SIST EN 12301:2020

SLOVENSKI STANDARD
01-september-2020
Nadomešča:
SIST EN 12301:2000+A1:2008
Stroji za predelavo gume in plastike - Kalandri - Varnostne zahteve
Plastics and rubber machines - Calenders - Safety requirements
Kunststoff- und Gummimaschinen - Kalander - Sicherheitsanforderungen
Machines pour le caoutchouc et les matières plastiques - Calandres - Prescriptions de
sécurité
Ta slovenski standard je istoveten z: EN 12301:2019
ICS:
83.200 Oprema za gumarsko Equipment for the rubber and
industrijo in industrijo plastics industries
polimernih materialov
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EN 12301
EUROPEAN STANDARD
NORME EUROPÉENNE
December 2019
EUROPÄISCHE NORM
ICS 83.200 Supersedes EN 12301:2000+A1:2008
English Version
Plastics and rubber machines - Calenders - Safety
requirements
Machines pour les matières plastiques et le caoutchouc Kunststoff- und Gummimaschinen - Kalander -
- Calandres - Prescriptions de sécurité Sicherheitsanforderungen
This European Standard was approved by CEN on 5 August 2019.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2019 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12301:2019 E
worldwide for CEN national Members.

Contents Page
European foreword . 3
Introduction . 4
1 Scope . 5
2 Normative references . 5
3 Terms, definitions and symbols . 7
3.1 Terms and definitions . 7
3.2 Symbols . 12
4 Safety requirements and/or protective measures . 12
4.1 General . 12
4.2 Control systems . 12
4.3 Protection against mechanical hazards . 15
4.4 Stability . 29
4.5 Electrical hazards . 30
4.6 Thermal hazards . 30
4.7 Protection against fire . 30
4.8 Hazards due to noise . 30
4.9 Hazards generated by neglecting ergonomic principles . 31
4.10 Hazards due to unexpected start-up . 31
4.11 Slip, trip and fall hazards . 31
4.12 Hazards generated by the materials being processed . 32
4.13 Hazards due to electromagnetic interference . 32
5 Verification of the safety requirements and/or protective measures . 32
6 Information for use . 36
6.1 General . 36
6.2 Instruction handbook . 36
6.3 Marking . 38
Annex A (normative) Noise test code . 39
Annex B (informative) List of significant hazards . 44
Annex C (informative) Examples of different types of calenders . 46
Annex D (informative) Examples of calendering processes . 47
Annex E (informative) Calculation of dimension L of the crushing zone (for rolls of equal
diameters) . 49
Annex F (informative) Fixed guards at the crushing zone . 50
Annex G (informative) Means of access . 51
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of Directive 2006/42/EC aimed to be covered . 52
Bibliography . 55

European foreword
This document (EN 12301:2019) has been prepared by Technical Committee CEN/TC 145 “Plastics and
rubber machines”, the secretariat of which is held by UNI.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by June 2020 and conflicting national standards shall be
withdrawn at the latest by June 2021.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 12301:2000+A1:2008.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this
document.
The main changes with respect to the previous edition EN 12301:2000+A1:2008 are as follows:
— the Scope is extended to cover also two-roll calenders forming an integral unit with an extruder
(roller head) and two or three-roll polishing, laminating or embossing units installed downstream of
extruders in film processing lines;
— the structure is modified;
— the list of significant hazards is moved to an informative annex;
— technical developments in safeguards are taken into account;
— requirements for braking system and roll separation are updated;
— revised type-A and type-B standards are taken into account;
— the performance levels of safety related parts of control systems are specified in accordance with
EN ISO 13849-1:2015;
— a full noise test code is provided in a normative annex.
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland,
Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United
Kingdom.
Introduction
This document is a type C standard as stated in EN ISO 12100:2010.
This document is of relevance, in particular, for the following stakeholder groups representing the market
players with regard to machinery safety:
— machine manufacturers (small, medium and large enterprises);
— health and safety bodies (regulators, accident prevention organizations, market surveillance, etc.).
