BRITISH STANDARD BSEN

1010-1:2004

Safety of machinery -
Safety requirements for
the design and
construction of
printing and paper
converting machines -
Part 1: Common requirements

The European Standard EN 1010-1:2004 has the status of a

British Standard

!CS 37.100.10; 85.100

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British Standards
BS EN 1010-1:2004

National foreword
This British Standard is the official English language version of
EN 1010-1:2004.
The UK participation in its preparation was entrusted to Technical Committee
MCE/3/9, Paper and printing machines - Safety, which has the responsibility
to:

aid enquirers to understand the text;

present to the responsible international/European committee any
enquiries on the interpretation, or proposals for change, and keep the
UK interests informed;
monitor related international and European developments and
promulgate them in the UK.

A list of organizations represented on this committee can be obtained on

request to its secretary.
Cross-references
The British Standards which implement international or European
publications referred to in this document may be found in the BSI Catalogue
under the section entitled "International Standards Correspondence Index",
or by using the "Search" facility of the BSI Electronic Catalogue or of
British Standards Online.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

This British Standard was Summary of pages

published under the authority
of the Standards Policy and This document comprises a front cover, an inside front cover, the EN title page,
Strategy Committee on pages 2 to 52, an inside back cover and a back cover.
21 December 2004
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document was last issued.

Amendments issued since publication

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© BSI 21 December 2004

ISBN O 580 45129 1

EUROPEAN STANDARD EN 1010-1
NORME EUROPEENNE
EUROPAISCHE NORM December 2004

ICS 37.100.10; 85.100

English version

Safety of machinery - Safety requirements for the design and

construction of printing and paper converting machines - Part 1:
Common requirements
Securite des machines - Prescriptions de securite pour la Sicherheit van Maschinen - Sicherheitsanforderungen an
conception et la construction de machines d'impression et Konstruktion und Bau van Druck- und
de transformation du papier - Partie 1: Prescriptions Papierverarbeitungsmaschinen - Teil 1: Gemeinsame
communes Anforderungen

This European Standard was approved by GEN on 7 June 2004.

GEN 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 Central Secretariat or to any GEN 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 GEN member into its own language and notified to the Central Secretariat has the same status as the official
versions.

GEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,
Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEA N COMMilTEE FOR STA NDARDIZATION

C OM ITE EUROPEE N DE NORMALIS A T I O N
EUROPAISCHES KOMIT EE FUR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2004 GEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1010-1:2004: E
worldwide for GEN national Members.
EN 1010-1 :2004 (E)

Contents Page

Foreword ..............................................................................................................................................................4
Introduction .........................................................................................................................................................5
Scope ......................................................................................................................................................5
2 Normative references ............................................................................................................................6
3 Terms and definitions ...........................................................................................................................8
4 List of significant hazards ..................................................................................................................10
5 Safety requirements and/or protective measures ............................................................................13
5.1 General ..................................................................................................................................................13
5.2 Requirements common to printing and paper converting machines ............................................13
5.2.1 Safeguarding of danger points ...........................................................................................................13
5.2.2 Guards and interlocks .........................................................................................................................15
5.2.3 Devices for setting-up, cleaning, trouble-shooting during the work process and
maintenance .........................................................................................................................................16
5.2.4 Explosion prevention and protection ................................................................................................17
5.2.5 Electrical equipment ............................................................................................................................19
5.2.6 Control systems ...................................................................................................................................20
5.2.7 Indicators, marking, actuators, prestart warning devices...............................................................22
5.2.8 Two-hand controls ...............................................................................................................................22
5.2.9 Electrosensitive protective devices (ESPDs) ...................................................................................23
5.2.10 Pressure sensitive mats, trip devices ...............................................................................................23
5.2.11 Safety position switches .....................................................................................................................23
5.2.12 Work platforms, access stairs, passageways and raised workplaces...........................................23
5.2.13 Stability .................................................................................................................................................25
5.2.14 High contact temperatures .................................................................................................................25
5.2.15 Noise .....................................................................................................................................................25
5.2.16 Radiation hazards ................................................................................................................................26
5.2.17 Immunity to electromagnetic disturbances ......................................................................................26
5.3 Common devices .................................................................................................................................27
5.3.1 Stationary knives .................................................................................................................................27
5.3.2 Rotary tools ..........................................................................................................................................27
5.3.3 Dangerous tools...................................................................................................................................27
5.3.4 Feeding units, delivery units (pile lifting and lowering devices) ....................................................27
5.3.5 Reel unwinding and rewinding devices for webs .............................................................................31
6 Verification of the safety requirements and/or protective measures.............................................33
7 Information for use ..............................................................................................................................37
7.1 Minimum requirements for machine markings .................................................................................37
7.2 Instruction handbook ..........................................................................................................................38
Annex A (informative) Classification of zones for printing presses and finishing machines
(relating to 5.2.4) ..................................................................................................................................39
Annex B (normative) Audible prestart warning devices ..............................................................................42
Annex C (informative) Risk analysis relating to the pitch angle of access stairs ....................................44
Annex D (informative) Example of layout of an instruction handbook ......................................................46
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 98/37/EC ...........................................................................................48

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 EN 1010-1 :2004 (E)

Annex ZB (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 94/9/EC ............................................................................................. 49
Bibliography ...................................................................................................................................................... 51

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EN 1010-1 :2004 (E)

Foreword
This document (EN 1010-1:2004) has been prepared by Technical Committee CEN/TC 198 "Printing and
paper machinery - Safety", the secretariat of which is held by DIN.

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 2005, and conflicting national standards shall be withdrawn at
the latest by June 2005

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 and ZB, which is an integral part of this
document.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland
and the United Kingdom.

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 EN 1010-1 :2004 (E)

Introduction
This European Standard is a type C standard as stated in EN 1070:1998.

The machinery concerned and the extent to which hazards, hazardous situations and events are covered are
indicated in the scope of this document.

For machines that have been designed and built according to the provisions of this C standard, the following
stipulation applies: When provisions of this type C standard are different from those which are stated in type A
or B standards, the provisions of this type C standard take precedence over the provisions of the other
standards.

This document consists of the following parts:

Part 1 Common requirements

Part 2 Printing and varnishing machines including pre-press machinery

Part 3 Cutting machines

Part 4 Bookbinding, paper converting and finishing machines

Part 5 Machines for the production of corrugated board and machines for the conversion of flat and
corrugated board.

1 Scope

1.1 This document applies to

printing machines for printing on paper and similar materials, including screen printing presses;
equipment used in the preparation of the printing process and additional equipment on printing machines
are also considered to be printing machines. This standard also covers machinery used for the handling
of paper, products, printing formes and inks (before and after the printing process) as well as machinery
for cleaning printing formes and checking the print quality (auxiliary printing machinery).

paper converting machines, i. e. machines to process, convert or finish paper, board and similar materials
which are processed, converted or finished in a similar manner.

NOTE Similar substrates are, for example, board, corrugated board, plastic film, aluminium foil, sheet metal and
photographic paper.

1.2 This document deals with all common significant hazards relevant to printing and paper converting
machinery when they are used as intended and under the conditions foreseen by the manufacturer (see
clause 4). This part of the standard defines the common safety requirements for all kinds of printing and paper
converting machines and related common devices and shall be used in connection with another part of the
EN 1010 series. The specific requirements specified in Part 2 and following parts of EN 1010 take precedence
over the respective requirements in EN 1010-1.

NOTE In addition, where a machine is not covered by a specific part of this standard, Part 1 of EN 1010 may be used
to establish the approach for dealing with the relevant risks.

1.3 This document is not applicable to printing and paper converting machines which are manufactured
before the date of publication of this document by CEN.

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EN 1010-1 :2004 (E)

1.4 This document does not apply to:

winder-slitters and sheeters in paper finishing (sheeters with unwinders) (see EN 1034-1:2000,
EN 1034-3:2000, prEN 1034-5:2001);

office-type collating machines equipped with friction feeders;

mail processing machines;

machines used for filling packages (such as machines for shaping, filling, and closing the package),

textile printing presses

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.

EN 294:1992, Safety of machinery- Safety distances to prevent danger zones being reached by the upper
limbs.

EN 349:1993, Safety of machinery- Minimum gaps to avoid crushing of parts of the human body.

EN 418:1992, Safety of machinery- Emergency stop equipment, functional aspects - Principles for design.

EN 563:1994, Safety of machinery- Temperatures of touchable surfaces- Ergonomics data to establish

temperature limit values for hot surfaces.

EN 574:1996, Safety of machinery- Two-hand control devices - Functional aspects - Principles for design.

EN 953:1997, Safety of machinery - Guards - General requirements for the design and construction of fixed
and movable guards.

EN 954-1:1996, Safety of machinery- Safety-related parts of control systems - Part 1: General principles
for design.

