.

°CLoad reduction factors

30354045505560

10,930,870,790,710,610,5

3) Short-circuit protection of wiresAll wires shall be protected from short-circuits by safety devices controlling any short-

circuit current in live wires, any short-circuit current running through the wire in order to switch offthis current before the temperature reaches dangerous value. This means that for PVC insulatedwires with tolerable working temperature up to 70°C in the short-circuit condition the wire shall notbe heated from 70°C up to 160°C during 5 seconds. In order to fulfill this requirement, one may usethe special table or the formula below, which was used for calculations:

t = [115 x S/Imin]2,where S - rated gauge of copper wire, mm2

I min - minimum short-circuit current, At - maximum non-protection time of protection device, sAutomatic circuit-breakers to be used for small gauge wires protection shall be of the type

that the electric power running through them does not exceed the accepted value determined bythermal stability of the wire to be protected and can be calculated as the product of Imin squaredcurrent by time t.

4) Short-circuit protection devices shall be selected not only with the purpose of conductorsprotection, but so they could correspond to the characteristics of other electrical devices to be usedunder these conditions. With respect to short-circuit protection of electronic devices one should takeinto account the recommendations of the technical documentation.

6.2.2.4. Conductors placed upstream the protection devicesConductors placed upstream the protection devices shall not have the special short-circuit

protection, provided that:- their gauge is equal at least to the gauge necessary for the conductors placed downstream

these protection devices;- each conductor with undersized gauge connected upstream the protection device shall not

be longer than 3 m;- conductors, subjected to the atmospheric exposure, shall be protected by use of casing or

pipeline;- conductors shall not be placed close to the flammable materials.

6.2.3. Overload protection

6.2.3.1. Electric motor protection6.2.3.1.1. Overload protection shall be provided for any electric motor with the power of

more than 1 kW and employed as a rule in continuously rated operation. Such overload protection isrecommended for any other motors, particularly for cooling pump motors.

Overload detection devices (except for those cases when built-in thermal protection devicesare used) and break contacts shall be incorporated in each conductor, except for neutral (N) andmiddle (M) conductor. All these contacts of the same electric motor shall be closed and opened at



the same time. However, in some cases, upon to the agreement with the Customer, the number ofoverload detection devices may be reduced.

6.2.3.1.2. For electric motors of frequent use, when it is difficult to provide overloadprotection for the reason that the time constant of a device is incompatible with the time constant ofprotected winding (of electric motor used for fast movements, clamping devices, acceleratedreversing mechanisms, high-speed drilling), short-circuit protection only can be used.

However, if the power exceeds 2 kW, it is advisable to use special protection devices (forexample, action-related relay of non-thermal type, thermal relay fed from the saturatingtransformers or thermal components built into the electric motor).

The use of built-in thermal components is also advisable for motors with worsening coolingcharacteristics (for example, because of the environmental pollution).

When protection by built-in thermal components is used, it may become ineffective(depending on types of electric motors) for electric motors with locked rotor. In this case additionaloverload relay may be used.

6.2.3.2. Protection against electric motor self-startingIf as a result of motor self-starting, after the overload protection device has been switched

off (for example, upon cooling of thermal relay heater), there may occur a dangerous situation,provisions shall be made for preventing the motor from self-starting.

6.2.3.3. Protection of connectorsAll current-carrying wires of feed circuits, except for neutral wire, connectors serving for

temporary loads connection (for example, appliances), shall have overload protection (breakcontacts and overload detection devices).

6.2.4. Protection against self-starting at power supply restoration, once it hasbeen disabled

If self-starting of electric motor or automatic activation of other elements, once the powersupply has been disabled and restored, may cause any danger or electric shock to maintenance staff,or any damage to the machine or to the workpiece, then it is necessary to prevent such self-starting.

If power supply cut-off is allowable for a split second during operation of the machine, zeroprotection with time delay may be used. When using contactors, opening with time delay andreclosing, under no circumstances shall impede immediate disconnection of these contactors fromcontrol equipment (limit switches, relays, control buttons).

6.2.5. Low-voltage protectionIn the event that unacceptable voltage drop may be the cause of the disturbance of electrical

equipment operation or damage to the machine or the workpiece or may be hazardous for theservice personnel, it is necessary to provide low-voltage safety element to ensure proper protectionat voltage decrease below the specified values.

6.2.6. Emergency switching and input circuit-breakerElectrical equipment of the machine shall comprise devices to ensure the following;1) stopping of the equipment in the case of emergency, and when necessary - reversing of

actions;2) disconnection of electrical equipment from power source.If in the both cases the same circuits are disabled, then to meet the requirements of the above

items, the same device that meets the requirements of items 6.2.6.l and 6.2.6.2. can be used.

6.2.6.1. Emergency switch mechanismIn order to prevent danger to the service personnel or to prevent the machine from damages,

the emergency switch mechanism shall disable hazardous elements of the machine as soon aspossible or stop the machine completely.



For this purpose one of the following methods shall be used:1) emergency switch mechanism is to be connected in such a way that power supply can be

disconnected from their associated circuits. This switch can be manual as well as remote beingoperated by disconnection of control circuits;

2) the control circuits are made so that all switching components are deactivatedsimultaneously by the same command in every supply circuit employed.

If, for example, several contactors are connected in parallel (for example, reversingcontactors or contactors for switching from star to delta for the same motor), all their controlwindings shall be disabled simultaneously.

In the case of reverse current braking, if it is required to use emergency braking or motorreversing to stop it, the involved power circuits shall be interrupted only when the specified safetyprecautions are fulfilled.

When using reverse current braking in combination with an emergency braking, all safetyprecautions against reversing of motor shall be taken.

A cut-off command shall pass to the interrupting device either through direct mechanicalconnection, or via opening a control circuit being usually live. These circuits shall meet therequirements as per item 6.2.7.

6.2.6.1.1. The emergency switch mechanism, according to the method mentioned in thesubitem 1) of item 6.2.6.1. above shall provide current cut-off, that is made up of maximum currentat motor braking and a sum of rated currents of other various equipment The emergency switchmechanism according to the method, mentioned in subitem 2) of item 6.2.6.1., shall have breakingcapacity sufficient to open a control circuit.

Switchgear that comes into operation at a signal, described in subitem 2) shall have the samebreaking capacity as the circuit-breaker described in subitem 1), but only for the circuits, directlyconnected to it.

If the breaking capacity of the emergency switch mechanism, in conformity with subitems1) and 2). (automatic circuit-breaker, contactor), is adequate, an interrupter or a relay can be fittedand, besides, it can also serve for overload protection and (or) short-circuit protection.

6.2.6.1.2. Actuating of the emergency switch mechanism shall not cause any danger to theservice personnel, either any damages to the machine, and it shall not also open a power circuit ofthe auxiliary equipment, like magnetic chucks, breaking facilities, CNC systems, etc., which shallalways be in working conditions, even in an emergency.

In the case, it is required for the safety of the service personnel, actuating of an emergencyswitch mechanism shall cause reverse motions.

When the emergency switch mechanism returns to the starting position, it shall not initiatereclosure of any circuit of the machine.

6.2.6.1.3. Emergency switch actuating device(s) is as follows:1) handle of the emergency switch mechanism;2) one or several control buttons having mushroom-shaped push rods;3) cable(s) pulled along the protected area to open a circuit in an emergency by drawing it or

when it is broken;4) protective rod(s) or pedal(s) without mechanical protective visor;5) any other similar components that can be more suitable for this purpose.Actuating devices shall be easily visible and accessible for operator from his work station

and control panel. If the machine has several work stations and control panels, or other importantplaces, an actuating device shall be easily accessible from each of them or each one shall be fittedwith an actuating device, which is preferable.

All these actuating devices shall be painted red. If actuating devices have the form of ahandle or a button, the surface behind or beneath them shall be painted yellow for contrast.

When several actuating devices are available, the subsequent starting of the machine is onlypossible when all actuating devices previously used in the disconnection are set manually to theinitial state, for which purpose (for example, when remote emergency switch mechanisms are used)these actuating devices shall be fitted with latches (mechanical).



Note. When several control buttons are used, mechanical interlock of the buttons isconsidered to be satisfactory if an emergency button is locked in the depressed position (switchingoff), with its manual return to the initial state (releasing).

6.2.6.2. Input switchA manual input switch shall disconnect the electrical equipment of the machine from power

source to perform cleaning of the machine, repair, service and to stop the machine for a long periodof time.

Large size machines with several mechanically independent units, each having each ownelectrical equipment, may be fitted with separate input switches for each unit.

If several power sources are used, each one may have an independent input switch. In theevent that manipulation of one of the input switches brings about personal hazards or equipmentfailure, it is necessary to provide a protection interlock.

Input switch(es) shall meet the requirements of items 6.2.6.2.1. - 6.2.6.2.3. and be of thetype listed below:

1) designed as an interrupter switch;2) designed as an interrupter with special auxiliary contacts, which, in all cases, cause load

interruption by a contactor prior to opening of interrupter main contacts;3) designed as an automatic switch;4) for small machines with rated current of no more than 16 A, if the total power of motors

installed does not exceed 2 kW, connector can be used.6.2.6.2.1. If the input switch is mounted within the operator's easy reach, then its breaking

capacity for the cases specified in subitems 1) and 2) of item 6.2.6.2. shall be similar to that ofemergency switch.

In the case, when connector is used as an input switch, then its breaking capacity shall be noless than rated current of the machine at rated voltage.

6.2.6.2.2. Automatic switches operated by external energy source (electric power,compressed air) may be employed as input switches subject to meeting the following requirements:

1) have a manual operating control (such a control shall not be possibly actuated from theoutside if there are other means outside to disconnect the switch).

2) when in closed state (locked in off position), their switching on manually or by remotecontrol shall not be possible.

6.2.6.2.3. The input switch arm shall be easily accessible and located at 1.2 m to 1.9 m fromthe floor or maintenance level. Mains voltage shall be connected from above. No other apparatusshall be located above the input switch.

6.2.6.2.4. The following circuits shall be powered bypassing the input switch:1) lighting circuits for lighting the machine when carrying out maintenance or repair works;2) connectors circuits to be used purely for connection of maintenance and repair tools (for

example, hand drills);3) circuits of low-voltage protection interrupters regardless of voltage values to be used only

for the automatic disconnection upon the failure of the power source;4) control circuits - as per item 6.2.6.2.6.In all these cases, a warning shall be put next to the input switch, and an appropriate

instruction in the maintenance manual, drawing attention at the fact that some circuits may remainconnected to the mains power source.

It is recommended that such circuits be equipped with their own independent interrupters(input switches).

Power supply circuits for CNC and programmable controllers can be connected to the mainspower supply without running through the input switch.

6.2.6.2.5. Protection shall be provided from any accidental touch with the parts, whichremain live after the input switch has been put in "OFF" position.

These parts shall be enclosed into separate casing covers, even when partitions are removed,which open an access to the disabled parts. It is necessary to provide warning signs on those specialcovers or plates.



This requirement does not apply to the input terminals of the input switch when it is putunder separate enclosure or included in extra-low voltage circuits as per items 6.2.1.2.2. and 6.2.1.3.

6.2.6.2.6. Orange paint is recommended for control circuit wires employed in interlockingspowered from an external source and remaining alive even after the input switch is cutoff. When thecables of these circuits are laid in separate covered channels (wire conduits), the colour is notimportant. If appropriate warning plates are to be provided for the circuits, then the requirements ofitem 6.2.6.2.5. shall not apply to them.

6.2.7. Protection upon the failureIf the failure of the electrical equipment may pose a threat, then appropriate measures shall

be taken to prevent their occurrence, such as- mechanical protection of the machine- control circuits interlock by mechanical movements- adding of circuits serving protection functions- circuits backup/duplication (tripling).Note. This requirement can be carried out, for example, by duplicating or tripling of circuits

combining control functions, which allows to perform control functions only when at least twocontrol signals are identical.

It is allowable to take one or several of the above measures in combination as well as othereffective actions; as this takes place, special attention shall be given to feedback signal failure (opencircuit).

6.2.7.1. If intermediate relays are employed in the protection circuits, which makes specialprotection measures ineffective when one of the relays fails, then the relays shall be backed up(duplicated), the contacts of each relay from this pair being connected to the corresponding circuitsin such a way as to ensure circuit protection when one of the relays fails.

Closing and opening of relay contacts shall be automatically controlled at least one timeduring a cycle of activation and deactivation of the machine.

6.2.7.2. Special protective circuits shall be actuated when a fault occurs, whereby acomponent or a device malfunction, short-circuit or power interruption will result in such conditionsas

1) fast shut-down;2) stop or reverse of those part movements that cause dangerous situations, whereby the

damage is prevented;3) using of protection enclosure that restricts access to the dangerous area.Moreover, dangerous situations for the personnel (or machine) as well as for the workpiece

(if it is specified in engineering documentation) shall be eliminated when faults occur.

6.2.8. Electromagnetic interference protection6.2.8.1. Electrical interference caused by the equipment shall be minimized. Tolerable limits

and the procedure for ascertainment of interference behaviour shall be based on requirements ofgenerally accepted international standards (publications) applicable to industrial high-frequencyequipment.

6.2.8.2. Undesirable effects of electrostatic and electromagnetic interference can beminimized with the use of proper filter, dwells, definite power levels, proper modes, types ofinstalling, etc.

The following measures are recommended for reducing interference levels, especially wheretransducers with low output signal level are used:

1) common connections or reference potential circuit - each common connection to beconsidered as a single circuit connected to the central reference point (or several points) andgrounded with insulated wires of large cross-sectional area;

2) machine frame related connections – in each equipment unit all structure-relatedconnections must meet in one common point; braided wires of large gauge are to be used betweendraw-out units and shells; wires running to the machine frame shall be as short as possible;



3) signal transmission - employment of electrostatic and electromagnetic screens, twistedwires and special arrangement (no crossing of wires at an acute angle) enables to prevent signaltransmission failure due to interference induced by control or power wires;

4) equipment separation - separation and (or) screening of sensitive equipment (pulsedevices and (or) devices with low-level signal) from switchgear such as electromagnetic relay,thyristors etc.

6.3. Control and alarm circuits

6.3.1. Power supply and protection of control and alarm circuits

6.3.1.1. Employment of transformers6.3.1.1.1. Transformers are advisable for complex machines with more than 5 coils of

electromagnetic devices (contactors, relays, of electromagnetic valves) or control devices andinstruments placed outside the shells for power supply of control and alarm circuits. Thesetransformers shall have individual windings and be connected to the input switch from load side,mainly to two phases.

6.3.1.1.2. Requirements for electronic equipmentThe employment of transformers is mandatory in supplying power to electronic control and

alarm circuits.6.3.1.1.3. Additional requirementsThe use of transformers for control circuits is mandatory.Control and alarm transformers shall power control and alarm circuits only and have the

reserve power exceeding the required value at least by 25 % to ensure possible connection of extraloads later on.

6.3.1.2. Direct connection of control circuits to the mains voltage is not acceptable.Note: Control circuits with no more than 5 coils of electromagnetic devices may be connecteddirectly to mains voltage without isolating transformer.

6.3.1.3. The use of several transformers (additional requirement)When several transformers operating simultaneously in continuous mode are used, each

transformer shall, wherever possible, power control circuits of certain mechanisms. Thus controlcircuits are required to be made in such a way that inoperative condition of one mechanism couldnot present any hazard or danger for the service personnel, machine or production process.

If the control and alarm circuits of the machine are powered from several transformers withthe same output voltages, it is recommended to connect primary windings of these transformers insuch a way that the secondary winding wires are matched in phase (i.e. have the same potential atthe same instant).

6.3.1.4. Overload protection6.3.1.4.1. Control and alarm circuits directly connected to the power source as well as those

circuits that power control and alarm transformers shall have short-circuit protection according toitems 6.2.2.2. and 6.2.2.3.

In deciding on protection devices it is essential to provide protection of contacts in theauxiliary devices circuits from being welded together in the event of short-circuit.

6.3.1.4.2. When control and alarm circuits are powered from transformers with one of thesecondary winding lead-out grounded, short-circuit protection shall only be provided forungrounded wire of the secondary circuit.

6.3.1.4.3. Overload protection is not obligatory for control and alarm circuits.6.3.1.4.4. Additional requirement



Energizing of electromagnets of valves, couplings and other solenoids shall be effected fromthe separate control circuit with an independent protection from control circuit that energizes relaysand contactors.

6.3.2. Control circuits

6.3.2.1. Voltages preferable for control circuits:1) For a.c. control circuits the following voltage is recommended: 110 V, 50 Hz.2) For d.c. control circuits 24 V voltage is recommended.Employment of 24 V, 50 Hz or 220 V, 50 Hz a.c. and 48 V or 110 V d.c. is possible for poweringof special devices of control circuits, which is subject to additional agreement with the Customer.6.3.2.1.2. Requirements for electronic equipmentOther low-voltage values are allowable for power supply of electronic circuits and devices designedfor operation with such voltages only.6.3.2.1.3. Additional requirement24 V or 48 V are not advisable for large machines, long connection circuits or where many contactsare connected in series (in view of possible voltage drop).

6.3.2.2. Protection against sudden starting of the machine with a short-circuit toground

6.3.2.2.1. Sort-circuit to ground of any control circuit shall under no circumstances initiate asudden start as well as dangerous movements of the machine and shall not impede its disconnection.

To fulfil this requirement, it is advisable to connect one side of control circuit to theprotection circuit and windings and contacts as per item 6.3.2.3.

6.3.2.2.2. Requirements for electronic equipmentIn electronic circuits a sudden start can be prevented by connecting of one side of control

circuit to the protection circuit. If the above mentioned protection measure is ineffective or for someother reasons it is impossible to connect electronic circuits to the protection circuit, other measurescan be taken to provide the same protection level.

6.3.2.2.3. Control circuits powered from a transformer which by some justified reasons arenot connected to the earthed zero wire shall be provided by insulation control device which eitherindicates earth or automatically opens the circuit when earth fault occurs.

6.3.2.3. Connection of windings, contacts, input-output devices6.3.2.3.1. Connection of windings and contactsIn case of control circuits with one side connected (or intended for connection) to the

earthed zero wire, one of winding terminals (it is desirable that this terminal should always have thesame marking) on each device with electromagnetic control (or a terminal of other electricaldevices) shall be directly connected to this side of control circuit. All contacts of the control devicesthat control the winding (or a device) must be located between other terminals of the winding (or adevice) and the other side of control circuit that is not connected to the earthed zero wire.

The following exceptions to this rule are allowed:1) protection relay contacts (for example, overload protection relay) can be located between

winding and the earthed zero wire, provided that these contacts and windings of the control devicesoperated by relay contacts are located in the same enclosure;

2) in special cases when different combinations of contacts result in getting the externalcontrol devices simplified (trolleys, cable drums, multipole connectors) and when the requirementsof the first paragraph of item 6.3.2.2.1. are observed.

6.3.2.3.2. Connection of input-output devices (requirement for electronic equipment)To avoid dangerous situations, input-output devices shall be incorporated in the control

circuit section, which is not connected to the earthed zero wire and to the reference potential.



6.3.2.4. Protection interlocks6.3.2.4.1. Operation of auxiliary devices1) If disconnection of an electric motor or mechanism used in auxiliary devices (for

example, in lubrication, cooling or chips removing devices) involves danger to the servicepersonnel, machine failure or damages to the products, then a sudden disconnection of such devices(for example, when protection relay is tripped) shall stop all electric motors which can cause anaccident when operating unless they are switched off simultaneously.

2) Additional requirementProper operation of auxiliary devices shall be controlled by appropriate devices (for

example, by pressure gauges).6.3.2.4.2. Interlocks between different mechanismsWhen simultaneous operation of different mechanisms can cause their failure, then

appropriate interlocks shall be provided to prevent such simultaneous operation.6.3.2.4.3. Interlocks in opposite motion controlAll contactors, relays, and electronic devices controlling those machine components that can

cause an emergency situation (for example, they can cause opposite motions) shall be protectedfrom improper operation. Reverse contactors intended for the control of direction of electric motorrotation shall be interlocked in such a way that, when switched on, they cause no short-circuit innormal conditions of operation.

6.3.2.4.4. PluggingWhen plugging is used for electric motor, measures shall be taken to prevent electric motor

reversing at the end of braking, if it is dangerous to the service personnel or can damage aworkpiece.

Employment for this purpose of a control component, which only operates in the function oftime, is not allowed.

Control circuits shall be composed in such a way that the electric motor rotation by hand orotherwise shall not result in its inadvertent switching on.

6.3.2.4.5. D.c electric motor protection from exceeding its rotation speed (from accelerationto overspeed).

To protect d.c. motors from exceeding of rotation speed above the allowable value, it isessential to use protection devices, when a danger of such cases exists. For shunted electric motorsor for separately exited electric motors, instead of such protection there can be used a componentthat controls opening of exiting circuit.

6.3.2.4.6. Overrun protectionIf overrun can cause an emergency, then any position transducer that usually controls the

normal cycle execution should be backed up by a position transducer for safely stopping of allrelative movements.

It is recommended that this second position transducer should directly de-energize theelectric motor power circuit or stop the machine completely.

6.3.2.5. "ON" and "OFF" operations shall be performed in the following way:1) "ON" operation to be done by supplying voltage to an appropriate circuit or, in the case of

using of electronic binary elements, by bringing them to the state that corresponds to logic 1;2) "OFF" operation to be performed by de-energizing of the appropriate circuit or, in the

case electronic binary elements are used, by bringing them to the state that corresponds to logic 0;3) "OFF" operation shall always cancel "ON" operation.If in technically justified cases (as an exception), one or several of the above requirements

can not be fulfilled, then other means of operation safety shall be provided.6.3.2.5.1. Start-up of the equipmentTo start the equipment up, an on-off switch with a key must be provided, which effects

voltage supply to the control circuits. This switch can be mounted on the main control panel. At thesame time, an indicating lamp, "Control circuits are closed", must be energized on the same panel.If the equipment is intended to work in automatic mode, then an indicating lamp, "Ready for



automatic operation", shall be provided on the control panel. If readiness is not available, thecontrol system shall detect a fault and display a message in accordance with item 6.3.3.6.

6.3.2.6. Cycle startCycle or process start shall only be possible when all precautions for safety of the personnel,

machine and workpiece are fulfilled, with the devices necessary to perform auxiliary operationsbeing in serviceable condition.

To ensure proper sequence of cycle and process starting, appropriate interlocks shall beprovided. To carry out set-up works, provision shall be made for switching-over to this mode, withreliable operation of the interlocks being maintained to ensure safety of the service personnel.

The circuits that provide execution of operations mentioned in items 6.3.2.6.1, 6.3.2.6.2.,6.3.2.6.3. shall be arranged in such a way as to cancel the execution of "ON" command in case ofany fault with them.

6.3.2.6.1. "Cycle on" control buttonsWhen several operators are operating the machine, each operator shall have its own "cycle

on" control button, which only starts the cycle when they are all held depressed at the same time inon-state.

A control switch with a lock is allowed to be additionally used, which only allows to usesingle or several (but not all) buttons, or provides a possibility of using "cycle on" buttons in acertain sequence.

6.3.2.6.2. Automatic cut-off at a cycle end and impossibility of cycle repetitionIn the case if it is allowed or accidental cycle repetition may cause an emergency, then

control circuits shall be made in such a way as to eliminate cycle repetition even in the case ofactuation of one of the controls on working place(s) of operator(s). The machine shall stop at theend of each cycle without interference on the side of operator. Each new cycle shall begin only afteractuation of all controls.

6.3.2.6.3. Operation by two handsThis item is applicable in combination with item 6.3.2.6.2.If for the safety reasons of an operator(s) operation by two hands is required, i.e. when

operator(s) shall keep his hands away from the dangerous area, then a control device of eachoperator shall have two buttons "Cycle on".

These control buttons shall be simultaneously in operating condition during the whole cycleor, at least, for the tine during which the duration of cycle shall not cause any dangerous condition.

Each pair of control buttons shall be arranged in such a way, that operator(s) shall useconstantly both hands.

Besides, operation from both the buttons shall be done for a limited period of time, theirpushing being non-simultaneous.

Note. The following time intervals are recommended: 0,2 sec 0,5 sec, 1 sec.The control circuit shall be designed so that if a time limitation has elapsed, then in order to

start a cycle both the buttons shall be first released and then pushed again.6.3.2.6.4. Using of one control panel for electric motors activation (additional requirement)For electric motors activation, which shall work prior to beginning of automatic cycle, it is

recommended to use only one control panel. However, if required, there shall be several "Stop"buttons.

6.3.2.7. Automatic mode, manual operation6.3.2.7.1. Machines with automatic cycle shall have, if necessary, the possibility of manual

individual operation of different elements to make checks or adjustments.When working in automatic mode, manual control buttons shall be disabled or shall operate

so as to exclude the possibility of intervention into machine automatic sequence.In manual operation, any possibility of automatic cycle start shall be excluded.Specific conditions of cycle start and safety precaution requirements shall be observed in

manual operation as well as in automatic cycle.



6.3.2.7.2. Additional requirementsOn machines with several operating control or other panels (for example, on index table

machines) each panel shall be fitted with individual devices for manual controlling of differentelements.

All manual controls (buttons, handles) shall relate to their panels. Each operator's panel orgroup of panels shall have locked up switches which allow to fulfil manual cycle control from thesepanels, in order to avoid accidental error in automatic mode.

6.3.2.8. Control of operation sequence in automatic cycle6.3.2.8.1. Travel sequence with electric controlIf continuous sequence of operation involves certain travels of the units (for example table

displacement), these travels must be directly controlled by path-control switches or positiontransducers which precisely define the position of these mechanisms.

If pressure transducer is served to restrict mechanism movements in hydraulic controlsystem by directly acting on the hydraulic system, the action of the transducer shall always beconfirmed by such a position transducer that directly restricts the mechanism travel or enablessubsequent actions.