Others can be affected by the level of machinery safety achieved with the means of the document by the
above-mentioned stakeholder groups:
— machine users/employers (small, medium and large enterprises);
— machine users/employees (e.g. trade unions, organizations for people with special needs);
— service providers, e.g. for maintenance (small, medium and large enterprises).
The above-mentioned stakeholder groups have been given the possibility to participate at the drafting
process of this document.
The machinery concerned and the extent to which hazards, hazardous situations or hazardous events are
covered are indicated in the Scope of this document.
When requirements of this type-C standard are different from those which are stated in type-A or type-B
standards, the requirements of this type-C standard take precedence over the requirements of the other
standards for machines that have been designed and built according to the requirements of this type-C
standard.
1 Scope
This document specifies safety requirements relating to the design and construction of calenders (see
3.1.1) intended for the calendering, polishing, laminating or embossing of rubber or plastics.
This document concerns the calender alone, including the following integrated components: cutting
device, stock guides, feeding device and secondary roller.
Annex C shows examples of various types of calenders and Annex D shows examples of calendaring
processes.
This document deals with all significant hazards, hazardous situations or hazardous events relevant to
the design and construction of calenders, when the machines are used as intended and under the
conditions of misuse which are reasonably foreseeable by the manufacturer during all the phases of the
life of the machine as described in EN ISO 12100:2010, 5.4 (see Annex B).
This document does not deal with:
— hazards generated by the processing of explosive materials, or materials which give rise to an
explosive atmosphere;
— hazards due to laser or ionizing radiation;
— hazards generated if the calender is installed in an explosive atmosphere.
Two roll mills are covered by EN 1417.
This document is not applicable to calenders manufactured before the date of its publication.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
CLC/TS 61496-3:2008, Safety of machinery - Electro-sensitive protective equipment - Part 3: Particular
requirements for Active Opto-electronic Protective Devices responsive to Diffuse Reflection (AOPDDR)
EN 349:1993+A1:2008, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body
EN 614-1:2006+A1:2009, Safety of machinery - Ergonomic design principles - Part 1: Terminology and
general principles
EN 619:2002+A1:2010, Continuous handling equipment and systems — Safety and EMC requirements for
equipment for mechanical handling of unit loads
EN 12198-1:2000+A1:2008, Safety of machinery - Assessment and reduction of risks arising from radiation
emitted by machinery - Part 1: General principles
EN 60204-1:2018, Safety of machinery - Electrical equipment of machines - Part 1: General requirements
(IEC 60204-1:2016, modified)
EN 60947-5-8:2006, Low-voltage switchgear and controlgear - Part 5-8: Control circuit devices and
switching elements - Three-position enabling switches (IEC 60947-5-8:2006)
EN 61000-6-2:2005, Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for
industrial environments (IEC 61000-6-2:2005)
EN 61000-6-4:2007, Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission
standard for industrial environments (IEC 61000-6-4:2006)
EN 61310-1:2008, Safety of machinery - Indication, marking and actuation - Part 1: Requirements for
visual, acoustic and tactile signals (IEC 61310-1:2007)
EN 61496-1:2013, Safety of machinery - Electro-sensitive protective equipment - Part 1: General
requirements and tests (IEC 61496-1:2012)
EN ISO 3744:2010, Acoustics - Determination of sound power levels and sound energy levels of noise sources
using sound pressure - Engineering methods for an essentially free field over a reflecting plane (ISO
3744:2010)
EN ISO 3746:2010, Acoustics - Determination of sound power levels and sound energy levels of noise sources
using sound pressure - Survey method using an enveloping measurement surface over a reflecting plane (ISO
3746:2010)
EN ISO 4413:2010, Hydraulic fluid power - General rules and safety requirements for systems and their
components (ISO 4413:2010)