EN 999:1998, Safety of machinery- The positioning of protective equipment in respect of approach speeds
of parts for the human body.

EN 1037: 1995, Safety of machinery - Prevention of unexpected start-up.

EN 1050: 1996, Safety of machinery- Principles for risk assessment.

EN 1070: 1998, Safety of machinery - Terminology.

EN 1088: 1995, Safety of machinery- Interlocking devices associated with guards - Principles for design
and selection.

EN 1127-1:1997, Explosive atmospheres- Explosion prevention and protection - Part 1: Basic concepts
and methodology.

EN 1760-1:1997:1997, Safety of machinery - Pressure sensitive devices - Part 1: General principles for the
design and testing of pressure sensitive mats and pressure sensitive floors.

6
 EN 1010-1 :2004 (E)

EN 1760-2:2001, Safety of machinery- Pressure sensitive 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 12626:1997, Safety of machinery- Laser processing machines - Safety requirements.

EN 13023:2003, Noise measurement methods for printing, paper converting, paper making machines and
auxiliary equipment - Accuracy categories 2 and 3.

EN 13463-1:2001, Non-electrical equipment for potentially explosive atmospheres - Part 1: Basic method
and requirements.

EN 13463-5:2003, Non-electrical equipment intended for use in potentially explosive atmospheres - Part 5:
Protection by constructional safety "c".

EN ISO 4871:19986 Acoustics - Declaration and verification of noise emission values of machinery and
equipment (ISO 4871:1996).

EN ISO 12100-1:2003, Safety of machinery - Basic concepts, general principles for design - Part 1: Basic
terminology, methodology (ISO 12100-1:2003).

EN ISO 12100-2:2003, Safety of machinery - Basic concepts, general principles for design - Part 2: Technical
principles (ISO 12100-2:2003).

EN ISO 14122-1:2001, Safety of machinery- Permanent means of access to machines and industrial
plants- Part 1: Choice of a fixed means of access between two levels (ISO 14122-1:2001).

EN ISO 14122-2:2001, Safety of machinery- Means of permanent access to machines and industrial
plants - Part 2: Working platforms and gangways (ISO 14122-2:2001).

EN ISO 14122-3:2001, Safety of machinery- Means of permanent access to machines and industrial
plants- Part 3: Stairways, stepladders and guard-rails (ISO 14122-3:2001).

EN ISO 14122-4:1996, Safety of machinery- Means of permanent access to machines and industrial
plants- Part 4: Fixed ladders (ISO 14122-4:2004).

EN 50014:1999, Electrical apparatus for potentially explosive atmospheres- General requirement.

EN 50015:1998, Electrical apparatus for potentially explosive atmospheres - Oil immersion "o".

EN 50016:1995, Electrical apparatus for potentially explosive atmospheres- Pressurized apparatus "p".

EN 50017:1998, Electrical apparatus for potentially explosive atmospheres - Powder filling "q".

EN 50018:2000, Electrical apparatus for potentially explosive atmospheres - Flameproof enclosures "d".

EN 50019:2000, Electrical apparatus for potentially explosive atmospheres - Increased safety "e".

EN 50020:1994, Electrical apparatus for potentially explosive atmospheres- Intrinsic safety "i".

EN 50039:1980, Electrical apparatus for potentially explosive atmospheres- Intrinsic safety "i".

EN 50281-1-2:1999, Electrical apparatus for use in the presence of combustible dust- Part 1-2: Electrical
apparatus protected by enclosures; selection, installation and maintenance.

7
EN 1010-1 :2004 (E)

EN 60079-14:1998, Electrical apparatus for explosive gas atmospheres - Part 14: Electrical installations in
hazardous areas (other than mines).

EN 60204-1:1997, Safety of machinery - Electrical equipment of machines - Part 1: General requirements

EN 60825-1:1994, Safety of laser products- Part 1: Equipment classification, requirements and user's guide.

EN 61000-6-2:2001 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards; Immunity for
industrial environment.

EN 61010-1:2001, Safety requirements for electrical equipment for measurement, control and laboratory
use- Part 1: General requirements (/EC 61010-1:2001).

EN 61310-1:1995, Safety of machinery- Indication, marking and actuation - Part 1: Requirements for visual,
auditory and tactile signals.

EN 61310-2:1995, Safety of machinery - Indication, marking and actuation - Part 2: Requirements for
marking.

EN 61496-1:1997, Safety of machinery - Electrosensitive protective equipment - Part 1: General

requirements and tests.

IEC 61496-2:1997, Safety of machinery - Electrosensitive protective equipment- Part 2: Particular require­
ments for equipment using active opto-e/ectronic protective devices.

CLC R 044-001:1999, Safety of machinery: ,,Guidance and recommendations for the avoidance of hazards
due to static electricity.

3 Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN 1070:1998 and the
following apply.

3.1
danger points
danger points are defined locations in the danger zone of machines where persons can be injured by
movements of

parts of machines;

tools of machines or parts of tools;

workpieces or parts of workpieces or

materials being processed.

NOTE Danger points can exist, for example, on 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.

Particular points of danger are:

crushing and shearing points;

trapping points;

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 EN 1010-1 :2004 (E)

inrunning nips;

cutting, punching and impact points.

3.2
inrunning nips
nips caused by rotating rollers, cylinders, rolls or drums creating the hazard for parts of the body or the whole
body to be drawn in. The risks exist between:

a) two counter-rotating rollers, powered or non-powered;

b) one rotating roller and an adjacent fixed part of the machine;

c) rollers rotating and conveyer belts in the same direction, but with different peripheral speeds or surface
properties (friction);

d) guide roller and driving belt, conveyor belt and possibly the web (see Figure 1 ).

lnrunning nips also exist on non-powered riding rollers (guide rollers) which are driven by the movement of the
web. This hazard may depend on a number of factors, e.g. type and strength of material, wrapping angle, web
speed, inertia.

a)

bb

0
d)

c)

0
�
�

Figure 1 - Examples of inrunning nips

3.3
integrated pile lifting and lowering devices
devices integrated into sheet and blank feeders or deliveries for lifting and lowering the sheet pile

3.4
format size
maximum size of blanks (maximum length times maximum width) that can be printed or converted by the
machine

3.5
routine and regular access
access to a danger point required for production reasons after each tool closing movement

3.6
web-type materials
webs of paper, board, foil or similar material which is to be handled or processed

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EN 1010-1 :2004 (E)

3.7
reel unwinding devices
those parts of a machine used for unwinding web-type material for processing

3.8
reel rewinding devices
those parts of a machine used for rewinding the processed web-type material

3.9
separating elements
elements on feeders of sheets or blanks or similar materials which separate the individual sheets, blanks etc.

3.10
raised workplaces
workplaces that are at least 0,5 m above the reference plane

3.11
infrequently used access
access to workplaces which are used for adjustments, make-ready and maintenance operations, but which
are not used for production purposes

3.12
smooth cylinders/rollers
rotationally symmetric smooth bodies (cylinders or rollers) without indentations and with no sharp or cutting
edges

3.13
residual pile monitoring
sensing devices monitoring the residual pile in the feeder. The machine is stopped before the last blank is fed
so that the blank safeguards the separating elements of the feeder

3.14
ESPD
electro-sensitive protective device

3.15
hold-to-run control device
control device where the actuator automatically returns to the start position when released and where machine
operation is started and maintained only as long as the actuator is held depressed

3.16
accessible danger zones
areas provided with guards or ESPDs, for example, for safeguarding which allow whole-body access

4 List of significant hazards

4.1 This clause contains all the significant hazards, as far as they are dealt with in this standard, identified
by the risk assessment significant to this type of machinery and which require action to eliminate or reduce the
risk. When carrying out the risk assessment, the machine designer will have to check whether the list of
hazards in Table 1 is complete and applicable with respect to the particular machine.

4.2 It is of great importance that the users of this standard, i. e. the designer, manufacturer or supplier, take
into account the following principal aspects in accordance with EN 1050:1996:

the intended use of the machine including setting-up (make-ready), cleaning and maintenance, including
foreseeable misuse;

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 EN 1010-1 :2004 (E)

- identification of the significant hazards.

