ISO 12643-1:2007

INTERNATIONAL ISO
STANDARD 12643-1
First edition
2007-03-01
Graphic technology — Safety
requirements for graphic technology
equipment and systems —
Part 1:
General requirements
Technologie graphique — Exigences de sécurité pour les systèmes et
l'équipement de technologie graphique —
Partie 1: Exigences générales
Reference number
©
ISO 2007
PDF disclaimer
This PDF file may contain embedded typefaces. In accordance with Adobe's licensing policy, this file may be printed or viewed but
shall not be edited unless the typefaces which are embedded are licensed to and installed on the computer performing the editing. In
downloading this file, parties accept therein the responsibility of not infringing Adobe's licensing policy. The ISO Central Secretariat
accepts no liability in this area.
Adobe is a trademark of Adobe Systems Incorporated.
Details of the software products used to create this PDF file can be found in the General Info relative to the file; the PDF-creation
parameters were optimized for printing. Every care has been taken to ensure that the file is suitable for use by ISO member bodies. In
the unlikely event that a problem relating to it is found, please inform the Central Secretariat at the address given below.

©  ISO 2007
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means,
electronic or mechanical, including photocopying and microfilm, without permission in writing from either ISO at the address below or
ISO's member body in the country of the requester.
ISO copyright office
Case postale 56 • CH-1211 Geneva 20
Tel. + 41 22 749 01 11
Fax + 41 22 749 09 47
E-mail copyright@iso.org
Web www.iso.org
Published in Switzerland
ii © ISO 2007 – All rights reserved

Contents Page
Foreword. iv
Introduction . v
1 Scope . 1
2 Normative references . 2
3 Terms and definitions. 4
4 Effective date. 11
5 Guarding of significant hazards. 11
6 Requirements for protection against other hazards . 30
7 Release from hazardous situation . 42
8 Control zones . 42
9 Controls . 43
10 Control stations . 53
11 Control systems. 58
12 Ergonomics and labelling of indicators and actuators. 60
13 Signals and warning devices. 60
14 Warning signs and labels . 63
15 Contents of instruction handbook. 64
Annex A (informative) Risk analysis relating to the pitch angle of access stairs . 67
Annex B (informative) Noise . 69
Annex C (normative) Area warning light system . 71
Annex D (informative) Example layout of instruction handbooks . 73
Bibliography . 75

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 12643-1 was prepared by Technical Committee ISO/TC 130, Graphic technology.
This first edition of ISO 12643-1, together with ISO 12643-2, cancels and replaces ISO 12648:2006, which
has been technically revised. This edition of ISO 12643-1, together with ISO 12643-3, cancels and replaces
ISO 12649:2004, which has been technically revised.
ISO 12643 consists of the following parts, under the general title Graphic technology — Safety requirements
for graphic technology equipment and systems:
⎯ Part 1: General requirements
⎯ Part 2: Press equipment and systems
⎯ Part 3: Binding and finishing equipment

iv © ISO 2007 – All rights reserved

Introduction
During the development of this part of ISO 12643, existing relevant standards of other countries were taken
into consideration. An effort has been made to take into consideration the requirements of many countries,
recognizing that national standards or laws may dictate national requirements. In cases where it was known
that there is a national requirement that differs from this part of ISO 12643, that has been noted.
This part of ISO 12643 was developed to harmonize the following U.S. and European safety standards:
⎯ ANSI B65.1, Graphic technology — Safety standard — Printing press systems;
⎯ ANSI B65.2, Binding and Finishing Systems;
⎯ ANSI B65.3, Safety standard — Guillotine paper cutters, mill trimmers, and integral handling equipment;
⎯ ANSI B65.4, Safety standard — Three-knife trimmers, including rotary, and single- and multiple-knife
trimmers;
⎯ EN 1010-1, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 1: Common requirements;
⎯ EN 1010-2, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 2: Printing and varnishing machines including pre-press machinery;
⎯ EN 1010-3, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 3: Cutting machines;
⎯ EN 1010-4, Safety of machinery — Safety requirements for the design and construction of printing and
paper converting machines — Part 4: Bookbinding, paper converting and finishing machines.
INTERNATIONAL STANDARD ISO 12643-1:2007(E)