EN ISO 4414:2010, Pneumatic fluid power - General rules and safety requirements for systems and their
components (ISO 4414:2010)
EN ISO 4871:2009, Acoustics - Declaration and verification of noise emission values of machinery and
equipment (ISO 4871:1996)
EN ISO 7731:2008, Ergonomics - Danger signals for public and work areas - Auditory danger signals (ISO
7731:2003)
EN ISO 9614-2:1996, Acoustics - Determination of sound power levels of noise sources using sound intensity
- Part 2: Measurement by scanning (ISO 9614-2:1996)
EN ISO 11201:2010, Acoustics - Noise emitted by machinery and equipment - Determination of emission
sound pressure levels at a work station and at other specified positions in an essentially free field over a
reflecting plane with negligible environmental corrections (ISO 11201:2010)
EN ISO 11202:2010, Acoustics - Noise emitted by machinery and equipment - Determination of emission
sound pressure levels at a work station and at other specified positions applying approximate environmental
corrections (ISO 11202:2010)
EN ISO 11204:2010, Acoustics - Noise emitted by machinery and equipment - Determination of emission
sound pressure levels at a work station and at other specified positions applying accurate environmental
corrections (ISO 11204:2010)
EN ISO 11688-1:2009, Acoustics - Recommended practice for the design of low-noise machinery and
equipment - Part 1: Planning (ISO/TR 11688-1:1995)
EN ISO 12100:2010, Safety of machinery - General principles for design - Risk assessment and risk reduction
(ISO 12100:2010)
EN ISO 13732-1:2008, Ergonomics of the thermal environment - Methods for the assessment of human
responses to contact with surfaces - Part 1: Hot surfaces (ISO 13732-1:2006)
EN ISO 13849-1:2015, Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design (ISO 13849-1:2015)
EN ISO 13850:2015, Safety of machinery - Emergency stop function - Principles for design (ISO 13850:2015)
EN ISO 13851:2019, Safety of machinery - Two-hand control devices - Principles for design and selection
(ISO 13851:2019)
EN ISO 13855:2010, Safety of machinery - Positioning of safeguards with respect to the approach speeds of
parts of the human body (ISO 13855:2010)
EN ISO 13856-1:2013, Safety of machinery - Pressure-sensitive protective devices - Part 1: General
principles for design and testing of pressure-sensitive mats and pressure-sensitive floors (ISO 13856-1:2013)
EN ISO 13857:2008, Safety of machinery - Safety distances to prevent hazard zones being reached by upper
and lower limbs (ISO 13857:2008)
EN ISO 14118:2018, Safety of machinery - Prevention of unexpected start-up (ISO 14118:2017)
EN ISO 14119:2013, Safety of machinery - Interlocking devices associated with guards - Principles for
design and selection (ISO 14119:2013)
EN ISO 14120:2015, Safety of machinery - Guards - General requirements for the design and construction
of fixed and movable guards (ISO 14120:2015)
EN ISO 14122-1:2016, Safety of machinery - Permanent means of access to machinery - Part 1: Choice of
fixed means and general requirements of access (ISO 14122-1:2016)
EN ISO 14122-2:2016, Safety of machinery - Permanent means of access to machinery - Part 2: Working
platforms and walkways (ISO 14122-2:2016)
EN ISO 14122-3:2016, Safety of machinery - Permanent means of access to machinery - Part 3: Stairs,
stepladders and guard-rails (ISO 14122-3:2016)
EN ISO 14122-4:2016, Safety of machinery - Permanent means of access to machinery - Part 4: Fixed
ladders (ISO 14122-4:2016)
ISO 7010:2019, Graphical symbols - Safety colours and safety signs - Registered safety signs
3 Terms, definitions and symbols
3.1 Terms and definitions
For the purposes of this document, the terms and the definitions given in EN ISO 12100:2010 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at https://www.iso.org/obp
3.1.1
calender
machine for processing rubber, plastics, solutions or dispersions by continuous drawing between two or
more rolls, which are supported at both ends by a frame
Note 1 to entry: The processing operations may be, for example:
— continuous calendering of sheets or profiles of rubber or plastics;
— application of one or more sheet(s) or layer(s) onto a support material;
— laminating of two or more sheets of rubber or plastics under pressure or by using heat or adhesive;
— embossing or polishing of plastics (for example smoothing roll stack).