The requirements of the proceeding paragraph should be ignored, if the position transducercan not be mounted due to small overall dimensions of the mechanism.

Dwell time devices shall only be used for verifying operations which present time-varyingfunction. They can never be used for travel restriction of the machine units.

6.3.2.8.2. Checking of operations execution (additional requirement)Interlocks shall be provided to prevent a new cycle if some operations have not been

completed (return, turning-over, checking, operation of heads).If memory have to be used for storing certain states, the stored information shall not be reset

with power switching-off, otherwise provision shall be made for interlocking that eliminatesinadvertent re-energizing with restoration of supply.

6.3.2.8.3. Interconnected travelsIf interconnection between some mechanisms is required for safe or continuous operation,

their performance shall be properly co-ordinated.

6.3.3. Methods and modes of equipment operation controlIf equipment is divided into stations, each station having one or more working heads (units),

provision shall be made, by means of control facilities, for each unit having the followingequipment condition:

6.3.3.1. "Exclusion"This condition shall exclude the working unit or assembly from normal working cycle of the

equipment, position control being retained at the same time. This condition shall be provided onlyfor those assemblies having such ability, nothing else being caused except for non-availability ofcertain kind of machining.

6.3.3.2. "Operation"This condition shall provide the operation of the working unit in one of the following

operation modes:6.3.3.2.1. "Automatic" - operating assembly shall be prepared for operation in automatic

mode with its incorporation in the whole equipment or in a single cycle for the working station.6.3.3.2.2. "Manual" or "Adjustment": operating assembly shall be prepared for local control

and shall enable division of the automatic cycle into simple movements. In this mode the controlsystem shall provide a multiple execution of the same movements. At the same time the equipmentfailure shall be excluded. Special "Stop" button is to be provided for movements which retain theiraction after releasing a button.



6.3.3.3. Transport unitTransport unit shall be controlled from the main control panel and provide the operation in

two modes:6.3.3.3.1. "Single cycle of transport unit": in this operation method, the transport facilities

shall be prepared to perform the whole cycle of parts transportation considering the positions ofworking stations and units.

6.3.3.3.2. "Manual transportation": this operation method shall allow division of automatictransportation cycle into simple movements.

6.3.3.4. Automatic mode of operation6.3.3.4.1. Equipment with automatic loadingEquipment with automatic loading shall be enabled to operate in the following modes:- general automatic cycle- part loading mode- part unloading mode.The general automatic cycle shall provide the following: continuous operation of the

equipment with feeding of blanks by loading device; machining of parts at every station;transportation of parts between operations; unloading of the machined parts by unloading device.The general automatic cycle should be enabled only on the full-loaded equipment with all interlocksin operation and with the parts available.

The control system shall provide for a single automatic cycle of equipment operation withthe possibility of division into operation cycle and transportation cycle.

Parts loading and their machining shall be performed in the equipment loading mode. In thiscase some interlocks associated with the availability of parts may be excluded from the operation.With full-loaded equipment, the subsequent operation in this mode shall be impossible andchanging-over to general automatic cycle is required.

Machining of all parts present in the equipment stations and their unloading shall beprovided in the unloading mode. Loading device shall not perform loading of parts. If necessary, thecontrol of parts availability may be omitted.

6.3.3.4.2. Equipment with manual loadingIn the machining on equipment with manual loading the workpiece and the finished part

shall move from one or two operators depending on whether loading and unloading stations arecombined or split.

In this case, the general automatic cycle will be just "Single", since the operator of loadingand/or unloading starts, upon the execution of a given operation, the automatic cycle of parttransportation and machining.

Depending on arrangement of loading and/or unloading stations there shall be two differentmethods or cycle start control:

- loading and/or unloading stations without barrier for isolating the dangerous area. Withsuch loading and/or unloading station there is no physical barriers between the operator and themachine. Therefore, the operator shall work by means of two-hand control with simultaneousinitialization device and with protection from repeated clamping of a part, if clamping is supposed.To start the cycle the operator shall use two-hand control where the operator operates the controlswith both hands as long as danger exists;

- loading and/or unloading stations with permanent or closable barriers. In this case, theoperator is guarded from the machine in the course of danger. When loading, the operator shallclamp the work part by means of two-hand control (if clamping is provided), the same control shallenable closing the protective guarding. At the same time the equipment receives the command tostart the cycle.

Similar safety requirements also apply to the unloading is in the case when loading andunloading stations are separated.

In any case common push-button control panel shall provide a division of general automaticcycle through the use of proper commands for separate movements.



General automatic cycle shall only be enabled with equipment fully loaded, all interlocksbeing enabled and parts available.

6.3.3.5. Distribution of commands in equipment operation controlThe equipment is already split by itself into working stations and units. Distribution of

control commands shall be based on this division.Each working station or unit shall have a push-button control panel including the following:

the control, if this is provided for, over incorporation/exclusion of this unit (head), cycle switchcontrol, manual head control, clamping/unclamping control (if available), spindle start/stop control(if available), rapid head return and necessary lamp signalling/warning lights.

Two or several stations or working heads (units) may be combined in one push-buttoncontrol panel, if required by the machine structure, provided that the above mentioned controlfeatures are retained for each station or working unit (head).

Moreover, equipment shall include a synoptic board. This board shall contain and clearlydefine, in the form of simplified equipment lay-out chart, all the lamp signalling of geometricalstations, memory and fault alarm signalling of different working units. Subject to agreement withthe Customer, this signalling shall be added with other possible signalling required by operationconditions of the given equipment.

The main push-button control panel is to be intended to receive all (control) commands ofputting into operation and cycle starting of the whole machine. This control panel shall also havecontrols of operation modes, clamping/unclamping controls (if available), cycle on/off controls,working heads return, emergency stop, manual control of transport unit.

For emergency stop control of the whole equipment one of the following two controlsystems shall be provided:

- if machine structure allows, one or two control cables are stretched along whole equipmentso as to cover the bigger part. In the case it is impossible and section of equipment is not covered, itis essential to provide emergency buttons on the push-button control panel close to these areas;

- if control system with control cables is unfeasible, all control panels shall have emergencybuttons.

6.3.3.6. Indication and diagnosticsIndication of positions of mechanisms or parts as well as working systems and operation

modes condition, execution of technological operations shall be provided for each equipment.Indication shall be effected by incandescent lamps and signaling means of appropriate colour. Theuse of other indicators is accepted on the agreement with the Customer. In deciding on controlequipment, it is preferred to use hydraulic equipment, limit switches, proximity switches, and etc.,with built-in indication of state.

All equipment shall be provided with readout of diagnostic messages on the equipment andservice systems malfunctions (operation of protection devices and various interlocks, malfunctionof limit switches, cycle overtime, malfunction of lubrication, cooling, hydraulic systems and etc.).The use of incandescent lamps may be appropriate to perform diagnostics on simple equipment.Segmented digital or alphanumeric indication shall be employed for the diagnostics of morecomplex equipment; provision shall be made for a special diagnostic device with message displayon the screen in accordance with performance capabilities of the diagnostic system. In every case,the type of diagnostics used shall be agreed with the Customer. Diagnostic system shall be passive,i.e. it shall not influence the process of equipment operation control. However, the cause of amalfunction is to be stored and kept until malfunction reset button is pushed.

6.3.3.6.1. Signaling circuitWhen using an individual signaling circuit not connected to the control circuit, it is desirable

to use voltage equal to 24 V a.c. or d.c. In this case 24 to 28 V indicator lamps are used.When using individual transformers built in the signaling devices, lamps for 6 V

(preferably) or 24 V shall be used. In this case the signaling circuit may be connected to the controlcircuit.



Electronic indication circuits may be designed for the voltage lower than 24 V. LEDs maybe employed for indication elements.

6.4. Design and location of electrical apparatus

6.4.1. General requirements for electrical equipment

6.4.1.1. Location of electrical equipmentElectrical equipment should be grouped together in one or several complete control units. It

is only allowed to mount on the machines those buttons, control switches, position sensors,couplings, motors that perform their function there.

Electric apparatus of large power may have individual complete control units for separatemachine units.

Heat generating elements (for example, resistors) shall be arranged so that temperature riseof all components inside the enclosure will remain within the tolerable limits.

Those components that generate considerable amount of heat, such as starting resistors toswitch on motors, shall be mounted in separate sections, ventilated as may be required.

6.4.1.2. Access to apparatus6.4.1.2.1. Electrical apparatus shall be installed in such a way as to provide an access to

them for replacement purpose as well as for their identification without moving the wires and theapparatus themselves. For those apparatus that require check-ups for appropriate actions or that mayrequire replacement, these actions shall be performed without dismantling of any machine units orparts except for opening of doors and removing of covers.

If special tools are necessary to dismantle the apparatus, they shall be supplied together withthe electrical equipment.

Electrical apparatus requiring an access for servicing and adjustments shall be placed at theheight of 0,4 to 2 m above the maintenance floor.

Contact clips of all apparatus and sets of terminals shall be located at the height of no lessthan 0,2 m from the maintenance floor. Moreover, sets of terminals shall be arranged so that wirescan be easily connected to them.

6.4.1.2.2. Additional requirementsElectrical apparatus or cells shall be mounted so as to provide an access to them for fixing

and simple replacement from the front without dismantling of load-carrying structure.6.4.1.2.3. Electric connectionsIf the equipment is designed for joint operation with other equipment, for example, a

machine tool and an interoperation transport, provision shall be made for electric connections(signal exchange) at the station of part transfer from one of the equipment to the other.

Electric connection shall be supplied to a terminal box located in the closest vicinity ofjointly operating equipment. Exchange of signals shall be effected via non-potential (dry) contacts.

6.4.1.3. Air gaps and leakage pathsElectrical apparatus shall be arranged in such a way that air gaps and leakage paths required

for them will correspond to those set in the standards for specific kinds of apparatus.Inside the protected enclosures conforming to item 6.2.1.1. a space between mechanical

parts which provide protection and live parts shall not be less than the value stated for air gaps andleakage paths in the table below, unless electrical insulating material is used.



T a b 1 e 20Space, no less than, at rated current, mmRated voltage,

V I > 63 A I > 63 Aup to 60 3 560 - 250 5 6250 - 380 6 8380 - 500 8 10500 - 680 8 10660 - 750 14 14750 - 1000 20 20

6.4.2. Complete control unitsComplete control units shall conform both to the following requirements and to the

requirements of item 6.4.1.

6.4.2.1. Degree of protectionTo ensure protection from direct contact with live parts and from foreign solids getting

inside, least degree of protection shall correspond to IP2X = (IEC - 529), but for easily accessiblesurfaces placed above the degree of protection shall be at least IP4X.

Protection from penetration of foreign solids and liquids shall be adequate considering theinfluence of the machine location environment (dust, chips and mechanical damages). Protectiondegree is also subject to sensibility of add-in components.

In the case when enclosure doors or covers are opened for normal operation of the machine(for example, to make the adjustment buttons or handles of some control switches easilyaccessible), adequate protection degree, no less than IP2X, shall be provided even when the doorsand covers are open.

Openings for air intake and exhaust during ventilation shall be protected from penetration ofchips and water and oil splashes by extra means (for example, using filters) or through appropriatearrangement and orientation.

If special enclosed space is used as a protective containment in the installation of completecontrol unit, then adequate degree of protection shall be provided for walls, doors, etc. againstpenetration of foreign solids, liquids and dust.

Some examples of electrical equipment and corresponding protection degrees are givenbelow (other protection degrees may be necessary as well, depending on specific environmentconditions of the installation):

1) ventilated, only containing starting resistors for motors and other equipment of largedimensions, - IP22;

2) ventilated, containing other equipment, - IP33;3) employed in ordinary mechanical plants and in metal-working industry - IP43;4) employed indoors where cleaning is made by water jet (from the hose), - IP55;5) for protection against fine dust, - IP65.

6.4.2.2. OpeningsAll openings in the enclosure, including those at the floor, base and in other parts of the

machine, shall be covered by manufacturer in such a way as to ensure the required protectiondegree for electronic equipment. Holes for laying wires shall be easily opened on the erection place.

No holes are allowed between enclosures of electrical equipment components and chambersof coolant, oil for lubrication and hydraulics or between those where oil or other liquid or dust mayget inside. These requirements are not applicable to electrical apparatus specially designed foroperation in oil (for example, electromagnetic couplings)or to the electrical equipment wherecoolant is used.



It is allowed to provide for appropriate holes at the base of the machine enclosures to let thecondensable moisture out.

If the enclosure has holes for its fixing, it is necessary to ensure that after finishing theinstallation they will not impair the required protection.

6.4.2.3. DoorsDoors are advisable (mainly detachable) for the enclosures, with vertically arranged hinges.The angle of opening is recommended to be no less than 95°. Doors shall normally be no

wider than 0,9 m.In case of doors locking with screws and bolts the latter shall be of captive type.

6.4.2.4. Layout of electrical apparatus6.4.2.4.1. At least 10% of spare area shall be provided in complete control units made to

custom design in order to provide for subsequent modifications of the equipment or adding it withsome more apparatus.

6.4.2.4.2. Additional requirementsNo electrical apparatus shall be mounted on doors, except for manual control facilities,

alarms and measuring devices.All apparatus energized from mains shall be grouped separately from those only operating in

control circuits.An input switch, described in item 6.2.6.2., subitems 1), 2), shall be mounted at the upper

part of the complete control unit (preferably at the right side), with the handle either in the front ofthe enclosure or on its side. No other apparatus shall be mounted above this switch.

6.4.2.5. Parts and elements unrelated to the electrical equipmentThe cabinets with electrical equipment shall not contain parts and elements unrelated to the

electrical equipment, such as1) mechanical parts requiring access under normal conditions of operation;2) moving parts (for example rotating shafts);3) facilities for equipment repair, not related to the electrical equipment.Electrical equipment shall be mounted so as not to restrain works on mechanical fettling of

the machine as well as maintenance of the mechanical, hydraulic or pneumatic equipment.

6.4.2.6. Arrangement and transport of complete control unitsDimensions of electrical panels and boards to be installed with electrical equipment shall

permit their passage through the openings of cabinets.Bulky and heavy complete control units to be detached from the machine during

transportation or located apart from the machine shall be provided with appropriate means forgripping them by cranes or other similar mechanisms.



6.5. Control devices

6.5.1. Requirements for control devices6.5.1.1. Arrangement and mountingControl devices shall be located in clean and dry place, wherever possible. They shall be

easily accessible for operation and maintenance. They have to be mounted so as to eliminate thepossibility of their damage by transport and other moving objects.

These control devices shall be positioned at the height of no less than 0,2 m from themaintenance floor. However, this requirement does not apply to those position sensors and controldevices that are actuated by foot. Requirements for manual control switches are mentioned in item6.6.2.1.

6.5.1.2. ProtectionAll control devices located outside the cabinets such as limit switches, electromagnetic

control valves, pressure relays, shall be protected from any effect of environment where machineoperates and against mechanical damages.

One or several of the following means shall provide protection:1) selection of appropriate place for these control devices;2) the use of materials and design of adequate strength to withstand mechanical effects;3) the use of shrouds and other means to prevent penetration of chips, dust, oil or coolant.Joints of shrouds, enclosures and other protection means are to be chemically resistant to

liquid, steam and gas used in the machine.Devices not mentioned in items 6.5.1.4. to 6.5.1.6. shall have protection degree of no less

than IP54.6.5.1.3. Control devices with connectorsIf connectors are used for junctions of control devices, the compatibility of their parts shall

be determined by similar design features or similar marking and (or) designation.The connectors that are attended during the normal operation mode shall be designed so as

to rule out their wrong connection.6.5.1.4. Position sensors (including proximity sensors)6.5.1.4.1. Mechanical position sensors shall be positioned so as to eliminate the possibility

of their failure in case of accidental overrun.Mechanical position sensors used in protection circuits shall be of a positive breaking action,

i.e. if the control of a device is in a position corresponding to its OFF-state, then the breakingcontacts must be open. This last position shall correspond to the travel length set by themanufacturer for satisfactory operation of the contacts. In this case the control shall be in operatingcondition. It shall receive direct rigid mechanical action.

If other types of position sensors (non-mechanical) are used for safe operation they shallensure the same degree of protection.

Position sensors with constant magnets can not be used to ensure safe work (for example, toprotect from overrun in accordance with item 6.5.2.4.6.).

Contact position sensors of instantaneous action are advisable in all cases except for thosewhen sensors are mounted in protection circuits.

When position sensors have no built-in adjustment components, then adjustable cams(stops) are to be fitted on the machine. Oval fastening holes for attachment of sensor should not beused for position adjustment.

6.5.1.4.2. Additional requirementPosition sensors are to be provided with a reversing-type contact component or only one

normally closed and one normally open contact. Three-position sensors operating in two directionsmay have this type of a contact set used for each direction. If many contacts are required, a relayshall be used. In the case when contacts of such pilot relay are used in protection circuits,requirements of item 6.2.7.1. shall be observed.

Position sensor design shall ensure least protection degree of IP55 in the process ofoperation.



If necessary, a mechanical drive shall be installed between the moving part and the controlof a sensor to provide better access and protection against water, oil, chips and etc.

6.5.1.5. Electromagnet mechanismsAll electromagnet mechanisms shall ensure normal operation after heating up to normal

steady-state temperature level of 65 -110 % of their rated value, except for those couplings forwhich fluctuations of 90-110 % are permissible regardless of air gap value, if it is adjustable.

N o t e: "Normal steady-state temperature" is the temperature that will be reached incontinuous operation mode in appropriate conditions and at rated voltage.

The windings shall not fail in continuous operation mode in appropriate conditions when thevoltage is exceeding the rated value by 10 %.

The windings of electromagnet mechanisms to be mounted outside the enclosures (controlvalves, brakes, couplings) shall be properly protected against condensation.

Terminal boxes or housings of windings or windings themselves shall ensure minimumprotection of IP55.

If a.c. electromagnets are used between the electromagnet and the unit under control, it isnecessary to provide an appropriate component (for example, spring component) to ensure completeclosing of magnetic circuit.

6.5.1.6. Pressure and thermal relays6.5.1.6.1. Contacts of pressure and thermal relays shall operate instantaneously and their

enclosures shall ensure the minimum protection of IP55 class.6.5.1.6.2. Additional requirementPressure and thermal relays are to be provided with one switching component or one

normally closed contact and normally open contact. Relay shall be used in the case of great numberof contacts. When contacts of such intermediate relay are connected to the protection circuit,requirements of item 6.2.7.1. shall be observed.

6.5.2. Requirement for manual switches and light signaling equipment6.5.2.1. Accessibility of switchesManual switch controls shall be easily accessible from operator's platform. They shall be

located at the height of no less than 0,6 m from operator's floor in such a way that operator canoperate them without being dangerously close to the moving or other parts of the machine.

The controls design and arrangement shall eliminate a possibility of accidental switching on.6.5.2.2. ProtectionProtection degree for controls, enclosures of control switches as well as caps of light

signaling accessories shall be at least IP54. The required protection degree is to be ensured whencontrols are subjected to the control action. Protection degree shall be no less than IP55.

6.5.2.3. Control buttons6.5.2.3.1. Relative arrangement of control buttonsThe related to each other "Start" or "On" and "Stop" or "Off" control buttons should be

arranged next to each other. "Stop" or "Off" buttons shall be positioned below or to the left of"Start" or "On" button, except when two "Start" or "On" buttons (or two groups of "Start" or "On"buttons) controlling the opposite direction of movement are available. In this case, "Stop" or "Off"buttons can be located in between.

6.5.2.3.2. Colour of control buttons1) Red colour shall only be used for "Stop", "Off" functions and for emergency button.Red colour is provided for "Stop" function or for de-energizing the main circuit, i.e. the

depression of red button should cause the equipment stop, switch it off or actuate a fire-alarmsignal.

2) Green colour if preferred for "Start" or "On" buttons that serve to enable switchgear.Neutral colour, such as black, white or grey, are accepted as well.

3) Buttons that serve at the same time for "Start" and "Stop" or "On" and "Off" functionsmay be the following ones:



- control buttons that with repeated depression will cause alternately "Start" and "Stop" or"On" and "Off" shall be black, white or grey. Do not apply red or green colour in this case.

- control buttons that, when depressed, initiate movements and, when released, stop themovements (for example, jog or set-up control buttons) shall be black, white, grey or green butblack colour is preferable. These buttons shall not be red.

4) Reset control buttons (for example, used with protective relays) shall be blue, black,white or grey with the exception of those reset control buttons serving to perform "Start" or "Off"functions as well, and in this case they shall be red.

5) Recommendations on colour application for control buttons are given in table 21.



Table 21Colour Function Application

Operation in emergency Emergency stop. Fire hazard preventionRed

"Stop" or "Off" General stop. Stop of one or several motors. Disabling of machine assembly.Cycle stop (should the operator push the button during cycle execution, themachine will stop upon completion of a cycle). Switchgear disconnection."Reset" combined with "Stop".

Yellow "Intervention" Interference to prevent abnormal condition or to avoid undesirable changes (forexample, machine mechanisms return to initial position before the cycleexecution, provided the cycle is not finished). Depression of yellow button maycancel commands meant to be performed before.

Green "Start" ** or "On" General start.Start of one or several motors.Enabling of machine assemblies.Activation of auxiliary functions. Connection of switchgear. Connection ofcontrol circuits.

Blue Any specific situation for whichthe colours shown in this tabledo not apply.

This colour serves to designate situations for which red, yellow, and greencolours are not applicable.

Black, grey, white No specific functions May be used for any functions with the exception for the buttons to perform only"Stop" or "Off" functions.Examples: 1. Black - jog or set-up operation mode. 2. White - control of auxiliaryactions having no direct relation to the operation cycle.

* - It is not recommended to apply other colours (for example, orange or brown) as to make clear distinction between different colours.** - If green or black colours are used for "Start" or "On" functions, it is recommended to apply green colour for preparatory operations,whereas black colour is for executive operations.



6.5.2.3.3. Designation of control buttonsIn addition to the functional designations it is recommended to indicate control buttons by

symbols either next to the button or directly on it, what is preferable.For example:1) "Start" or "On" - I,2) "Stop" or "Off" - 0,3) buttons performing "Start" and "Stop" or "On" and "Off" functions alternately, -4) control buttons which, when depressed, initiate movements and, when released, stop

movements -6.5.2.3.4. Mushroom-shaped control buttonsRed mushroom-shaped control buttons are designed for emergency stop both in manual and

automatic cycle. Mushroom-shaped control buttons of other colours may be used as "Cycle start" buttons

when two hand control is required (ref. 6.2.6.3.) or on machines with mechanical guards. In suchcases, pushbuttons shall be red. It is recommended to use black or grey colours.

6.5.2.4. Light signaling accessories (signaling lamps)Lamps fitted with screw bases are not used for light-signaling accessories, being energized

from voltages up to 24 V. It is recommended to use lamps with bayonet bases.6.5.2.4.1. ApplicationPowered illuminating fixtures (generally luminous signs) are intended to indicate the

following:1) that operator shall perform a certain action;N o t e. In such cases the most frequently used colours are red, yellow, green and blue;2) confirmation of either position or state command or confirmation of changing or transient

process being run;Note. In such cases the most frequently used colours are blue and white, and in specific

cases green.6.5.2.4.2. Blinking lamp signallingFlashing lamp signalling is used for highlighting the information, particularly to add

expressiveness, in the following cases:1) to draw more attention;2) to cause immediate action;3) to show a mismatch between the command sent and the actual state of the associated unit;4) to show the changing process under operation (flashing during transient process)If flashing indication with different flashing frequency is usedfor information of different

level of importance, then the higher frequency flashing shall denote more important information.6.5.2.4.3. Colours of light signalling fixturesAs shown in column 2 of Table 22 below, red, yellow, green colours are to be used for light

signaling fixtures.These three colours shall not be used for light-signalling fixtures to designate any other

functions.Blue and white colours for light-indicating fixtures are to be used in other cases, as shown in

table 22.



Table 22

Colour Meaning Explanation ApplicationRed Danger or alarm Warning of a possible danger or of a

state which requires immediate action.Switched on state of the power consuming equipment that cando harm to the personnel.Pressure drop in lubrication system. Temperature exceeds thetolerable (safe) values. Immediate stop of the machine in caseof overload.Protective device action caused a stop of an importantmechanism.Danger from live and moving parts.

Yellow Warning Changing of state or warning of thischanging.

The switch is in "Setting up" position Overload that may only exist for a certain period time.Automatic cycle run.

Green Safety Indication of a safe state or enabling acycle as well as freedom of actions.

Switched on state of the power consuming equipmentCoolant circulation.Automatic control of temperature rise is enabled.Machine is ready to operate - all necessary devices are inoperation, set in the initial position; pressure in the hydraulicsystem or motor-generator output voltage corresponds to therated voltage etc

Green Automatic cycle progressBlue Dedicated, for

special cases, ifthere is a need insuch signal.

Blue colour may be assigned to anysignal, which do not bear the functionsof the above mentioned colours: red,yellow and green.

Selection of speed or rotation direction. Indication of a remotecontrol. Device is in end position. Creep speed of support ormechanism.

White Not for specificsignals.

For any purpose: may be used whenapplication of the three colours: red,yellow and green (for example, forconfirmation) is doubtful.

Input switch is enabled. Choosing of speed and rotationdirection. Auxiliary actions regardless to the automatic cycleare enabled.Cycle is complete and the machine is prepared for newswitching on.



6.5.2.5. Control buttons with built-in alarm6.5.2.5.1. General requirementsThe control buttons with built-in alarm are to meet the following requirements:1) not to change the colour both when in enabled and disabled state;2) to return a pushbutton to the initial position by itself after it is released.Meanings of colours shall strictly correspond to Table 23 given below; if they are not shown there,

directions of items 6.5.2.3.2. and 6.5.2.4. should be followed. If a control button with built-in alarm cannot meet these requirements, control buttons and light-signaling accessories should be used separately.