Graphic technology — Safety requirements for graphic
technology equipment and systems —
Part 1:
General requirements
1 Scope
This part of ISO 12643 provides safety specifications for the design and construction of new machines used in
printing press systems and in binding and finishing systems. It includes equipment used in a stand-alone
mode, or in combination with other machines, including ancillary equipment, in which all the machine
actuators (e.g. drives) of the equipment are controlled by the same control system.
The requirements listed in this part of ISO 12643 are applicable to the equipment covered by all parts of
ISO 12643, unless otherwise noted. Requirements specific to press and binding and finishing equipment and
systems, that are not included in this part of ISO 12643, are given in ISO 12643-2 and ISO 12643-3,
respectively.
This part of ISO 12643 addresses recognized hazards specific to equipment and systems in the following
areas:
⎯ mechanical;
⎯ electrical;
⎯ slipping, tripping, falling;
⎯ ergonomics;
⎯ noise;
⎯ radiation;
⎯ fire and explosion;
⎯ thermal;
⎯ other emissions.
It is advisable that technologies not identified in this part of ISO 12643 incorporate the safety principles set
forth herein in their design.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
ISO 8031, Rubber and plastic hoses and hose assemblies — Determination of electrical resistance
ISO 11553-1, Safety of machinery — Laser processing machines — Part 1: General safety requirements
ISO/TR 11688-1, Acoustics — Recommended practice for the design of low-noise machinery and
equipment — Part 1: Planning
ISO 11689, Acoustics — Procedure for the comparison of noise-emission data for machinery and equipment
ISO 12100-1, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology
ISO 12100-2, Safety of machinery — Basic concepts, general principles for design — Part 2: Technical
principles
ISO 12643-2:2007, Graphic technology — Safety requirements for graphic technology equipment and sys-
tems — Part 2: Press equipment and systems
1)
ISO 12643-3:— , Graphic technology — Safety requirements for graphic technology equipment and sys-
tems — Part 3: Binding and finishing equipment
ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human responses to
contact with surfaces — Part 1: Hot surfaces
ISO 13849-1:1999, Safety of machinery — Safety-related parts of control systems — Part 1: General
principles for design
ISO 13850, Safety of machinery — Emergency stop — Principles for design
ISO 13851, Safety of machinery — Two-hand control devices — Functional aspects and design principles
ISO 13852, Safety of machinery — Safety distances to prevent danger zones being reached by the upper
limbs
ISO 13854, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body
ISO 13855, Safety of machinery — Positioning of protective equipment with respect to the approach speeds of
parts of the human body
ISO 13856-1, Safety of machinery — Pressure-sensitive protective devices — Part 1: General principles for
design and testing of pressure-sensitive mats and pressure-sensitive floors
ISO 14119:1998, Safety of machinery — Interlocking devices associated with guards — Principles for design
and selection
ISO 14120, Safety of machinery — Guards — General requirements for the design and construction of fixed
and movable guards
1) To be published.
2 © ISO 2007 – All rights reserved