The calender can be equipped with power operated wheels for the horizontal movement of the complete machine,
e.g. for engaging/disengaging it from an extruder head during setting-up operations.
Note 2 to entry: Figure 1 shows a typical calendering sequence and the positions of most of the components and
zones defined hereafter. Figure 2 shows a typical 3-roll stack supplied by an extruder.
Note 3 to entry: Annex C shows examples of various types of calenders.
Note 4 to entry: Annex D shows examples of various calendering processes.

Key
rubber/plastic circuits
cord/fabric circuit
calendered product circuit
1 calender rolls 4 stock guides
2 secondary rollers 5 feeding devices
3 cutting devices 6 working zones
Figure 1 — Example of a 4-roll calender showing the materials circuit for bilateral coating of
(textile or metallic) fabric or cords
Key
1 calender roll 5 cleaning zone
2 extruder head 6 crushing zone
3 frame 7 working zone
4 film
Figure 2 — Example of a 3-roll stack supplied by an extruder
3.1.2
calender roll
roll which is positioned in relation to other calender rolls in order to process the material
Note 1 to entry: The roll can be counterbored or drilled to enable its temperature to be controlled by fluid
circulation.
3.1.3
secondary roller
roller, which is used to support the calendering process
Note 1 to entry: It can be driven and temperature regulated.
Note 2 to entry: Examples of secondary rollers are: pressure rollers, embossing rollers, filament guide rollers,
tension rollers, stripper rollers, crease removing rollers, take-off rollers.
3.1.4
cutting device
equipment for trimming the edges of the sheet to one or more specified widths
EXAMPLE Fixed knives (wires or blades), rotating knives (cutting discs).
3.1.5
stock guides
devices located on either side of the feed zone which determine the width of the sheet to be calendered
and retain the stock thus preventing it from extending beyond the normal working area
3.1.6
feeding device
equipment for feeding and distributing the stock in the feed zone
EXAMPLE Table, grid, chute, conveyor, reciprocating feed conveyor.
3.1.7
stopping angle
angle through which the calender rolls rotate from the stop signal triggered by a protective device until
the calender rolls have come to rest
3.1.8
feed zone
zone in which stock (rubber or plastic etc.) and/or material (cords, web, fabric etc.) is fed into the
calender
3.1.9
working zone
area around the calender or standing zone where the operators carry out their normal duties
3.1.10
crushing zone
zone existing between two calender rolls close to each other rotating in opposite directions towards the
nip
Note 1 to entry: See Figure 3.
Key
1 crushing zone
2 danger zone
S line dimensioned at the entrance to the crushing zone
X length of calender roll
L depth of the crushing zone, expressed in millimetres
D diameter of the calender rolls, expressed in millimetres
α stopping angle, expressed in radians
F radius equivalent to the length of the arcs of circle on the calender rolls corresponding with the specified
stopping angle, expressed in millimetres
a
S needs to be taken as 12 mm when the rolls are theoretically in contact, irrespective of the roll diameter.
b
LD6×
; where the roll diameters are different D shall be taken as the larger diameter
c
D
F = α
NOTE 1 The danger zone is the volume at the inrunning side of the rolls circumscribed by the length X of the rolls
and the shaded cross-section. This section is delimitated by:
— the line dimensioned S at the entrance to the crushing zone (see 3.1.10);
— the two arcs of circle on the calender rolls corresponding with the specified stopping angle α (see 3.1.7);
— the arc of a circle whose centre is the middle of the line dimensioned S and whose radius F is equivalent to the
length of the arcs of circle on the calender rolls corresponding with the specified stopping angle α.
NOTE 2 An example for the calculation of L is given in Annex E; L remains constant irrespective of the nip
between the rolls.
Figure 3 — Crushing and danger zones at the calender rolls
=
3.1.11
setting
preparing the machine for production, machine set-up, etc.
3.1.12
cleaning
removal of dust, residual material on the rolls, etc.