Control buttons with built-in alarm shall not be used for setting and jogging movements as well asfor emergency shutting-down.

Control buttons with built-in alarm shall not be used as light-signaling fixtures when built-inbuttons serve, in depressed state, to check out working order of lamps.



Table 23Colour and

purposeMeaning Explanation Application and notes

1 2 3 4RedIndication

x "Stop" or "Off" and in some cases "Return"(when this button serves to perform "Off"function as well).

Yellow (amber)Indication

Attention or warning Enabling of actions which eliminateemergency state..

Some values (current, temperature) reachtheir tolerable values. Depression ofyellow control button can eliminate someactions set for execution before.

GreenIndication

Machine or assembly is ready tooperate

"Start" or "On" after permission is given witha pushbutton became illuminated.

Start of one or several auxiliary motors.Enabling of machine units.Enabling of magnetic chucks and plates.Cycle start or start of its partial sequence.(Operations)

BlueIndication

Any situation to which the abovementioned colours and whitecolour do not apply.

Any other functions not being provided withthe above mentioned colours and whitecolour.

Indication or instruction for operator toperform a certain job (for example, tomake an adjustment - upon completion ofthis action the operator enables thepushbutton to confirm execution)

White(colourless)Confirmation

Constant response alarm thatconfirms a live circuit or thatan action or a movement beganor switched over.

Closing a circuit, enabling or preliminaryswitching (pre-selection).

Enabling of the auxiliary circuit havingno direct relation to the operation cycle.Enabling or switching the directions,feed, speed and etc.

* the use of red control buttons with built-in alarm is not recommended, however, if they are provided, their function shall strictly comply withthe requirements of item 6.5.2.3.2.



6.5.2.5.2. Application1) IndicationPushbutton shall light up in order to indicate the operator that the illuminated pushbutton

may or must be pushed or, in certain cases, the operator shall first perform a certain action and thenpush the button. The acknowledgement or execution of an instruction commanded by depression ofa button is confirmed with the lamp switching off.

Sequence of action: the pushbutton lights up, and then a button is pressed.Note: 1. In these cases, the most frequently used colours are yellow, green or blue.2. To attract attention, for example, in the case of an emergency, flashing alarm may be

used. With this application of the control button, depression of a pushbutton can switch a flashingsignal on to the continuous lighting. A button can function only in accordance with therequirements of item 6.5.2.3.2. Continuous lighting is actuated as long as emergency exists. Anemergency state is eliminated by special operation.

2) ConfirmationUnder depression of non-illuminated pushbutton its lamp switches on. This Indicates that

the instruction provided by pressing a button is acknowledged or executed.Sequence of action: a lamp lights up only after a button is pushed.Note: 1. As a rule, white colour is applied with this purpose.2. White control buttons with built-in indication are used with flashing lights to give an

instruction of "double confirmation". Upon depression of a pushbutton a lamp lights up and flashes,confirming the beginning of starting process, successive operation or transient process. Uponcompletion of these processes, the indication automatically changes on to the continuous lighting,confirming that the process has been stabilised.

6.5.2.5.3. ApplicationRecommendations on colour usage with different functions of the control buttons with built-

in lamps are given in table 23.

6.6. Wires and cables

6.6.1. Types of wiresSingle-stranded wires may be used for connections only between stationary parts. In all

other cases as well as under vibration flexible and multi-stranded wires shall be used.All 0,5 mm2 wires and over shall be multi-stranded and flexible.All connections subjected to frequent moves shall be provided with highly flexible wires.The use of bare wires is allowed on the load side downstream the input switch, provided that

their diameter is no less than 3 mm (for round section wires) or their thickness at least 2 mm (forsquare section wires). They shall be rigidly wired between stationary parts and properly protectedfrom accidental touching.

6.6.2. Insulation of wiresInsulation of wires should offer high chemical resistance (for example, to lubrication or

liquids used in the machine) of no less than PVC insulation usually provides.Wires intended for specific conditions of operation (for example, exposure to high

temperatures, liquids or solvents) shall nave insulation specially designed to work in theseparticular conditions.

Mechanical strength and thickness shall be such that insulation is not damaged duringoperation or wire routing, especially when pulling of cables in channels.

Dielectric strength shall be sufficient to withstand voltages as specified in item 6.10.2., butno less than 1500 V for wires intended for operation under voltages higher than 50 V a.c. RMS or120 V d.c. peak value.

6.6.3. Wire cross-section (gauges)Wire gauges shall be such as to withstand maximum continuous current under normal

operation conditions considering the environment influence (for example, cooling, close location of



heat dissipating elements and units). The effects the conductors have upon the elements and unitslocated in close proximity may limit their permissible temperature.

Gauges of insulated wires for laying:1) inside the enclosures;2) between the separate enclosures of one machine;3) between the above enclosures and the machine;4) between separate parts of the machine;5) on and inside the machine,shall meet the requirements of items 6.6.3.1. - 6.6.3.3.Note: (for electronic equipment)Wires of electronic circuits, carrying stabilized currents of no less than 2 A, located inside

the enclosures for protection of electronic equipment may differ from those wires as per items6.6.3.1. and 6.6.3.3.

6.6.3.1. Maximum permissible loadsWire gauges shall be determined in accordance with columns 2 and 3 of Table 18 depending

on the maximum permissible current in the associated circuit under normal operation.Wire gauges at the reduced values of the maximum permissible currents shall be determined

in accordance with columns 4 and 5 of the same Table.If wires are intended for laying inside building walls, the gauge of their conductors is

determined according to the rules set for electrical equipment of the building.Thermal equivalent current may be used to determine the gauges of wires working at

variable load, i.e. R.M.S. of direct current provided that duty cycle duration is considerably lessthan a time constant of wire heating.

6.6.3.2. Voltage dropThe need in wires with gauges greater than specified in item 6.6.3.1. may arise to avoid

intolerable voltage drop when switching on power to the coils of d.c. electromagnets during electricmotor start or under different short-time overloads, particularly in extended circuits or when wireswith small gauges are used. In such cases, consideration must be given to wire impedance, short-time overload current, voltage drop in power source connection points and tolerable voltage drop onterminals of elements to be powered.

6.6.3.3. Minimum gauges for copper wiresFor mechanical strength reasons, gauges for copper wires shall not be less than specified in

Table 24 below.

Table 24Minimum gauge of copper wires, mm2, no less than

single-core multicore

2-core

Location and purpose

flexible rigidshielded without shield

3-core andmultiple-core

Outside the enclosuresConnection of machineparts subjected to frequentmoves (flexible wires only)Connection of circuitswith very low currents

I

1

1

1.5

-

1.5

0.75

1

0.3

0.75

1

0.5

0.75

1

0.3

Inside the enclosuresConnection of circuits withvery low currents

0.750.2

0.750.2

0.750.2

0.750.2

0.750.2



Wires with smaller gauges may be used in those cases when it is required by electricalequipment design, providing reliability in operation.

6.6.3.4. Minimum gauges for aluminium wires shall not be less than 16 mm2.

6.7. Wiring

6.7.1. General requirements6.7.1.1. ConnectionsAll connections, especially those for protective circuits, shall be protected from accidental

loosening.Connecting means in all cases shall match the gauge and type of conductors to be

connected. N o t e: If some terminal types are not suitable for connection of small gauge multi-

stranded wires, in this case adequate connections can be achieved by means of lugs for connectionof wire ends.

Only one conductor should be connected to one terminal. Connection of two or moreconductors to one terminal is only accepted in case that the terminals are designed for this purpose.

If for maintenance of the machine it is required to remove, displace, or change theconnections made with special tools, it is necessary to supply such tools to the Customer and toprovide its servicing.

6.7.1.2. Arrangement of wiresAll wires shall be routed directly from one terminal to another without intermediate

connections. Branching is only allowed in easily accessible yet closed terminal boxes, or inbranching boxes, refer to item 6.7.1.6.

Wire loops of sufficient length shall be made in the boxes to provide disconnections andreconnections.

2) Conductors' ends of multicore wires shall be fastened if they are subjected to excessivemechanical load.

3) Protective wire should be laid alongside the live wires in order to reduce loop impedancein case malfunctions occur.

6.7.1.3. Connection to moving partsConnection to components mounted on the doors or other moving parts shall be done with

flexible wires so as to allow frequent and easy opening of doors without fear of their possibledamage. Wires shall be fastened both to moving and fixed parts of the machine regardless of theirends being connected to the terminals or not.

6.7.1.4. Wires destined for different circuitsWires destined for different circuits may be laid next to each other in a common channel or

may run through a multicore cable. If they are intended for different voltages they shall be separatedwith appropriate partitions or have high-voltage insulation, where high voltage is applied to thewires in this enclosure.

The circuits not running through the input switch shall be laid separately from thosepowered through the input switch.

6.7.1.5. Cable lugsIf possible, the use of solder lugs should be avoided. If electrical equipment is subjected to

intensive vibrations under normal operation, the use of solder lugs is not allowed.Soldered connections are only accepted when these components have terminals designed for

soldering. If this electrical equipment is subjected to intensive vibrations under normal operation,the wires shall be fastened by mechanical means at a small distance from solder points.

6.7.1.6. Terminals and junction boxesAll terminals shall be installed inside easily accessible enclosure. Junction and inlet boxes

installed on the machine as well as corresponding entrance holes shall have the minimum protectionlevel of IP54. Cover seals shall be resistant to corrosive liquids, steam and gas used in the machine.



It is recommended that these boxes do not have through entrance holes. However, ifprovided, they shall ensure the minimum protection level of IP54, even when applying mechanicalload after these boxes are installed in place.

The required protection level shall not depend on the installation method of a box.

6.7.2. Marking of wires6.7.2.1. Marking of protective (PE) or neutral (N) wiresProtective wire shall be easily identifiable by design, location, marking or colour. When

colour is used for identification it shall be yellow-green (double colouring). When single-coreinsulated wire is used as protective wire, such colour coding shall be applied throughout the length.

Yellow-green colour coding is intended solely for the protective wire.Neutral wires of power circuits and midpoint wires shall be easily identifiable by design,

location, marking or colour. When colour is used for marking of the wires, blue colour should beused.

When power circuits contain neutral wire or midpoint wire, blue colour is unacceptable formarking any other wires of this circuit.

6.7.2.2. Marking of other wiresIf colour coding is used to mark single-core wires, it is recommended to use the following

colours (especially for machines):1) power circuits (a.c. or d.c.) - black;2) control circuits (a.c.) - red;3) control circuits (d.c.) - blue;4) wires of process lighting circuits should be of black colour.As a rule, the control circuit wires that are connected to protective or neutral wires shall not

be marked with yellow-green or, in case of using neutral wire, with blue colour. However,connection of control circuit to the protective wire shall be marked with yellow-green colour.

Blue colour is recommended both for a.c. control circuit and to neutral wires (light blue). Inboth cases the same blue colour is accepted. Distinction by means of different colour hues is notrequired, because the differentiation of power circuits and control circuits d.c. should be providedby other means (for example, by arrangement or marking of terminals).

Green, yellow and combination of several colours is unacceptable in marking single-corewires. This requirement does not extend to using of different cores with one- and multi-colourinsulation in multicore wires.

Different cores of multicore wires can be marked by numbers or by colour. Cable shall beused in wiring of control cabinet lighting circuits powered before the lead-in circuit breaker.

6.7.3. Wiring inside the enclosuresElectrical equipment shall be designed in such a way as to provide the possibility of

changing the wiring from the front side of the enclosure.6.7.3.1. Installation in internal ducts1) Ducts inside the enclosures shall not be filled up to more than 90% (of their accepted

capacity) as to make provisions for adding the wires through these ducts later on.2) Wires run outside the ducts shall be properly fixed.6.7.3.2. Terminal and connector sets1) When more than 10 conductors run into the enclosure, terminal or connector sets shall be

provided for them in control circuits and alarm circuits as well. Such connecting components shallhave conventional alphanumeric marking. Power cables and cables of measuring circuits can bedirectly connected to apparatus terminals.

2) Additional requirementsFor connection to the components mounted on detachable doors provision shall be made for

fitting terminal or connector sets on panels, enclosures or on the doors.6.7.3.3. CheckpointsRequirements for electronic equipment



To facilitate fault detection and necessary adjustments, it is recommended to providecheckpoints on PCBs. If these points are available, they shall be:

1) marked in corresponding circuits with conventional graphical symbol "Checkpointindicator";

2) easily accessible;3) properly insulated;4) placed at a sufficient distance from each other as to enable connection of check wires.Provision should be made (for example, voltage dividers) for peak voltage value limitation

up to 1000 V between these checkpoints or between these points and protection circuit.

6.7.4. Wiring outside the enclosures6.7.4.1. Routing in external ductsAll wires running outside the cabinets, except for those having appropriate protection shall

be arranged in the ducts that provide proper mechanical protection as well as sufficient protectionagainst fluids, chip and dust.

1) Ducts sizes shall be of those as to enable to lay additional cables, except for power cables.2) Wires insulation shall be protected from damages where it comes in contact with sharp

edges, threads and rough surfaces.3) Wires may run in the ducts available inside the machine bed, without additional

protection, subject to IP54 class protection provided against fluids, chip and dust getting inside.4) All ducts shall be fixed and arranged in such a way as to prevent mechanical damages and

wearing.5) The ducts shall have partitions for separation of power cables (wires) and those of control

circuits.6) Cables (wires) of measuring circuits shall be laid in separate ducts.The duct route shall not pass through machining area and those areas where coolant is used.

They shall be arranged in such a way as not to be damaged by load handling and transportingmechanisms.

Ducts of external connections used for wiring between the machine and enclosures orbetween the machines shall be properly fixed and placed at a suitable distance from any movingpart of the machine. The lowest part of a channel to be laid in passageways shall be at the height ofat least 2 m from the floor.

When design of the building allows laying of ducts or wires, it is necessary to follow therequirements of item 6.6.3.1.

7) In order not to mix up conduits for protection of wires with oil and water pipes, it isrecommended to lay conduits apart from these pipes, not being intended for electrical usage. If it isimpossible, all pipes shall be properly marked.

8) Additional requirementsDucts shall meet the following requirements:- to be made of sheet steel, at least 1 mm thick, or other material providing the same rigidity;- the minimum class of protection shall be of IP33.When terminals are placed inside the conduits, the class of their protection shall be of IP54

and terminals shall be arranged in such a way as not to damage wires. Mounting of terminals insidethe conduits on the machines is not acceptable;

- they shall be fitted with removable covers. They shall not have holes other than requiredfor laying cables.

6.7.4.2. Connection to movable units of the machineFlexible wires shall be used in making connections to those units with electrical equipment

inside that are movable or subjected to displacement during adjustments.Cable sheaths shall withstand loads caused by moving parts as well as by effect of oil,

coolant, chip and heating.1) Movable cables shall be secured so as to prevent mechanical loads and core kinks at the

points of their connection.



Hanging loop shall be long enough to provide 10 times greater the bending radius than cableouter diameter.

If movable connections pass near moving parts, it is necessary to provide a distance of noless than 25 mm as to protect wires from being damaged, with this distance between moving partsand wires being permanent. If it is impossible to maintain such a distance, it is necessary to providefixed barriers between wires and moving parts.

2) If pendants are provided, their frames shall be supported with a hanger so as to avoidtension in electrical wires.

3) Flexible hoses shall ensure proper protection against oil, coolant and dust.Flexible spiral wrap hoses shall not be used for fast and frequent moves.The ends of metal conduits shall be properly connected with grounded parts of the machine.6.7.4.3. Connection of devices on the machineIn compact machines having a number of switching units (such as limit switches, control

buttons) connected in series and (or) in parallel, it is recommended that the connecting wires arelaid to lead terminals thus forming intermediate, well-arranged checkpoints protected withenclosure. These control points shall be shown in the corresponding diagrams.

6.7.4.4. Connector assembliesThe connector sockets shall be connected on power supply side.1) For circuits different from those being considered in items 6.2.1.2.3. and 6.2.1.3.,

connector plugs and sockets shall be made so that contacts of protection circuit close earlier thancontacts of live circuits and, conversely, they shall not open until all wires of the circuit beingconnected to the plug are de-energized.

2) Connector plugs and sockets shall be of such types that exclude accidental contact withlive parts even during their switching on and off.

3) Connector plugs and sockets shall fit each other in size and provide sufficient contactpressure and resistance to wearing in order to achieve constant electrical contact in all circuits. Airgaps between connector contacts shall correspond to voltages applied. These gaps shall remainfixed when connecting and disconnecting plug and socket parts.

4) Connector plugs and sockets remaining connected under normal operation shall beprovided with special devices to prevent accidental disconnection.

5) Connector sockets for rated current from 25 A and higher or those being fitted whereprotection level higher than of IP43 is desired, shall be provided with covers to protect against dustand liquids getting inside when the plug is removed.

6) When more than one plug and socket is used in the same electrical equipment, they shallbe properly marked. To avoid misconnection, it is recommended to have mechanical code.

7) Sockets for household use shall not be applied in control circuits6.7.4.5. Dismounting for transportationIf dismounting is envisaged for some parts of the machine in the transportation, then

appropriate terminals or connectors shall be provided for all wires to be connected. Such terminalsor connectors shall be properly covered, while wires and the associated terminals shall have thesame marking.

6.7.4.6. Reserved wiresAll channels containing wires for different circuits (except for those used in power circuits)

are to be provided with extra wires to make modifications and repair.



6.8. Electric motors and actuators

6.8.1. General requirementsAll electric motors and actuators shall comply with the standards of IEC-34. (International

Electrotechnical Commission)

6.8.2. DimensionsDimensions of electric motors shall comply with the standards of IEC-72. (International

Electrotechnical Commission).

6.8.3. Specifications6.8.3.1. Specifications of electric motors shall be chosen depending on the conditions they

are to operate in. On this basis, they may be subdivided into:1) electric motors for continuous operation;2) electric motors for frequent starting and braking by plugging;3) electric motors with increased motor slip for drives of machines having high moment of

inertia (for example, electric motors for presses);6.8.3.2. In deciding on the electric motor, attention must be given to the following:1) tilting moment and minimum turning moment during acceleration, which should be

comparable with moment of resistance of the machine;2) required maximum torque, rated torque required for continuous operation;3) overload capacity and slip values;4) starting and braking frequency;5) change of load as function of time. 6.8.3.3. Additional requirementsElectric motors insulation class shall not be lower than heat resistance of 120 (E) in IEC-85.

For reversible motors and for more than 7.5 kW motors it is recommended to employ built-inthermal protection or equivalent overload protection.

Power supply voltage of actuators (including electromagnetic drives) should not exceed 220V a.c.

For electric motors and actuators mounted at a height of more than 2.5 m it is allowable,when laying the cable, to use sections of cable unprotected from mechanical damages at the area ofmotor or actuator connection, the unprotected cable length being no more than specified below:

Power of the loadskW

Unprotected cable lengthmm

5.010.020.030.0

over 50.0

150250350450500

6.8.4. Type of enclosureThe protection level of a.c. electric motors with built-in impeller to cool the stator, or

without it, as a rule, shall be of IP44. Additional ventilation may be required in individual cases.Electric motors built-in as an integral part of the machine shall be mounted so as to ensure

their appropriate protection from mechanical damage and keep their temperature within the limitsspecified in the present technical specifications.

6.8.5. Mechanical vibrationsIf motors with limited vibration are required for proper operation of the machine, then this

characteristic shall be indicated on the nameplate and in the list of the electrical equipment.



6.8.6. Methods of motor connection to the mainsWhen exact power rating data is not available, direct connection to the mains is allowable

for electric motors of up to 15 kW. For motors with high starting current this value shall be reducedrespectively.

Note. The Customer shall pay attention to the following factors that may influence theallowable rated power in case of direct connection of the motor:

1) characteristic of the supply main at the point of the machine connection;2) characteristics of supply main transformer(s);3) power supply specifications.4)

6.8.7. ArrangementElectric motors shall be arranged so as to provide easy access for inspection, repair, and

lubrication as well as for cables disconnection and dismantling. Tension adjustment or change ofbelts, chains and clutches are to be convenient.

Particularly easy access shall be provided for fastening screws, terminals, slip rings, brushesand lubrication points.

In the replacement of motors, safety shall be provided to avoid their damage.The recesses for the motor installation shall be clean, dry, with ventilation holes coming

directly outside the machine. The holes shall be located high enough above the floor or themaintenance platform, so as to keep them out of dust, chips and water drops during cleaning.

There shall be no holes between motor niches and any other niches when they do not meetthe above requirements.

6.8.8. NameplatesIf motor is built into the machine or if the nameplate on a motor placed in niche is not

clearly visible, it is necessary to fix a duplicate of this nameplate just close to the motor in an easilyaccessible place.

A nameplate that shows a direction of motor rotation shall be provided if the rotation inwrong direction may be dangerous to the operator or may cause damage to the machine.

6.9. Connection of appliances and local lighting

6.9.1. Connection of appliances6.9.1.1. Power supplyIf electrical equipment or machine is fitted with connector sockets for appliances the last

may be connected to the supply circuit through the lead-in circuit breaker on the main side or to thetransformer secondary.

Contacts shall be provided for the connectors in order to connect protective wire, however itis not required if power is supplied according to item 6.2.1.2.3. or 6.2.1.3.

If appliance is fed from transformer, its rated power shall be no less than 100 VA. Thefollowing voltages are recommended for transformer secondary windings: 110V, 50 Hz; 220V,50Hz.

If extra-low voltage is required for safety reasons, then it is recommended to apply 24 V,50Hz.

6.9.1.2. ProtectionShort-circuit protection shall be provided for ungrounded wires of the circuits that power

appliances connected through the sockets.6.9.2. Local lighting of the machine6.9.2.1. Power supplyStationary or built-in lamps may be directly supplied with the mains voltage, however, the

voltages shall be limited to 250 V are.



It is advisable to power the local lighting circuits, especially incandescent lamps, from atransformer with isolated windings.

Wires for portable lamps shall have protective wire if they do not comply with therequirements of items 6.2.1.2.3. and 6.2.1.3.

6.9.2.2. Lighting circuits protectionAll ungrounded wires of lighting circuits shall have short-circuit protection by automatic

circuit breakers specially connected into such circuits.6.9.2.3. LuminairesLuminaires shall be suitable for use in production area.Lamp holders to be made of insulating material.If the supply voltage is over 42 V, the light switch shall not be built into lamp-holder or

mounted at the break of a supply cable. However, this switch may be mounted on the lamp.Lamps reflectors shall be fixed to lighting fittings, but not to lamp-holder.6.9.2.4. Luminescent lampsWhen using luminescent lamps, it is necessary to minimize stroboscopic effect.

6.10. TestsElectrical equipment of each machine shall be subjected to the following tests or checks:1) insulation test as per item 6.10.1.;2) voltage test as per item 6.10.2.;3) check of protective circuit continuity as per item 6.10.3.;4) no-load test as per item 6.10.4.1.One machine of each type shall be subjected to the following type tests:1) on-load operation as per item 6.10.4.2.;2) other tests as per item 6.10.2.

6.10 1. Insulation testInsulation resistance measured at 500 V d.c. applied between short-circuited wires of power

circuit and directly connected to them control and alarm circuits on the one side, and protectioncircuit that includes machine frame on the other, shall be no less than 1 megOhm.

If control circuits have no direct connection to the power circuits, it is necessary to carry outindividual tests:

1) between power circuits and protective circuit;2) between power circuits and control and alarm circuits;3) between control and alarm circuits and protective circuit.For electrical equipment of large dimensions it is allowable to carry out separate tests for

each unit.Components that may be damaged by the test voltage when it appears on terminal clamps

can be short-circuited during the test.Control and alarm circuits with the voltage lower than 42 V, including circuits as per items

6.2.1.2.3. and 6.2.1.3., shall be tested if they do not incorporate electronic elements.Circuits not being tested are to be connected to the protective circuit during the tests.Note: Before the test voltage is supplied, all deliberate connections between power

circuits, control and alarm circuits made for protection purpose shall be eliminated. Uponcompletion of a test these connections shall be restored.

6.10.2. Voltage testsElectrical equipment shall be subjected to voltage test during 1 min., where voltage is

supplied:1) between short-circuited wires of power circuits, including any control and alarm circuits,

connected directly to the power circuits and protective circuit, including machine frame;2) between control and alarm circuits (if available) with rated voltage from 42 V a.c. and

110 V d.c. and higher, not being directly connected with power circuits and protective circuit.



The value of test voltage shall make up 85% of the lowest voltage that have been used fortesting of elements and units prior to installation at the minimum a.c. voltage of 1500 V.

Such voltage shall be supplied from the transformer with power rating of at least 500 VA.Individual tests of separate units are accepted for electrical-equipment of large dimensions.Elements and units that are not designed for such high test voltage (rectifiers, capacitors,

electronic units) may be switched off during a test. Nevertheless, any interference suppressioncapacitors connected between the live parts and unprotected current-conducting parts shall not bedisconnected and shall withstand this test.

6.10.3. Check of protective circuit continuityProtective circuit continuity check shall be carried out by visual inspection, whether it

corresponds to the requirements of item 6.2.1.2.1.In case of a doubt, it is necessary to check the resistance between terminal clamps of outside

protective wire and any unprotected current-conducting part of electrical equipment and machine(frame); this resistance shall be no more than 0,1 Ohm.

6.10.4. Performance tests6.10.4.1. No-load performance testsOnce electrical equipment has been connected to the power circuit with appropriate

parameters (for example, with the highest limits of supply voltage variations) it is necessary tocheck all parts of electrical equipment for proper functioning and following the right controlsequence.

Special attention shall be given to the check of emergency shutdown components foroperable condition.