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EN 1010-1 :2004 (E)

Table 1 - Significant hazards, danger zones, safety measures

Safety measures: reference to
clauses in
Significant hazards Danger zone EN 1050:
EN ISO
1996
this standard 12100-1:
Annex
2003
A
Mechanical hazards Production area: 4.2.1 1
crushing - between rollers, cylinders, drums 5.2.1.1, 5.2.1.2
shearing - short linear movements 5.2.1.3
cutting or severing - wheels for floor travel 5.2.1.4
entanglement - revolving handwheels 5.2.1.5
drawing-in - crushing hazards with parts of building 5.2.1.6
trapping - guards 5.2.2
impacts - accessible danger zone 5.2.3.1
- make-ready, cleaning, maintenance 5.2.3.2, 5.2.3.3,
operations and trouble shooting (hold- 5.2.3.4
to-run)
- safe threading of web-type material 5.2.3.5
- impact hazards in passageways, access 5.2.12.1.4
ways
- stationary knives 5.3.1
- rotary tools 5.3.2
- transport of hazardous tools 5.3.3
- on feeding and delivery units (pile lifting 5.3.4.3 to
and lowering devices) 5.3.4.10
- unwinding and rewinding units for web- 5.3.5
tvoe material
Mechanical hazards - stability 5.2.13.1 4.2 1
generated by: - movable machines 5.2.13.2
- feeding units, delivery units 5.3.4.1, 5.3.4.2,
Mass and stability, 5.3.4.11, 7.2.5
Mass and velocitv
Slipping, tripping, falling Work platforms, access stairs, 5.2.12 4.2.3 19
passageways, steps, floor coverings
Electrical hazards - electrical equipment (equipment made 5.2.5.1, 5.2.5.7 4.3 2
Direct or indirect live under electrical fault conditions)
contact - supply disconnection device, stop 5.2.5.2, 5.2.5.3
Thermal radiation category
(burns) - rectifier drives 5.2.5.4
- degree of protection 5.2.5.5
- measurinq devices 5.2.5.8
Thermal hazards Hot machine parts 5.2.14, 7.2.4 4.4 3

Burns due to possible

contact
Hazards generated by All machines 5.2.15, 7.2.4 4.5 4
noise
Hearing damage
Interference with
speech communication
Accidents due to
interference with the
perception of acoustic
signals
Stress
Hazards generated by Machines with laser and UV-light 5.2.16, 7 4.7 6
radiation
UV-radiation, laser

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 EN 1010-1 :2004 (E)

Table 1 (concluded)

Safety measures: reference to

clauses in
Significant hazards Danger zone EN ISO EN 1050:
this standard 12100-1: 1996
2003 Annex A
Hazards from explosion - machinery using flammable liquids or 5.2.4, 7.2.4 4.8 7.2
dusts
Hazards generated by - design of actuators and displays 5.2.7 4.9 8
neglect of ergonomic - safety access, workplaces, catwalks, Annex B
principles in machine passageways 5.2.12.1.1,
design 5.2.12.1.3,

Unhealthy body 5.2.12.1.4,

postures 5.2.12.1.5

Unsuitable construction, - footsteps, handles 5.2.12.2

place or identification of - balance of weight 5.2.2.5
actuators - avoidance of irritating reflection 5.2.2.6
Failure, malfunction of - machinery with safety circuits 5.2.6 10
control system 5.2.8 to 5.2.11

Faults or failures in - conductor identification 5.2.5.6

safety circuits - separation of chucking cones 5.3.5.4
malfunction of software
External effects on I immunity to electromagnetic disturbances 5.2.17 10.3
electrical devices

5 Safety requirements and/or protective measures

5.1 General

Machinery shall comply with the safety requirements and/or protective measures of this clause. In addition,
the machine shall be designed according to the principles of EN ISO 12100 for hazards relevant but not
significant, which are not dealt with by this document (e. g. sharp edges of the machine frame).

5.2 Requirements common to printing and paper converting machines

5.2. 1 Safeguarding of danger points

5.2.1.1 lnrunning nips on cylinders, rollers, drums, rolls and similar parts shall be safeguarded by guards
or by applying the safety distances specified in EN 349:1993.

On guide rollers, the safety distance specified for the arm is considered to be sufficient where risk assessment
has determined that whole-body or head access cannot be expected.

Guards shall be designed as follows:

a) as guards without openings or with openings for feeding the material (for example sheets, blanks, webs,
work pieces). The safety distances shall be established in relation to the width of the opening in
accordance with EN 294:1992 (see Figure 2).

These guards shall be interlocked with the dangerous movements in accordance with 5.2.2 or they shall be
fixed to the machine. When the interlocking guard is open, one of the measures set out in 5.2.3 shall become
effective.

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EN 1010-1 :2004 (E)

+ +
�

Figure 2 - Safeguarding of inrunning nips

b) on smooth-surface rollers or cylinders as fixed nip bars extending across the entire working width,
designed in suitable sections. The clearance between the bar and the respective machine part, for
example, cylinders, rollers with a smooth surface etc., shall not exceed 6 mm (see Figure 3).

\ E
E

+ � i �

+
Figure 3 - Safeguarding an inrunning nip by means of a fixed nip bar

5.2.1.2 The use of trip devices for safeguarding inrunning nips shall be permitted only if the condition
defined in 5.2.10.2 is satisfied.

5.2.1.3 Linear movements are considered to be sufficiently safe if the maximum distance between
moving part and fixed part does not exceed 4 mm.

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 EN 1010-1 :2004 (E)

NOTE For example, when inserting printing plates, starting and stopping movements of tools; oscillating rod and
lever systems between upper and lower tool of riveting, eyeletting and stitching machines (see Figure 4 ).

Figure 4 - Example of a linear movement on a plate clamping device

5.2.1.4 On machines which travel under power, the crushing points between wheels and floor shall be
safeguarded. Safeguarding of crushing points is achieved, for example, by providing foot guards fixed such
that there is a distance of no more than 15 mm between the runway and the lower edge of the guard.

5.2.1.5 Handwheels and cranks shall be so designed that they do not automatically rotate when the
machine operates at production speed. This is achieved, for example, where handwheels and cranks are
decoupled by pressure springs during the production run.

5.2.1.6 Where machines with movable parts are used in the workroom, the instruction handbook shall
require users to erect machines in such a way that the hazard of crushing of persons between movable
machine parts and the building is prevented.

5.2.2 Guards and interlocks

5.2.2.1 Guards shall satisfy the requirements of EN 953:1997. Interlocking shall satisfy the requirements
of clauses 5 and 6 of EN 1088: 1995.

Stopping times vary with the type of machine used, but should be as short as possible.

For interlocking, see 5.2.11 (safety position switches with approach reaction) and 5.2.6 (control systems).

5.2.2.2 For fence-type enclosures, the safety distances according to EN 294:1992 apply. A further
requirement is that the distance between the floor and lower edge of the fence does not exceed 200 mm and
between the floor and upper edge is at least 1,4 m.

5.2.2.3 Guards and access doors in enclosures which are opened or removed frequently in the
production process or for setting-up operations shall be interlocked with the hazardous movements. Guards
which do not have to be opened frequently shall be fixed in such a way that their removal necessitates the use
of tools. These guards may also be interlocked with the hazardous movements.

15
EN 1010-1 :2004 (E)

NOTE Guards and doors are removed "frequently", including for maintenance purposes, if they are removed, for
example, at least once per working shift. Guards and doors are removed for "setting-up" purposes, for example:

to supply the material to be processed;

to change the size;

to change tools;

for make-ready;

for washing-up.

5.2.2.4 Automatic travel of movable guards shall not create danger points. EN 953:1997 shall be
complied with.

5.2.2.5 Guards that can be opened shall be safeguarded against gravity falls if this creates a risk of injury.
Measures to prevent such gravity falls include, for example,

devices for balancing the weight;

pneumatic springs;

latches which automatically hold the parts open;

power-driven worm gear drives actuated by hold-to-run;

by ensuring that the centre of gravity of the guard in the open position is sufficiently far behind the axis of
rotation.

Springs used for balancing the weight shall be designed such that, in the event of a spring failure, no
dangerous closing movement may occur. Compression-type springs are to be preferred.

5.2.2.6 Where production processes need to be observed, guards shall ensure permanent sufficient
vision of the functional point without being impaired by reflections. This requirement is satisfied, for example,
by mesh-type guards painted in matt black.

5.2.3 Devices for setting-up, cleaning, trouble-shooting during the work process and maintenance

5.2.3.1 Where accessible danger zones cannot be observed from positions from which hazardous
movements can be started, one of the following requirements shall be satisfied:

where accessible danger zones are safeguarded by a fence-type enclosure, it shall not be possible for
the person(s) within the enclosure to close the interlocking access gate or an additional control device
shall be provided outside the enclosure in such a position that it cannot be actuated from the inside. Any
hazardous movement shall be permitted only after the access door has been closed and the control
device been actuated;

where accessible danger zones are safeguarded by means of ESPDs, an additional control element shall
be provided outside the danger zone that cannot be reached from any position in the danger zone.
Provisions shall be made that the hazardous movement can only be started after the person has actuated
the additional control element.

5.2.3.2 When the interlocking guard is opened or removed or if a person has entered the danger zone
and there are danger points unprotected, it shall only be possible to start a machine by means of

a) Hold-to-run control devices

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 EN 1010-1 :2004 (E)

1) with a displacement limited to a maximum of 25 mm or with a maximum operating speed of 1 m/min,

2) with displacement limited to a maximum of 75 mm or with a maximum operating speed of 5 m/min

where there would be no substantially increased hazard and where the measures defined in 1) above
would reduce the ability of the machine to perform its function .