3.2 Symbols
α stopping angle of the calender roll when running with production speed v
p
α maximum stopping angle of the calender roll when running with maximum speed v
max max
α reduced stopping angle of the calender roll when running with reduced speed v
r r
v production rotational speed of calender rolls
p
v maximum rotational speed of the calender rolls
max
v reduced rotational speed of the calender rolls
r
D (larger) diameter of the calender rolls
F length of arc α on the calender roll surface
F length of arc α on the calender roll surface
r r
S height of entrance of the crushing zone
L depth of crushing zone
4 Safety requirements and/or protective measures
4.1 General
Calenders shall comply with the safety requirements and/or protective/risk reduction measures of this
clause. In addition, the machine shall be designed according to the principles of EN ISO 12100:2010 for
relevant but not significant hazards, which are not dealt with by this document (e.g. sharp edges).
The hydraulic equipment and its components shall be designed in accordance with EN ISO 4413:2010.
The pneumatic equipment and its components shall be designed in accordance with EN ISO 4414:2010.
4.2 Control systems
4.2.1 General
The safety related parts of the control system shall be designed in accordance with EN ISO 13849-1:2015.
The required performance level (PL ) for each safety function is specified in the relevant subclauses.
r
In the case where the calender is provided with a mode selector, it shall be in accordance with
EN ISO 12100:2010, 6.2.11.10.
4.2.2 Starting
The start of an operation shall be possible only when all safeguards are in place and functional
(see EN 60204-1:2018, 9.2.3.2). The machine shall only be started by actuation of the start device
provided for that purpose.
4.2.3 Normal stopping
A normal stop device shall be provided to bring the machine to a complete stop.
The normal stop command shall function as a stop category 0 or 1 in accordance with EN 60204-1:2018,
9.2.2, depending on the used technology.
4.2.4 Emergency stop devices
The emergency stop devices shall comply with EN ISO 13850:2015. For electrical braking, stop category
1 of that standard shall apply. For calenders with simple mechanical braking systems which are not
dependent on electrical energy, stop category 0 may be selected. An emergency stop device shall be
provided on the control panel of the calender. Other emergency stop actuators shall be installed in the
vicinity of and on each side of the working zones.
The actuation of any emergency stop device shall
— cause stopping of the calender rolls in accordance with 4.2.6;
— allow the roll separation or cause automatic roll separation on machines equipped with protective
device requiring automatic roll separation (see 4.3.1.3, 4.3.1.4, 4.3.1.5 and 4.3.1.6);
— allow the rescue reverse movement in accordance with 4.2.7;
— cause the stopping of all integrated components according to PL = c;
r
— trigger a visual and/or auditory signal, with manual resetting.
See also EN 60204-1:2018, 10.7.
4.2.5 Failure of energy supply
An interruption or a failure of the power supply shall not result in a loss of safety function and restoration
of the energy supply shall not result in the automatic restarting of the machine (see EN ISO 12100:2010,
6.2.11.4 and 6.2.11.5).
Failure of the energy supply which causes opening of a contactor of one of the roll drive motors shall also
cause stopping of the rolls as specified in 4.2.6.
The calender shall also be equipped with a device to enable roll separation to be achieved even in the
event of energy failure (see 6.2.3 m)).
4.2.6 Braking system
In case where the calender rolls can stop without material from maximum speed within a maximum
stopping angle α of 120° there are no specific requirements for braking system.
max
In the case where inrunning nips are protected by fixed guards there are no specific requirements for
braking system and stopping angle (see 4.3.1.2).
In the case where inrunning nips are protected by an interlocking guard with guard locking function in
accordance to PLr = d, there are no specific requirements for braking system and stopping angle.
If one or more of the inrunning nips are protected by:
— interlocking guard without guard locking or with guard locking function according to PL = a, PL = b
r r
or PL = c; or
r
— trip devices (e.g. trip bar),
the affected calender shall be equipped with a two channel braking system in accordance with PL = d,
r
category 3 using:
— either two mechanical brakes, spring operated; or
— one mechanical brake, spring operated and an electronic braking system, operating also without
power supply.
Braking shall be started as soon as a protective device is actuated.
The overall system stopping performance (see EN ISO 13855:2010, 3.1.2) shall be calculated taking
power failure into account.