6.10.4.2. Performance test under loadWith the machine operating under rated load in continuous or special mode, the excess

heating of the employed components over the rated ambient temperature shall be no more than thelimit value defined in the present technical specifications.

It is necessary to make sure that all parts of electrical equipment are in good operation,particularly, that switching off and restoring power supply of the machine can cause no danger tothe service personnel and no undesirable operation of the electrical equipment or the machine.

For safety reasons, it is necessary to check reliability of electrical equipment emergencyshutdown under load by means of tripping devices. If this test involves possible fault, appropriatemeasures shall be taken to eliminate it.

6.10.5. Other testsIn the course of standard testing of the machine by visual inspection, trial run or by means

of calculations, it shall be checked for conformity to the requirements of the present standard,except for the requirements as per items 6.10.1. - 6.10.4.



7. HYDRAULIC EQUIPMENT

7.1. Fluids

7.1.1. Types of fluidsAll hydraulic systems shall operate on oils indicated in table 15 OTU-2-2000.Synthetic non-flammable fluids and water-glycol fluids are to be used subject to the

Customer's approval.

7.1.2. Operating temperaturesHydraulic systems shall be designed so that the temperature of operating fluid does not

exceed the temperature rating for a given fluid.

7.1.3. Fluid contamination in hydraulic systemsHydraulic system shall be separated from lubrication and cooling systems. No leak is

tolerated from one system into another system.

7.2. Hydraulic systemsIn designing or manufacturing hydraulic systems the Supplier shall adhere to generally

accepted standards and OTU-1-2000. The apparatus are to be supplied by companies listed in OTU-2-2000.

Preference is given to the fitting of hydraulic systems with the hydraulic apparatus of plug-in-type or module-type.

7.2.1. Peak pressuresDesign, manufacturing and adjustment of systems shall be so as to reduce pressure peaks to

a minimum. The employed component elements shall withstand peak pressures.

7.2.2. Protection7.2.2.1. Protection from excessive pressure

Every hydraulic system shall have a device limiting the maximum pressure.7.2.2.2. Adjustable controlsAdjustable elements are to be equipped with devices interlocking adjustment when required.

Plates attached to pressure regulating devices by the Manufacturer shall have the distinct indicationof minimum and maximum limits of the operating pressure.

7.2.2.3. Interrelation of auxiliary devicesIn the event that the same equipment has a great number of automatic (or manual) devices

and if the fault of one of them can cause damage to the equipment, it is necessary to provide for theinterlocking safety guards. Wherever possible they shall stop all operations (but release neitherretainers nor indexing mechanism clutch nor holders) in order to protect the personnel againstinjury when the operations are interrupted.

7.2.2.4. Interrelation of pumpsIf several pumps are involved in operation, provision shall be made for their interlocking.7.2.2.5. Interlocking of pump operation sequenceIn the event that confusion of pump operation sequence can inflict an injury on personnel,

damage the apparatus or render production process inconsistent, it is necessary to provide for theappropriate interlocking system in order to ensure the correct sequence of operations.

7.2.2.6. Protection of pumps connected in parallelIf pumps are connected in parallel it is necessary to provide for valves designed to isolate an

individual pump while the others are in operation.7.2.2.7. Protection against pressure dropThe system shall be equipped with protection means ensuring the equipment shutdown as

the pressure drops below the minimum value required for reliable operation.



7.2.3. Cycle durationVariations in work load and fluid temperature shall not cause deviations incompatible with

operation and duration of the cycle. The equipment systems that requires constant feed speed shallhave constant output irrespective of the counter-action force, pressure instability and fluidtemperature fluctuations.

7.2.4. Emergency control systemEmergency controls shall have the following features:1) Retainers, indexing mechanism clutches, couplings, clamps, fixing elements are not to be

released;2) They shall be of instantaneous action;3) They shall be independent and not sensitive to adjustments of other controls or the

reduction of output;4) They shall have a shut-off valve in supply lines upstream the servo valve;5) All emergency operations shall only be brought into operation by means of one electrical

emergency control;6) They shall as quick as possible put the equipment into the least hazardous conditions for

the operator and the equipment.

7.2.5. Reset controlIn the event that the apparatus is controlled automatically, it is necessary to provide for

independent manual control that can put servomechanisms back to initial position of movement (ifequivalent electrical controls are not available).

7.2.6. Sequence controlIf operation desequencing can cause dangerous conditions, failure of the equipment and

disruption of production process, it is necessary to use hydraulic apparatus with mechanical control,interrupter-limiters or other position-sensitive devices.

7.2.7. Successive operationSystems of such equipment that has two or more movable head components, slides,

servomechanisms (or a combination of the listed elements) shall be designed so as to operate inrequired sequence irrespective of load variations.

7.2.8. Simultaneous operationIn the event that the flow of fluid from one pump is used for simultaneous control over two

or more servomechanisms, provision shall be made for devices designed to distribute proportionallythe fluid so that both the servomechanisms operate properly.

7.2.9. Gradual speed variationFor large mass components in movement it is desirable that the transition phase between

two considerably different speeds is reached by means of hydraulic devices with mechanical controlallowing obtaining gradual variation of speed.

7.2.10. Protection against inertia loadsIn the event that considerable inertia loads affect the operation of actuators, provision shall

be made for protection against maximum permissible pressure between the valve and controlactuator.

7.2.11. Change from movement of fast travel to feedWhen changing from movement of fast travel to feed the feed starting point shall be

constant within certain limits of the work to be performed and shall be valid. The feed starting point



being constant, the changing from movement of fast travel to feed shall be effected by means of acam mechanism acting directly on switching throughout the period of feed.

7.2.12. Control of equipment component movementThe component movement control system on equipment with linear movement shall allow,

when the equipment is non-operated, the rod manual movements without effecting hydraulics andmechanics switching-off and operating control valves. Therefore, all conditions of the workerssafety shall be observed.

7.2.13. Uncontrollable movementsThe system shall be designed so as to prevent uncontrollable movements in any cycle phase

including the time of idle operation, pump start and stop. For the control of vertical or tilting powerdrive heads even though they are equipped with a counterweight, provision shall be made for thedisplacement of a movable part and, consequently, it is necessary to avoid quick downwardmovement both if the movement control fails and the connection between the movable part and thecounterweight breaks. If absence (failure) of control might present hazard (ref. item 7.5.2.) neveruse the apparatus with spring positioning (e.g., a valve with spring return).

7.2.14. Servovalve circuitryServovalves may be those used to actuate servodrive and at the same time to direct and

perform infinitely variable control of flow.7.2.14.1. Servovalve positioningServovalves shall be positioned as close to control mechanisms as possible in order to

maintain the minimum volume of fluid passing between the valve and mechanism.7.2.14.2. Emergency valvesA shut-off valve shall be provided in fluid supply system upstream the servovalves to ensure

emergency stop (ref. item 7.2.5.).7.2.14.3. System drainage preventionServovalves of both the feed and return lines shall be equipped with devices preventing

arbitrary fluid drainage out of valves, pipes and servomechanisms when the system is not operating.7.2.14.4. Type and position of filtersServovalve supply lines shall be equipped with fine full pressure filters to be installed

upstream the servovalves (ref. item 7.4.1.).7.2.15. Partial shut-off of centralized plantsWith respect to machines with centralized distribution (featuring drain and pressure

pipelines which serve the distribution units of the machine that provide feeding of individual unitsor for performing special functions), provision shall be made for shut-off devices (ball valvesmounted on pressure pipelines and one-way valves on return lines) capable to serve, if necessary,separate units or functions of main distribution lines, with the feeding being supplied from thedistribution mains.

7.3. Hydraulic system embodiment

7.3.1. Arrangement of hydraulic unitsHydraulic units shall be arranged so as:1) to be at 600-1800 mm from the floor level except for the case when they have to be

installed in a different way considering overall dimensions, functions to be performed or pipelinearrangement;

2) to allow easy access for adjustment and maintenance without causing interference withother units;

3) to ensure adequate protection when operating at elevated temperatures or when subjectedto corrosive materials;

4) to ensure adequate protection against failures or damage caused by transport means or asa result of work conducted nearby or by waste, chip and other pollutants;



5) not to rest, under normal conditions, upon hydraulic pipelines;6) not to be mounted on cabinets with electric apparatus (ref. section 6).Provision shall be made for special trays to accommodate possible external leaks (caused

also by maintenance operations) from individual hydraulic components and units located outsidethe hydraulic plant or projecting beyond its overall dimensions. As for manual drive unitarrangement, refer to Section 5.

7.3.2. Stroke limit switchesStroke limit switches shall be designed so as to allow their fixing after stroke adjustment.

7.4. Fluid filtrationHydraulic systems shall be equipped with filters for removal of contaminants from fluid.

Degree of cleanliness shall meet the requirements set by the Manufacturer of the employedequipment units. Dimension-types of filters are to ensure good performance of the plant even withtheir partial clogging (caused by build-up of hard particles); filter sizes with 2:1 ratio of the filterrated capacity in relation to the fluid flow are tolerated. Filter arrangement and location shall enablefilter element replacement leaving the pipeline untouched. The filters shall be accessible formaintenance and be installed outside the tank except for cases when for functional reasons notrelated to the filter they have to be placed inside. Presence of a plate with indication of filterelement type is imperative. It shall be attached on a visible side of the filter mounting position. Thefilter shall be equipped with an indicator showing filter clogging level. Filter replacement orcleaning interval shall be specified.

7.4.1. Filters for pressure and drain linesComplete fluid filtering is preferable. If hydraulic system operates with equipment requiring

a higher degree of purity then an additional filter should be installed in its feed line. The pressureinside the filter casing shall not exceed pressure rating specified by the Manufacturer. Filters shallbe furnished with clogging indicators.

7.4.2. Intake pipeline filtersFilters installed below fluid level shall have dimensions ensuring their durability. When

maximum filter capacity is required the lowest pressure drop caused by a brand-new clean filterinstalled below fluid level, shall not exceed 0,03 bar. When non-flammable fluid is used themaximum pressure drop shall not exceed 0,02 bar. Filters placed above fluid level shall be used inaccordance with the filter Manufacturer's recommendations and be equipped with an indicatorshowing the degree of filter clogging. When the filter is installed below fluid level provision shallbe made for filtering element replacement without draining the tank. Self-cleaning filters shall beactuated automatically.

7.4.3. Magnetic filtersMagnetic filters, if provided, shall be installed in the drain section of a tank. Magnetic filters

built into mechanical filters are acceptable. Magnetic filters shall be installed so as to provide freeaccess and prevent contamination in repair operations.

7.5. Valves7.5.1. Valves and other automatic controls shall be mounted on the panel by means of

special mounting plates in accordance with ISO/DIS 4401 and ISO/DIS 5783 standards. Design ofthe valves shall prevent an incorrect assembly. Valves shall be installed in tanks above maximumfluid level; exception is made for cases when it is required to change their location in order toimprove operation. If a valve features leaks discharge, it shall be directly connected with the tankvia a separate pipeline having no narrow section.

7.5.2. ApplicationIn the installation of valves it is necessary to consider the effect of gravity on the main valve

components in order to ensure adequate safety conditions. When multiple-way spring-return valves



are so arranged that the main component of a valve is in the vertical plane, the spring force shall beapplied to the main component in a downward direction. The given initial position of the multiple-way spring-return valve will be used for system protection. For actuating of locating pins, indexingdevices, retainers and any other drive units that shall be stationary on starting, stopping or electriccircuit failure, two-way springless valves are to be used. Two-way springless distributing valvesshall have a mechanical lock to maintain valve position.

7.5.3. Pressure controlWhen pressure control in several points of the hydraulic system is required it makes sense to

use multiple-way manometric switches.7.5.4. Electrical valvesElectrical valves shall have the following features:1) electrical magnet shall be enclosed in a housing with IP 65-type protection;2) provision shall be made for manual actuation of an electrical valve with the cap or the

coil housing ON; however, the possibility of an accidental starting is to be excluded;3) electrical connectors shall meet ISO/DIS 4400 standard.

7.6. Cylinders

7.6.1. Cylinder alignmentAlignment of cylinders joined rigidly with carriages or other movable elements that are

driven by them shall not create lateral or radial loads on the piston rod and carriage.

7.6.2. Non-rigid installationCylinders installed without rigid mounting shall be used in accordance with Manufacturer's

requirements including working stroke length selection, load and internal stop application.

7.6.3. Design characteristicsCylinder shall meet the following design requirements:1) provision shall be made for replacement of seals and gaskets; the same condition applies

to cylinders even though they are not an integral part of the equipment;2) when the cylinder head is used as piston stop an adjustable shock absorber shall be built

into the cylinder head or an external-type deceleration speed regulator shall be provided;3) seal assemblies in a piston rod shall be replaced without dismounting the cylinder;4) piston rods shall be manufactured of hard material to minimize scratches, they are to be

corrosion-proof and resistant to wear by materials in contact;5) cylinders failing to perform a full stroke shall be equipped with valves discharging

trapped air and which are accessible from outside.

7.7. Rotary hydraulic motors

7.7.1. MarkingWhen data marking (original) applied to the motor is not sufficiently visible, it is necessary

to provide for its copy to be put in a more visible place as close to the motor as possible. Theoriginal marking remains on the motor. Whenever backward rotation of one-way motors can causedanger or damage tooling, the shaft rotation direction shall be indicated on the motor or drive unitin a conspicuous place and the flow direction shall be precisely and clearly shown in graphicaldiagrams.

7.7.2. Motor selectionWhen selecting a rotary motor it is imperative to consider motor start and stop torque, load

variation effect as well as kinetic load energy in motion. Motors characteristics shall correspond tofluids to be used.



7.7.3. Motor installationConnection of motors with the mechanism they actuate shall be sufficiently rigid to avoid

operating load, temperature variations or maximum torque rotation causing misalignment of a unit.When a flexible coupling is used it shall be easily accessible. Motor leak discharge pipes (drain)shall be connected directly to the tank via a separate pipeline without throttling (refer item 7.9.2.9.)

7.7. Pumps

7.8.1. MarkingWhen original data marking applied to the pump is not sufficiently visible, it is necessary to

provide for its copy to be put in a more visible place as close to the pump as possible. The originalmarking remains on the pump. Besides, rotation direction shall be indicated on each pump in aconspicuous place.

7.8.2. Pump selectionPumps shall be suited for fluids to be used and they shall either be installed on machines or

have flange connections as per ISO/D 3019/11 with a propeller shaft on one side only. Pumps withbuilt-in electric motors are not allowed.

7.8.3. Pump installationPumps and corresponding drive units shall be installed outside the tanks and fixed on plates

off the bath plane; connection with the motor shall guarantee maximum alignment of the unit not tobe broken by working load or maximum torque. If the pump is mounted on a balcony, or ifspecified in the Contract, the plate attachment shall be made by means of damper supports (refer toSection 5). Pump leak discharge pipes (drain) shall be directly connected to the tank via a separatepipeline having no narrow section (ref. item 7.9.2.9.).

7.8.4. Pump-to-motor connectionA flexible coupling shall be provided between the pump and drive motor. Connections

located in an open place and rotary shafts shall have guards with fixing elements that can be takenoff with tools.

7.9. TanksIt is necessary to avoid usage of the equipment compartments as tanks. It is essential to

make separate tanks with pumps located on the outside (central station).When several separate tanks are used in a hydraulic system appropriate efficient devices

shall be provided to maintain fluid level in each tank. Hydraulic tank surface cleaning interval shallbe specified.

7.9.1. Tank installation7.9.1.1. Tank arrangementTanks shall be arranged so as to provide easy access to the fillers with doors and guards

intact. Fluid type plate shall be affixed next to the fillers. When the tank is at a height of more than1200 mm above floor level, provision shall be made for the system allowing to top up the tankusing no ladders or benches.

Pipe connection requirements are described in item 7.9.2.13.7.9.1.2. Level indicatorsAll tanks shall be equipped with maximum and minimum fluid level indicators located in

plain view. These indicators shall be provided on the side topping-up branch pipe.In the event that the equipment occupies a large area and fluid leaks can not be found at the

working place, it is necessary to provide an electrical minimum level indicator with a signalingsystem on the control panel and with an end-of-cycle stop device. The minimum level indicatorshall correspond to 75 mm level above the upper surface of a suction filter as well as an inlet of theintake pipeline. Maximum level indication shall correspond to the level required to meet the



demand in a specified volume (refer to item 7.9.2.1.) with the pump stopped and the plant switchedoff.

7.9.1.3. ThermometersIf necessary, tanks shall be equipped with thermometers.

7.9.2. Tank design7.9.2.1. VolumeMinimum tank capacity in litres shall correspond to the three-minute delivery of a pump

(l/min) (except for cases when adjustable pumps are employed (used) if elevated pressure, forcedcooling, ambient conditions, etc. do not require another tank). An additional tank shall be providedwith the volume of 10 % of total fluid capacity to ensure a free space above the surface for thermalexpansion and separation of air from fluid. Maximum fluid volume of a tank in litres shall beindicated on an identification plate attached to a visible side of the tank.

7.9.2.2. Tank baseThe tank shall be equipped with legs or other kind of supports so that the tank base is

located 150 mm above floor level to facilitate removal of fluid drain from the tank and improve heatdissipation. The legs or other supports of the tank shall have at least 4 holes or slots for attachmentto foundation; their bearing area shall be sufficient for levelling by means of adjusting pads.

7.9.2.3. Internal partitionsProvision shall be made for one or several rigid partitions to facilitate contaminant

accumulation, air separation and fluid heat dissipation. The partition (or partitions) shall bearranged so as to separate fluid discharge and pump inlet zones but not to block air passing betweenthe tank compartments. Dimensions and arrangement of the partition (partitions) shall such as todirect the fluid flow along the tank side walls. The partition (or partitions) shall have appropriateslots to ensure maximum speed of the fluid passing through the holes equal to 0.6 m/sec.

7.9.2.4. Holes to be used for cleaningFor cleaning it is necessary to provide two or more holes which allow cleaning of the total

hydraulic tank surface. If overall dimensions of the surface with the holes for tank cleaning on it areless than 400 mm, the maximum dimensions of the rectangular opening shall be 150 mm, roundopenings shall be minimum 150 mm in diameter. If overall dimensions of the surface are more than400 mm, the minimum dimensions of the rectangular opening shall be 325 x 400 mm, roundopenings are to be 400 mm. If sealing of the above hole caps is required gaskets shall comply withthe type of hydraulic fluid to be used and be suitable for multiple application. Hardening masticsand adhesive materials are not suitable for sealing. Hole caps with the weight exceeding 20 kg shallhave hooking fixtures for lifting devices. Threaded openings in the tankward direction for the capfixing shall be blind.

7.9.2.5. Tank bottomThe tank bottom configuration shall ensure complete drain of hydraulic fluid.7.9.2.6. Tank topTanks shall be equipped with covers preventing contamination of any type. If certain

elements have to be mounted on the tank, the upper part of the tank shall be rigid to reducevibration. The tank top shall be welded to the body along the perimeter or fastened with screws orpins. If the tank cover is fastened with threaded elements, it is necessary to provide for its multiple-use gaskets compatible with the hydraulic fluid to be used. It is preferable that fixing elements areto be mounted on the Inside of the tank. The tank top shall be so designed and manufactured as toavoid surface recesses trapping liquid and solid contaminants. Probable leaks from devices installedabove the tank shall be accommodated in ducts located on the outside as well as have dischargelines to prevent leaks on the floor. Hole edges on a cover shall be 20 mm higher than its upperplane. The covers shall be securely fastened with screws or pins and provide for installation ofgaskets between mated surfaces. When parts are fixed to the upper plate by means of threadedelements threaded openings shall be blind.

7.9.2.7. Drain pipelineThe drain pipeline shall be separated from the suction pipeline by means of partitions. The

drain pipeline shall terminate below minimum fluid level in the tank and at a distance from the tank



bottom of at least 50 mm or equal to 1,5 of the pipe diameter (whichever is bigger). The drain pipeend shall have 45° chamfer; besides, a diffuser shall be provided. Pipe connections crossing the tanktop shall be 20 mm higher than the top surface and ensure tightness. For pipes entering the tankthrough side walls or bottom, nipples or flanges shall be used to avoid leaking. In the event that thepipe is below oil level, it is necessary to provide for a system preventing an accidental dischargefrom the tank.

7.9.2.8. Suction pipelineThe suction pipeline shall have minimum number of connections and bends.The pipeline cross-section shall provide for a tolerable pressure drop in a pump in

compliance with the pump Manufacturer's requirements. The starting point of a pipeline shall be atleast 50 mm above the highest point of the tank bottom and at a minimum distance of 75 mm or 1,5of a pipeline diameter (whichever is bigger) below the minimum operating level. The suctionpipeline end shall have 45° chamfer. Requirements for pipe passing through the tank walls aredescribed in item 7.9.2.7.

7.9.2.9. Leak-tapping pipelineThis type of a pipeline shall be separated from a drain pipeline of the plant. Unless

otherwise specified in the technical requirements, the pipeline end shall be located above themaximum fluid level. Requirements for entering the tank through the walls are described in item7.9.2.7.

7.9.2.10. Pipe coating and paintingExternal and internal painting shall correspond to the type of fluid to be used. When internal

coating is required it shall also comply with the type of fluid to be used.7.9.2.11. Tank drainageIt is necessary to provide one or several drain pipes in the most suitable points of the tank

bottom. The minimum diameter of drain holes shall be 25 mm. Provision shall be made for shut-offvalves; their cross-section shall correspond to the cross-section of drain holes.

7.9.2.12. TransportationThe tank shall be designed so as to allow its handling with a fork lift truck or crane causing

no deformation to the tank even though it is filled with fluid. Besides, provision shall be made forfour lifting rings rigidly welded to the tank which withstand the weight of full tank and tank-mounted instruments.

7.9.2.13. FillerWhen filler is located on the tank top it shall be 20 mm above top surface. It is necessary

that netted filter has a mesh size of 1 mm or less. The netted filter shall be arranged in such a waythat would require special instruments for its dismounting. The filter assembly shall be equippedwith an internal metal hood for protection of mesh. The pipe connection assembly shall ensureminimum flow rate of 20 l/min. Filler cap shall provide a quick closing and be connected to theunion assembly by means of a chain. The filler assembly shall be fixed on the tank using sealedelastic gasket that corresponds to the type of fluid to be used.

7.9.2.14. BreatherIt is necessary to provide one or several breathers to maintain pressure close to atmospheric

under changes of fluid level. The breather may be built into the filler assembly. It shall have a filterwith a purification degree of 40 micron as well as a cap ensuring appropriate protection of the filtermedium.

7.10 Accumulators

7.10.1. HomologationAccumulators shall be manufactured arid homologated in accordance with the standards

described in Section 8. Documents to be approved shall be forwarded along with the equipment inan envelope separately from the documentation (refer to Section 4).



7.10.2. Accumulator installationAccumulators shall be easily accessible for maintenance and pressure control as well as for

dismounting. Pressure accumulators shall be charged with nitrogen only.

7.11. Heat exchangersNormal operation of the equipment with the application of designated fluids shall be

guaranteed within the ambient temperature range specified in a form enclosed with the quotationrequest and the contract. However, if upon taking all technical precautions in operation, theoperating fluid temperature exceeds 55 °C (or 40 °C for non-flammable fluids), a heat exchanger isto be used. Heat exchangers shall be protected from excessive pressure. The plant shall be equippedwith automatic devices to maintain the operating fluid temperature within maximum and minimumvalues specified in item 7.1.2., with coolant flow being limited to minimum; among the abovedevices a system shall be provided to turn the equipment off at the end of a cycle in the event thatthe temperature exceeds the control value. The type of a coolant as well as selection of a coolingsystem (water or air) and position of a heat exchanger is subject to agreement with the Customer.Water-cooled heat exchangers shall be manufactured of corrosion-proof material and thecondensate shall not enter hydraulic plant units. In deciding on a type of water as a coolantindustrial recirculating water shall be used.

The heat exchanger design shall provide an easy access to heat exchange elements in orderto clean out their surfaces from debris and scale. Return water flow shall be vertical. A debriscollector tank with a fitting for its routine removal shall be installed at the bottom of the heatexchanger. The branch pipes that admit and offtake media shall be fitted with inserts for mountingof thermometers. Filters with efficiency factor no less than 95 % shall be installed before water heatexchangers.

7.12. ConnectionsPipe and connection requirements are described in section 5.7.12.1. On the pipeline sections where the L/D ratio is more than 100 the maximum rate of

operating fluid shall not exceed:1) 4-5 in/sec in the pressure line under the operating pressure of 125 bar or less;4-12 m/sec - if the pressure exceeds 125 bar;2) 3-4 m/sec in the drain line.On the pipeline sections where the L/D ratio is less or equal to 100 (hydraulic distributors or

panels) the maximum rate of operating fluid shall not exceed:1) 5-6 m/sec in the pressure line under the operating pressure of 125 bar or less;5-12 m/sec in the pressure line if the operating pressure exceeds 125 bar;2) 3-4 m/sec in the drain line.On the intake section of a pipeline (oil tank -pump) the maximum rate of operating fluid

shall not exceed0,5-1,0 m/sec;1,0-1,5 m/sec - under the forced supply conditions.On the overflow valves and bleeders the maximum rate of operating fluid shall not exceed

25-30 m/sec.7.12.2. Flexible hosesFlexible hoses shall have the bursting pressure-to-maximum operating pressure ratio higher

than 4:1 and have outer surface resistant to oil, ozone, hydraulic fluid effect; inner surface shall beresistant to operating fluid to be used.

7.12.3. Application of pipelines as supportsAs a rule, the pipes shall not be used as supports for fitting valves or other devices; they can

only be used when pipes are not open to deformation or other damage as a result of vibration fromdevices as well as load effect in their operation.

7.12.4. Hydraulic panels



Hydraulic panels intended for distribution and regulation of the operating fluid flow, notrepresenting standard elements when taken alone and not designated for assembly of the standardhydraulic apparatus on them, shall only be used with the Customer's consent.