ISO 14122-1, Safety of machinery — Permanent means of access to machinery — Part 1: Choice of a fixed
means of access between two levels
ISO 14122-2, Safety of machinery — Permanent means of access to machinery — Part 2: Working platforms
and walkways
ISO 14122-3, Safety of machinery — Permanent means of access to machinery — Part 3: Stairs, stepladders
and guard-rails
2)
ISO/TR 15847:— , Graphic technology — Graphical symbols for printing press systems and finishing sys-
tems, including related auxiliary equipment
IEC 60079-1, Electrical apparatus for explosive gas atmospheres — Part 1: Flameproof enclosures “d”
IEC 60079-2, Electrical apparatus for explosive gas atmospheres — Part 2: Pressurized enclosures “p”
IEC 60079-5, Electrical apparatus for explosive gas atmospheres — Part 5: Powder filling “q”
IEC 60079-6, Electrical apparatus for explosive gas atmospheres — Part 6: Oil-immersion “o”
IEC 60079-7, Explosive atmospheres — Part 7: Equipment protection by increased safety “e”
IEC 60079-11, Explosive atmospheres — Part 11: Equipment protection by intrinsic safety “i”
IEC 60079-14, Electrical apparatus for explosive gas atmospheres — Part 14: Electrical installations in
hazardous areas (other than mines)
IEC 60079-18, Electrical apparatus for explosive gas atmospheres — Part 18: Construction, test and marking
of type of protection encapsulation “m” electrical apparatus
IEC 60204-1, Safety of machinery — Electrical equipment of machines — Part 1: General requirements
IEC 60825-1, Safety of laser products — Part 1: Equipment classification, requirements and user’s guide
IEC 60947-2, Low-voltage switchgear and controlgear — Part 2: Circuit-breakers
IEC 60947-3, Low-voltage switchgear and controlgear — Part 3: Switches, disconnectors, switch-
disconnectors and fuse-combination units
IEC 60947-5-1, Low-voltage switchgear and controlgear — Part 5-1: Control circuit devices and switching
elements — Electromechanical control circuit devices
IEC 61010-1, Safety requirements for electrical equipment for measurement, control, and laboratory use —
Part 1: General requirements
IEC 61310-1, Safety of machinery — Indication, marking and actuation — Part 1: Requirements for visual,
auditory and tactile signals
IEC 61310-2, Safety of machinery — Indication, marking and actuation — Part 2: Requirements for marking
IEC 61310-3, Safety of machinery — Indication, marking and actuation — Part 3: Requirements for the
location and operation of actuators
IEC 61496-1, Safety of machinery — Electro-sensitive protective equipment — Part 1: General requirements
and tests
2) To be published.
IEC 61496-2, Safety of machinery — Electro-sensitive protective equipment — Part 2: Particular requirements
for equipment using active opto-electronic protective devices (AOPDs)
EN 1127-1, Explosive atmosphere — Explosion prevention and protection — Part 1: Basic concepts and
methodology
EN 1760-2, Safety of machinery — Pressure sensitive protective devices — Part 2: General principles for the
design and testing of pressure sensitive edges and pressure sensitive bars
EN 12198-1:2000, Safety of machinery — Assessment and reduction of risks arising from radiation emitted by
machinery — Part 1: General principles
EN 13023, Noise measurement methods for printing, paper converting, paper making machines and auxiliary
equipment — Accuracy categories 2 and 3
3)
NFPA 79 , Electrical Standard for Industrial Machinery
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 13849-1:1999 and the following
apply.
3.1
actuator
part of the actuating system to which an external actuating force is applied
[24]
[IEV 441-15-22]
NOTE 1 The actuator can take the form of a handle, knob, pushbutton, roller, plunger, trip wire, pressure-sensitive mat,
etc.
NOTE 2 There are some actuating means that do not require an external actuating force, but only an action; e.g. light
beams. Such actuating means are not considered to be actuators.
3.2
armed condition
machine status in which machine motion can be automatically initiated
NOTE Zero speed (3.64) can be considered to be an armed condition.
3.3
audible alarm
horn, bell or other distinctive audible warning device that sounds to indicate impending machine motion
3.4
authorized person
person identified by management as having special training or designated to act in specified situations
NOTE Examples of “specified situations” include:
⎯ special tasks to be performed;
⎯ the function of the adjustments in the work zone;
⎯ proper operation of adjustments and controls;

3) Available from National Fire Protection Agency, Batterymarch Park, Quincy, Massachusetts, USA 02169-7471;
www.nfpa.org.
4 © ISO 2007 – All rights reserved