For interlocking guards and trip devices, if EN ISO 13855:2010 cannot be respected, interlocking guards
with guard locking shall be adopted.
For trip bar, the rolls shall be brought to rest within a maximum stopping angle α of 120° even in the
max
case of failure of the energy supply. Where the maximum rotating speed of the calender rolls v is
max
greater than 120 m/min, α may vary proportionally to v up to a maximum value of 160°.
max max
EXAMPLE For calender rolls with a maximum rotating speed v of 140 m/min then:
max
α =120×=140
max
with PLr = d, category 3, where αmax is expressed in degrees.
See also 6.2.2 and 6.2.3 a).
The manual release of the brake shall be interlocked with the control circuit in accordance with PL = d,
r
so that the powered rotation of the calender rolls is prevented as long as the brake is manually released.
4.2.7 Rescue reverse movement
Following stoppage of the calender rolls due to opening of an interlocking guard or voluntary or
involuntary actuation of a trip device or actuation of an emergency stop device, it shall be possible to
make a reverse movement of the rolls by actuation of a dedicated hold-to-run control device in
accordance with EN ISO 12100:2010, 3.28.3 or a manually operated device (e.g. hand wheel) in order to
release a person trapped between the rolls or between a roll and the material.
This control device shall function without the need for manual resetting and independently of the
position of the mode selector specified in 4.3.1.8.4; it shall be clearly labelled “Rescue Reverse
Movement”. The reverse velocity of the rolls shall not exceed 5 m/min. The rescue reverse movement
shall stop under action of the brake as soon as the manual control is released. The visual and auditory
warning signals specified in 4.3.1.8.4 shall be given (see 6.2.3 p)).
The requirements of 4.3.1.8.4 for safety related parts of the control system (SRP/CS) for the hold to run
control and for speed limitation shall be applied.
A rescue reverse movement is not required, if
— an automatic roll separation > 120 mm is possible within 12 s, in accordance with PL = d, category 3;
r
or
— the inrunning nip is protected by a fixed guard (see 4.3.1.2); or
— the inrunning nip is protected by an interlocking guard with guard locking (see 4.3.1.3) with a
performance level at least PL = d for the locking function.
r
The roll separation shall not create additional hazards, e.g. crushing between roll and fixed part.
See 6.2.3 b).
4.3 Protection against mechanical hazards
4.3.1 Preventing access to the crushing zone
4.3.1.1 General
The access to the crushing zone (see Figure 3) when the rolls are rotating shall be prevented by one or
more of the following means:
— fixed guards in accordance with 4.3.1.2; or
— interlocking guards in accordance with 4.3.1.3; or
— trip bar in accordance with 4.3.1.4; or
— pressure sensitive mat or floor in accordance with 4.3.1.5; or
— a non-mechanically actuated trip device in accordance with 4.3.1.6, e.g. light curtain in accordance
with EN 61496-1:2013 or scanners in accordance with CLC/TS 61496-3:2008.
The end of an activation of a trip device or closing of an interlocking guard shall not automatically initiate
any further movement. A new start command shall be required. A separate device for manual reset shall
be installed in a position giving full view of the danger zone and designed in accordance with
EN ISO 13849-1:2015, 5.2.2, except for rescue reverse movement see 4.2.7.
If the smallest horizontal gap between the machine frame and
— an interlocking guard is ≥ 100 mm; or
— a non-mechanically actuated trip device is ≥ 150 mm,
an operator can stand between the guard/trip device and machine frame. In this case, restarting of the
dangerous movements while an operator remains in that area shall be prevented by additional protective
measures (e.g. presence sensing devices), unless for technical reasons this is not possible, e.g. due to a
part of the machine being in the way.
The closing movement to engage the calender rolls shall be possible only:
— when the interlocking guards are closed or trip devices are not actuated; or
— by a hold-to-run control device and closing speed limited to 10 mm/s in accordance with PL = c; the
r
control station shall be positioned in a place that gives the operator a clear view of the dangerous
area.