Design of the hydraulic panels weighting more than 20 kg together with the hydraulicapparatus installed on them, shall provide for the application of load-lifting mechanisms inmounting and maintenance.

7.13. Identification platesPlates with identification of hydraulic system unit as per hydraulics diagram shall be fixed

on the machine board in the vicinity of each unit.



8. PNEUMATIC EQUIPMENT

8.1. Supply line

8.1.1. Working pressureThe equipment shall be designed for normal pressure of 0.53 ± 0.02 MPa (5.3 ± 0.2 kgf/cm2)

in air supply line and ensure continuous operation with 80 % pressure drop in relation to pressurerating in the air supply line. Pneumatic supply lines having the pressure up to 1.0 MPa (10 kgf/cm2)are allowed subject to agreement with the Customer's.

8.1.2. Type of connection to the supply linesThe equipment shall be provided with a single tapping from the supply line via a fast-

response shut-off valve and manual rapid action device (completed with a special identificationplate having "open" and "closed" inscriptions on it) which allows, ensuring personnel safety, toswitch the machine off and at the same time evacuate residual air; in the event that provision ismade for reservoirs mounted on equipment, the manual device shall be placed at the outlet of thereservoir. A separate independent feed with appropriate tap is allowable for running groups ofaccessories. When fastening of the equipment to the floor by anchor bolts is not required connectionof the equipment shall be accomplished by means of a quick-release pipe connection specified inthe order. While feeding groups of press accessories, quick-release pipe connections of a "PressBlock" V 85M 3/8" - type shall always be used.

8.1.3. Multichannel feedingIf the equipment is fed from several sources, provision shall be made, if necessary, for

appropriate devices to prevent any damage due to the absence of one of the power sources.8.1.4. Feed for actuation of protective meansThe pressure for pneumatic actuation of protective means shall be such that to prevent any

injury to hands or fingers at closing the means of protection.

8.1.5. Plug sockets for pneumatic toolsAir supply connector plug socket shall be provided on welding plants at each position to

feed pneumatic tools during repair and service.

8.2. Systems

8.2.1. General instructionsCompanies indicated in OTU-2-2000 shall supply pneumatic apparatus.Pneumatic systems shall be so designed that to maintain minimum air consumption, heat

generation and to minimize driving force losses. Employment of pneumatic logic circuits, evenpartially, (both static and dynamic, of low and high pressure) by the Supplier is subject toagreement in writing; as this takes place, the adopted system and embodiment methods both offunctional diagrams and the installation are specified.

8.2.2. ProtectionWhen pressure in the supply line is not sufficient or missing which can endanger the

operator or damage the equipment (e.g., in clamping parts), provision shall be made for a safetydevice indicating the lack of pressure and stopping the machine.

8.2.3. Adjustment devicesAdjustment devices shall be easily accessible and arranged in such a way as to prevent

possibility to be actuated by unauthorized persons and designed with consideration of adjustment



within the ratings of safe performance. All pressure adjustment controls shall have marks indicatingminimum and maximum values.

8.2.4. Changes of load and speedPneumatic systems shall be designed so that to compensate load changes depending upon

the job to be performed. Pneumatic systems shall be equipped with damping devices for smoothspeed decreasing prior to the stop of moving units. Systems that service two or more heads, slidesor other operating facilities shall be so designed that to ensure normal performance of each unitirrespective of the load changes.

8.2.5. Systems operating in harmful mediaPneumatic control systems operating under the elevated temperature conditions or in the

presence of toxic materials shall be so designed and arranged that to enable their maintenance andrepair causing no dangerous or noxious conditions to operators.

8.2.6. Pressure peaksPneumatic systems design and manufacture shall ensure minimum pressure peaks.

Component units of the equipment shall, in their turn, be strong enough and withstand theseincreased loads.

8.2.7. Uncontrollable movementsPneumatic systems shall be designed so that to prevent uncontrollable movements of the

pneumatic operating devices in all cycle phases including pressure delivery to the equipment uponemergency interference. Movable part support shall be provided for drive of vertical or inclinedworking heads, even for those having counterweights; this is intended on the chance both when themovement is disrupted and when the connection between movable parts and counterweights isbroken. Devices with spring positioning (e.g. control valves with spring return) shall not be usedwhen drive failure can cause dangerous situation. Electrically driven pneumatic devices shall beinstalled in such a way as to prevent equipment breakage, personnel injuries or decrease in accuracyin case of electrical fault.

8.2.8. Inoperative position of valvesAdjustment or approach of other drive shall not influence the inoperative position of valves.

8.2.9. Approach start pointIn changing from fast movement phase to working feed phase the approach start point shall

be the same within the limits specified for a particular type of work to be performed.

8.2.10. Part travelIt is necessary, where possible, to avoid part travel only through the pneumatic system.

Movements through hydro-pneumatic systems are allowable. On the equipment with linearmovement the drives for part travel, in case the equipment is not operating, shall allow manualmovement of rods without disconnection of hydraulic, pneumatic devices and without actuation ofdrive control valves. In any case all safety precaution conditions for the operators shall be observed.

8.2.11. Emergency stopAll machines shall be equipped with emergency stop devices located in the place easily

accessible from the normal working position of the operator. In the event that the electrical devicesare also provided on the equipment, the emergency pneumatic drive shall be inter-linked with theemergency electrical drive. Cycle stop drive shall interlock all hazardous movements irrespective ofthe position of a moving part.



8.3. Arrangement of circuits

8.3.1. Automatic drivesAutomatic drives shall be mounted as close to the starters as possible in order to reduce the

time of interaction and air consumption.

8.3.2. Stroke limitersStroke limiting devices shall ensure stroke adjustment and interlocking.

8.3.3. Arrangement of instrumentsInstruments shall be arranged so that to provide easy access for maintenance and control

(also refer to item 8.2.5.). Where possible, they shall be placed at a height of 600-1800 mm from theaccess level. Installation of instruments within the equipment is to be avoided; they shall be placedin a separate casing. In any case the instruments shall be reliably protected against the damage frommeans of transport. Instruments that can get out of order due to dust or dirt shall be protectedproperly; their location shall be agreed upon with the Customer. Installation of pneumatic apparatusin cabinets for electric apparatus is not allowed.

8.3.4. DrainagePneumatic systems shall be equipped with vent valves for condensate drainage located at the

lowest points.

8.3.5. Manual controls and signalling systemsColour of buttons and signal lamps (pneumatic only) shall correspond to specification of

tables 22, 23 with respect to the electrical equipment.

8.4. Cabinets and compartments

8.4.1. LocationIf the Customer agrees upon the employment cabinets they shall be located in places

convenient for maintenance.

8.4.2. LocksAll cabinets and compartments shall be equipped with hinged doors to be opened

horizontally or with sliding doors.The doors shall be in a closed condition and mechanical units shall be used for their locking.

Compartments shall be properly protected from liquid, oil, chip and dirt penetration.

8.4.3. Wall thicknessThe doors of cabinets and compartments as well as other doors shall be made of sheet steel

no less than 2 mm thick or light alloys no less than 6 mm thick.

8.5. Connections

8.5.1. Rigid pipelinesRigid pipelines shall be of the same type as pipelines used for hydraulic plants. Under the

maximum working pressure up to 79 bar the bursting pressure-to-maximum working pressure ratioequals 8:1.

8.5.2. Flexible hosesFlexible hoses shall have the bursting pressure-to-maximum working pressure ratio of more

than 5:1 as well as oil-resistant inside surface and oil-and-ozone-resistant outside surface.



8.5.3. Application of pipes as supportsAs a rule, the pipes shall not be used as supports when fitting valves or other devices;

however, they can be used only when pipes are not subject to deformation or other damage as aresult of device vibration as well as load effect in their operation.

8.6. Filters, drying plants, lubrication units, pressure regulators

8.6.1. FiltersPneumatic system shall be equipped with special devices for air filtering and trapping of all

substances which can cause harmful effect to the plant operation. Filters shall be placed as close tothe device they relate to as possible; in any case the plant shall be fitted with air filters at the inlet.These filters shall have the sizes that enable to filter double the demand of air. The filters shall bemanufactured and arranged in such a way that allows cleaning and replacement of the filter elementwithout pipeline removal; their location shall provide easy access. Where possible, the system shallbe equipped with devices indicating that filter cleaning or replacement is required. Filterreplacement or cleaning tentative intervals shall be specified.

8.6.2. Moisture separatorMoisture separator-filter for tapping of condensate shall be installed at the inlet of

pneumatic system.

8.6.3. LubricatorsIf necessary, provision shall be made for the appropriate devices of air lubrication. They

shall be arranged in an easily accessible place and shall not upset operation of the equipment. It isnot necessary to have a centralized system of lubricators.

On the equipment where lubricators are hardly visible it is necessary to provide for electricallevel indicators with possible cycle interruption and signalling system on the control panel.Adjacent to the lubricator an identification plate with the type and amount of oil to be poured andthe number of drops per minute shall be provided.

8.6.4. Pressure regulatorIf necessary, pressure regulators with pressure gage shall be mounted at the filter outlet;

avoid interrupted mode of their operation (cyclic or pulsating).

8.7. GasketsAll packing elements shall be made of materials resistant to air, lubricants and moisture

which can be present in the plant.

8.8. Cylinders

8.8.1. Adjustment of cylindersRigidly mounted cylinders shall be adjusted relative to slides or other movable elements to

be actuated by cylinders so that not to create lateral or radial load on a piston rod or slide.

8.8.2. Design specificationsCylinders shall meet the following design requirements:1) possibility to replace seals and gaskets in the cylinders inclusive of those not integral to

the equipment;2) in cases when the head parts of a cylinder are used as elements for piston stopping an

adjustable shock absorber shall be built in the head or an outside drive for slowing down shall beprovided;

3) piston rods shall be made of material being so hard that to minimize scratches; they shallbe protected against corrosion and abrasion when in contact with other materials;



4) seals of a piston rod shall be replaced without disassembly of the cylinder.

8.9. Compressors

8.9.1. Installation of compressorsCompressors shall be installed as per requirements of Section 2, "Rules for installation and

safe operation of stationary compressor plants, air channels and gas conduits".Compressors and units incorporating them shall be easily accessible for repair and service

and shall be installed in places protected from inadvertent damages. If they are put into a closedarea there should be sufficient room for access to all their components. When compressors andmotors are installed within the equipment they shall be put on sufficiently secure and easilyremovable foundations for repair. Compressors connected in series shall be correspondinglyinstalled and stationary assembled so that to keep their position under normal working conditions.When compressors are connected in parallel, the pipelines shall be fitted with valves in order thateach compressor can be stopped while the others are in operation.

8.9.2. Marking of compressorsThe marking of each compressor shall contain the following data:1) manufacturer's name and address;2) identification symbol;3) serial number;4) output and maximum working pressure.If upon compressor assembly the marking in not visible, it shall be repeated in places where

it can be easily read. The original (factory) marking shall be left in place. Direction of a compressorrotation shall be shown on it in an easily observable place.

8.10. Valves

8.10.1. Adjustable valvesAdjustable valves shall be so mounted that to lock the adjustment.

8.10.2. Valve mountingWhere possible it is necessary to use valves set on individual mounting plates in accordance

with ISO 5599/1 standards. The valves used shall be labelled to avoid incorrect assembly.Hydraulic panels can be applied with the Customer's consent.

8.10.3. Valve drainageDrain openings of all pneumatic devices shall be equipped with the appropriate tapping and

mounted so that particles to be removed by the compressed air do not cause damage to theequipment or injury to an operator. Air exhaust of the power circuits shall be provided withdampers. As for driving circuits, the dampers shall be provided in the event that noise level exceedsthe allowed limits (ref. section 5). However, they shall not affect the operation in any case.

8.10.4. Electric valvesElectropneumatic valves shall have the following characteristics:1) they shall have a protective casing;2) bolts for fixing of caps shall be protected against their loss (non-losable type);3) they shall have a system preventing loss of the body cap (usually this is a chain);4) provision shall be made for the electric valve manual control without cap or coil case

removal; however, an inadvertent actuation shall be excluded;5) connecting elements shall correspond to ISO/4400.



8.11. Vessels working under pressure8.11.1 Vessels or their components purchased in foreign countries shall meet requirements

of RF Gosgortechnadzor Regulations.Deviations from the Regulations shall be agreed upon with RF Gosgortechnadzor prior to

signing the contract. As this takes place the organization (association, enterprise) purchasing vesselssubmits VNIIneftemash resolution upon the acceptability and validity of the deviations.

The installation of vessels shall be effected in accordance with Section 6, "Rules forarrangement and safe operation of vessels operating under pressure"

8.11.2. Strength calculation, design and manufacture of vessels to be purchased abroad shallbe performed as per local standards. It is allowable to use the Supplier's standards subject toapproval by VNIIneftemash of the fact that the requirements of these standards are no less severethan local ones. Conformity of the materials of foreign grades with requirements set by theRegulations and the possibility of their application shall be approved by VNIIneftemash (Moscow,phone No. /095/-232-16-63).

8.11.3. Amendments and revisions to the technical documentation which are necessary inrepair or maintenance of vessels purchased in foreign countries shall be agreed upon with themanufacturer, where possible, and with VNIIneftemash in all other cases.

8.11.4. The maker shall supply each vessel with a certificate in the form specified in GOST25773-83 and with a manual for its mounting and maintenance.

8.11.5. An identification plate as per GOST 12971-67 shall be attached to each vessel.It is allowed to omit the identification plate for vessels less than 325 mm in outer diameter.

As this takes place all necessary data shall be applied to the vessel body.The identification plate shall contain the following data:1) trade mark or the maker's name;2) name or identification symbol of a vessel;3) ordinal number of a vessel as per numbering system of the maker;4) manufacture year;5) working pressure, MPa (kgf/cm2);6) calculated pressure, MPa (kgf/cm2);7) test pressure, MPa (kgf/cm2);8) maximum and/or minimum permissible operating temperature of the wall, °C;9) vessel weight, kg.For the vessels with separate cavities having different pressure ratings, trial pressure values

and wall temperatures these data shall be indicated for each cavity.8.11.6. The certificate shall be accompanied with:1) vessel drawings indicating main dimensions;2) calculation for strength and attached sketches of: vessel walls, filters, caps, grates for

tubes and flanges;3) regulations on vessel actuation in winter period.For vessels working under multiple-applied loads with number of cycles depending upon

pressure, heat deformation or other effects more than 1000 cycles throughout the operation, thecalculation for fatigue strength shall be attached with the indication of operating life of safeoperation.

8.11.7. The following vessels do not require documentation:1) vessels and cylinders with capacity of no more than 0.025 m3 (25 l); their pressure in

MPa (kgf/cm2) multiplied by capacity in m2 (l) does not exceed 0.02 (200);2) vessels working under pressure to be generated upon explosion inside them in

compliance with the production process;3) vessels working under vacuum;4) air reservoirs for the brake rigging of rolling stock of railway transport, vehicles and

other transport means;5) vessels made of non-metal materials;6) air cooling apparatus applied as capacitors and coolers;7) steam and hot-water heating devices;



8) tube furnaces;9) machine parts not being separate vessels (pump or turbine bodies, cylinders of engines

of steam, hydraulic, air machines and compressors); continuously operating, structurallyenclosed (installed on the common base with the compressor) intercoolers and oil-and-moisture separators of compressor plants, pump air boxes;

10) vessels made up of pipes with inner diameter of no more than 150, without manifolds;vessels made up of pipes no more than 150 mm in inner diameter with manifolds.

8.11.8. Vessel design shall be reliable, it shall ensure safety in operation and provide for thepossibility of their complete draining, cleaning, washing, scavenging, inspection and repair.

Devices impeding outer and inner inspection of vessels (mixers, coil pipes, jackets, plates,partitions and other attachments) shall be, as a rule, detachable.

When welded devices are used, provision shall be made for their removal with the aim ofouter and inner inspection and return to the original position that follows.

In the event that the vessel design does not allow outer and inner inspection or hydraulictest, which are specified in the requirements of the present Regulations, the originator of the projectshall describe in the installation and maintenance manual the procedure, intervals and volume ofcheck to be effected in order to ensure timely trouble-shooting and elimination of defects.

Design of internal devices shall ensure air evacuation from the vessel during hydraulic testand water drain after hydraulic test.

The vessels shall have pipe connections to fill and drain water as well as to evacuate air inhydraulic test.

Each vessel shall be provided with a valve, tap or other device that allow to control lack ofpressure in the vessel prior to its opening; and the vessel medium shall be drawn off to a place safefor the maintenance personnel.

8.11.9. Strength calculation of vessels and their elements shall be performed as per currentstandard technical documentation (GOST, OST, RD, RTM). When the documentation is notavailable, the strength calculation is to be performed as per methods agreed upon with thespecialized research organization.

8.11.10. The vessels that change their spatial position in operation shall have devicespreventing self-overturning.

The design of vessels to be heated with hot gases shall ensure proper cooling of walls underpressure to the calculated temperature.

In order to check welding quality of rings strengthening holes for hatches, manholes andpipe connections, a check hole shall be provided in the ring, if it is welded on the outside, or in thewall if the ring is welded on the inside of the vessel.

Electrical equipment and vessel grounding shall be made in accordance with Rules forarrangement of electric installations.

8.11.11. Vessels shall be fitted with sufficient number of hatches and sight holes forinspection, cleaning and repair of vessels as well as mounting and dismounting of innerdemountable devices.

Vessels made up of cylinder body and grates with tubes (heat-exchangers) secured in themand vessels designed for transportation and storage of cryogenic liquids can be made withouthatches and holes irrespective of the vessel diameter provided that manual is available describingprocedures and a list of items for inspection.

Vessels more than 800 mm in inner diameter shall have hatches; vessels less and equal to800 mm in inner diameter shall have small hatches.

The inner diameter of round hatches shall be no less than 400 mm. Oval hatch dimensionsalong the minimum and maximum aperture axes shall be no less than 325 x 400 mm.

The inner diameter of round hatches or the size along the minimum axis of oval smallhatches shall be no less than 80 mm.

Hatches and small hatches shall be located in places acceptable for maintenance.Hatch covers shall be detachable. Welded covers are allowed on vessels Isolated on the

basis of vacuum.Covers of vessels or hatches weighting more than 20 kg shall be equipped with lift-

revolving and other devices for opening and closing.



The design of pivot and insert bolts, yokes, as well as clips of hatches, covers and theirflanges shall prevent them from spontaneous movement.

If the vessel has pipe connection, detachable bottoms or covers having the diameter of noless than diameters of the above hatches ensuring the possibility of inner inspection hatches can beomitted.

8.11.12. Vessels can have the following bottoms: ellipsoidal, hemispherical, toroidal-spherical, spherical without flange, taper flanged, taper without flange, flat flanged, flat withoutflange.

The convex section height of ellipsoidal bottoms measured along the inner surface shall beno less than 0,2 of an inner bottom diameter. It is allowed to decrease this size by consent with thespecialized scientific research organization. Toroid-spherlcal bottoms shall have:

- the convex section height measured along the inner surface of no less than 0,2 of aninner diameter;

- the inner flange radius of no less than 0.1 of an inner bottom diameter;- the inner radius of curvature of the central section of no more than an inner bottom

diameter.Spherical bottoms without flange can be applied with weld flanges, and:- the inner radius of the bottom sphere shall be no more than an inner vessel diameter;- weld joint of a flange and bottom shall be made with continuous penetration.In weld convex bottoms comprising several sections with weld seams arranged along the

cord the distance from the weld seam to the bottom center shall be no more than 1/5 of an innerbottom diameter.

Circular seams of convex bottoms shall be at a distance of no more than 1/3 of an innerbottom diameter.

Taper bottoms without flange shall have the central angle of no more than 45°. Central anglecan be increased up to 60° when approved by the relevant specialized scientific researchorganization.

Flat bottoms with a ring groove and barrel (flange) manufactured by means of mechanicalboring shall be made of a forged piece. It is allowed to manufacture the flat flange bottom of sheetsteel in the event that the flange is made by pressing or running-in sheet edges with 90° bend.

For flanged and transition elements of vessels, except for convex bottoms, compensatorsand stretched necks for welding of fittings, the distance from the point where the flanged elementrounding begins to the weld seam center line shall be taken from Table 26 based on flanged elementwall thickness.

Table 26Thickness of the flanged element wall, S, mm Distance up to the axis of the weld seam, no

less than, mmUp to 5

From 5 to 10From 10 to 20

Over 20

152S + 5s + 15

S/2 +25

8.11.13. Weld seams of vessels shall be butt joint.Weld tee joints and corner joints while welding up flat bottoms, flat flanges, grates for

tubes, pipe connections, hatches, jackets are allowed.The above weld seams shall have full penetration.When welding fixing rings and bearing elements the application of lap welds is allowed.Weld seams shall be fault detectable and accessible for control in manufacturing, mounting

and maintenance of vessels, which is specified in the present Rule requirements, relevant standardand technical requirements.

Design gap in corner and tee joints is allowed in cases specified in the technicaldocumentation agreed upon with RF Gospromatomnadzor.



Longitudinal seams of adjacent shells and bottom seams of vessels shall be shifted relativeto each other for a distance of 3-fold across the width of the thickest element but no less than 100mm between the seam axes.

It is allowed not to shift the above seams relative to each other in vessels meant foroperation under pressure not exceeding 1.6 MPa (16 kgf/cm2) and temperature not exceeding 400°C having the rated wall thickness of no more than 30 mm on condition that the seams are made bymeans of automatic and electroslag welding; and the point of seam crossing is controlled with themethod of 100 % radiography or ultrasonic flaw detection.

In welding external and internal devices (bearing components, plates, jackets, partitions,etc.) to the vessel body it is allowed to cross weld seams with butt joints of the body subject to priorchecking of the body seam section to be crossed by means of radiation monitoring or ultrasonicflaw detection.

In case of welding bearing or other elements to the vessel body the distance between theedge of the vessel weld seam and the edge of an element weld seam shall be no less than thethickness of a vessel body wall, but no less than 20 mm.

The distance between the edge of a vessel weld seam and the edge of an element weld seamshall be no less than 20 mm for vessels made from carbonic and low-alloy manganite and silico-manganite steel to be heat-treated after welding irrespective of the body wall thickness.

In horizontal vessels, local overlapping of circumferential (transverse) weld seams withsaddle-type supports is allowable throughout the length not exceeding 0,35 ЦД; with a padding itshall not exceed 0.5 ПД, where Д is outer diameter of the vessel. As this takes place, theoverlapping sections of weld seams shall be checked by means of radiation monitoring or ultrasonicflaw detection throughout the length.

8.11.14. In butt-weld joints of vessel elements with various wall thickness the gradedjunction from one element to another shall be provided by gradual tapering of the thicker elementedge. Slope angle of the junction surface shall not exceed 20 °.

If the difference in thickness of the elements to be welded is no more than 30 % across thewidth of a thin element and does not exceed 5 mm, the application of weld seams without priortapering of a thick element is allowable. The seam shape shall ensure smooth change from the thickelement to the thin element.

When butting cast part to tube parts, rolled steel or forged pieces it is necessary to considerthat the nominal calculated thickness of a cast part is 25-40% wider than the equivalent calculatedthickness of a tube element wall, rolled steel or forged piece; therefore the change from a thickelement to a thin element shall be made so that the thickness of a cast part end is no less than thenominal calculated value.

8.11.15. Openings for hatches, small hatches and pipe connections shall be located, as arule, outside of weld seams.

It is allowed to arrange openings:- on longitudinal welds of cylindrical and taper shells of vessels if the diameter of openings

is no more than 150 mm;- on circumferential welds of cylindrical and taper shells of vessels having no limitations on

the diameter of openings;- on seams of convex bottoms having no limitations on the diameter of openings providing

100 % checking of weld bottom seams by means of a radiation method and ultrasonic flawdetection.

For welding pipe connections and hatches weld seams shall be done with full penetration.On toroid-spherical bottoms it is allowed to arrange openings only within the limits of the

central spherical segment. In this case the distance from the opening edge to the bottom center to bemeasured along the chord shall be no more than 0.4 D (where D is an outer diameter of the bottom),

8.11.16. Tolerances specified in this section shall be observed in the manufacture of vesselsand their components.

Deviation of an outer (inner) shell diameter, cylindrical flanged elements of bottoms, madeof plates and forged pieces shall not exceed ± 1 % of the nominal diameter.

The relative out-of-roundness (ovality) in any cross-section shall not exceed 1 %. Value ofovality is determined by formula:



- in a cross-section without pipe connections and hatches

2 (D max – D min)a = -------------------------- 100 %

D max + D min

- in a cross-section with pipe connections and hatches

2 (D max – D min – 0.02d) a = -------------------------------------100 %

D max + D min

Where D max, D min are the maximum and the minimum outer diameters of a vesselrespectively, mm;

d is an inner diameter of a pipe connection or hatch, mm.The value of relative ovality for vessels with the shell wall thickness-to-inner diameter ratio

of 0.01 and less can be increased to 1.5 %.Relative ovality of vessel elements operating under external pressure shall not exceed 0.5 %.Inclined drift (angularity), f of edges in weld seams shall not exceed F = 0.1 S + mm, but no

more than the corresponding values shown in Table 27 for the vessel elements.

Table 27Maximum inclined drift (Angularity), f of edges in butt joints, mm

Of shells Of ball tanks and bottoms made ofleafed (petal-like) pieces

Taper bottoms

Irrespective of D * 5000 5000 2000 20005 6 8 5 7

D* is an inner diameter, mm.

Shift of plate edges, G measured along the middle surface in butt joints defining the vesselstrength shall not exceed G = 0.1S but no more than 3 mm.

Shift of edges in circumferential welds except for seams made by electroslag welding shallnot exceed values shown in Table 28. Shift of edges in circumferential welds made by electroslagwelding shall not exceed 5 mm.

