SIST ISO 12643-2:2008

INTERNATIONAL ISO
STANDARD 12643-2
First edition
2007-04-01

Graphic technology — Safety
requirements for graphic technology
equipment and systems —
Part 2:
Press equipment and systems
Technologie graphique — Exigences de sécurité pour les systèmes et
l'équipement de technologie graphique —
Partie 2: Systèmes et équipement pour la presse




Reference number
ISO 12643-2:2007(E)
©
ISO 2007

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ISO 12643-2:2007(E)
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ISO 12643-2:2007(E)
Contents Page
Foreword. iv
Introduction . v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions. 2
4 Effective date. 4
5 Guarding of significant hazards. 4
6 Requirements for protection against other hazards . 21
7 Additional requirements for functions, operations, colours and mechanical specifications,
of manual control devices . 26
8 Control systems for screen printing presses . 27
9 Control zones for web presses having multiple folders. 27
10 Signals and warning devices. 27
11 Contents of instruction handbook. 29
Annex A (informative) Hazards associated with printing press systems. 33
Annex B (informative) Explosion-protection zones. 36
Annex C (informative) Emission levels of sheet-fed presses resulting from tests conducted in
Europe. 39
Bibliography . 44

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ISO 12643-2:2007(E)
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.
ISO 12643-2 was prepared by Technical Committee ISO/TC 130, Graphic technology.
This first edition, together with ISO 12643-1, cancels and replaces ISO 12648:2006, 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 and systems
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ISO 12643-2:2007(E)
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
⎯ 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
The International Organization for Standardization (ISO) and the International Electrotechnical Commission
(IEC) draw attention to the fact that it is claimed that compliance with 5.7.2 of this part of ISO 12643 may
involve the use of one or more patents concerning the use of electro-sensitive protective devices (ESPDs) in
the delivery area. The patents identified are:
⎯ German Patent DE 103 10 236 B3
⎯ PCT patent application WO 2004/078626 A1
ISO takes no position concerning the evidence, validity and scope of this patent right.
The holders of this patent right have assured ISO that they declare not to enforce any rights resulting from the
patents identified above against any third parties in any countries that intend to comply with the ISO/TC 130,
CEN/TC 198, ANSI B65 standards, or any other local or regional standards that use the ISO/TC 130
standards or the relevant parts thereof or any derivative standards thereof. In this respect, the statement of
the holders of this patent right is registered with ISO. Information may be obtained from:
Heidelberger Druckmaschinen AG
Intellectual Property R3
Kurfürsten-Anlage 52-60
D-69115 Heidelberg
Germany
Tel: +49-6221/92-3027
Fax: +49-6221/92-3099
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights other than those identified above. ISO shall not be held responsible for identifying any or all such patent
rights.

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INTERNATIONAL STANDARD ISO 12643-2:2007(E)

Graphic technology — Safety requirements for graphic
technology equipment and systems —
Part 2:
Press equipment and systems
1 Scope
This part of ISO 12643 provides requirements specific to press equipment and systems. It is used in
conjunction with the general requirements given in ISO 12643-1.
This part of ISO 12643 provides additional safety requirements for the design and construction of new press
equipment and the auxiliary equipment integrated into the press control system.
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 12643-1:2007, Graphic technology — Safety requirements for graphic technology equipment and
systems — Part 1: General requirements
ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human responses to
contact with surfaces — Part 1: Hot surfaces
1)
ISO 13849-1:1999 , Safety of machinery — Safety-related parts of control systems — Part 1: General
principles for design
ISO 13852, Safety of machinery — Safety distances to prevent danger zones being reached by the upper
limbs
ISO 13855, Safety of machinery — Positioning of protective equipment with respect to the approach speeds of
parts of the human body
EN 378-1, Refrigerating systems and heat pumps — Safety and environmental requirements — Part 1: Basic
requirements, definitions, classification and selection criteria
EN 1539, Dryers and ovens, in which flammable substances are released — Safety requirements