⎯ all types of hazards in the area where the task is to be performed;
⎯ the application of equivalent, alternative protection to perform the task;
⎯ improper actions that can cause injury and the consequences of those improper actions.
3.5
auxiliary device
mechanism or machine, either built-in or attached, used for the production process
3.6
barrier guard
guard (3.21) that reduces or prevents physical access to a hazard zone by closing off access to an area
containing one or more hazards
EXAMPLE A perimeter fence or tunnel guard.
3.7
binding and finishing system
combination of machines functioning in an integrated configuration to turn an incomplete printed product into a
finished product by means of one or more processes, such as cutting, folding, binding, stitching, gluing,
wrapping, etc.
3.8
Category 0 stop
uncontrolled stop
stopping by immediate removal of power to the machine actuators (3.29)
[IEC 60204-1]
3.9
Category 1 stop
controlled stop with power available to the machine actuators (3.29) to achieve the stop and then removal of
power when the stop is achieved
[IEC 60204-1]
3.10
Category 2 stop
controlled stop with power left available to the machine actuators (3.29)
[IEC 60204-1]
3.11
continuous run
machine motion at a steady speed initiated by a momentary-contact control
3.12
control station
defined location containing one or more controls
3.13
control zone
control configuration of single or multiple machine motions using the same control devices
NOTE See Clause 8.
3.14
drive
mechanism, divided into the following two general categories, which causes a machine or any of its elements
to move:
⎯ drives with no stored energy, which include, but are not limited to, direct-motor drives;
⎯ drives having stored energy, which include, but are not limited to, motor-flywheel-clutch drives and
hydraulic-pneumatic drives
3.15
electrical hazard
source of potential injury or death from electric shock or burn
NOTE Adapted from ISO 12100-1:2003.
3.16
electro-sensitive protective device
ESPD
apparatus that detects the presence of a person or part of a person or object in a defined area, using any
detection means including, but not limited to, photoelectric, light screen, ultrasonic, etc.
3.17
emergency stop device
manually actuated control used to initiate an emergency stop function (3.18)
NOTE Adapted from ISO 13850:1996.
3.18
emergency stop function
mechanism activated by a single human motion and intended to halt machine activity in order to avoid injury to
persons, damage to machinery or damage to work in progress
3.19
exposing device
machinery used for creating images by exposing photo-sensitive material such as printing plates or printing
formes
3.20
fixed guard
guard (3.21) that is securely affixed by fasteners that require a tool(s) to remove in order to gain access to an
area with a significant hazard
3.21
guard
physical barrier that restricts access to a significant hazard
3.22
hazard point
location of a hazard on a machine where a person can be injured
3.23
hazard zone
any area within and/or around machinery in which a person is exposed to risk of injury or damage to health
NOTE Adapted from ISO 12100-1:2003.
3.24
hold-to-run control
control that starts and maintains machine motion only as long as the control is activated
6 © ISO 2007 – All rights reserved

3.25
inch
jog
〈operation of machinery〉 machine motion requiring maintained activation engagement of a hold-to-run control
and which will continue until the control is released or until a pre-determined displacement (limited inch) has
been reached
3.26
infrequently used workplace
area in which an activity is carried out, such as observation, make-ready, jam clearing, minor servicing,
crossing inserting hoppers or conveyer belts, etc., that is routine, repetitive, integral to (but not necessarily
during) production, and done only on an occasional basis
3.27
in-running nip
in-going nip
area created either by two rotating components that are rotating inward, or by one component rotating toward
an adjacent surface
See Figure 1.
NOTE Rollers rotating in the same direction do not create a hazardous in-running nip if the rollers have the same
surface characteristics and circumferential speeds.

a) Two counter- b) Two rolls c) Two rolls d) One rotating roll e) Belt, chain or
rotating rolls rotating in the rotating in the and an adjacent web which is
same direction same direction, fixed object driving, or being
at different but with driven by, a roll
speeds different
surface
properties
(friction)
Figure 1 — In-running nips
3.28
interlock
〈for safeguarding〉 arrangement that interconnects guard(s) or device(s) with the control system and/or all or
part of the electrical energy distributed to the machine
[IEC 60204-1]
3.29
machine actuator
power mechanism used to affect motion of a machine
[ISO 13850:1996]
3.30
maintained-contact control
control that remains in an open or closed state after its activation
3.31
maintenance
operation(s) required to assure that the machine remains in acceptable operating condition and that is/are
usually performed when the machine is not available for production
NOTE Maintenance (for example, repairing or replacing broken, worn or damaged parts; performing lubrication;
preventive servicing) is normally performed by qualified maintenance personnel, or operators, who have been trained
about the types of hazards in the area in which their tasks are to be performed and about how these hazards can be
avoided. Such maintenance is generally performed with energy isolated, when possible.
3.32
make-ready
tasks preceding a production run, such as adjusting ink controls for proper colour, plate alignment for proper
registration, adjusting pressures, measurement with quality control devices, etc.
3.33
manual control device
mechanism comprising part of the actuating system to which a manual action is applied
[24]
NOTE Adapted from IEV 441-15-22 .
3.34
mechanical hazard
source of potential injury to a person created by motion of machinery, components or material
EXAMPLES Crushing and shearing points; trapping points; in-running nips; cutting, punching and impact points; gear,
chain and worm drives; V-belt, flat belt, cord and rope drives; pulling and supporting elements on continuous conveyors;
spoke wheels and fly wheels; shafts and shaft ends; rollers; slides; push rods and similar parts, tools and clamping
devices.
3.35
momentary-contact control
control that is opened or closed only during its actuation
3.36
motion control
control that initiates machine movement or movement at zero speed (3.64), or places the machine in the
armed condition (3.2)
3.37
motion-control station
station that contains a motion control (3.36)
3.38
motion zone
area defined by any machine component, or group of machine components, which is driven directly by the
system drive motor(s) or machine actuator(s) (3.29), or indirectly by other means
3.39
movable control station
control station that is permanently wired to the equipment, but which can be moved within a range limited by
the length of the attached cable
3.40
movable guard
guard (3.21) that does not require a tool to move or remove it to gain access to a significant hazard
3.41
nip guard
guard (3.21) located at an in-going nip
EXAMPLES Nip bar, finger bar, finger guard.
8 © ISO 2007 – All rights reserved