Table 28Maximum permissible displacement of edges to be jointed in

circumferential welds, mmThickness of plates to be

welded, S, mmon monometalic vessels On bimetal vessels on the side of

corrosive layerUp to 20 0.1S + 1From 20 to 50 0.15S but more than 5

50 % of the thickness of aplating layer

From 50 to 100 0.04S +3.5 * 0.04S +3 but no more than thethickness of a plating layer

Over 100 0.025S+5 * but no more than 10 0.025S +5 but no more than 8and no more than the thicknessof a plating layer

* In case of building-up on surfaces jointed with 1:3 tilt for the weld joints having edgedisplacement of more than 5 mm.



The displacement of edges in butt-weld joints of pipes shall not exceed values shown in Table 29.

Table 29Pipe wall thickness, S, mm Maximum permissible displacement of

edges, mmUp to 3

From 3 to 6From 6 to 10From 10 to 20

Over 20

0.2S0.1S + 0.3

0.15S0.05S +1

0.1S but no more than 3

Tolerances not indicated in the section shall correspond to the requirements of standardtechnical documentation (technical specifications or standards).

All weld seams shall be marked with the welder personal stamps, which allows tracing theperson who made it.

The stamp is applied at 20-30 mm distance from the weld seam edge on the outside. Ifdifferent welders weld outer and inner seams, the stamps are applied only on the outside in the formof a fraction with the outer seam welder stamp being positioned in the numerator, denominatorindicating inner seam welder stamp.

If the same welder performs the weld joints of a vessel, it is allowed to apply welder stampnext to the identification plate or another open place. On longitudinal welds the stamp shall beapplied at the beginning and at the end of a seam, at 100-mm distance from a circumferential weld.On a shell (sidewall) with a longitudinal weld less than 400 mm in length it is allowed to apply onestamp. On a circumferential weld the stamp shall be applied in the crossing point of acircumferential weld and longitudinal weld and further on in every 2 m but at the same time eachseam shall have no less than two stamps. The stamp is applied on the outside. Longitudinal andcircumferential welds of vessels having walls less than 4 mm thick can be stamped by means of anelectrograph or indelible paints.

Stamp area shall be surrounded with a clearly visible frame applied by means of indeliblepaints or electrograph.

.11.18. The amount of checking by means of ultrasonic flaw detection or radiation methodshall correspond to the scope specified in Table 30 below. The checking refers to butt, corner, teeand other weld joints of vessels and their elements (bottoms, shells, pipe connections, hatches,flanges etc.) including hatch and pipe connection joints with the vessel body.

The specified amount of checking refers to every weld joint. Weld joints mating (crossing)areas are subject to mandatory testing with ultrasonic flaw detection or radiation method.

Ultrasonic flaw detection or radiation testing of seams made in welding internal andexternal devices to the vessel body shall be carried out if specified in engineering documentation.

Table 30Vessel group (refer to Table 31) Length of weld seams to be tested, in % of total seam length

1234

100100

no less thanno less than

Weld joints of vessels equipped with quick-detachable covers shall be tested by means ofultrasonic flaw detection or radiation method in the amount of 100 % irrespective of the abovevessel group.

The vessel group is defined depending on rated pressure, wall temperature and nature of theoperation environment as per Table 31.

Table 31Vessel Rated pressure Wall temperature Operation environment



group MPa (kgf/cm2) ° C1 Over 0.07 (0.7) Whatever Explosion or fire hazardous or of class 1, 2 of

hazard as per GOST 12.1.007-762 Up to 2.5 (25) Below –70

Above 400Over 2.5 (25)Up to 4 (40)

Below –70Above 200

Any except for that specified for the vesselgroup I

Over 4 (40)Up to 5 (50)

Below –40Above 200

Over 5 (50) Whatever3 Up to 1.6 (16) From –70 to –20

From 200 to 400Any except for that specified for the vesselgroup I

Over 1.6 (16)Up to 2.5 (25)

From –70 to 400

Over 2.5 (25)Up to 4 (40)

From –70 to 200

Over 4 (40)Up to 5 (50)

From –40 to 200

4 Up to 1.6 (16) From –20 to 200

8.11.19 All vessels are subject to hydraulic test after the manufacture.Vessels that have protective coating (enamelling, lining) or insulation are to be subjected tohydraulic test prior to application of the coating or insulation.Vessels that have outer casing are to be subjected to the hydraulic test prior to insulation of thecasing.Hydraulic test of vessels except for cast ones shall be performed by means of testing pressure Pпрthat is calculated by formula

[δ] 20Pпр = 1.25 ---------------------

[δ] t

where P is a calculated pressure of the vessel, MPa (kgf/cm2); [δ] 20 and [δ] t are acceptabletensions for the material of a vessel and its elements respectively at 20 °C and calculatedtemperature, MPa (kgf/cm2).

The [δ]20/[δ]t ratio is assumed based on that material out of vessel component materials(used for shells, bottom, flanges, fixing elements, pipe connections and others) for which the valueof this ratio is the least.

Hydraulic testing of vessels and parts made of casting shall be carried out with the testpressure calculated by formula

[δ] 20Pпр = 1.5 -----------------

[δ] t

It is allowed to test castings upon mounting and welding in an assembled unit or completevessel by applying the test pressure assumed for vessels provided 100 % of castings are checked bymeans of non-destructive methods.

Test pressure is to be applied when performing hydraulic tests of cryogenic vessels, withvacuum available in isolating space. The test pressure value (Pпр) is determined by formula:

Pпр = 1.25P – 0.1 MPa (1.25P – 1 kgf/cm2).



8.11.20 Horizontal position is allowable when carrying out hydraulic tests of verticalvessels, provided sufficient strength of the vessel body is ensured, for which purpose the vesseldevelopment contractor shall carry out strength calculation subject to the approved method of vesselresting in the hydraulic test.

In this case the test pressure shall be assumed with consideration of hydrostatic pressureworking on the vessel during its operation.

In composite vessels with 2 or more working cavities designed for different pressures eachcavity shall be subjected to the hydraulic test by applying test pressure that is defined based oncavity pressure rating.

Testing procedure shall be stipulated in engineering project and specified in themanufacturer's manual for mounting and maintenance.

8.11.21. Test pressure value and test results shall be entered in the vessel certificate.8.11.22. The following defects are not allowable in weld joints of vessels:1) cracks of all kinds and directions located in the weld metal along the fusion line and in

seam-adjacent area of the based metal, including microcracks detected by microanalysis;2) incomplete penetration (faulty fusion) in weld seams located at the root of a weld or

along the cross-section of the weld joint (between individual beads and layers of theseam and between the base metal and weld metal);

3) undercuts of the base metal, pores, slag and other inclusions with dimensions exceedingpermissible values shown in standard engineering documentation of Minkhimmash andMintyazhmash RF (Chemical machine-building industry and heavy machine-buildingindustry of Russian Federation).

4) rolls5) unfilled craters and burns-through6) blowholes7) edge displacement above the standards specified in the present Rules.8.11.23. In order to control operation and ensure safe maintenance conditions the vessels

shall be equipped with the following:1) shut-off or shut-off and regulating fittings;2) pressure measuring instruments;3) temperature measuring instruments;4) safety devices;5) liquid level gauges.Vessels fitted with quick-removable gates shall have safety devices eliminating the

possibility of vessel actuation under pressure when the cover is closed incompletely and coveropening when the pressure is present in the vessel.

8.11.24. Shut-off and regulating fittings shall be installed on pipe connections directlyconnected to the vessel or on pipelines delivering the operating medium to and withdrawing it fromthe vessel. In case of successive connection of several vessels the project designer determines thenecessity in installation of such fittings.

Fittings shall have the following marking:1) trade mark and the manufacturer's name2) conventional passage, mm3) conventional pressure, MPa (kgf/cm2)4) medium flow direction5) material grade.On a flywheel of the shut-off fittings direction of its rotation shall be indicated when

opening or closing the fittings.8.11.25. Vessels for explosion- and fire-hazardous substances, substances of 1 and 2 class of

hazard as per GOST 12.1.007-76 as well as fire- or gas-heated evaporators shall have a check valveon the pump inlet line or compressor inlet line which closes automatically with pressure from thevessel. The check valve shall be installed between the pump (compressor) and shut-off fittings of avessel.

8.11.26. The fittings having more than 20-mm conventional passage, made of alloy steel ornon-ferrous metal shall have a passport (certificate) of standard form specifying data on chemical



composition, mechanical properties, heat treatment cycle and results of manufacturing qualitycontrol by non-destructive methods.

8.11.27. Each vessel and independent cavities with different pressures shall be equippedwith direct-acting pressure gauges. The pressure gauge may be mounted on a vessel or pipelineunion upstream of the shut-off fittings.

Pressure gauges shall have accuracy class no less than2.5 - for the working pressure of a vessel up to 2.5 MPa (25 kgf/cm2);1.5 - for the working pressure over 2.5 MPa (25 kgf/cm2).Nominal body diameter of pressure gauges to be mounted at a height of up to 2 m above the

level of the observation platform shall be no less than 100 mm; at a height of 2 - 3 m the diametershall be no less than 160 mm.

It is not allowable to install pressure gauges at a height over 3 m above the level of anobservation platform.

Three-way cock or similar device shall be mounted between the pressure gauge and vesselfor routine checks of pressure gauges by means of a standard pressure gauge.

Where necessary and subject to operation conditions and properties of the mediumcontained in the vessel, the pressure gauge shall be equipped with a siphon pipe, oil buffer or otherdevices protecting it against direct effect of medium, temperature and ensuring reliable operation ofthe pressure gauge.

On vessels operating under pressure above 2.5 MPa (25 kgf/cm2) or at medium temperatureover 250 ° C as well as with explosion-hazardous media or noxious substances of 1 and 2 grade ofdanger as per GOST 12.1.007-76 it is allowed to mount a separate pipe connection with a shut-offunit for connection of the second pressure gauge instead of the three-way cock.

Pressure gauges and pipelines connecting them with the vessel shall be protected againstfreezing,

8.11.28. The vessel that is designed for pressure less than that of its supply source shall haveautomatic reducing device with a pressure gauge and a safety valve installed downstream of thereducing device on the low-pressure side.

If a bypass line is mounted it shall also be equipped with the reducing device.8.11.29. Each vessel shall be equipped with safety devices protecting from build-up of

pressure above the permissible value. The manufacturer shall supply the safety valve with acertificate and operation manual.

Safety valves shall be mounted on pipe connections or pipelines directly connected to thevessel.

Connecting pipes of safety valves shall have protective means against freezing of operatingmedium in them.

When several safety valves are mounted on one pipe connection (pipeline), cross-sectionarea of the pipe connection (pipeline) shall be no less than 1.25 of total cross-section area of valvesmounted on it.

In defining cross-section area of connecting pipes more than 1000 mm long it is necessary toconsider their resistance value.

Sampling of the operation media is not allowed from those pipe connections where safetyvalves are mounted (and at the sections of connection pipes that come from the vessel to valves).

Safety valves shall be located in places accessible for their maintenance.Installation of fixtures between vessels and safety valves as well as behind safety valves is

not allowed.Discharge pipes of safety valves and impulse lines shall be equipped with drainage devices

for condensate removal in places where condensate can be accumulated.Installation of shut-off units or other fittings on drainage pipes is not allowed; the medium

that is discharging from safety valves shall be withdrawn to a safe place.Calculation of safety valves for rated capacity of passage and pressure rating should be

carried out according to "Regulations for construction and safe operation of vessels working underpressure".



8.11.30. Vessels operating at changing wall temperature should be equipped with devicesmonitoring speed and uniform warming up along the length and height of a vessel as well asreference points to control heat transfer.

The need to equip the vessels with the above devices and reference points as well as thevalue of permissible speed of vessel warming up and cooling is determined by the project designerand is indicated in certificates or vessel mounting and maintenance instructions by themanufacturer.

8.11.31. When fluid level control is required for vessels with the media boundary line, levelindicators shall be used.

In addition to the level indicators, the vessels may be fitted with sonic, light and othersignalling devices and level interlocks.

Level indicators shall be mounted in vertical or inclined position according to themanufacturer's instruction; as this takes place, the fluid level should be clearly visible.

At least two direct-acting level indicators shall be mounted on vessels to be heated withflame or hot gases where fluid level drop below the permissible level can occur.

Permissible high and low levels shall be indicated on each fluid level indicator.The project designer shall determine permissible high and low fluid levels. The transparent

fluid level indicator should be long enough to cover the whole range so that the bottom is at least 25mm below the lower and the top above the upper permissible liquid level respectively.

When installation of several indicators along the whole vertical extent is required, theyshould be arranged so as to ensure continuity in reading of fluid levels.

Level indicators shall be equipped with fittings (cocks and valves) for their disconnectionfrom the vessel and blowing.

A guard device shall be provided when using glass or mica as a transparent component inlevel indicators in order to protect the personnel against injury in the event of their bursting.

8.11.32. For transportation of vessels, counterflanges shall be secured prior to the shipment.Pipe connections and flanges shall be tightly covered in order to prevent penetration of

moisture and different contaminants during transportation.8.11.33. Packing shall ensure safety of the vessel in set position and protect pipe

connections and flanges from mechanical damage during handling and transportation.In the event that the set position of a vessel does not eliminate the possibility of damaging

pipe connections and flanges, provision shall be made for their protection.8.11.34. Technical documentation shall be supplied in two copies for each vessel in Russian

language and enclosed in a watertight package. 8.11.35. Documentation shall be dispatched together with the vessel in one of the following

ways:1) in a box containing shut-off fittings and test instruments;3) by mail – if it is not possible to effect the dispatch as described in items 1) and 2).The shipper's papers shall contain information of the way documentation has been

dispatched and its location.8.11.36. The passport (warranty certificate) for a vessel operating under pressure shall be in

the supplier's language and have Russian translation.Paper size: 297 x 210 or 288 x 203.8.11.37. The manufacturer shall prepare the passport in duplicate, in hard cover, for a vessel

operating under pressure and dispatch it together with the vessel. If the vessel is to be partiallymounted by the Customer, the Supplier shall send the certificate for the preassembled parts as partof the supply.

8.11.38. Identification plates All adjustment, automatic and manual control units shall have plates alongside (but not

fixed on them) indicating functions of the controls in a language as specified in Section 5.



9. OTHER EQUIPMENT

9.1. LubricationThe equipment shall be furnished with lubrication plates indicating lubrication points and oil

top off and change intervals.Lubrication points shall be shown with plates in Russian language and in the Supplier's

language indicating type of oil and grease to be used.

9.1.1. Oil mist lubrication Oil mist lubrication is only allowed for pneumatic system components and high RPM

spindle heads.

9.1.2. Lubricator typeCentralized lubrication plantThese plants shall be fully automatic on transfer lines and special outfits.The equipment that is not intended for mass production can be equipped with non automatic

type of lubricator but it shall be centralized anyway.When several types of lubricants are employed, different points of centralized lubrication

should be grouped by lubricant type. Tanks of centralized lubrication system shall have plates fixedalongside indicating the lubricant type, tank capacity, filling intervals (expressed in hours ofequipment operation). Oil mist lubrication may be non-centralized. Manufacturers specified inOTU-2-2000 shall supply lubrication devices.

9.1.3. Type of lubricationThe Supplier shall deliver equipment designed to operate with Russian-made oils and

greases as per OTU-2-2000.If Russian made lubricants do not conform with specifications of the supplied equipment,

then products of the following manufacturers may be employed subject to the Customer’s approval:Shell, Mobill, Esso, British Petroleum, Castrol, Aral, Kluber Lubrikation.

If the above listed manufacturers can not offer products with required properties, theSupplier shall employ other lubricants subject to the Customer’s approval and provide, along withthe supplied equipment, the following: annual need for the employed products, a certificate oflubricant conformity to Russian sanitary standards and a specimen of the lubricant in the amount of5 kg (l).

Protection meansAutomatic lubrication plants shall be equipped with safety devices to switch the equipment

off at the end of cycle for lack of lubricant and generate an alarm signal. When considerable time isrequired to stop rotating parts of the equipment (e.g., rotary generators of mid-frequency heaterelements) it is necessary to let the lubricant plant operate for some time after the stop.

Tanks. Using equipment compartments as tanks is not advisable. The lubricant tank shall belocated outside the equipment, where possible.

Tank capacity shall be sufficient for at least 50 hours of operation. The construction andinstallation of tanks shall provide an access for regular cleaning.

9.1.6. Filler necksAll oil filler necks shall have such dimensions as to ensure quick charging and easy access

without removal of doors and protective shields. A plate should be fixed next to the filler neckspecifying type of oil to be employed. If the tank is mounted over 1200 mm above the floor level,provision shall be made for a system allowing oil charging without using any ladders or supports.



9.1.7. Level indicatorsAll tanks shall have clearly visible indicators of minimum and maximum fluid level; the

indicators should be mounted on the same side where the filler neck is located. It is mandatory thattanks of centralized automatic system have indicators with electric signalling system of minimumlevel to stop the equipment at the end of cycle when the level drops to a minimum.

9.1.8. Pipelines and connectionsPipelines may be fitted with valves and other devices provided they would not be open to

destruction caused by vibration and working load.

9.1.9. Contamination of fluidLubrication and hydraulic systems shall be separated in order to avoid mutual contamination

caused by leaks.

9.1.10. Arrangement of componentsThe arrangement of control apparatus shall be such as to provide access during repair and

checking, at a distance of 600-800 mm from the access level, where possible. Lubricant feedingplant, on the contrary, shall not be located farther than 1200 mm from the same access level.

9.1.11. DistributionWhen lubricant is supplied to the points of lubrication by pressurisation in one of the main

distribution lines, different distributors should be connected in series, with safety device beingmounted at the farthest point from the pump.

9.2. Cooling of tools

9.2.1. General requirements for the projectThe plant arrangement shall be such as to enable easy inspection of different units. Tooling

and machine tool shall be so manufactured that to prevent buildup of chip and coolant. The streamof coolant shall be sufficient to provide washing of attachments and the whole working area as wellas part and tool cooling. Therefore nozzles and jets must not be employed.

9.2.2. SupplyAll components of a cooling plant including a bath for collecting of coolant waste, a coolant

cleaning system and probable heat exchangers are at the Supplier's competence. If necessary or ifspecified in the order, oil and chip separating systems shall be provided.

9.2.3. Coolant typesThe Supplier shall use coolants with properties similar to those for coolants specified in

OTU-2-2000.

9.2.4. SafetyAs lack of coolant can cause tool or part damage in the machining, it is necessary to use a

device for coolant feed control and for emergency stop.

9.2.5. Safety guardsWorking area of a machine shall have appropriate safety guards to prevent coolant leaks or

chip flying off.

9.2.6. Coolant feed controlCoolant feed or feed cut-off shall be realized by the following means:1) pump starting or stopping;2) mechanical valve;



3) pneumatic control.Using of hydraulic valves is not allowable. Depending on the type of a machine and

according to specifications of the order coolant feeding system shall provide the following threemodes:

1) continuous feeding;2) intermittent feeding;3) no feeding.

9.2.7. BathsBaths for collecting of coolant shall be placed separately from the machine unless otherwise

specified in the contract. A separately located bath shall be mandatory solution for equipmentintended to machine workpieces made of aluminium-alloyed materials. When it is envisaged toinstall the bath in the machine bed (subject to approval by the Customer in writing), the bed designshall provide easy and convenient access for inspection and cleaning. In the event that the level offluid is in the bath is not visible, a level indicator shall be provided. All baths shall be provided withconveniently arranged slip-proof covers. In case of separately located bath an electrical pump shallbe mounted on it; connection to the equipment shall provide easy removal of the bath and therelated accessories when cleaning or repair is necessary. Tentative intervals of the bath cleaningshall be specified.

9.2.8. Piping along transfer lineA coolant feed pipeline with branch lines to working and washing areas shall be provided

throughout the length of transfer lines. Its location on the whole vertical and along horizontal extentof the equipment is subject to agreement with and approval by the Customer and shall bedetermined to provide the best access to the equipment units and tooling for repair. Such pipelinesshall not be longer than 15 m; if the equipment exceeds this length, a coolant feed pipeline shouldbe divided into sections. Every section of the pipeline shall be fitted with a set of adjusting gatevalves mounted at places approved by the Customer. Operation of these valves shall be controlledpneumatically, each one being controlled with a selector switch located on the control panel. Suchpipelines shall be dismountable into 3-4-m long sections. Easy disassembly of one section of thepipe is required. The pipeline diameter shall ensure a minimum fluid flow rate of 2.5 m/sec. Ontransfer lines with workpiece carriages the Supplier shall provide for the possibility of collectionand withdrawal of discharge fluid beneath the gliding plane of the transporter. The arrangement ofappropriate discharge chutes (as shown in item 4.3.2.) shall be indicated in the installation diagram.

9.2.9. Pipelines and connections.Pipelines shall have an appropriate diameter to ensure free flow of coolant. The pipelines

can be equipped with valves and other devices which shall not be subjected to occurring vibrationsand loads.

9.3. Distribution of various fluids on board the equipment.Refer to the appropriate items relative to distribution of oil by hydraulic plants, of air,

lubricating oil and coolants.

9.3.1. Supply.For trouble free operation of the equipment provision shall be made for the type of fluid and

the working pressure that is specified in the Appendix to Contract Quotation Request.

9.3.2. Connection to the mainsOnly one tapping for connection to the mains shall be provided on the equipment. The

tapping shall have a selector valve of fast action, where possible, and, if necessary, a filter and anemergency stop device as well as devices for pressure and temperature regulation.



9.3.3. Safety guardsThe manufacture and homologation of safety guards shall be in accordance with the

Standards of an institution specified in the Contract. Provision shall be made for signalling deviceswarning about insufficient pressure and possible stop of the equipment in emergency situations.

9.3.4. Adjustment devicesAdjustment devices shall be easily accessible, besides, they shall be located in places

protected from unauthorized persons; the devices shall be designed to prevent their setting beyondthe rated range of safe operation. All pressure adjustment controls shall have marks indicatingminimum and maximum values.

9.3.5. Circuits exposed to harmful media.Circuits of devices operating at elevated temperatures or with toxic materials shall be

guarded and arranged in such a way that their maintenance would not cause damage and lead todangerous situations for operators.

9.3.6. Type of wate.rAll water consuming units shall be designed for operation with employment of re-circulated

water. When it is not possible to employ the above mentioned water, industrial water can be usedsubject to prior approval by the Customer.

9.3.7. Water drainage.Drains for re-circulated and industrial water shall be suited for forced recuperation except

for cases when it is not possible (bath washing and overflow etc.), with drains of contaminated andclean water being separate.

9.3.8. Arrangement of apparatus.In the arrangement of apparatus provision shall be made for free access for service and

inspection; wherever possible, it shall be installed at a height of 600-1800 mm from the accesslevel. It is necessary to avoid installation of the apparatus inside the equipment, otherwise theaccess might be impeded; in any case, the apparatus shall be protected against impacts caused bytransport facilities. Appropriate protection shall be provided for the apparatus that can become dirtyor dusty. The apparatus arrangement is subject to prior agreement with and approval by theCustomer.

9.3.9. Cabinets.Cabinets shall be manufactured of sheet steel no thinner than 2 mm.

9.3.10. Filters.The manufacture and arrangement of filters shall enable cleaning or replacement of the

filtering element without disassembly. Where possible, the plant shall be equipped with devicesindicating the need of filter cleaning or replacement. Tentative intervals of cleaning or replacementshall be specified.

9.3.11. Gas containers.Gas containers shall be employed in accordance with standards indicated in item 8.11.,

OTU-1-2000.



10. GENERAL REQUIREMENTS ON ERGONOMICS

10.1. Ergonomic requirements to the equipment for rational organization ofthe operator's station

10.1.1. In case of easy work which does not require free movements of the operator and alsofor medium laborious works conditioned by specialties of the process the operator's station shouldbe arranged in sitting position.

10.1.2. Operator's station shall be arranged in accordance with the requirements of GOSTstandards:

GOST 12.2.032 SSBT – "Operator's station for works in sedentary position. Generalergonomic requirements";

GOST 12.2.033 SSBT – "Operator's station for works in standing position. Generalergonomic requirements";

GOST 12.2.049 "Production equipment. General ergonomic requirements";GOST 21889 "Operator's seat. General ergonomic requirements";GOST 226713;GOST 12.2.064.10.1.3. Design of production equipment and operator's station shall provide optimum

position of the operator, which is achieved by adjustment ofoperation surface height, seat, space for feet;- seat and feet rest height (when operation surface height is not adjustable). In this case the

operation surface height is to be set for operator's height of 1800 mm.For those operators lower in height the optimum working posture is achieved by increasing

seat and feet rest height by amount of difference between operation surface height for 1800 mmoperator and operation surface height optimum for the operator's actual height.

10.1.4. Operation surface shape of various types of equipment shall be determined withconsideration of the nature of work to be performed. It can have a cutout for the operator's body or arecess for table machines, etc. Where necessary, armrests shall be mounted on the operation surface.

10.1.5. The feet rest shall be adjustable in height, at least 300 mm wide and at least 400 mmlong. Feet rest surface shall be corrugated. 100 mm skirting must be provided along the front edge.

10.1.6. Design and relative position of elements at the operator's station (controls, datadisplay devices, etc.) shall correspond to anthropometrical, physiological and psychologicalrequirements and also the nature of the work.

10.1.7. Operator's station arrangement shall ensure fulfillment of labour operations withinthe reach of the motor field.

10.1.8. Carrying out of "Often" (frequent) and "very often" (very frequent) operations shallbe provided within easy reach of the operator.

10.1.9. The operator's station arrangement and the equipment design shall provide uprightand unobstructed position of the operator's body or its inclination forward no more than 15 °.