1) ISO 13849-1:1999, has been cancelled and replaced by ISO 13849-1:2006.
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ISO 12643-2:2007(E)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 12643-1, ISO 13849-1:1999 and the
following apply.
3.1
access height in the sheet-fed press delivery zone
dimension of the maximum opening into the area below the sheet gripper, measured between the access level
(floor, fixed platform or footboard) and the lower edge of fixed machine parts (e.g. fixed guard, fixed cover,
fixed parts such as a sheet stop)
See Figure 1.
3.2
alcohol dosing equipment
device(s) used to regulate the amount of alcohol in the dampening water of offset printing presses
3.3
automatic plate clamping device
mechanism used to secure a printing plate during the automatic or semi-automatic changing of the plates
3.4
bypass
temporary, time-limited suppression of one or more safety functions through the use of safety-relevant parts of
a control system
3.5
coating unit
coater
machine that applies a predetermined thickness of a liquid substance (e.g. glue, varnish, ink, etc.) on
substrates made of paper or a similar material
3.6
continuous flow drying and curing device
mechanism built into printing presses to dry and cure inks and coatings that have been applied to substrates
(e.g. by hot air, IR or UV radiation)
3.7
crawl speed
continuous movement at a steady slow speed, and initiated by a momentary contact control
3.8
cylinder screen printing press
sheet-fed machine in which the substrate (sheet) to be printed is pressed against the screen by an impression
cylinder
3.9
digital printing press
machine in which the image is printed directly from data stored in digital form without using an intermediate
material
3.10
enabling device
mechanism that needs to be in a specified state or condition in order for a second actuator or device to start a
machine under hold-to-run control, and which will stop machine movement as soon as one of the hold-to-run
controls is released or the status of the mechanism changes
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ISO 12643-2:2007(E)
3.11
forms printing press
leporello printing press
machine for the production of continuous forms where paper webs printed with one or more colours are
accordion-folded or wound onto a reel
NOTE In addition to the printing section, the machine consists of devices for punching, remaliners (sprocket
punching), cross perforation, longitudinal perforation and leporello (zig-zag) folding.
3.12
gravure press
machine consisting of a printing cylinder; an inking system, in which ink is applied to the printing cylinder by an
ink roll or spray and the excess is removed by a doctor blade (device for scraping excess ink off a
gravure cylinder); and an impression cylinder covered with a rubber composition, which presses the substrate
into contact with the ink in the cells of the printing cylinder
3.13
pile turner
device attached to sheet-fed printing presses and used to turn piles of printed paper for further processing,
such as back-printing on a second run
3.14
powder spraying device
equipment used to spray powder onto the printed material on the delivery side of sheet-fed printing presses
3.15
press system
printing press and a series of machines that supply substrate into and through the printing press and guide or
direct the substrate to a cutting, folding or delivery device that delivers the product to the last working station
integrated with the printing press control system
3.16
printing forme
printing plate
base material that stores the image to be printed (pictures and/or text) and transfers ink onto a substrate, thus
printing the image
3.17
printing table
supportive surface to hold the substrate to be printed during the printing process (as on certain types of
screen printing presses)
3.18
proofing press
machine with manual feeding and delivery used for printing a small number of copies, and generally used for
assessing print quality before the printing forme is mounted in the production machine
3.19
reel rewinding device
part of a machine used for rewinding the processed web-type material
3.20
reel turner
device used to turn reels (webs) of substrate for easier handling; e.g. for correct positioning of the reel when
feeding webs to printing presses
3.21
reel unwinding device
part of a machine used for unrolling web-type material for processing
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ISO 12643-2:2007(E)
3.22
screen frame
device for taking up the printing screen
3.23
screen printing press