3.42
normal operation
usual functioning and conditions that exist during set-up, make-ready, production and minor servicing,
adjusting and cleaning performed by operators, but not including maintenance (3.31) operations
3.43
operating position
location where normal functions (make-ready and other routine, repetitive tasks) requiring control of the main
drive motor(s) are performed
3.44
permissive period
time interval during which machine motion can be initiated
NOTE See 13.2.3.
3.45
personnel warning light
red or green light used to indicate the ready, running and safe conditions of the machine relative to personnel
safety
NOTE These lights are not the same as machine status lights (3.57).
3.46
portable control station
control station that can be disconnected from one location, moved to another location and be reconnected
NOTE This is not the same as a remote control (3.51).
3.47
positive mechanical action
linkage of one component with another component such that movement of the former inevitably compels
movement of the latter, either by direct contact or by a rigid connection
NOTE 1 This definition also applies to a component that prevents any movement of another component by virtue of its
presence.
NOTE 2 When the movement of one mechanical component simply allows another component to move freely (e.g. by
gravity, spring force, etc.), there is no positive mechanical action of the former component on the latter.
3.48
positive opening
contact separation as the direct result of a specified movement of the actuator (3.1) through non-resilient
members, e.g. those not dependent on springs
3.49
raised workplace
area where functions are regularly performed, and are at least 0,5 m above access level
3.50
ready condition
status of a machine in which motion can be initiated by the operator
3.51
remote control
access connection to one or more control stations of a machine by use of an external communication link
NOTE This is not the same as portable control station (3.46).
3.52
routine and regular access
repetitive access to a hazard point that is required during normal production activity
3.53
safe condition
machine status in which movement of the main drive motor(s) (prime mover) of the motion zone is prevented,
which may apply to the entire machine or to one or more motion zones, and which exists only when one or
more stop/safe or emergency stop pushbutton(s) is/are latched in the depressed position
3.54
separating element
part on feeders of sheets, blanks or similar materials that separates the individual sheets, blanks, etc.
3.55
significant hazard
potential source of severe or disabling injury or death
3.56
smooth cylinder
smooth roller
elongated body, solid or hollow, with a circular cross-section having a smooth surface with either of the
following:
a) grooves no more than 4 mm deep (measured in the radial direction) and no more than 8 mm wide
(measured in the circumferential direction), with no sharp or cutting edges (see Figure 2); or
b) grooves no more than 4 mm wide (measured in the circumferential direction), with no sharp or cutting
edges
NOTE “Cylinders” includes plate cylinders, blanket cylinders, impression cylinders, etc. Ink rollers, dampening water
rollers or distribution drums are not considered to be cylinders as defined in this part of ISO 12643.
Dimensions in millimetres
Figure 2 — Smooth roller/cylinder
3.57
status light
light that indicates machine status or machine process condition
NOTE Status lights are not the same as personnel warning lights (3.45).
3.58
tool
implement, such as a key or wrench, designed to operate a fastener
NOTE An item such as a coin or fingernail file is not considered to be a tool.
3.59
trip bar
protective bar that, when pushed, activates the interlocked safety system of the machine
10 © ISO 2007 – All rights reserved