For hold-to-run devices designed as two-hand controls, the same limitations of displacement and speed shall
apply.

Any two-hand control device shall satisfy the requirements defined in 5.2.8. The stopping path shall be as
short as technically feasible.

Starting the machine in the hold-to-run mode after opening an interlocking guard may be done without
operating a selector switch, if production operation during hold-to-run control is positively prevented by the
interlocking device.

A selector switch is required for machines which allow two modes of hold-to-run control {hold-to-run control
with one actuator and two-hand control).

b) Manual operation

Devices which allow manual operation of the machine or parts of the machine shall be designed so that
persons are not exposed to danger.

5.2.3.3 From the place of operation of the hold-to-run control, it shall be possible to observe the danger
points and danger zones.

5.2.3.4 Where hold-to-run controls are being used for safeguarding a danger point, starting the machine
in the hold-to-run mode after opening the interlocking guard shall only be possible when other interlocking
guards outside the area that can be observed by the operator are closed.

5.2.3.5 Safe threading of the web-type material shall be ensured. On power-driven web threading devices,
access to danger points shall be prevented by guards.

Access to danger points is considered prevented if, for example,

on rope-type threading devices, the inrunning nips between threading rope and idler pulley are
safeguarded. Safeguarding may include the provision, on the outside of the pulleys, of a fixed disc, the
radius of which is at least 120 mm larger than that of the pulley,

on power-driven bar-type threading devices with transport chains, the inrunning nips between chains and
chain wheels are provided with guards filling the inrunning nips as far as possible,

threading is carried out under hold-to-run control with speed limitation.

5.2.4 Explosion prevention and protection

5.2.4.1 All electrical and non-electrical equipment and components intended for use in potentially
explosive atmospheres shall be designed and constructed according to good engineering practice and
conform to the required categories for group II equipment to ensure avoidance of any ignition source as
specified in 5.3 of EN 1127-1:1997. To classify the category of the equipment, it shall be subjected to an
ignition hazard assessment in accordance with 5.2 of EN 13463-1:2001.

5.2.4.2 Explosion prevention and protection is not required for machinery where there are no flammable
liquids with a flash point below 55 °C being used and no flammable liquids are sprayed or heated to a
temperature above flash point under operating conditions. All other machinery shall be designed to satisfy the
requirements specified in EN 1127-1:1997 for the zones described in Annex A.

17
EN 1010-1 :2004 (E)

NOTE 1 For washing units on printing presses, see 5.6.6 of prEN 1010-2:2001.

NOTE 2 Heating of a flammable liquid occurs under operational conditions, for example, in film and printing plate
development units with bath heating.

For information about conductive flooring, see requirements for instruction handbooks in 7.2.4.

5.2.4.3 Electrical equipment

5.2.4.3.1 Any electrical equipment intended for use in a potentially explosive atmosphere caused by gas,
vapour, mists or dust shall comply with the requirements of EN 50014. Where relevant, these requirements
may be supplemented or modified by EN 50015:1998, EN 50016:1995, EN 50017:1998, EN 50018:2000,
EN 50019:2000, EN 50020:1994 and EN 50039:1980 as appropriate.

5.2.4.3.2 Group II category 1G, 2G or 3G equipment for installation in a particular zone shall be selected
according to clause 5 of EN 60079-14:1998.

5.2.4.3.3 Group II category ID, 20 or 30 equipment for installation in a particular zone shall be selected
according to EN 50281-1-2:1999.

5.2.4.4 Non-electrical equipment

5.2.4.4.1 All non-electrical equipment, intended for use in a potentially explosive atmosphere caused by
gas, vapour, mist or dust, shall comply with the requirements of EN 13463-1:2001 and EN 13463-5:2003 and,
where relevant, the European Standards to be applied for the specific type of ignition protection.

5.2.4.4.2 Group II category 1G or ID equipment, for installation in zone O or 20 respectively, shall not
contain any effective ignition source during expected malfunctions or rare malfunctions.

5.2.4.4.3 Group II category 2G or 20 equipment, for installation in zone 1 or 21 respectively, shall not
contain any effective ignition source during normal operation or expected malfunction.

5.2.4.4.4 Group II category 3G or 30 equipment, for installation in zone 2 or 21 respectively, shall not
contain any effective ignition source during normal operation.

5.2.4.5 The surface temperature of all parts of category 1 and 2 non-electrical equipment likely to come
into contact with potentially explosive atmospheres and the temperature of the potentially explosive
atmosphere shall not exceed 80 % of the ignition temperature in °C of the gases or vapours. The temperature
of all surfaces which can come into contact with dust clouds shall not exceed 2/3 of the minimum ignition
temperature in °C of the dust cloud.

5.2.4.6 On surfaces where the deposition of potentially glowing dust cannot be positively prevented, the
surface temperature of all parts of non-electrical equipment shall not exceed the minimum ignition temperature
of the dust layer reduced by 75 K.

See prEN 50281-1-3:2002.

5.2.4.7 Brakes and clutches shall be designed such that they cannot be a source of ignition in
accordance with EN 13463-5:2003.

5.2.4.8 Undesirable electrostatic discharges shall be avoided by earthing and interconnecting all the
metallic components.

Note Further information on this topic is given in the CENELEC report R044-001 "Safety of machinery - Guidance
and recommendations for the avoidance of hazards due to static electricity".

5.2.4.9 Hoses and pipes used for exhausting flammable dusts and other flammable materials (paper,
6
plastic etc.) shall be conductive and electrostatically grounded (resistance less than 10 0). Respective
reference shall be made in the instruction handbook.

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 EN 1010-1 :2004 (E)

5.2.4.10 Hoses and pipes for inks, coating substances and impregnating materials and glues as well as for
exhausting solvent vapours shall be conductive and electrostatically grounded (resistance less than 106 0).

Note See 7.2.4 for information in instruction handbook.

5.2.4.11 The distance between the electric drive motor and the agitator for viscosity control and the outer
flange of the agitating device shall be at least 50 mm (lantern-type fixing). It is also recommended that a disc
should be mounted on the shaft to increase the preventive effect.

Note This prevents solvents evaporating from the agitator shaft from reaching the motor (see Figure 5).

2--------r:I

ffi E
E

� I

Key
1 Drive motor
2 Agitator
3 Top view

Figure 5 - Distance between drive motor and agitator (lantern)

5.2.4.12 The electric drive motor on recirculating pumps on supply tank for inks, coating substances,
impregnating material or glues shall be protected in accordance with EN 50018:2000 with regard to ignition
protection. Where protective motor switches are mounted on the pump, EN 50019:2000 is sufficient.

5.2.5 Electrical equipment

5.2.5.1 All electrical equipment shall be designed such that electrical hazards (for example electric shock,
burns) according to EN 60204-1:1997 are prevented. The requirements of EN 60204-1:1997 shall be fulfilled,
taking into account the following additional requirements.

5.2.5.2 Machines shall be provided with a supply disconnecting device in accordance with 5.3.2 a) or c)
of EN 60204-1:1997. The device shall be provided with a means to be locked in the OFF position. Where the
operation of the emergency stop control devices causes galvanic disconnection from the power supply by
undervoltage tripping, a circuit-breaker in accordance with 5.3.2 c) of EN 60204-1:1997 is required. Where
circuits as specified in 5.3.5 of EN 60204-1:1997 are not disconnected by the supply disconnecting device,
such circuits shall be provided with their own disconnecting device.

See also 5.2.7.5.

5.2.5.3 Emergency stop devices shall be designed in accordance with 9.2.5.4.2 of EN 60204-1:1997
either as a category O stop or as a category 1 stop. On machines where inrunning nips are safeguarded by trip
bars according to 5.2.10, the emergency stop shall function as a category 1 stop.

See also 5.2.6.1.2.

5.2.5.4 On rectifier drives, the actuation of an emergency stop control device may, as a deviation from
9.2.5.4 of EN 60204-1:1997, cause stopping of the drive as a category 2 stop according to 9.2.2 of
EN 60204-1:1997 if

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EN 1010-1 :2004 (E)

pulse blocking in the rectifier and

disconnecting the voltage supply to encoder and associated control circuitry

are separate functions in accordance with category 3 of EN 954-1:1996.

5.2.5.5 Electrical devices and conductors shall be installed in such a way that damage from mechanical
stresses and environmental influences are prevented. Electrical devices should be to IP 54 according to
EN 60529: 1991.

5.2.5.6 For insulated single-core conductors laid between two terminals inside an enclosure (for example,
a switch cabinet), one of the following methods shall be used for conductor identification:

identification by number or alphanumerically;

identification by colour in accordance with 14.2.4 of EN 60204-1:1997;

securing conductors in position, for example by using comb-type wire fixing in such a way that any
confusion of conductors when changing electric components is safely prevented;

or another adequate method.