machine using printing formes with woven material (sieve-like screens) that partially allow ink to penetrate
through the material
3.24
sheet-fed press
machine for printing sheet-size substrates, including proofing presses, in which sheets may be fed by feeders
(automatic or manual), or from sheeters attached to unwinding units
3.25
speed limit
control that when activated, prevents acceleration of machine motion
3.26
washing device for roller/cylinder
equipment integrated into the printing press for washing cylinders and rollers such as ink rollers, blanket
cylinders, printing cylinders, plate cylinders
3.27
washing equipment for printing formes
machines for washing printing formes outside the printing press
EXAMPLE Screen washing equipment.
3.28
web-fed press
press in which a substrate passes through the printing couple, or couples, in a continuous form, as fed from a
roll
3.29
web-type material
web of paper, board, foil or similar material that is to be handled or processed
4 Effective date
This part of ISO 12643 is applicable 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. The guarding requirements of ISO 12643-1 apply.
5.2 Guard openings
Guard openings shall comply with ISO 12643-1.
In addition, on sheet-fed flexographic printing presses, the feed opening between the side lays and the sides
of the machine shall be guarded by means of adjustable or self-adjustable guards.
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ISO 12643-2:2007(E)
EXCEPTION — On sheet-fed printing presses that are also used for printing on board, sheet metal or other
inflexible materials, it is possible that for production reasons ISO 13852 (as required by ISO 12643-1) cannot
be applied in the feeding area. In this case, the height of the material-feeding aperture shall be as small as
possible, but shall not exceed 20 mm. The existence of residual risk shall be identified in the instruction
handbook.
5.3 Guarding in-running nips
5.3.1 Guarding in-running nips on sheet-fed presses
If technically feasible, trip nip bars in accordance with ISO 12643-1, shall be used where frequent access is
required to the area during machine motion, and cylinders are directly accessible after the interlocking guard
has been opened.
If it is not possible to use trip nip bars as described above, hold-to-run control speed limitations defined in
ISO 12643-1 apply.
NOTE Use of trip nip bars is not possible, for example, on small-size offset presses where trip nip bars would impede
access to the cylinder for activities such as plate changing.
Where cylinders have gaps that exceed those defined for smooth cylinders (see ISO 12643-1), trip nip bars, in
accordance with ISO 12643-1, should be used. Nip guards shall not be used with these cylinders. For such
trip guards, the requirements of Category 3 of ISO 13849-1:1999 shall be satisfied and the interlocking system
shall be designed such that the requirements for stopping paths defined in ISO 12643-1, 9.7 are satisfied. Trip
nip bars and cylinder gaps shall be designed such that cylinder nips cannot be accessed behind trip nip bars,
thus causing a hazard.
To comply with the requirements of ISO 12643-1, the interlocking systems normally will have to be designed
such that, after opening the interlocking guard, a predetermined number of revolutions, depending on the
functional characteristics of the trip guard, is not exceeded.
5.3.2 Guarding in-running nips on web-fed presses
In-running nips that are not in the operator's view from the position where the hold-to-run control or enabling
device is operated shall be safeguarded by additional measures.
NOTE For example, such measures include:
⎯ guarding;
⎯ an electrically interlocked, movable nip bar on the outgoing side between the two blanket cylinders of a web offset
printing press, that ensures that the bar is in position prior to reverse movement.
On machines with varying web paths where such measures for safeguarding the in-running nip existing
between blanket cylinders during the reverse movement are not feasible, the following procedure using a
hold-to-run with limited inch control is permitted, providing all of the following conditions are met:
⎯ speed shall not exceed 3 m/min;
⎯ movement shall not exceed 1,2 cylinder revolutions;
⎯ a stop control element with mechanical latch (such as a stop/safe pushbutton) or an emergency stopping
device shall be in the immediate vicinity of the in-running nip;
⎯ a distinctive audible warning signal, different from the audible warning signal used for forward inch, shall