3.60
trip nip bar
movable protective bar located at an in-running nip which, when pushed, activates the interlocked safety
system of the machine
3.61
two-hand control
safety device that consists of two manual control devices that must be operated simultaneously by a single
operator to initiate potentially hazardous machine motion
3.62
warning period
time interval during which machine motion is prevented and a warning is given to personnel that machine
motion is about to occur
3.63
wireless control
transmission of commands and signals between a machine-control system and the motion-control station(s)
using means other than a physical connection
3.64
zero speed
condition of machine movement in which the drive control system is actively holding the machine at a position
and while machine movement is not discernible, machine movement can be initiated without warning
NOTE Zero speed can be considered to be an armed condition (3.2).
4 Effective date
This part of ISO 12643 applies to new machines manufactured after December 31 of the year following the
year of issue of this part of ISO 12643.
5 Guarding of significant hazards
5.1 General
Guarding, consistent with operation of the machine, shall be provided in those areas where it is recognized
that operators are exposed to significant hazards. Exposure to significant hazards is not considered to exist if,
during normal operation, the distance to the hazard complies with those specified in ISO 13852. Machinery
shall be designed according to the principles of ISO 12100-1 and ISO 12100-2 for hazards that are relevant,
but not significant, and which are not covered by this part of ISO 12643.
Significant hazards vary from machine to machine. It is important that each machine be evaluated to
determine what hazards might exist and that shall be guarded.
Machines should be designed to allow normal production operations such as make-ready, wash-up, operator-
performed maintenance or troubleshooting without machine motion. Where machine motion is required to
perform these functions, guards and safety devices shall provide protection against hazards. These
operations shall be carried out using a hold-to-run device as specified in 5.4; 5.6; ISO 12643-2:2007, 5.3.2; or
ISO 12643-2:2007, 5.7.4.2 (for folder delivery). Where moving components or product flow require
surveillance, equipment shall be designed to allow the needed visibility and to allow adjustments, if needed, to
equipment operation with the guards remaining closed.
EXAMPLES A transparent guard or remote viewing system.
5.2 Guards
5.2.1 Guard types and travel
5.2.1.1 Type of guards
For the purpose of this part of ISO 12643, there are two types of guards, fixed and movable.
Guards that do not have to be opened frequently shall be interlocked or shall be fixed in such a way that their
removal necessitates the use of a tool (see 3.58), such as a key or wrench, designed to operate a fastener.
All movable guards shall be interlocked in accordance with 5.5.
Guards that are designed to be opened, removed, and/or moved at least once per working shift (on average)
during normal operation, for make-ready (set-up) operations, or to permit access to a hazardous area, with or
without the use of a tool, shall be interlocked.
NOTE 1 A typical working shift is 8 h.
Guards and doors may be removed for set-up and for other purposes.
NOTE 2 Examples include, but are not limited to:
⎯ to supply the material to be processed;
⎯ to change the format;
⎯ to change tools;
⎯ for make-ready.
The interlock system shall operate as described in 5.5.1.
When the interlocking guard is open, one of the measures set out in 5.6 shall become effective.
Where production processes need to be watched, guards shall be designed to ensure sufficient visibility of the
functional process and not to impair vision by reflections.
EXAMPLES Mesh-type guards painted in matte black, placement of lighting behind the guard, etc.
Guards shall not create any additional significant hazards to personnel and shall satisfy the requirements of
ISO 14120.
5.2.1.2 Automatic travel of movable guards
Automatic travel of movable guards shall not create any significant mechanical hazards.
NOTE This can be achieved, for example, by limiting the force of the guard movement. The following guidelines are
suggested:
a) 50 N or less where the likely contact surface of the guard is a blunt edge or projection and there is no risk of cutting
or stabbing injuries; or
b) 150 N or less where the likely contact surface of the guard is a plane such that there is no risk of a crushing injury.
Higher values can be chosen based upon risk analysis.
12 © ISO 2007 – All rights reserved