5.2.5.7 All electrical equipment shall be designed such that it will withstand the testing specified in 19.2 to
19.6 of EN 60204-1:1997. Voltage tests as specified in 19.4 of EN 60204-1:1997 are not required for
electronic control circuits provided by computer systems or electronic control components.

5.2.5.8 Measuring devices which are part of machines shall comply with EN 61010-1:2001.

5.2.6 Control systems

5.2.6.1 Control requirements for machines which do not require routine and regular access to danger
points.

5.2.6.1.1 In the hydraulic/pneumatic control system, the safety-related parts shall satisfy at least category 1
(6.2.2) of EN 954-1:1996.

In the electric/electronic control system, the safety-related parts shall satisfy at least category 3 (6.2.4) of
EN 954-1:1996. Only single main contactors may be provided.

The minimum requirement is that faults in the auxiliary relays and auxiliary contactors in the control circuit
shall be detected and hazardous movements stopped. When using computers or PLC (Programmable Logic
Control) for monitoring, safety-related malfunctions shall be detected and lead to disconnection.

When using computers or PLC, this requirement may be satisfied, for example, by monitoring the function of
safety-related signals using parallel computer control systems or redundant contact-type circuit breaking
principles. Any malfunctions shall result in the hazardous movement being stopped.

Safety-related parts of control systems include, for example, emergency stop circuits, electric interlocking
circuits, limitation of displacement or operating speed on hold-to-run controls. For safety aspects, see also
definitions in EN 954-1:1996.

External influences and faults in these parts of the control systems may cause hazardous movements and
hazards.

Depending on the type of machine, hazardous movements include, for example:

- unintended start-up or unintended speed increase up to production speed;

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 EN 1010-1 :2004 (E)

unintended movement following an intended movement (unintended cycle);

unintended continuation of a movement where stopping of the movement is intended.

A hazard may, for example, also be the build up of potentially explosive atmospheres by faults in the control
systems.

NOTE See Bibliography and IEC 61508.

5.2.6.1.2 On rectifier and inverter drives, the control system shall be designed such that, in the event of any
guard or safety device causing the machine to stop, the main contactor will also be switched off, for example
by using an electric/electronic timer for switching it off after a preset time or any other adequate measure such
as the application of a mechanical brake with a braking torque greater than the drive torque of the motor.
Safety devices are, for example, emergency stop devices, ESPDs, interlocked guards, trip devices.

On rectifier and inverter drives which feed energy back into the electric circuit during stopping, appropriate
control-related measures shall be taken, in addition to pulse blocking, to ensure that the main contactor is
switched off no later than after elapse of the normal stopping time, or any other adequate measure to that
effect. During hold-to-run control operations, there is no need to disconnect the main contactor during the
release time of the prestart warning device (see Annex B).

NOTE 1 On rectifier and inverter drives, the speed of rotation of the motor is changed, for example, by shifting the
supply voltage frequency.

5.2.6.1.3 When an emergency stop device is fitted with a main contactor which detects a low voltage
condition, it shall disconnect the main power supply at least of category 1 of EN 954-1:1996.

NOTE The opening contact of the emergency stop device directly disconnects, for example, the power supply to the
low-voltage tripping coil.

5.2.6.1.4 Mutual interlocking of safety devices safeguarding individual areas each of which can be
observed by the operator shall satisfy the requirements of at least category 1 of EN 954-1:1996. Interlocking
may be computer controlled.

For areas to be observed, see 5.2.3.6.

5.2.6.1.5 Residual pile monitoring systems shall comply with category B of EN 954-1:1996.

5.2.6.2 Increased control requirements for machines which require routine and regular access to danger
points, for example guillotines, hand-fed platen machines, hand-fed screen printing presses and hand-fed
label punching machines.

5.2.6.2.1 In the hydraulic/pneumatic control system, the safety-related parts shall satisfy at least category 3
(6.2.4) of EN 954-1:1996.

In the electric/electronic control system, the safety-related parts shall satisfy category 4 (6.2.5) of
EN 954-1:1996. Main contactors shall be provided in duplicate. Faults in the main contactors shall be detected
and lead to lockout.

For requirements of position switches, see 5.2.11.

5.2.6.2.2 Electronic braking systems on their own shall not be admissible on machines with routine and
regular access. Such braking systems require the provision of additional mechanical brakes for back-up. The
mechanical brake torque shall be greater than the maximum electric drive torque of the rectifier and inverter
drive.

NOTE Electronic brakes exist, for example, on rectifier and inverter drives where the braking effect is caused by
energy being fed back into the circuit.

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5.2.7 Indicators, marking, actuators, prestart warning devices

5.2.7.1 The requirements relating to indicating, marking and actuators as defined in EN 61310-1:1995
and EN 61310-2:1995 shall be satisfied.

5.2.7.2 On machines where overall vision is restricted and communication between operating personnel
is difficult, prestart warning devices shall be provided which positively give a clearly distinguishable audible
signal before the machine starts. The requirements defined in Annex B shall be satisfied. In addition to an
audible warning device, one or more visual warning devices may be required.

Overall vision may be restricted and communication between operating persons be difficult

if the machine length exceeds 7 m,

or

if, on printing machines, there is more than one printing unit side frame and the machine height,
measured from floor level, exceeds 1,6 m,

or

if, on automatic platen machines, the control panels are in positions from which the waste discharge area
cannot be observed.

Where prestart warnings are frequent, the stipulations defined in 5.3 of EN ISO 12100-2:2003 shall be taken
into consideration.

5.2.7.3 Machines shall be provided with at least one operating element for starting and stopping. This
function can also be achieved by a power supply disconnecter mounted on the machine. Control switches for
starting and stopping and their related operating elements shall satisfy the requirements of EN 60204-1:1997
and 3.7.8 of EN ISO 12100-2:2003.

5.2.7.4 Operating elements of control switches for starting hazardous movements shall be safeguarded
against unintended actuation.

5.2.7.5 Machines shall be provided with separate main control switches for each type of energy used.
The requirements of EN 1037:1995 shall be satisfied.

5.2.7.6 For emergency stopping devices, the requirements of EN 418:1992 and EN 60204-1:1997 shall
be satisfied.

5.2.8 Two-hand controls

5.2.8.1 Two-hand controls as safety devices are acceptable only if any hazardous movement stops when
only one of the two actuators is released. The hazardous movement shall come to a stop in a time that, taking
into consideration the hand approach speed, ensures there is no danger for the operator. The hand approach
speeds specified in EN 999:1998 shall be taken as a basis. The requirements of type Ill of EN 60204-1 shall
be satisfied.

5.2.8.2 For hydraulic/pneumatic two-hand controls, the requirements specified for type Ill A and for
electric/electronic two-hand controls, the requirements specified for type Ill B of EN 574:1996 shall be satisfied.

5.2.8.3 As a deviation from 5.2.8.2, hydraulic/pneumatic two-hand controls safeguarding danger points
requiring routine and regular access shall satisfy the requirements specified for type Ill B and
electric/electronic two-hand controls the requirements specified for type Ill C of EN 574:1996.

5.2.8.4 Two-hand controls on trailing cables used for make-ready and trouble-shooting are permissible in
accordance with 5.2.3.4. In these circumstances, EN 999:1998 is not applied. Trailing cables shall have

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 EN 1010-1 :2004 (E)

sufficient strength to withstand any mechanical stresses to be anticipated and be provided with measures to
prevent the lead being pulled out of its connection point.

5.2.9 Electrosensitive protective devices (ESPDs)

5.2.9.1 ESPDs shall satisfy the requirements of type 2 of EN 61496-1:1997 and IEC 61496-2:1997.

5.2.9.2 As a deviation from 5.2.9.1, ESPDs which safeguard routine and regular access to the danger
zone shall satisfy the requirements of type 4 of EN 61496-1:1997 and IEC 61496-2:1997.

5.2.9.3 The hand approach speed specified in EN 999:1998 shall be used as a basis for determining the
correct positioning of the ESPD. For ESPDs fitted as start-up inhibiting devices, EN 999:1998 does not apply.
Additional safety devices shall be installed.

5.2.9.4 Where ESPDs are used for preventing whole-body access to safeguarded danger zones, at least
two ESPD beams shall be provided at a height of 400 mm and 900 mm respectively.

5.2.10 Pressure sensitive mats, trip devices

5.2.10.1 Pressure sensitive mats shall satisfy the requirements of EN 1760-1:1997, trip bars shall satisfy
the requirements of EN 1760-2:2001. The requirements of category 3 of EN 954-1:1996 shall be satisfied (see
4.15 of EN 1760-1:1997 or 4.18 of EN 1760-2:2001). Trip devices and pressure-sensitive mats which
safeguard routine and regular access to a danger point shall comply with category 4 of EN 954-1:1996.