be used;
⎯ a red flashing light shall be provided that can be seen during the warning and permissive periods, and a
red warning light (steady burn, not flashing) shall be provided during operating time of the hold-to-run
control in the immediate vicinity of any unguarded in-running nip that cannot be observed.
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ISO 12643-2:2007(E)
5.3.3 Guarding in-running cylinder nips on newspaper presses
In deviation from ISO 12643-1, nip guards may be used for web-fed newspaper printing presses on cylinder
gaps of up to 19 mm circumferential slots (see ISO 12643-1). For new machines, however, efforts should be
made to limit cylinder gaps to 12 mm circumferential.
NOTE Some press cylinder lock-up devices, such as on newspaper presses, require gaps up to 19 mm, measured
without the blanket. With the blanket in place, the gap is reduced significantly.
5.3.4 Guarding in-running nips on cylinder screen printing presses
On cylinder screen printing presses, the in-running nip on the printing cylinder shall be safeguarded.
NOTE This can be achieved, for example, by interlocking guards, or guarding by the screen printing forme.
Where the printing forme is used as a means of guarding, additional protective measures are required for
lifting and removal of the printing forme.
Such additional measures can include electrical interlocking, which allows cylinder rotations only under
hold-to-run control according to ISO 12643-1 as long as the printing forme is lifted.
5.4 Interlocks
5.4.1 General
Interlocks shall function in accordance with ISO 12643-1.
5.4.2 Continuous motion at crawl speed with an interlocking guard open
As an exception to ISO 12643-1, if the only hazard being protected by the interlocking guard is an in-running
nip, continuous machine motion at crawl speed with a guard open shall be permitted only if all in-running nips
remain guarded by either a nip guard or a trip nip guard conforming to the requirements of ISO 12643-1.
Maximum crawl speed is determined by the ability of the slowest acting trip nip guard to safeguard the hazard.
5.4.3 Closing an interlocking guard
As an exception to ISO 12643-1, closing the interlocking guard on dampening, coating or inking devices may
initiate the rotation of dampening or coating ductor rollers or metering rollers if it is ensured that at this time no
hazard points can be accessed.
NOTE Restarting any independently driven dampening, coating, metering, or ink fountain rollers can be required in
order to prevent malfunctions due to dried up coating or dampening agents.
5.5 Hold-to-run controls
5.5.1 General
In addition to the requirements of ISO 12643-1, the specific requirements set forth in 5.5.2 and 5.5.3 apply.
5.5.2 Specific requirements for sheet-fed presses
When interlocking guards are opened and any exposed hazard point is not safeguarded, sheet-fed printing
press systems shall only be allowed to be started under hold-to-run according to ISO 12643-1.
When interlocking guards are opened and all hazards are protected, crawl speed is permitted under the
provisions of 5.4.2.
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ISO 12643-2:2007(E)
When interlocking guards are opened and direct access to unprotected in-running nips on plate cylinders,
blanket cylinders, and impression cylinders, or unprotected hazard points on the sheet transport system is not
possible, the machine may be started under hold-to-run control according to ISO 12643-1. In this case,
continuous run while an interlocking guard is open shall not be possible.
NOTE 1 “Sheet transport systems” are, for example, gripping systems, transport drums.
NOTE 2 “Direct access” is, for example, possible where in-running nips can be reached after falling in or where nips
are located in the immediate vicinity of places where setting-up or cleaning operations need to be carried out.
5.5.3 Specific requirements for forms presses
In deviation from the requirements of ISO 12643-1, on forms printing presses, starting the machine by
two-hand control with guards open shall be possible with a speed higher than 10 m/min where this is required
for production reasons and all of the following requirements are met.
⎯ other interlocking guards outside the area that can be observed shall be closed;
⎯ a selector switch shall be used for this kind of operation;
⎯ hold-to-run speed shall be as low as possible under production conditions;
⎯ a warning shall be provided in the instruction handbook (including, a statement of the operator's