5.2.1.3 Protection against gravity falls of guards
Guards that can be opened shall be safeguarded against gravity falls if such a fall creates a risk of injury.
EXAMPLE The following are examples of means that may be used for safeguarding:
⎯ devices for balancing the mass;
⎯ pneumatic springs;
⎯ devices which automatically hold the parts open;
⎯ power-driven worm gear drives actuated by hold-to-run controls if the hazard points can be observed from the
position where the hold-to-run control is actuated;
⎯ ensuring that the centre of gravity of the guard in the open position is sufficiently far behind the axis of rotation to
prevent closing.
Springs used for balancing the mass shall be designed such that no hazard shall result from failure of the
spring or movement of the guard. Compression-type springs are preferred. Springs shall not display any
permanent deformation, even after extensive use.
5.2.2 Guard positioning
5.2.2.1 Guard distances and gaps
The safety distance between the guard and the in-running nip is measured from that point where the distance
between the rotating surfaces, or the rotating surface and a fixed surface, is 10 mm (see Figure 3). Safety
distances shall be as specified in ISO 13852.
The design and construction of the barrier guard shall ensure that personnel cannot encounter the hazard by
reaching up, over, under, around or through the barrier guard.
The safety distance for guide rollers shall be a minimum of 120 mm.
Dimensions in millimetres
Figure 3 — Measuring safety distance at the in-running nips
5.2.2.2 Reaching upwards
If there is a low risk (as determined by risk assessment) from the hazard zone when reaching upward, then
the height of the hazard zone shall be 2 500 mm or more, as specified by ISO 13852. Otherwise,
a) either the height of the hazard zone shall be 2 700 mm or more; or
b) other safety measures shall be used.
[8]
NOTE For further information on risk assessment, see ISO 14121 .
5.2.2.3 Reaching over protective structures
If there is a low risk (as determined by risk assessment) from a hazard zone when reaching over a protective
structure, the horizontal distance to the hazard zone as specified in Table 1 shall be used as minimum values.
There shall be no interpolation of the values specified in that table. Therefore, when the known height of the
hazard zone, a, the height of the protective structure, b, or the horizontal distance to the hazard zone, c, is
between two values in Table 1, the value used shall be that which provides the higher level of safety.
Table 1 — Horizontal distance to hazard zone for low risk
Dimensions in millimetres
Height of protective structure

a
Height of b
hazard
1 000 1 200 1 400 1 600 1 800 2 000 2 200 2 400 2 500
zone
a
Horizontal distance to hazard zone
c
b
— — — — — — — — —
2 500
2 400 100 100 100 100 100 100 100 100 —
2 200 600 600 500 500 400 350 250 — —
2 000 1 100 900 700 600 500 350 — — —
1 800 1 100 1 000 900 900 600 — — — —
1 600 1 300 1 000 900 900 500 — — — —
1 400 1 300 1 000 900 800 100 — — — —
1 200 1 400 1 000 900 500 — — — — —
1 000 1 400 1 000 900 300 — — — — —
800 1 300 900 600 — — — — — —
600 1 200 500 — — — — — — —
400 1 200 300 — — — — — — —
200 1 100 200 — — — — — — —
0 1 100 200 — — — — — — —
a
Protective structures less than 1 000 mm in height are not included because they do not sufficiently restrict movement of the body.
b For hazard zones above 2 500 mm, see 5.2.2.2.

If there is a high risk (as determined by risk assessment) from a hazard zone when reaching over a protective
structure, the horizontal distance to the hazard zone as specified in Table 2 shall be used as minimum values.
There shall be no interpolation of the values specified in Table 2. Therefore, when the known height of the
hazard zone, a, the height of the protective structure, b, or horizontal distance to the hazard zone, c, is
between two values in Table 2, the value used shall be that which provides the higher level of safety.
14 © ISO 2007 – All rights reserved

Table 2 — Horizontal distance to hazard zone for high risk
Dimensions in millimetres
Height of protective structure
a
Height of b
hazard
b
1 000 1 200 1 600 1 800 2 000 2 200 2 400 2 500 2 700
1 400
zone
a
Horizontal distance to hazard zone
c
c
— — — — — — — — — —
2 700
2 600  900  800  700 600 600 500 400 300 100 —
2 400 1 100 1 000  900 800 700 600 400 300 100 —
2 200 1 300 1 000 1 000 900 800 600 400 300 — —
2 000 1 400 1 300 1 100 900 800 600 400 — — —
1 800 1 500 1 400 1 100 900 800 600 — — — —
1 600 1 500 1 400 1 100 900 800 500 — — — —
1 400 1 400 1 400 1 100 900 800 — — — — —
1 200 1 500 1 400 1 100 900 700 — — — — —
1 000 1 500 1 400 1 000 800 — — — — — —
800 1 500 1 300  900 600 — — — — — —
600 1 400 1 300  800 — — — — — — —
400 1 400 1 200  400 — — — — — — —
200 1 200 900 — — — — — — — —
0 1 100 500 — — — — — — — —
a
Protective structures less than 1 000 mm in height are not included because they do not sufficiently restrict movement of the body.
b
Protective structures lower than 1 400 mm should not be used without additional safety measures.
c
For hazard zones above 2 700 mm, refer to 5.2.2.