10.1.10. When it is not possible to adjust the height of operation surface and feet rest,employment of equipment with fixed height of the operation surface and feet rest is allowable.

10.1.11. To provide convenient, closest possible approach to the table or machine, provisionshall be made for feet space with dimensions at least 150 mm in depth, 150 mm in height and 350mm in width.

10.1.12. In the equipment design and arrangement of operator's station account must betaken of anthropometrical data of women (when only women are employed) and men (when onlymen are employed); general average data of women and men shall be considered if the equipment isoperated by both women and men.



10.2. Ergonomic requirements to toggle-type switches10.2.1. Toggle type switches shall be used to effect quick operations switching on/off and

changing over of electric circuits when visual control of the switch is required.10.2.2. Shape and dimensions of drive components of toggle-type switches shall correspond

to anthropometrical data of the operator's fingers and provide maximum convenient hold of thedrive element while under control taking into consideration special personal outfit. Shape of drivecomponents shall be cylindrical, taper or parallelepiped like. The end of a cylindrical drivecomponent can be made ball- or blade-shaped; the taper base of a taper drive element shall face theoperator.

10.2.3. In case of a large number of switches on the control panel their drive elements shallbe coded according to shape dimensions and colour.

Colour marking on the face plane of drive elements is allowable. Colouring of driveelements shall ensure reliable identification of toggle-type switches.

10.2.4. Drop of elastic resistance shall be felt, with a typical audible click, when operatingdrive elements of toggle-type switches from one position to another.

10.2.5. Positions of drive elements of toggle-type switches such as "upward", to the right","push" shall correspond to the "switched on" operation state; "down", "to the left", "pull" positionsshall correspond to switched off state.

10.2.6. When toggle-type switches are arranged in line their positioning "vertically" or"inward" of the operator's panel is not allowable except for individual cases stipulated by specialconditions of the application.

10.2.7. Toggle switches used as emergency switches shall be protected with special coversor located in panel recess.

10.2.8. Legend or symbols shall be used to indicate functions of drive elements of toggletype switches.

10.2.9. Legend and symbols shall be arranged on the control panel in close vicinity of adrive element on any side provided the operator's hand as well as the drive elements will notinterfere with the identification marks when manipulating drive elements.

10.2.10. In two-position toggle switches the angle of drive element displacement (along thecenterline) when moving it from one position to another shall be 40-60 °; in three-position switchesit shall be 30-50 °.

10.2.11. The working surfaces of drive elements shall have no sharp edges and flats. Ifnecessary, it is allowable that drive element surfaces have flats with transition radius of no less than0.2 mm for light-duty-type toggle and no less than 0.5 mm for heavy-duty toggle.

10.2.12. Knurling is not allowable on working parts of controls except for cases stipulatedby special conditions of application and with observing hygienic requirements.

10.2.13. When toggle switches are arranged in line on the control panel, the distancebetween centerlines of drive elements shall be no less than 19 mm; when operating in gloves it shallbe no less than 25 mm. When rows of toggles are arranged inward the panel, the spacing shall be noless than 25 mm and when operating in gloves it shall be no less than 35 mm.

10.3. Ergonomic requirements to key-actuated and pushbutton switches10.3.1. Key-actuated and pushbutton switches are used for quick switching off/on

operations, selecting of required parameters, typing and entering of control commands.10.3.2. Drive elements of pushbutton switches and selectors shall have circular or

rectangular cross-section in horizontal plane when viewed from the working surface. When thedrive elements are to be coded they may be of different shape.

10.3.3. Drive elements of key-actuated switches shall have rectangular shape.10.3.4. Edges of button and key working surfaces shall be rounded and have no burrs and

indents.10.3.5. To ensure secure hold of the finger the working surface of buttons and keys shall

have slight concavity. In case of rectangular buttons and those with diameter of 3-5 mm flat



working surface with no concavity is allowable. If necessary, it can be spherical or have a smallbead projecting over the working surface or buttons and keys.

10.3.6. Knurling is not allowable on the working surfaces of buttons and keys except forcases conditioned by special conditions of application.

10.3.7. When button and key-actuated switches are used with illumination less than 300 Lxand operation frequency over 50 pushes per minute, drive elements size and interspacing should beincreased by a factor of 1.5 – 3; as this takes place, maximum permissible pushing force shall notexceed 0.6 N.

10.3.8. These requirements are not applicable to operator's station area of limited space.10.3.9. Button and key-actuated switches and selectors shall react when the drive element is

pressed.10.3.10. Button and key-actuated switches and selectors shall have indication of

"ON"/"OFF" position. For push-to-lock switches the height of a protruding key or button over thepanel should be 5-10 mm when in OFF position and 1-3 mm in ON position; light signal indicationcan be added, if necessary. If necessary, ON position of nonlocking switches shall be indicated bylight signal or by special non-luminous indicators.

10.3.11. On panels with numerous switches the drive elements shall be coded by shape,dimensions and colour.

10.3.12. When pushbutton and key-actuated switches are used on the control panel,minimum spacing between drive elements and other controls shall be at least 15 mm; whenoperating in gloves it shall be no less than 25 mm.

10.3.13. To avoid an accidental push, the drive elements of pushbutton and key-actuatedswitches used for the most important operations shall be protected with a ring, beads betweenbuttons and keys and by placing them lower than the panel surface or using additional means ofblocking.

10.3.14. Buttons arranged in a row and also multiple-button switches shall be positionedhorizontally; in cases conditioned by special character of application vertical arrangement isallowable.

10.3.15. When employment of button-keys of different sizes appears to be necessary indesigning button and key fields, modular principle should be used in the selection of their sizes andspacing. All meaningful dimensions shall be multiple of the basic module. Function-colour codingshould also be used.

10.4. General ergonomic requirements for rotary switches10.4.1. Rotary switches are used for ON/OFF switching operations, successive switching

over and smooth continuous or stepwise (discrete) adjustment.10.4.2. Turning the switch clockwise shall cause switching on, parameter increase; when

turned counterclockwise it shall cause switching off, parameter decrease. As this takes place,principle shall be observed that movement of indicator unit pointer should correspond to movementof the controls.

10.4.3. Drive elements of rotary switches shall be reliably secured on the axis to excludetheir turning-through and jumping-off.

10.4.4. Initial positions of one-type drive elements of rotary switches shall be similarlyoriented on the panel, maximum number of positions being 24.

10.4.5. Drive elements of step-type rotary switches (type 1 and 2) shall have indication (anarrow, point, mark) and also secure position fixation to provide quick and unambiguousidentification of the switch position.

10.4.6. Panels featuring switches with drive elements of 1 and 2 types shall have graduationlines corresponding to the switch fixed positions; the pointer shall be positioned on the driveelement as close to the fixed scale as possible.

10.4.7. When designating drive elements uniformity shall be adhered in arrangement andgraphical style of inscriptions and symbols; the inscriptions and symbols shall be put in immediatevicinity of drive elements.



10.4.8 If several inscriptions relate to one and the same drive element they can be arrangedaround the drive element. Drive elements shall not interfere with the inscription reading.

10.4.9 With a large number of switches on the panel they shall be coded by dimensions,shape, color, plane orientation, illumination.

10.4.10 Inscriptions and symbols shall be used to designate functions of drive elements.Inscriptions shall be short and comprehensible during quick reading, abbreviations shall beconventional.

10.4.11 Inscriptions on rotary drive elements of the switches are not allowed except for thecases when there is not enough space for their arrangement and therefore scale-type drive elementsare used.

10.4.12 Sizes of the drive elements of rotary switches shall be chosen in compliance withthe force amount.

When switches are arranged on the panel the minimum distance between drive elementsshall be 20 mm during one-hand operation and 70 mm during two-hand operation. During operationin gloves the minimum distance between drive elements shall be 25 mm.

10.4.13 For sake of space on the panel it is allowed to use rotary switches combined on theaxle (no more than 3 switches on one axle).



11. GENERAL SAFETY REQUIREMENTS TO EQUIPMENTEquipment shall have devices for waste disposal (including liquid, paste, and solid matters)

and devices, eliminating leakage and spillage.

11.1 Requirements to basic structural elementsConstituent parts of the equipment (incl. wires, pipelines, cables, etc.) shall be manufactured

so as to eliminate the possibility of their accidental damage causing danger.Design of the equipment with gas-, steam-, pneumatic-, hydraulic and other systems shall

meet safety requirements valid for these systems and SSBT GOSTs.Moving parts of the equipment which are the source of danger shall be guarded, excluding

those parts which can not be guarded due to their functional designation.In the event that machine actuators represent danger to personnel and can not be guarded, it

is necessary to envisage for the alarms signalling the start of the machine and means stopping andswitching off the power supply.

When necessary the equipment shall have local illumination complying with operationconditions (explosion hazard, high humidity, etc.), herewith the accidental contact with live parts ofthe equipment shall be eliminated.

Equipment design shall envisage for the alarm and where necessary – automatic stop andshutdown devices in case of dangerous faults, emergencies and operating conditions close todangerous.

Equipment tools and actuators as well as gripping clamps and hoisting devices shall beequipped with means preventing dangerous conditions at full or partial shut-down of supply(current, fluid in hydraulic systems, compressed air, etc.) to the drives of these tools, and shall havedevices eliminating self-actuation of the drives at restoration of power supply.

The equipment design shall envisage for the electrical shock protection (including cases offaulty operation of personnel) and shall have zeroing and grounding.

The equipment shall have build-in devices to trap hazardous substances emitted into the airduring operation, especially when M/LTV ratio >1, where M- mass of emissions in g/h, LTV – limitthreshold value of hazardous substance concentration in working area in mg/m3.

With no build-in local exhaust provision shall be made for the place where such device hasto be installed. Build-in local exhaust shall have the following parameters: working aperture size ofsuction pipe, air volume exhausted under various conditions of equipment operation.

All multipurpose machine tools , presses, moulding and core machines shall have lamps oflocal lighting for observation of tool operation from safe distance.

11.2 Requirements to controlsControls shall be manufactured and arranged so as to ensure the convenience of their use,

prevent danger of injury and eliminate the possibility of their accidental switching off and on.Controls shall eliminate spontaneous movements of mechanisms and units. When required

they shall be equipped by interlocking devices, eliminating the possibility of simultaneousmovements of the equipment units.

It is not allowed to activate movements of different elements of the machine by means ofconsecutive travel of one control (e.g. clamp actuation and spindle start) if this may cause injury.

Arrangement of controls (levers, fly-wheels, handles, etc.) shall not cause pinching andpushing of a hand against other controls or machine parts.

Handles, “star” wheels, flywheels with spikes and handles rotating quickly at mechanisedtravel of machine parts shall be automatically switched off during this travel.

On machines and automatic lines with large service range it is required to duplicate controls.In this case an interlock, eliminating simultaneous use of duplicated controls shall be provided.“Stop” buttons shall be located max.10 m apart.

Controls (incl. electrical) shall be located at least 600 mm and not higher than 1800 mmabove floor level.



Should the controls be located higher than 1800 mm, the access to them shall be provided byfootboards, steps, ladders and platforms, which have to be properly secured.

Corresponding warning tables shall be located above the controls changing of which isallowed only at low speed or at a stop of moving parts.

Braking units shall be provided for the machines where auxiliary operations are performedwith main movement units being switched off.

The equipment shall be primarily controlled by means of push buttons and switches whichhave to be mounted on portable control panels and only when it is impossible due to technologicalreasons the controls can be mounted on frame itself, providing good view field of the work zone.

Design of pushbutton station and its location shall eliminate unexpected (accidental) start.Control buttons for automatic and tuning modes shall be grouped on keyboard (panel) as per type ofmodes.

Control buttons shall have clear inscriptions and symbols as per their functions. Inscriptionsand indications shall be embossed or etched, corrosion-proof, and abrasion-resistant.

Control units, including button stations and electrical control boards shall be protectedagainst metal chips and other fine-dispersed materials.

Buttons of foundry and similar machines shall be dust-proof.Push rods of control buttons shall be made from current- insulating material of different

colors depending upon the performed functions. Push rods of working and emergency “STOP”buttons shall be made of red painted materials.

Emergency “STOP” button shall have a “mushroom” form and completely protrude over thebutton box surface.

Push rods of “START” and any other control buttons shall be recessed 2-3 mm in the buttonbox.

In all cases when operator shall wear gloves during operation “STOP” buttons shall bepalm-buttons.

Emergency and working “STOP” buttons shall be duplicated in placed of often personnelappearance and in all dangerous equipment places.

Handles of control levers and control instruments shall be made from low-heat –conductingmaterials.

Levers calculated for the small hand force is recommended to make with ball heads 30-40mm in diameter. Levers envisaged for considerable efforts shall be made with profile (pear-like)heads.

To prevent spontaneous or accidental actuation of the handles or levers they have to be fittedwith reliable catchers (locks). In case of faulty catchers, actuation of handles by action of gravity orspring shall be directed towards the switching off.

When deciding on the direction of lever or handle movement consideration shall be given tothe fact that it is easier to move something forward and backward, than to the sides. Movements in ahorizontal plane are more rational than in a vertical plane.

Control systems of automated machines and transfer lines shall eliminate the possibility oftheir spontaneous changing from tuning or operation mode into automatic and shall eliminate anyspontaneous movement of any mechanism in case of power failure.

Machines (transfer lines) which can not be observed completely from the operator’s placeand where their sudden actuation can cause injuries of the personnel coming across (near the line)have to be equipped with warning alarm (sound, light or combined), automatically actuating bypressing of start button on the control panel and duration of alarm shall be at least 15 s.

Equipment shall be put in operation automatically after the completion of alarm.

11.3 Requirements to protective means included in production equipmentdesign

Protective means shall be ready prior to operation start and shall be interlocked so thatoperation is not possible when protective means are disabled or faulty.

Protective means shall function continuously or come into action in case of danger or whena person approaches dangerous zone.



Means of protection shall be accessible for service and control.If necessary protective means shall be equipped with automatic control devices.Moving parts of the machines, loading and handling devices shall be guarded to prevent

injuries.Guarding structures shall have reliable fixtures, be firm, do not cause inconvenience during

equipment operation, cleaning or setting up.Depending upon the designation and regularity of their usage guards shall be made as

hinged or easily removable continuous metal or plastic enclosures.When constant observation over the enclosed object is required or to arrange for the air

inflow it is allowed to make louvers, openings (up to 10 x 10 mm) in the guard or use mesh-guardswith mesh size of 10 x 10 mm max.

Enclosures shall have handles, brackets and any other devices for comfortable and safeholding of the enclosure during its opening or removing. Hinged enclosures opening upwards shallbe fitted with devices ensuring their reliable fixing in the open state.

Removable enclosures shall have fixtures which do not require keys or screwdrivers duringenclosure removing (deviations from this requirement are allowed only for rarely removableenclosures).

Processing zone shall be guarded by means of a protective device (screen) in order to protectoperator and personnel from injury caused by flying off chips and coolant splashes.

Sight glass of these devices shall be manufactured from hardened or triplex glass whichdoes not lose transparency during operation. Detachable, hinged or removable safety devices shallmove without considerable efforts.

They shall not cause sufficient inconvenience in operation, cleaning and setting up of themachine. Protective means shall be reliably secured, self-opening shall be excluded.

On specialised equipment and transfer lines in automatic mode movement of the devicesguarding processing zone, shall be interlocked at switching on and off of the working cycle.

Machine and transfer line units moving at more than 10 m/min and projecting beyond thebed overall dimensions, shall be guarded along the zone of their movement outside the machinebed.

External ends of the machine and transfer line units moving at speed up to 10 m/min andprojecting beyond the bed overall dimensions shall be painted with alternate light-yellow and redstripes 30-50 mm wide at 75° to horizon level.

Audible, light and colour alarms and warnings shall be used as signalling elements in caseof danger.

During manual placing of the parts and mechanical clamping the gap between the part andclamp shall not exceed 5 mm or additional safety measures shall be envisaged (see GOST12.2.029).

11.4 Special requirements to different machines

11.4.1 Turning lathesRotary devices for securing of workpieces shall have smooth outside surfaces.Machines with projecting parts shall have guards.Lead screws and shafts shall have protective guards.Automated bar stock lathes and turret lathes shall have protection along the length of a bar

fitted with noise-absorbing device.On automatic multi-spindle lathes at the end of the bar machine shall automatically switch

off and light alarm shall illuminate.

11.4.2 Milling machinesNon-working parts of the milling cutter on universal, special and specialised machines and

milling cutters of the universal vertical milling machines shall be guarded to prevent chip scattering.On medium –size and large size machines tool clamping shall be mechanised.



On horizontal milling machines projecting rear ends of spindles and cleaning rods which cancause injury shall be guarded.

Special and specialised milling machines designated for machining without cooling of dust-forming materials shall be equipped with dust collectors connected to separate or group suctiondevices and, if possible to dust suction units.

11.4.3 Planners and shapersTo prevent dangerous consequences of table ejection in the case of its uncoupling from the

drive element machines shall have braking cushioning gears.On planners and shapers the lifting of a cutting tool in idle mode shall be automatic.Shapers shall be equipped with chip collectors.Spontaneous sinking of a ram after slotter switching off shall be prevented.Collecting trays for oil and coolant leakage shall be envisaged for the chip collectors.

11.4.4. Wheel and band cutting-of machinesClamping devices of machines shall provide for the reliable fixing of blanks.Machines shall be equipped with a device for holding and delivery of blanks to the cutting

zone as well as for supporting of the cut blank part.Rotary saw cutting-off machines shall have saw guard (protection) except for the section in

the cutting zone.Band saw machines shall be equipped with devices (catchers) which promptly catch saw

band in case of its break.Band saw shall be covered with safety enclosure, allowing to adjust the amount of saw open

section in accordance with the size and profile of the metal to be cut.

11.4.5 Drilling and boring machinesProvision shall be made for the devices preventing spontaneous sinking of spindles,

brackets, sleeves, cross-bars and heads.Tool clamping in a spindle of boring machines shall be mechanised.

11.4.6 Machines operating with abrasive wheelsThese machines shall have safety hoods guarding the wheel or general hoods guarding the

machining area.Their assembly and disassembly shall be easy and quick.Machines designated for the operation without cooling shall be equipped with hoods - dust

collectors having unions connected to a group or a separate dust suction unit.Dust collecting hoods shall ensure at least 99,5% dust trapping during main operation and

wheel dressing and shall have large fractions collector and small hatches for cleaning.The equipment purchase contract shall provide for the complete supply with the dust

suction unit.Design of a nozzle for the coolant supply shall provide cooling of the abrasive wheel along

its height and shall not hamper the installation of a safety visor.Coolant supply switching on and off shall be interlocked with switching on of the workpiece

rotation in circular grinding machines and with starting and stopping of a table in surface grindingmachines.

Abrasive wheels shall be dressed automatically or by means of reliably secured attachmentsexcept for the grinding and stripping machines where dressing can be performed without securingthe dressing device.

Stripping and grinding machines shall be equipped with supporting tables and safety screenswith sight glasses interlocked with starting and stopping of a drive motor.

On surface grinding machines with electro-magnetic plates provision shall be made forlocking which switches off the table movement should the power supply to the plate be broken.



Tailstock quill backing off on circular grinding machines during grinding shall be excluded.In this case provision shall be made for the device allowing to compensate part elongation as aresult of heating during grinding.

Indication of abrasive tool change intervals is required.

11.4.7 Automatic linesLines serviced on both sides shall have passages ensuring safe movement of personnel as

well as guards preventing persons access to the operating machines and units. Safety guards shallhave electric locking systems disconnecting line operation sequence if they are removed.

Spontaneous sinking and turning shall be excluded in handling (lifting) devices and inturning mechanisms of buffer storage and feeders.

Lines shall have interlocks eliminating the possibility of unit operation when workpiece isnot secured or when they are placed incorrectly in the working position.

Under automatic operation mode the line interlocking system shall eliminate the possibilityof subsequent movement of mechanisms prior to the completion of previous movements envisagedby the operating cycle.

Control over the common functions of the line operation shall be concentrated on the centralcontrol panel; machines in the line shall have button control systems, used during adjustmentoperations.

Central control board shall have an alarm indicating enabled or disabled condition of theline and its machines as well as the operating mode of the line.

Control panels of the separate machines shall have indication of the enabled and disabledstate of the machine.

The line shall be equipped with visible (audible) along the entire length of the line light(sound) signalling system which warns about the line start.

Light signals shall also indicate the line operating mode.Provision shall be made for quick and convenient emergency line shut-down by personnel in

the maintenance area.In case of overhead transport its height from floor level in the area of personnel

passageways shall be no less than 2 meters and they shall have guards preventing parts fallingdown.

Lines shall be equipped with devices for chip removal from all machines, reliable protectionagainst scattering of chips, coolant, fragments of an accidentally broken tool, etc.

11.4.8 Electrical erosion and electrochemical machinesThey shall be equipped with trapping devices for aerosol and gas, emitting in the machining

area with 100% efficiency as well as with unions for connection of machines to the special exhaustventilation.

Design of machine air-ducts for gas and aerosol withdrawal shall provide the possibility oftheir regular cleaning from oil, soot and other depositing contamination.

Electrode – tool and electrode – part, to which the voltage is applied shall be reliablyisolated from the machine body.

All current carrying wires shall have protection eliminating the possibility of voltagetransition to the machine body.

Mechanisms representing the parts of the machine sets and generating considerable noiseand vibration (machine generators of pulse currents, centrifuges, pumps, etc.) shall be sound-proof(covered with sound-absorbing hoods, etc.) and mounted on vibration proof supports.

Control panels shall be equipped with a light signalling system indicating machineconnection to the electrical network and current supply to the discharge circuit.

To prevent wrong switching which can cause damages or accidents the machine shall havelocking devices.

Plate with the requirement to ensure the exact operational level of working liquid over theprocessed part pre-set for this particular machine model shall be attached on clearly visible place onthe machine.



To avoid ignition of inflammable liquid medium the machines shall be equipped withautomatic devices for their shutdown when the working liquid level drops below the designatedvalue (8-10 cm above the processed surface) as well as for trapping and draining of the fluid to atank when the liquid overflows the bath.

Should the mixture of oil and kerosene be used as working liquid, its temperature shall notexceed 50°C during operation, when kerosene is used – the temperature shall not exceed 30°C.

In case of the working liquid heating above the said temperatures machines shall beequipped with cooling system.

If kerosene is used as working liquid, the electrical lamps of local lighting shall be explosionproof.

To ensure fire safety of the ventilation systems as well as for the cleaning of the exhaust airreleased into atmosphere the machines shall be equipped with automatic fire extinguishing systemand provided with filters included in the machine set.

Electrical spark discharge machines shall have devices for automatic discontinuation ofvoltage supply and capacitor discharging during fulfilment of operations requiring the operator’scontact with current carrying sections (when changing electrode, removing and placing of theprocessed part or measuring the part on the machine, etc.).

On electro-impulse machines with bath capacity up to 300 l provision shall be made for theconvenient manual discharge of slime from the bath and on machines with bath capacity exceeding300 l slime removal shall be mechanised.

Anode- mechanical and electrical contact machines shall have reliable protection of theworking personnel against mechanical injuries, working fluid splashes and luminous radiation. Onelectro- chemical machines provision shall be made for the device eliminating the possibility ofworking chamber opening prior to the power supply switching off on the electrolyte supplying unit.

Metal surface hardening plants shall have special dielectric fixtures for securing of thetreated part.

Vibrator rod of the plant shall be properly insulated along the entire length up to the fixingpoint of the electrode used for treatment.

Earthing elements of the electrical erosion machines shall be manufactured so that toeliminate the possibility of fire hazard in case of static electricity as a result of a flow of the non-current carrying liquids in pipelines.

Approximate periods of slime discharge from the bath shall be indicated.Manual and mechanical slime discharge shall eliminate leakage of these substances by

installation of the special collectors.Intervals of air-duct cleaning from oil, soot and other deposits shall be indicated.

11.4.9 Mechanical presses for cold stamping of metalsControl instruments, engage and brake clutches shall not allow inadvertent or spontaneous

press switching on.Corresponding pressure relay shall be installed for automatic shutdown of the press when

air pressure in the air duct drops.Engage and brake system structure shall ensure their reliable operation, convenient

adjustment and replacement of worn parts. During operation in “single stroke” mode engagementunits and braking gears shall provide automatic clutch disengagement and engagement of the brakeafter each stroke with the slide stop in basic extreme position.

To prevent double strokes of a slide it is necessary to equip presses with double airdistributor.

Brake system shall perform mechanical braking irrespective of power supply; release thebrake mechanically or by means of power source (electrical current, air, etc.)

Braking angle shall be no less than 15° of crankshaft turning angle.If engage clutch and brakes are located on opposite ends of the shaft, in-between there must

be an interlock ensuring engagement of the brake immediately after clutch disengagement and notallowing brake actuation prior to the full clutch disengagement.



Single crank presses with force of more than 100 t and double crank presses with force ofmore than 63 t shall have individual electrical motors for adjustment of space between dies. Motorstart shall be interlocked with the press start so that during adjustment period switching on of thepress shall be impossible.

Upper and lower adjustment limits of the space between dies shall be restricted by limitswitches when performing the adjustment by motor as well as with the appropriate indicators whenadjusting manually.

Presses operated by working team shall be equipped with group control actuated by bothhands of every operator. This control allows to bring the press into operation only if all startingdevices are enabled simultaneously.

On 2- and 4-crank presses there should be no less than two control panels on front and rearside of the press.

Each press installed in transfer lines shall have an individual control panel in addition to thecentral control panel.

Each press operating in a single stroke mode shall be equipped with a safety deviceeliminating injuries of hands in dangerous zone (two-hand actuation, photocell protection, movableenclosure, part loading outside the working area – “hand – mark”, etc.).

Press (slide stroke) control buttons (handles) shall be located at a height of 700 –1200 mmfrom the floor level.