5.2.10.2 After tripping the stop function, the length of the movement of the trip device shall be longer than
the stopping path of the hazardous movements.

5.2.11 Safety position switches

5.2.11.1 The requirements of clauses 5 and 6 of EN 1088:1995 shall be satisfied.

5.2.11.2 For safety position switches built in accordance with EN 60947-5-1:1997 and installed in
accordance with EN 60204-1:1997, it may be assumed that malfunctions are not likely to occur. For machines
where routine and regular access is not required, it is therefore sufficient to provide only one position switch
for each interlocking guard.

5.2.11.3 Short circuits between two electric wires outside the switch cabinet due to physical impacts can
be prevented by mechanical protection of the cable (for example locating within ducts, in the machine frame).

5.2.12 Work platforms, access stairs, passageways and raised workplaces

5.2.12.1 General requirements

5.2.12.1.1 For operation, make-ready and regular maintenance, safe workplaces including their means of
access and passageways shall be provided according to EN ISO 14122-1:2001, EN ISO 14122-2:2001,
EN ISO 14122-3:2001 and EN ISO 14122-4:2004.

5.2.12.1.2 Floor coverings shall be slip resistant. This may be achieved, for example, by using profiled steel
plate or material satisfying the requirements of classification group R 10 of EN ISO 14122-2:2001.

5.2.12.1.3 The minimum clear height for passage shall comply with the stipulations of EN ISO 14122-2:2001.
Where this clearance cannot be complied with for constructional reasons, the protruding parts shall be padded
and provided with danger marking.

5.2.12.1.4 Raised permanent workplaces should have a clear working area of at least 1,5 m2 per person and
the smallest width should be 1,0 m unless this inhibits ergonomic requirements (for example, handling of
objects).

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EN 1010-1 :2004 (E)

5.2.12.1.5 The maximum pitch angle on access stairs shall be 45 °. Depending on the results of risk
assessment, other means of access may be appropriate. For infrequently used workplaces which cannot be
accessed by stairs,secured ladders may be used if the access height does not exceed 2m.

NOTE For example of a risk analysis, see informative Annex C.

5.2.12.2 Additional means for infrequently used access platforms

5.2.12.2.1 Good ergonomics and safe body postures should be achieved, for example, by the following
measures:

sufficient number of handholds some of which can be reached from the reference level;

mobile platforms;

permanently fixed and hinged platforms.

5.2.12.2.2 Requirements for steps (fixed or hinged)

For single steps, access levels may be permanent platforms or catwalks. The following dimensions apply for
steps:

normal step height .:::. 300mm

maximum step height 500mm

minimum width (1 foot) 200mm

minimum width (2feet) 300mm

minimum length 300mm

Where multiple steps (fixed or hinged) are needed, the reference level shall have an effective width of at least
500mm. The following dimensions apply:

maximum height of upper step (standing area) 1 200mm

maximum separation of intermediate steps 300mm

minimum length of step 200mm

maximum height without railing 1 200mm

Steps shall always be provided with handles.

The size of platforms that are used for standing infrequently or for a short time shall be at least
(200x 200) mm.

5.2.12.2.3 Where handles are required,the following dimensions apply:

minimum handle depth 40mm

minimum handle length 11 0mm

minimum handle diameter 20mm

5.2.12.2.4 Hinged platforms up to a height of 0,5m to 1,6 m shall be provided with at least one handrail.
Hinged platforms shall be secured against unintended movement and shall be easy to handle.

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 EN 1010-1 :2004 (E)

5.2.13 Stability

5.2.13.1 Machines shall be so designed and equipped that no unforeseeable changes of position can
occur. The requirements of EN ISO 12100-2:2003 shall be satisfied.

Unforeseeable changes of position are prevented, for example, by

adequate dimensioning of base;

low centre of gravity;

means for anchoring;

adequate design of wheels on track-mounted assemblies.

5.2.13.2 Movable machines (machines on wheels) shall be safeguarded against unintended travel.
Unintended travel of wheels and castors with no brakes may, for example, occur on the following machines:
small UV dryers, damping water devices, jogging tables, sheet folding, riveting, stitching and eyeletting
machines, strapping and tying machines, bundling presses, printer slotters, rotary die-cutters and combined
machines (in-line).

Unintended travel is prevented, for example, if

out of four wheels, at least one,

out of two wheels and two castors, at least one castor,

out of four castors, at least two

can be locked.

Where possible, automatic locking devices should be fitted, such as self-locking gears, for example.

5.2.14 High contact temperatures

The contact temperatures of accessible hot parts on machines shall not be higher than the limit values
specified in EN 563:1994.

Safeguarding against contact with heated parts is possible by insulation or distance guarding, for example.

For information in the instruction handbook, see 7.2.4.

5.2.15 Noise

The machines shall be so designed and constructed that risks from airborne noise emission are reduced to
the lowest level particularly by applying measures at source to control noise (see, for example,
EN ISO 11688-1:1998). The success of these applied noise reduction measures is assessed on the basis of
the actual noise emission values (see clauses 6 and 7) in relation to other machines of the same family.

Sound measurements to determine the noise emission shall be carried out in compliance with the
requirements specified in EN 13023:2003.

For information about noise in the instruction handbook, see 7.2.3.

NOTE The most significant sources of noise are, for example:

- gearing (toothed gears)
- hydraulic devices
- compressors, pumps

25
EN 1010-1 :2004 (E)

- exhaust and blast air nozzles

- suction devices (paper dust, trimmings)
- paper embossing
- cutting, die-cutting, creasing of paper, board, paper grinders
- cylinder rolling motion
- paper stops
- separation of paper or board from printing form.

5.2.16 Radiation hazards

5.2.16.1 Laser devices incorporated in machinery shall comply with the requirements of EN 12626:1997
and EN 60825-1:1994. The equipment shall be provided with fixed or interlocking guards in order to prevent
access to positions where laser radiation emission is above the category 1 limit values according to
EN 60825-1:1994 during the intended use of the machine. For reasons of repair, it may be necessary for
trained personnel to operate the machine for short periods of time without fixed or interlocking guards. If this
requires access to positions where laser radiation emission is above the category 1 limit values, additional
safety measures need to be taken in accordance with EN 60825-1:1994.

NOTE 1 Laser devices are, for example, laser exposing devices, laser gravure equipment, laser cutting devices.

Additional safety measures are, for example, instructing personnel in the use of personal protective equipment.

For user information, see clause 7.

5.2.16.2 The level of ultraviolet radiation emitted by machinery shall not exceed category 1 limit values of
Table D.1 of EN 12198-1:2000 for permanent workplaces as well as for occasionally occupied positions.
Actual radiation values shall be determined according to Annex D.1 and Table D.2 of EN 12198-1:2000.

NOTE UV radiation is emitted, for example, by UV exposing equipment and UV dryers.

The values specified for category 1 in Annex D.1 of EN 12198-1:2000 relate to the maximum duration of
exposure of 8 hours per day. Where the location of measurement points or normal conditions of operation
allow the expected time of exposure lexp per person to be less than the maximum duration, the UV-B/C
radiation limit value 1 x 10·3 W/m2 may be multiplied by the factor 8/texp (lexp in hours). The UV-A radiation limit
value is 1O W/m2 for exposure times from 1 OOO s to 8 hours. If the exposure time is less than 1 OOO s, the limit
value for radiation emission is calculated by dividing the radiation value of 10 OOO J/m2 by the exposure time
defined in seconds.

A lower maximum duration of exposure may be expected on UV exposing equipment, for example, where the
emission of radiation is interrupted for procedural reasons in the preparatory phase of the exposing operation
(feeding of the copy, travel to required position).

Hazards due to ozone caused by UV radiation shall be avoided at the design stage. Possible measures for
reducing ozone emission are low-ozone UV lamp units or provision of exhaust equipment.

5.2.17 Immunity to electromagnetic disturbances

Printing and paper converting machines shall have sufficient immunity to electromagnetic disturbances to
enable them to operate safely as intended and shall not fail to danger when exposed to levels and types of
disturbances as specified in EN 61000-6-2:2001. The manufacturer of the printing and paper converting
machines shall design, install and wire the equipment taking into account the recommendations of the
supplier(s) of the parts or subassemblies to ensure that any effects of electromagnetic disturbances shall not
lead to unsafe operation and/or failure to danger.

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 EN 1010-1 :2004 (E)

5.3 Common devices

5.3.1 Stationary knives

5.3.1.1 On stationary knife blades, a guard shall be provided for the cutting edge of the knife, wherever
possible. This does not apply to bed knives in cross cutters.

5.3.1.2 Stationary knife blades which can be tilted shall be protected against contact, even when not in
the working position.