5.2.3 Guard openings
Guard openings shall comply with the requirements of ISO 13852. For guarding in-running nips that are
accessible while a movable guard is open, see 5.3.
5.3 In-running (in-going) nips
Hazards from in-running nips may exist between the following:
⎯ two counter-rotating surfaces, powered or non-powered (see Note);
⎯ one surface rotating toward an adjacent fixed part of the machine;
⎯ surfaces rotating in the same direction, but with different peripheral speeds or surface properties, such as
friction;
⎯ guide roller and driving belt, conveyor belt, and unwind/rewind devices;
⎯ non-powered riding rollers (guide rollers) that are driven by the movement of the product.
NOTE An example of a non-powered surface is a roller that is driven by movement of product. For non-powered
surfaces, this hazard will depend on a number of factors (e.g. type of material, wrapping angle, inertia, etc.)
Examples of in-running nips are shown in Figure 1.
5.4 Guarding in-running nips
5.4.1 General
All in-running nips that are accessible during normal operation shall be guarded by one or more of the
following types of guards:
a) barrier guard or fence guard with or without openings; if the guard has an opening, the safety distances
shall be established in relation to the width of the opening in accordance with Table 3;
b) nip guard (only allowed on smooth rollers/cylinders), as bars designed in suitable sections and extending
across the entire working width (see Figure 4 for examples of nip guards);
c) trip nip bars shall be in accordance with 9.6.
When machine motion is reversed, out-going nips that do not generally pose a hazard can become in-running
nips and shall be guarded as such.

Figure 4 — Examples of nip guards
Whenever possible, the angle between the surface of the cylinder and the surface of the guard should be 90°
to prevent wedging. However, if other design considerations, such as stiffness of the guard, web path, etc.,
make the use of a 90° angle less desirable, an angle of not less than 60° is permitted (see Figure 5).

Key
1 tangent
a
Preferred.
b
Acceptable.
Figure 5 — Minimum cylinder-to-guard angle
16 © ISO 2007 – All rights reserved

Table 3 — Safety distances L for regular openings for persons 14 years of age and above
sr
Dimensions in millimetres
Safety distance
L
sr
Part of body Illustration Opening
Slot Square Round
Finger tip
e u 4 W 2 W 2 W 2
4 < e u 6 W 10 W 5 W 5
Finger up to
knuckle joint
6 < e u 8 W 20 W 15 W 5
or
hand
8 < e u 10 W 80 W 25 W 20
10 < e u 12 W 100 W 80 W 80
12 < e u 20 W 120 W 120 W 120
a
20 < e u 30 W 850 W 120 W 120
Arm up to
junction with
30 < e u 40 W 850 W 200 W 120
shoulder
40 < e u 120 W 850 W 850 W 850

NOTE The dimensions of openings e correspond to the side of a square opening, the diameter of a round opening and the
narrowest dimension of a slot opening.
a
If the length of the slot opening is u 65 mm, the thumb will act as a stop and the safety distance can be reduced to 200 mm.

The clearance between the nip guard and the respective machine part shall not exceed 6 mm under its normal
operating configuration (for example, plate or blanket installed on the cylinder, if applicable) (see Figure 6). On
small-format machines, the clearance should be smaller, if possible, considering both safety and production
concerns.
Nip guards shall not be shaped or oriented such that a “wedge pocket” is created (see Figure 7 and Figure 8).
The shapes shown in Figure 7 may be used as trip nip bars, since activation of the trip nip bar stops
hazardous motion, as specified in 5.7.4.
Dimensions in millimetres
Figure 6 — Safeguarding an in-running nip by means of a fixed nip guard

Key
1 wedge pocket
Figure 7 — Shapes creating wedge pockets

Figure 8 — Shapes not creating wedge pockets
5.5 Interlocks
5.5.1 Opening an interlocking guard
When an interlocking guard is opened, moved or removed while the
...