responsibility and a description of safe working practices).
5.6 Automatic format setting operations
Where a hazard exists, automatic format setting operations may be performed at speeds up to, and including,
0,5 m/min without additional safety measures. However, if there is a crushing hazard for the head or trunk of
the body, format setting shall be permitted only with a hold-to-run control. The location of the hold-to-run
control shall allow the operator to clearly see the hazard points.
EXAMPLES Automatic format setting devices include sheet side lays, suction heads, turner bars, compensators,
slitters, etc.
If additional safety measures are needed in the area of the format setting device, personnel shall be protected
from motion of the device(s) by one or more of the following methods:
a) provision of trip devices;
b) a separate stop device that is not included in the emergency stop circuit of the printing press;
c) zone control using the emergency stop circuit.
5.7 Additional safeguarding methods for machine devices and components
5.7.1 General
General requirements for guarding are defined in ISO 12643-1.
5.7.2 Feeding units, delivery units (pile lifting and lowering devices)
5.7.2.1 Guarding sheet gripper from unintentional hand access
In the area of the sheet delivery any unintentional access to movable parts of the sheet gripper system from
above and from the side shall be prevented by fixed or interlocked protective devices. At the sides and in the
area of the sample sheet removal, these protective devices shall reach down at least to the bottom edge of
the sheet gripper system.
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ISO 12643-2:2007(E)
Any residual risk caused by reaching underneath protective devices (e.g. in order to remove sample sheets or
to place wedges in the pile) shall be indicated in the instruction handbook (see ISO 12643-1).
5.7.2.2 Guarding rotating sheet gripper systems from full body access
In the area of rotating sheet gripper systems on sheet deliveries, measures for safeguarding the full body
access of persons shall be in place on all access sides if either
⎯ the access height, h, is 800 mm or more (see Figure 1); or
⎯ full body access is necessary more than once a week.
NOTE Full body access more than once a week is generally only necessary when make-ready and cleaning work
can be carried out only by accessing the area with the whole body.
5.7.2.3 Safeguarding full body access by electro-sensitive protective devices (ESPDs)
5.7.2.3.1 Arrangement of light beams of ESPDs for machines having a single access level
The light beams of the ESPD on machines having a single access level shall be arranged as specified in
Table 1 and shown in Figure 1. For the arrangement of light beams of the ESPD on multi-level machines, see
5.7.2.3.3. The requirements of ISO 13855 relating to the horizontal distance between the light beams and the
rotating gripper systems need not be met.
NOTE The primary protective action lies in the prevention of unexpected start-up of the press. In addition, the basic
shape of the printing press, the delivery pile carrier and the pile itself prevent or impede unhindered access to the hazard
zone, making consideration of access time to the hazard unnecessary.
For information in instruction handbooks on the residual hazards of ESPDs, see 5.7.2.3.4 and
ISO 12643-1:2007, 15.6.
Table 1 — Arrangement of the ESPD in relation to the access height
Dimensions in millimetres
Access height Arrangement of the ESPD in relation to the access level(s)
a b c
h Light beam 1 Light beam 2 Light beam 3

d
h u 1 200 300 not required 400 below h (h − 400)
in the centre between light
d
1 200 < h u 1 500 300 400 below h (h − 400)
beam 1 and 3
h > 1 500 300 700 1 100
a
Arrangement measured from the access level or from a fixed or swinging platform; due to the structural tolerances at the location of
installation, the permissible tolerance for the arrangement is ± 35 mm.
b
Light beam between light beam 1 and 3, if the distance between light beam 1 and light beam 3 is greater than 500 mm.
c
A maximum of 1 100 mm in height.
d
See Figure 1.
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ISO 12643-2:2007(E)
Dimensions in millimetres

Key
1 light beam 1 5 sample sheet removal
2 light beam 2 6 sheet
3 light beam 3 7 access height, h
4 reset button 8 sheet gripper system
Figure 1 — Access height in the delivery zone
5.7.2.3.2 Bypassing light beams
5.7.2.3.2.1 General
For the functions of sample sheet removal, insertion of wedges into the pile,
...