4.3.1.2 Fixed guards
Fixed guards as defined in EN ISO 14120:2015, 3.2 shall prevent the access to the danger zone from all
sides in combination with the calendar frame.
Safety distances shall be in accordance with EN ISO 13857:2008, Table 2, Table 3 and Table 4.
If the fixed guard is positioned between the calender rolls:
— it shall extend along the whole length of the rolls; and
— the gap between the guard and the surface of the roll shall be ≤4 mm; and
— the angle between the guard and the tangent to the surface of the roll shall be ≥ 90°.
Examples of layout are given in informative Annex F. Other profiles may be used but circular cross
sections are prohibited.
A feeding device alone shall not replace a fixed guard positioned between the calender rolls. However, it
may contribute to protecting access to the inrunning nip.
In this case:
— it shall fulfill the above requirements for guards positioned between rolls;
— it shall be associated with fixed guards preventing access to the inrunning nip according to
EN ISO 13857:2008, Table 2, Table 3 and Table 4.
Where for operating processes (for cleaning or setting operations, for example) the access into the danger
area is necessary a fixed guard shall not be used but an interlocking guard according to 4.3.1.3 shall be
installed.
In the case of a fixed guard positioned between the calender rolls, there is no need for automatic roll
separation.
4.3.1.3 Interlocking guards
The interlocking function shall be in accordance with PL = d.
r
Interlocking guards without guard locking shall be positioned in accordance with EN ISO 13855:2010,
Clause 9.
Safety distances shall be in accordance with EN ISO 13857:2008, Table2, Table 3 and Table 4.
The type of interlocking device shall be selected in accordance with EN ISO 14119:2013.
The braking system shall be in accordance with 4.2.6.
If interlocking guards with guards locking are used, the unlocking signal of the guard locking shall be in
accordance with PL = c.
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The opening of an interlocking guard shall:
— cause automatic roll separation at least in 50 mm within 5 s, in accordance with PL = d, category 3.
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The roll separation shall not create additional hazards e.g. crushing between roll and fixed part; and
— allow rescue reverse movement as specified in 4.2.7.
If the interlocking guard with guard locking has a performance level at least PL =d for the locking
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function, the automatic roll separation is not necessary.
A feeding device installed as in 4.3.1.2 shall act as an interlocking guard with guard locking which shall
allow the rolls to rotate only when the feeding device is in position and which does not allow to remove
the feeding device from the working position until the rolls have come to rest. The PL of the control
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circuit shall be the same of interlocking guard with guard locking.
4.3.1.4 Trip bar
The trip bar is a mechanically actuated trip device in form of a horizontal rigid bar which when actuated
by any part of the body shall:
— cause stopping of the calender rolls as specified in 4.2.6;
— cause automatic roll separation at least in 50 mm within 5 s, in accordance with PL = d, category 3.
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The roll separation shall not create additional hazards e.g. crushing between roll and fixed part;
— allow rescue reverse movement as specified in 4.2.7.
The trip bar shall meet the following requirements:
— it shall be actuated by a displacement not exceeding 10 mm created by a movement of the operator's
body toward the rolls;
— actuation of the bar shall not require a force greater than 200 N, on each end and at the middle of the
trip bar;
— wherever the pushing action occurs along the length of the bar, the 10 mm displacement of the bar
shall trigger at least one position sensor actuated in the positive mode (see EN ISO 14119:2013, 5.4);
— return of the trip bar to its rest position shall not cause restarting. A separate device for manual reset
shall be installed in a position giving full view of the danger zone and designed in accordance with
EN ISO 13849-1:2015, 5.2.2 (for rescue reverse movement see 4.2.7).
See also 6.2.3 c) and 6.2.3 d).
The protection shall be completed with a fixed guard or interlocking guards with guard locking in
accordance with 4.3.1.3 preventing access to the crushing zone from below the trip bar. This guard shall
be so designed as to prevent foothold. Moreover, if there is access from the sides of the calender to the
ends of the rolls on the inrunning side, lateral fixed guards shall be provided taking account of safety
distances specified in EN ISO 13857:2008, Table 2, Table 3 and Table 4.