5.3.2 Rotary tools

5.3.2.1 On rotary tools such as circular cutters, perforating knives, perforating tools, rotary slitting tools,
rotary bending tools, circular saws, the inrunning nips and that part of the peripheral area which is not used for
the process shall be protected against contact. Preference shall be given to guards which do not have to be
removed for tool change. The requirements of 5.2.1.1 shall be satisfied as far as possible.

5.3.2.2 Split rotary tools shall be positively fastened to the tool carrier.

5.3.3 Dangerous tools

For the transport and storage of dangerous tools of machines such as knives, devices, for example knife
boxes, shall be provided to prevent injuries from being caused by the tools. This requirement also applies to
individual tools forming part of assemblies.

5.3.4 Feeding units, delivery units (pile lifting and lowering devices)

5.3.4.1 The pile lifting and lowering device shall be designed such that it can withstand a static load test
with a load of 1,25 times the maximum load capacity without showing permanent deformations or apparent
defects. It shall withstand a dynamic load test with a load of 1,1 times the maximum load capacity under
normal operating conditions.

5.3.4.2 On pile lifting and lowering devices with production format sizes over 2,5 m2 , the breaking
strength of the steel link chains shall be at least 6 times the permissible static load; on pile lifting and lowering
devices with production format sizes below 2,5 m2 , it shall be at least three times the permissible static load.
Calculations shall be based on a specific density of at least 1 400 kg/m3 for paper and at least 200 kg/m3 for
corrugated board.

5.3.4.3 On pile lifting and lowering devices with production format sizes over 2,5 m2 and a lifting height
over 1,5 m, provisions shall be made to prevent the pile carrier from moving more than 100 mm in the event of
failure of a rope, chain, supporting nut or gear drive or leaking hoses or pipes.

The requirement is satisfied for screw drives, for example, by providing an additional nut of the same type as
the supporting nut in order to back up the supporting nut in the event of a breakage or thread wear. The
requirement is satisfied for chains (or ropes), for example, by providing one or more unloaded double chains
which take over the load and function of the operating chain in the event of a chain breakage.

This does not apply to gears which are rated for double load. This does not apply to pile lifting and lowering
devices with a hydraulic or pneumatic drive if, in the event of leakage in the pipe system, the lowering speed
of the pile carrier does not accelerate to more than 1,5 times the speed under normal operating conditions.

5.3.4.4 On pile lifting and lowering devices with production format sizes over 2,5 m2 , the area below the
pile carrier plate shall be safeguarded by guards or by ESPDs. EN 999:1998 need not be considered. For
ESPDs, the requirements of 5.2.9.4 shall be taken into consideration.

5.3.4.5 On pile carrier plates, the danger points between the edges of the pile carrier plate and the place
where the operator may stand shall be safeguarded as follows:

27
EN 1010-1 :2004 (E)

a) on feeders with production format sizes of up to 1,0 m2 and on delivery units with production format sizes
of up to 0,175 m2 , the pile carrier plate shall be allowed to lower automatically

only down to a height of 120 mm above the base of operation

and

further down to the base only in the hold-to-run control mode.

Danger points may alternatively be safeguarded by one of the measures listed under b).

b) on feeders with production format sizes of over 1,0 m2 and on delivery units with format production sizes
of over 0,175 m2 , one of the following protective measures shall be provided in order to safeguard the
exposed edges of the pile carrier plates:

resilient, non-switching, overhanging shields mounted on the pile carrier plate with their forward
edges protruding over the hazardous edges by at least 250 mm (see Figure 6),

1 2somm

2
Key

1 Pile carrier plate

2 Overhanging shield
3 Foot

Figure 6 - Overhanging shield

ESPDs in front of the pile carrier plate edges, EN 999: 1998 need not be considered.

a horizontal distance of 300 mm between the vertical projection of the machine frame and the pile
carrier plate; the projecting parts of the machine frame shall not be higher than 1,5 m above the base.
Carrier arms projecting into the safety distance (300 mm) shall be at least 120 mm above the base
(see Figure 7)

28
 EN 1010-1 :2004 (E)

E E
E E
0 0
0 N
I!)
E
E
1 0
0
C')

IT
Figure 7 - Safeguarding by deflecting parts of the machine frame

trip devices

hold-to-run control on feeders at a distance of at least 850 mm from the danger point and at a
position from where the danger point is in the operator's view.

c) on feeders and delivery units with production format sizes over 2,5 m2 , the danger point on the pile carrier
plate edges shall be safeguarded by one or more of the following safety devices:

guard,

ESPDs in front of the edge of the pile carrier plate, on board feeder and delivery units by an ESPD
fitted at a distance of 300 mm minimum from the edge of the pile carrier plate.

5.3.4.6 Where platforms or catwalks are fitted to the feeding or delivery unit, the danger point between
platform or catwalk and the edge of the pile carrier plate shall be safeguarded. This can be achieved, for
example, by one of the following measures:

minimum distance of 120 mm between pile carrier edge and edge of platform,

ESPDs in front of the pile carrier edge, EN 999: 1998 need not be followed,

horizontal distance of 300 mm between the vertical projection of outer edge of the machine frame and pile
carrier edge with deflecting parts of the machine frame arranged at a distance of no greater than 1,5 m
above platform or catwalk,

trip devices.

5.3.4.7 On sheet feeding and delivery units, the crushing and shearing points caused by the upward
movement of the pile or pile carrier plate shall be safeguarded. Safeguarding may, for example, be done by
one of the following measures:

safety distances in accordance with EN 349:1993,

trip devices,

29
EN 1010-1 :2004 (E)

guards,

hold-to-run operation.

5.3.4.8 Separating elements on feeders shall be so designed that their movement does not create danger
points. Where blanks are fed from the bottom of the pile, safeguarding is achieved, for example, by residual
pile monitoring on feeders.

The danger points on separating elements outside the side lays on feeders shall be safeguarded for every
format size used. This may be achieved, for example, by using concertina-type bellows or additional guards.

Where blanks are fed from the top of the pile, the requirement is satisfied if safety distances between suction
heads are used or if suction heads touch down only under spring force.

5.3.4.9 Danger points on suction head drives (see Figure 8) that can be accessed during the production
process shall be safeguarded by guards completely enclosing the head, only leaving the bottom open.

Danger points caused by moving parts (such as forwarding sucker, lifting sucker) outside the suction head
shall be safeguarded, for example, by one of the following measures:

distance of at least 25 mm between moving parts (for example, forwarding sucker) that are accessible
during production,

parts are moved only by springs with a non-hazardous low force (for example, pressure foot, lifting
sucker),

danger points (shearing and crushing hazards) are protected by guards.

The drive shaft of the suction head shall be completely enclosed.

Key
1 Forwarding sucker
2 Lifting sucker
3 Pressure foot

Figure 8 - Movements associated with the suction head

30
 EN 1010-1 :2004 (E)

5.3.4.10 lnrunning nips on the feedboard rollers on the sheet feeding system and on forwarding rollers
shall be safeguarded (see Figure 9). This can be achieved, for example, by

using a deflection of 25 mm,

using a deflection of 15 mm with roller widths limited to 25 mm or

providing guards in accordance with 5.2.1.1 b).

Key
1 Feeding table
2 Transport rollers
3 Feedboard rollers
4 Direction of feeding

Figure 9 - Feedboard and transport rollers

5.3.4.11 On pile lifting and lowering devices (feeding and delivery devices), the following additional
information shall be clearly marked:

a) permissible operating pressure on pneumatically-driven pile lifting and lowering devices;

b) permissible operating pressure on hydraulically-driven pile lifting and lowering devices, as long as the
pressure generator is not a component part of the pile lifting and lowering device;

c) maximum carrying capacity;

d) for format sizes above 2,5 m2 , a sign indicating that travelling on the device is forbidden.

5.3.5 Reel unwinding and rewinding devices for webs

5.3.5.1 On unwinding and rewinding devices where the reel is driven by a belt on the reel circumference
(see Figure 10), the danger point between the reel and the belt shall be safeguarded by interlocking guards or
fence-type enclosures if the pressure between belt and reel is more than 300 N. Safeguarding may also be
required for pressures less than or equal to 300 N if a hazard is created by the speed of the machine.

Guards shall be provided for protecting the inrunning nips on the drive belt guide rollers (see Figure 11).

31
EN 1010-1 :2004 (E)

5.3.5.2 On unwinding and rewinding devices, the inrunning nips at reels and pressure rollers and reels
and support rollers shall be safeguarded by means of guards or safety devices with approach reaction (trip
devices, pressure-sensitive mats, ESPDs). The safety device selected shall be effective for all reel diameters.
Access to the inrunning nip from the side shall not be possible. Included in this requirement is the
safeguarding of the inrunning nip facing the machine, if a drawing-in hazard exists when the diameter of the
reel is small (at the beginning of the rewinding process) or the diameter of the pressure roller is small.