“Start” buttons actuated by two hands shall be no less than 300 mm and no more than 600mm apart.

The surface of the press pedal shall be flat, non-slippery, with rounded butt end and a stopfor the boot toe at the distance of 110 – 130 mm from it.

The pedal shall be protected with a rigid hood open only at the operation side andeliminating the possibility of its inadvertent actuation.

The upper edge of a hood shall be rounded to exclude foot injury during its placing on thepedal.

The force applied to pedal for the press switching on shall be within 2,5 – 3,5 kg.Bearing surface of a starting pedal shall be mounted at a height of 80 – 100 mm from the

floor level. Actuation of the press working stroke shall be initiated after depressing the pedal to 45 –74 mm, respectively.

Presses shall be fitted with fuses preventing their break-down in case of overload.Open single-frame presses shall be equipped with rigid guards of a crank mechanism and a

crankshaft which do not allow their parts falling in case of accidental failure.Automatic feed mechanisms and other means of mechanisation on presses (part discharging

units, etc.) shall be provided with corresponding guards if their operation can be of danger to thepersonnel.

Safety devices shall meet the following main requirements:- eliminate the possibility of hands getting under the lowering slide (die) or to remove hands

from the zone of lowering slide (connecting rod).- be fixed automatically in a secure position prior to the slide getting into the safety position;- provide protection at each slide lowering. For this purpose the safety device shall be

interlocked with clutch engagement mechanism or be closely linked to the slide;- to allow adjustment when the slide stroke value and closed height of the press are changed.-do not prevent controlling the working space during stamping and do not cause injuries

during operation.If required to stamp large blanks held by hands, provision shall be made for changing over

or switching off of a safety device and fixing it in the required position.

11.4.10. Moulding and core machinesOn machines with tilting mechanisms the working (dangerous) zone shall be guarded or if

guarding is not possible the zone shall be marked with yellow signalling colour.Machine design shall provide for the locking systems not allowing to break the sequence of

process operations.



Starting device for actuation of moving parts of the machine shall be put into operation byboth hands or to be located at some distance to avoid contact of operator with moving sections ofthe machine.

To remove sand clots and other foreign particles from mould and core surfaces as well asmodels and core boxes the machines shall be equipped with suction devices.

Tilting operations of mould boxes (core boxes) with the overall mass of 6 kg and more shallbe mechanised.

Machines with rotary arm require fixing of the arm in the working position. Rotation of finalsqueezing arms shall be mechanised if they require force of more than 5 kg.

On vibration squeeze machines the unbalanced masses shall be reliably secured to thevibration rotor.

The design of moulding and core sand-blowing machines shall envisage the following:- automation of clamping operations of the core boxes, sand blowing, table lifting and

lowering, core boxes delivery to the area under the blow plate;- interlocks eliminating sand blowing prior to full tightening of the sand box ( mould box)

to the blow plate and table lowering until full drop of pressure in sand-blowingreservoir;

- safety guards for the case of sand spillage in the gap between core box and the blowplate.

- Design of the machine envisaged for the manufacturing of hot box cores shall providethe following:

- suction units with 100% efficiency of harmful gases and vapours trapping and with pipeconnections to draw gas – air mixture off;

- mechanisation and automation of core and box extraction;- on machines with gas heating of the tooling the gas heating unit shall be equipped with

device shutting gas supply off in case of air supply stop and with air pressure meters forgas pressure checking.

- On complex mechanised moulding – knocking out transfer lines provision shall be madefor:

- local top and side suction devices on air cooling and spraying positions of a masterpattern plate with sand humidity of less than 3%.

- side suction units in position of filling of the mould box with a mixture;- ventilation covers on plants for mould box knock-out;- mechanisation of operations related to harmful and difficult labour conditions (steam-

heating of the mould boxes, casting extraction from the lower mould box and theirhanging on the overhead conveyor, return of empty mould boxes to moulding areas,etc.);

- ventilation panels for uniform intake on foundry conveyor sections where metal ispoured into the moulds;

- cooling tunnels on the foundry conveyor through which moulds are transferred from thepouring section to the knocking out plant.

11.4.11 Machines for castings cleaning and core extractionThe structure of batch-operated barrels shall envisage devices preventing the barrel drive

actuation during loading and eliminating personnel access to the barrel during discharge.Barrel lids and their locks shall be rugged, reliably locked to withstand the centrifugal force

and castings impacts.Barrel body shall have sound-proof sheathing made from sheet rubber or other materials for

noise dampening.Batch-operated tumbling barrels shall have braking gears and units for reliable fixing of the

barrel position during loading and discharge.Plants for shot-blast cleaning shall have:- guards,- curtains and seals preventing shot and dust escaping from their working zone.



- locking system eliminating possibility of shot-blast device when doors and shutters areopen.

- normal sound isolation. They shall not create additional noise as a result of vibration ofthe walls themselves.

- locking system eliminating the possibility of a start of shot blasting units while operatingwith a manual shot blast nozzle (work inside the chamber).

Basically the design shall envisage that personnel is outside the chamber when cleaning thecastings.

Machines for castings cleaning and core removal shall be equipped with exhaust ventilationsystems with traps for large fractions and highly efficient cleaning of sucked air.

Water cleaning high pressure chambers shall have:- special attachments for rotation of castings to be cleaned in a horizontal plane which are

controlled by means of a console placed outside the chamber.- chamber doors locked to the water monitor operation (when doors are open the water

monitor turns off).- pipes and hoses with metal braiding for high pressure water supply to water monitors

shall be isolated from maintenance personnel and connected to water monitors only frominside of the chamber.

When arranging the operator’s working places inside chambers provision shall be made forsound-proof cabins supplied with fresh air.

Mechanised and automatic lines for cleaning, chipping and stripping of castings shallenvisage:

- mechanisation and automation of both main process operations and operations of gateand head removal, castings placing to the conveyor and their transfer from position toposition, tilting, removal of stripped castings from the conveyor.

- equipment and transportation sections with harmful substances and heat emissions shallbe fitted with built-in local suction units and covers.

11.4.12 Die casting machinesDie casting machines shall have:- interlocks for the process operations, eliminating moulding when the die is not closed;- protection eliminating the possibility of die closing during maintenance operations on

the open die (cleaning, lubricating);- such design of the machine locking unit that eliminate the possibility of die opening

during operation cycle under the effect of molten metal. In automatic and semi-automatic modes – time relay for keeping castings in moulds in order to eliminate theoperator’s injury due to premature opening of a die;

- safety hoods and shields in all machine zones where accidental sputtering of moltenmetal can occur;

- covers and local suction units trapping at least 95% of harmful emissions.Safety screen on the side of operator shall be locked to the machine operation.Hydraulic lines of the machine shall be fire safe due to application of non-flammable

working fluids or hardly inflammable fluids with oil properties.During equipment designing stage it is required to indicate the place of leakage and oil

collectors (pit or channel 300 mm deep and 400 mm wide).

11.4.13 Chill casting machinesChill casting machines shall:- eliminate the self-closing of separate parts of chill during cleaning, painting, core

mounting;- provide reliable fixing of chills to tables and have stops of table rotation;- ensure tight joint of chill parts and their clamping while pouring with force preventing

molten metal leak from the chill during pouring operation;



- on multi-station machines operations of metal pouring into chills and application ofsafety coatings on their working surfaces shall be mechanised and equipped with aventilation panel.

On automatic chill casting lines provision shall be made for mechanisation of chill sprayingwith parting liquid, pouring, gate removal, casting knock-out and discharge from the machine.

11.5 Requirements to working platforms and staircases11.5.1 Equipment with control panels and other devices hardly or non-accessible from the

floor and requiring constant or regular adjustment, checking and repair shall be fitted withstationary, detachable, folding platforms, foot-boards and ladders. Bearing surfaces of foot-boards,cover plates of the platforms and stairs shall eliminate foot slipping (steel, patterned, punched metalsheets, etc.). In case of floor covers with holes, the size of a hole shall not exceed 20 mm.

11.5.2 During work at elevation of up to 1000 mm and one-hand operation of less than 2min. it is necessary to use fixed or folding platforms 400 – 500 mm wide, or separate steps or foot– boards with plan dimensions no less than 200 x 300 mm. During work at elevation of more than1000 mm and two-hand operation of more than 2 min. it is necessary to use fixed or foldingplatforms at least 700 mm wide.

11.5.3 When climbing onto the platform at least 4 times per shift it is necessary to mountstationary ladders no less than 700 mm wide, with 50-60° inclination to the floor and steps 120 –250 mm wide. Distance between steps – 170 – 200 mm.

11.5.4 When climbing onto the platform 3 times per shift as a maximum and for short timeworks carried out directly from the ladder, it is necessary to install stationary ladders with 65-70°inclination to the floor and steps 80 – 90 mm wide. Distance between steps – 220 – 225 mm.

11.5.5 Ladders of more than 10 m in height shall be fitted with rest platforms every 5 m.Ladder width shall be at least 500 mm, distance between steps – 300 mm maximum.

11.5.6 Installation of spiral stairs is not allowed.11.5.7 The platform and ladders shall have handrails of 1000 mm in height, continuous

guard of at least 100 mm at foot level and stairs landing at height of 500 mm.Inclined stairs shall have rails on both sides 1000 mm from step level and flat metal steps at

least 150 mm wide, eliminating slipping.11.5.8 If platforms are placed at a height of less than 2200 mm from the floor their side

surfaces shall be painted in signal colour under GOST 26568.11.5.9 Working platforms shall have tables indicating the allowed total and concentrated

load calculated for the platform. In this case bearing elements of platforms and ladders shallwithstand the load of no less than 500 kgf/m2.

11.5.10 To adjust or repair the equipment mechanisms located at a height up to 3000 mm,the following shall be used, if required:

- ladders to be leaned against the wall with 60° inclination to the floor with bearing hookseasily fixed on the equipment framework – for operation for 2 minutes as a maximum;

- mobile ladders with platform for operation for more than 2 minutes.11.5.11 To adjust or repair mechanism placed at a height of more than 3000 m from the

floor level the equipment shall be fitted with stationary, detachable or folding platforms andladders.

11.6 Safety requirements determined by peculiarities of installation and repairworks, transportation and storage

The equipment shall envisage the devices providing safety and convenient installation andrepair.

When the application of load lifting means is required, the equipment and its componentshaving inconvenient for fastening design shall have attachments (points) for lifting (with cranes,jacks, etc.).



11.7 General fire protection rulesWhen choosing the process equipment to be installed in the production workshops and

warehouses, in places with explosion and fire- hazardous processes it is necessary to envisageexplosion- and fire prevention measures in compliance with GOST 12.1.004-91 and GOST12.3.047-98 for each particular process equipment piece, e.g.:

- sealing of the process equipment, arrangement of trays, welts or pits;- installation of local suction units on free standing equipment (hoods, board suction units,

etc.), carrying out of explosion and fire- hazardous operations in chambers or cabinets;- employment of devices for recording of pre-explosion concentrations of light-explosive

liquid vapours or combustible gases;- arrangement of interlocks for shut-down of the conveyor, process plants or utilities,

ventilation systems and aspiration systems in case of fire;- installation of fire restraining- or stop valves, automatic valves, fire barriers, etc;- employment of devices (hoods, etc.) for the protection of production equipment containing

fire and explosion- hazardous substances from damage and accidents;- arrangement of the emergency drainage system for light combustible liquids and

combustible liquids from the process equipment and reservoirs, and daily usage tanks;- employment of fixed fire-extinguishing plants, internal fire- water supply;- arrangement of fire alarm;- employment of the equipment in compliance with fire and explosion hazard zone class,

groups and categories of explosion hazardous mixtures in compliance with safety operation rules.grounding of the process equipment;- arrangement of light-weighted non-combustible shields or screens, placing of fire- and

explosion hazardous processes in the separate rooms;- installation of automatic fire extinguishing systems for the equipment protection

(Appendix 2 “Equipment” NPB 110-99);- replacement of light-inflammable and combustible liquids with non-combustible or lower

combustible liquids;To ensure the enhanced strength and reliability (accident-free operation) of the process

plants, units and pipelines for the light inflammable liquids shall be made taking into account thefollowing:

- Steel for the tanks, units and pipelines shall be chosen in compliance with State Standardsallowing for their operation conditions and chemical reactivity of used or transported liquids;

- pipelines shall be made from seamless pipes and connected by welding. Flangeconnections are allowed only at the points of their connection to the equipment (units) or to thevalves;

- structure strength shall be ensured by application of the strength safety coefficient as perthe calculation – at least 1,5 of ultimate strength;

- leakage proof shall be ensured by 100% check of the welds by physical (non-destructive)test methods (X-raying, gamma-raying, etc.;

- equipment and pipelines working under excess pressure shall be pressure tested for 1,5 ofworking pressure, but no less than working pressure + 0,5 Mpa;

- ensure static discharge;- equipment and pipelines shall be subjected to a pressure test under the working pressure.Note: Requirements of high strength and reliability (accident-free operation) of capacity

equipment and pipelines shall be indicated in the technical documentation for their manufacture andin the project documentation.



APPENDIX 1LIST

of ozone-destructive substances subject to state regulation during their import to the RussianFederation and export from the Russian Federation

List A

No. Group Substance NameGroup 1

1.2.3.4.5.

CFCI3CF2CL2C2F3CI3C2F4CL2C2F5CI

(ХФУ –11)(ХФУ –12)(ХФУ –113)(ХФУ –114)(ХФУ –115)

FluorotrichloromethaneDifluorodichloromethane1,1,2-Trifluorotrichloroethane1,1,2,2,-TetrafluorodichloroethanePentafluorochloroethane

Group 2

6.7.8.

CF2BrCICF3BrC2F4Br2

(Galon1211)(Galon1301)(Galon2402)

DifluorochlorobromomethaneTrifluorodibromomethane1,1,2,2- Tetrafluorodibromomethane

List B

No. Group Substance NameGroup 1

1.2.3.4.5.6.7.8.9.10.

CF3CIC2FCIC2F2CI4C3FCI7C3F2CI6C3F3CI5C3F4CI4C3F5CI3C3F6CI2C3F7CI

(ХФУ –13)(ХФУ –111)(ХФУ –112)(ХФУ –211)(ХФУ –212)(ХФУ –213)(ХФУ –214)(ХФУ –215)(ХФУ –216)(ХФУ –217)

TrifluorochloromethaneFluoropentachloromethaneDifluorotetrachloroethaneFluoroheptachloropropaneDifluorosextachloropropaneTrifluoropentachloropropaneTetrafluorotetrachloropropanePentafluorotrichloropropaneSextafluorodichloropropaneHeptafluorochloropropane

Group 2

11. CCI4 Carbon tetrachloride (ЧХУ) or TetrachloromethaneGroup 3

12. C2H3CI3* Methylchloroform (MXB), or 1,1,1- Trichloroethane

* - This formula is not related to 1,1,2- Trichloroethane.



List C

No. Group Substance NameGroup 11.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.31.32.33.34.35.36.37.38.39.40.

CHFCI2CHF2CICH2FCIC2HFCI4C2HF2CI3C2HF3CI2CHCI2CF3C2HF4CICHFCICF3C2H2FCI3C2H2F2CI2C2H2F3CIC2H3FCI2CH3CF3CI2C2H3F2CICH3CF2CIC2H4FCIC3HFCI6C3HF2CI5C3HF3CI4C3HF4CI3C3HF5CI2CF3CF2CHCI2CF2CICF2CHCIFC3HF6CIC3H2FCI5C3H2F2CI4C3H2F3CI3C3H2F4CI2C3H2F5CIC3H3FCI4C3H3F2CI3C3H3F3CI2C3H3F4CIC3H4FCI3C3H4F2CI2C3H4F3CIC3H5FCI2C3H5F2CIC3H6FCI

(ГХФУ –21)(ГХФУ –22)(ГХФУ –31)(ГХФУ –121)(ГХФУ –122)(ГХФУ –123)(ГХФУ –123)(ГХФУ –124)(ГХФУ –124)(ГХФУ –131)(ГХФУ –132)(ГХФУ –133)(ГХФУ –141)(ГХФУ –141b)(ГХФУ –142)(ГХФУ –142b)(ГХФУ –151)(ГХФУ –221)(ГХФУ –222)(ГХФУ –223)(ГХФУ –224)(ГХФУ –225)(ГХФУ –225ca)(ГХФУ –225td)(ГХФУ –226)(ГХФУ –231)(ГХФУ –232)(ГХФУ –233)(ГХФУ –234)(ГХФУ –235)(ГХФУ –241)(ГХФУ –242)(ГХФУ –243)(ГХФУ –244)(ГХФУ –251)(ГХФУ –252)(ГХФУ –253)(ГХФУ –261)(ГХФУ –262)(ГХФУ –271)

FluorodichloromethaneDifluorochloromethaneFluorochloromethaneFluorotetrachloromethaneDifluorotrichloroethaneTrifluorodichloroethaneTrifluorodichloroethaneTetrafluorochloroethaneTetrafluorochloroethaneFluorotrichloroethaneDifluorodichloroethaneTrifluorochloroethaneFluorodichlorethaneFluorodichlorethaneDifluorochloroethaneDifluorochloroethaneFluorochloroethaneFluorosextachloropropaneDifluoropentachloropropaneTrifluortetrachlorpropaneTetrafluorotrichloropropanePentafluorodichloropropanePentafluorodichloropropanePentafluorodichloropropaneSextafluorochloropropaneFluoropentachloropropaneDifluorotetrachloropropaneTrifluorotrichloropropaneTetrafluorodichloropropanePentafluorochloropropaneFluorotetrachloropropaneDifluorotrichloropropaneTrifluorodichloropropaneTetrafluorochloropropaneFluorotrichloropropaneDifluorodichloropropaneTrifluorochloropropaneFluorodichloropropaneDifluorochloropropaneFluorochloropropane

Group 241.42.43.44

CHFBr2CHF2BrCH2FBrC2HFBr4

(ГБФУ-21В2)(ГБФУ-22В1)(ГБФУ-31В1)(ГБФУ-21В4)

FluorodibromomethaneDifluorobromomethaneFluorobromomethaneFluorotetrabromoethane



List C cont.No. Group Substance Name

45.46.47.48.49.50.51.52.53.54.55.56.57.58.59.60.61.62.63.64.65.66.67.68.69.70.71.72.73.74.

C2HF2Br3C2HF3Br2C2HF4BrC2H2FBr3C2H2F2Br2C2H2F3BrC2H3FBr2C2H3F2BrC2H4FBrC3HFBr6C3HF2Br5C3HF3Br4C3HF4Br3C3HF5Br2C3HF6BrC3H2FBrC3H2F2Br4C3H2F3Br3C3H2F4Br2C3H2F5BrC3H3FBr4C3H3F2Br3C3H3F3Br2C3H3F4BrC3H4FBrC3H4F2Br2C3H4F3BrC3H5FBr2C3H5F2BrC3H6FBr

(ГБФУ –23В3)(ГБФУ –23В2)(ГБФУ –24В1)(ГБФУ –31В3)(ГБФУ –32В2)(ГБФУ –33В1)(ГБФУ –41В2)(ГБФУ –42В1)(ГБФУ –51В1)(ГБФУ –21В6)(ГБФУ –22В5)(ГБФУ –23В4)(ГБФУ –24В3)(ГБФУ –25В2)(ГБФУ –26В1)(ГБФУ –31В5)(ГБФУ –32В4)(ГБФУ –33В3)(ГБФУ –34В2)(ГБФУ –35В1)(ГБФУ –41В4)(ГБФУ –42В3)(ГБФУ –43В2)(ГБФУ –44В1)(ГБФУ –51В3)(ГБФУ –52В2)(ГБФУ –53В1)(ГБФУ –61В2)(ГБФУ –62В1)(ГБФУ –71В1)

DifluorotribromomethaneTrifluorodibromomethaneTetrafluorobromomethaneFluorotribromomethaneDifluorodibromomethaneTrifluorobromomethaneFluorodibromomethaneDifluorobromomethaneFluorobromomethaneFluorosextabromopropaneDifluoropentabromopropaneTrifluorotetrabromopropaneTetrafluorotribromopropanePentafluorodibromopropaneSextafluorobromopropaneFluoropentabromopropaneDifluorotetrabromopropaneTrifluorotribromopropaneTetrafluorodibromopropanePentafluorobromopropaneFluorotetrabromopropaneDifluorotribromopropaneTrifluorodibromopropaneTetrafluorobromopropaneFluorotribromopropaneDifluorodibromopropaneTrifluorobromopropaneFluorodibromopropaneDifluorobromopropaneFluorobromopropane

List E

No. Group Substance NameGroup 11. CH3Br Methyl bromide



LIST of products*containing ozone-destructive substances, given in List A

subject to state regulation during their import to the Russian Federationand export from the Russian Federation

List D

ProductAir conditioners for passenger cars and trucks (irrespective of whether they are installed in thecar or not)

Domestic or commercial refrigerating sets and conditioners/ thermocompressors**, e.g.RefrigeratorsFreezersAir dryersWater cooling plantsIce makersConditioners/ thermocompressors

Aerosol (spray) products, except for the medical spraysPortable fire-extinguishersInsulating shields, panels and pipe coatingsFluoroplastics

* - except for the cases when these products are transported in containers with privateproperty or domestic appliances or any other similar non-commercial situations which are out ofCustoms regulations.

** - In case when they contain substances, given in the list A as a cooling medium and/or inthe product insulation material.



APPENDIX 2“Equipment” (Fire Prevention Rules) NPB 110-99

RoomsAutomatic fireextinguishers

Automatic firealarm

Rooms

Standard floor space figure1 2 3

1. Storage rooms for unique issues, reports,manuscripts and other documents of peculiar value(incl. archives (files) of operating departments).Storehouses and storage rooms of service cataloguesand inventories in the libraries and archives withpublications fund:500.000 pieces and more2. less than 500.000

Irrespective of area

Irrespective of area Irrespective of area3. Exhibition halls* 1000 m2 and more Less than 1000 m2

4. Storage and demonstration rooms for the museumvaluable exhibits.*


5. Buildings of cultural and entertainment purpose:5.1. In cinema theatres and clubs with stage andmore than 700 seats with grate bars**.5.2. In clubhouses with stages having the followingdimensions, m: 12,5 x 7,5; 15x 7,5; 18 x 9 and 21 x12 with up to 700 seats.**5.3. In clubhouses with stages of 18 x 9; 21 x 12 mwith more than 700 seats and with stages of 18 x 12;21 x 15 m irrespective of seats number, as well as inthe cinemas **/***.5.4. In concert and cinema-concert halls ofphilharmonic orchestras with 800 seats and more.5.5. Decorations, theatre properties, jointer’s shops;fodder, tool and household storage; rooms for thestorage and manufacturing of advertisements;production purpose and stage service rooms; roomsfor animals, attic above auditorium.






6. Valuables depositories:6.1. In banks As per VNP 001-95/ Bank of Russia6.2. In pawnshops Irrespective of area7. Shooting pavilions of movie studios. 1000 m2 and more Less than 1000 m2

7.1. Luggage rooms for hand luggage (except for theautomatic cell luggage rooms) and combustiblematerials storehouses (included those at airports) onthe following floors:8.1 ground floor and basement8.2 elevated floors

Irrespective of area Less than 300 m2

9. Rooms for the storage of combustible or non-combustible materials in combustible packaging ifthey are located:9.1 Under tribunes (stands) of any seating capacity inindoor sporting facilities;9.2 In indoor sporting facilities with 800 and moreseats.9.3 Under tribunes (stands) with 3000 and more seats

300 m2 and more

100 m2 and more100 m2 and more

100 m2 and more

Less than 100 m2

Less than 100 m2



in outdoor sporting facilities;10. Rooms for computers, connected processors andtelecommunication network knots, archives ofmagnetic and paper media, plotters, serviceequipment, system programmers, data preparationsystems, as well as space under the detachable floorsand suspended ceiling (except for the PCs, locatedon users’ working places and do not requiring theservice zones).


11. Shopping facilities integrated in the otherpurpose buildings:11.1 basement and ground floors11.2 Elevated floors

200 m2 and more500 m2 and more

Less than 200 m2

Less than 500 m2

12. Production purpose facilities located in scientificand research establishments and other publicbuildings.

To be equipped in compliance with therequirements of table 1 of these norms.

13. Any other public purpose buildings, includingbuild-in or built-to.

Irrespective ofarea

* - This requirement does not cover the rooms:temporary used for exhibitions: foyer, entrance hall, etc.)where valuables are stored in the metal safes.

** - Drenchers shall be established under grate bars of the stage and rear stage, under thelower level of the working galleries and lower passage bridges connecting the galleries, as well asin safes of folded decorations and in all stage openings, included those of portal, pockets, and rearstage; as well as part of mezzanine occupied with inbound stage equipment and handling devices.

*** - Sprinkler system shall be installed at: stage and rear stage covers, all working galleriesand passage bridges, except for the lower ones, mezzanine (except for the build-in stageequipment), stage pockets, rear stage, as well as store rooms, job shops for easel and spacedecorations, dust extraction chamber.



EquipmentTable 2

Automatic fireextinguishers

Automatic firealarm

Rooms

Norm1 2 3

1. Paint booths with combustible and inflammableliquids.2. Dry-ovens3. Cyclones (separators) for combustible wastescollection.4.. Transformers with oil cooling system, voltage500 kV220 – 330 kV110 kV, installed close to hydro electric stations5. Oil breakers, installed in the closed switchinggears6. Test stations of mobile electric stations andplants with diesel and gas- electrical power unitsfixed on trucks or trailers.7. Racks higher than 5,5 m for storage ofcombustible materials in combustible packaging.8. Oil reservoirs for hardening.

Irrespective of type

“ – “

“ – “irrespective of powerPower200MBAWith single power63MBAAt oil weight of 60 kgand more

Irrespective of areaIrrespective of area

3 m2 and more

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