The trip bar shall extend over the full length of the calender rolls.
It shall be fitted at a height (1 200 ± 50) mm (above the level on which the operator stands) and be
positioned according to Figure 4.
See also 6.2.3 e).
Linear dimensions in millimetres, α in radians

Key
1 trip bar (in rest position)
L depth of crushing zone (see Figure 3)
F length equivalent to the stopping arc length at vmax,
D larger diameter of the calender rolls
α stopping angle
Figure 4 — Positioning of the trip bar
4.3.1.5 Pressure sensitive mats or floors
Pressure sensitive mats or floors shall be in accordance with EN ISO 13856-1:2013, positioned in
accordance with EN ISO 13855:2010, Clause 7.
Actuation of the trip devices shall:
— cause stopping of the calender rolls as specified in 4.2.6;
— cause automatic roll separation at least in 50 mm within 5 s, in accordance with PL = d, category 3.
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The roll separation shall not create additional hazards e.g. crushing between roll and fixed part;
— allow rescue reverse movement as specified in 4.2.7.
4.3.1.6 Non-mechanically actuated trip devices
Light curtains shall be in accordance with EN 61496-1:2013, type 3 or type 4 positioned in accordance
with EN ISO 13855:2010, Clause 6. Scanners shall be in accordance with CLC/TS 61496-3:2008, type 3.
Actuation of a non-mechanically actuated trip device shall:
— cause stopping of the calender rolls as specified in 4.2.6;
— cause automatic roll separation at least in 50 mm within 5 s, in accordance with PL = d, category 3.
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The roll separation shall not create additional hazards, e.g. crushing between roll and fixed part;
— allow rescue reverse movement as specified in 4.2.7.
4.3.1.7 Inhibition of interlocked guards or protective devices for setting only
4.3.1.7.1 General
For machine setting it can be necessary to rotate or move the calender rolls with one or more guards or
protective devices, preventing access to the inrunning nip, inhibited. In this case, safety of the operator
shall be achieved using a specific control mode activated by a mode selector according to 4.2.1 that
disables all other control modes. The safety related part of the control system (SRP/CS) shall be in
accordance with PL = d, category 3. Operation of the hazardous elements shall only be possible if:
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a) a guard positioned at a distance from the crushing zone according to the dimensions specified in
EN ISO 13857:2008, Table 4 and 4.3.1.2 of this standard (see Figure 5) is detected in accordance with
PL = d, category 3 acting as an interlocking guard specified in 4.3.1.3; or
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b) the requirements in 4.3.1.7.2, 4.3.1.7.3 or 4.3.1.7.4 are fulfilled for the specific movement.
Key
1 danger zone
2 cleaning zone
3 guard positioned in accordance with EN ISO 13857:2008 and 4.3.1.2 of this standard
Figure 5 — Example of a guard specifically designed for cleaning in the danger zone of the rolls
4.3.1.7.2 Requirements for calender rolls rotation during setting
If one or more guards or protective devices preventing access to the inrunning nip are inhibited and the
guard mentioned in 4.3.1.7.1 a) is not used, the rotation of the calender rolls shall only be permitted if all
the following requirements are fulfilled:
— the rotation of the calender rolls shall be controlled by continuous actuation of a hold-to-run control
device in accordance with PL = c. If the hold to run control is fitted on a portable unit, it shall be a
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three-position enabling switch as defined in EN 60947-5-8:2006, 2.2; and
— the rotation speed shall be limited to a maximum of 3 m/min according to PL = d; and
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— the gap between both the calender rolls themselves and between the calender rolls and the fixed
parts shall be more than or equal to 50 mm; the interlocking circuit between separation and calender
rolls rotation shall be in accordance with PL = c; and
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— the control station shall be positioned in a place that gives the operator a clear view of the dangerous
area.
4.3.1.7.3 Requirements for closing movement for setting the gap between the calender rolls
If one or more guards or protective devices preventing access to the crushing zone are inhibited and the
guard mentioned in 4.3.1.7.1 a) is not used, the closing movem
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