For trip devices, pressure-sensitive mats, see 5.2.10, for ESPDs, see 5.2.9.

Figure 10 - Belt drives

'
-l- - _I_,_
'

Figure 11 - Safeguarding of belt inrunning nips on belt drives

5.3.5.3 Where shaftless unwinding or rewinding is used, the chucking cones shall be designed so that
they can only be inserted in the hold-to-run control mode. Control switches shall be arranged such that danger
points between the chucking cones and the reel can be observed from the position of the hold-to-run control
allocated to the unwinding and rewinding unit. The hold-to-run speed shall not exceed 5 m/min (see
5.2.3.3 a2).

For automatic reel loading, see 5.3.5.11.

5.3.5.4 Provision shall be made to prevent unintentional separation of the chucking cones after the reel
has been lifted. This is prevented, for example, where separation is only possible in the hold-to-run control
mode with a maximum speed of 2 m/min or by two-hand-control or separation of the chucking cones after
leaving the reel loading position is prevented by interlocking devices such as pressure sensing devices.

Separation of the chucking cones during the unwinding and winding motion shall be prevented. This is
achieved, for example, by electrically interlocking the drives such that the separation of the cones is prevented
whilst the winding is in motion. The control requirements of 5.2.6.1 shall be satisfied.

32
 EN 1010-1 :2004 (E)

5.3.5.5 On shaftless unwinding and rewinding units, it shall be ensured that the unit can only be started
after the chucking cones are fully inserted. This is ensured, for example, by monitoring the position of the
chucking cones by means of pressure sensing devices.

5.3.5.6 On shaftless unwinding and rewinding devices, hazards caused by small diameter reels being
ejected shall be prevented.

This is prevented, for example, by one of the following measures:

changing of reels at lower speed;

positively preventing the reel from being lowered to a diameter less than the minimum reel diameter
specified by the supplier;

fitting an adequate safety device to the unwinding unit.

5.3.5.7 If danger points between lifting arms and machine frame cannot be avoided by built-in design or
be safeguarded, the lifting arms shall only be movable in the hold-to-run control mode. Control switches shall
be arranged such that danger points can be observed from the actuation position. The hold-to-run speed shall
not exceed 5 m/min (see 5.2.3.2 a2).

5.3.5.8 On reel unwinding and rewinding devices, the risk of drawing in between the end surface of a
rotating paper reel and fixed parts or lifting arms shall be safeguarded if the distance is less than 25 mm.

5.3.5.9 On reel stands, reel splicers and turrets with movable parts, all danger zones where the risk of
crushing exists shall be safeguarded according to EN 349:1993 or provided with guards according to
EN 294:1992.

Risk of crushing may exist between movable parts such as lifting arms, paper reel and devices for reel
acceleration, cutting, splicing and gluing devices and fixed parts such as side frames, connecting bars or the
floor.

Alternatively, hold-to-run operation of reel stands and reel splicers is admissible only if all danger zones can
be observed from the operating position.

5.3.5.10 On semi-automatic reel transport systems, transport of the material reel to the reel stand shall be
done in the hold-to-run control mode with a maximum speed of 20 m/min. The stopping path shall not exceed
200 mm. It shall be possible to overlook the total transport way from the respective hold-to-run control position.

5.3.5.11 On automatic reel loading systems, the danger zone existing on the unwinding unit shall be
completely safeguarded, for example by ESPD. Danger zones exist, for example, between material reel and
fixed machine parts, between material reel and lifting arm and floor, between material reel and chucking cones.

For safeguarding the danger zone by ESPD, see 5.2.9.4.

6 Verification of the safety requirements and/or protective measures

Table 2 describes methods used to verify if the safety requirements and measures described in Clause 5 are
complied with. It also contains references to the respective subclauses of this standard.

33
EN 1010-1 :2004 (E)

Table 2 - Methods used to verify safety requirements and protective measures

A: inspection, B: functional test, C: measuring, D: drawings and calculations

Clause Safety requirements and/or measures A B C D

Note 1 Note 2 Note 3 A Note 4

5.1 General
5.2 Common requirements for printing and paper converting machines
5.2.1.1 Guards on inrunning nips X X X

5.2.1.2 Safeguarding of inrunning nips by trip devices X X

C
5.2.1.3 Safeguarding of linear movements below 4 mm X X X

5.2.1.4 Safeguarding of powered wheels travelling on floor X X

5.2.1.5 Safeguarding of revolving handwheels X X

5.2.1.6 Information about crushing point with parts of building X X

5.2.2.1 Requirements for guards X X

5.2.2.2 Requirements for fence distances X X

5.2.2.3 Requirements for fixed and interlocking guards; criteria for X X

selection of interlocking guards
5.2.2.4 Requirements for power driven movable guards X X

5.2.2.5 Safeguarding against gravity falls X X

5.2.2.6 Requirements for sufficient visibility X X

5.2.3.1 Safeguarding accessible danger zones X X

5.2.3.2 Hold-to-run control with guards open X X X

5.2.3.3 View of danger points under hold-to-run X

5.2.3.4 Mutual interlocking of observed danger zones X X

5.2.3.5 Web threading X X X

5.2.4.1 Explosion prevention and protection, selection of suitable X X

equipment
5.2.4.2 Explosion prevention and protection, flash point above X X
55 ° c
5.2.4.3 Explosion prevention and protection on electrical X X
equipment
5.2.4.4 Explosion prevention and protection on non-electrical X X X
equipment
5.2.4.5 Explosion prevention and protection, limitation of surface X X X
temperature
5.2.4.6 Explosion prevention and protection, limitation of surface X X X
temperature
5.2.4.7 Brakes and clutches, prevention of ignition sources X X

5.2.4.8 Prevention of electrostatic charges X X X

5.2.4.9 Explosion prevention and protection on exhaust hoses and X X X

pipes
5.2.4.10 Explosion prevention and protection on exhaust hoses and X X X
pipes

34
 EN 1010-1 :2004 (E)

Table 2 (continued)
A B C D
Clause Safety requirements and/or measures
Note 1 Note 2 Note 3 A Note 4

5.2.4.11 Explosion prevention and protection on pumps X X

5.2.4.12 Explosion prevention and protection on pumps X X

5.2.5.1 Requirements for electrical equipment with regard to X X X

electrical hazards
5.2.5.2 Supply disconnecting devices X X

5.2.5.3 Emergency stop devices X X

5.2.5.4 Rectifier drives X X

5.2.5.5 Requirements for electrical components and conductors to X X

prevent hazards from mechanical stresses and
environmental influences
5.2.5.6 Requirements for identification of single-core insulated X
conductors
5.2.5.7 Testing of protective bonding, insulation resistance, X X X
voltage, residual voltage and functional tests
5.2.5.8 Requirements for measuring devices X X

5.2.6 Requirements for control systems X X X

5.2.7 Requirements for indicators, displays, control switches, X X X

start-up warning devices
5.2.8 Requirements for two-hand controls X X X X

5.2.9 Requirements for ESPDs X X X X

C
5.2.10 Requirements for pressure-sensitive mats, trip devices X X X X

5.2.11 Requirements for safety position switches X X X

5.2.12 Requirements for work platforms, access stairs, X X X

passageways, raised workplaces
5.2.13 Requirements for stability X X

5.2.14 Protection against high contact temperatures X X

D D
5.2.15 Protection against noise emission X X

5.2.16 Protection against radiation hazards (laser, ultraviolet X X X

radiation
5.2.17 Immunity to electromagnetic disturbances X X

5.3 Common devices

5.3.1 Safeguarding of stationary knives X X

5.3.2 Safeguarding of rotary tools X

5.3.3 Devices for safe transport and storage of dangerous tools X

5.3.4 Feeding units, delivery units (pile lifting and lowering devices)
5.3.4.1 Stability of feeding and delivery units X X X X

5.3.4.2 Requirements for strength of steel chains X X

5.3.4.3 Measures in the event of chain and rope failures X X X

35
EN 1010-1 :2004 (E)

Table 2 (continued)
A B C D
Clause Safety requirements and/or measures
Note 1 Note 2 Note 3 A Note 4

5.3.4.4 Safeguarding of danger areas below pile carrier plates X X X

5.3.4.5 Safeguarding of danger point between pile carrier plate X X X

and floor
5.3.4.6 Safeguarding of danger points between edge of pile X X X
carrier plate and catwalk, platform
5.3.4.7 Safeguarding of danger points during upward movement X X X
of the carrier plate
5.3.4.8 Safeguarding of danger points at separating elements X X

5.3.4.9 Safeguarding of danger points at suction head drives X X

5.3.4.10 Safeguarding of inrunning nips on feedboard and transport X X X

rollers
5.3.4.11 Marking on the units X

5.3.5 Reel unwinding and rewinding devices for webs

5.3.5.1 Safeguarding of inrunning nip between reel and drive belt, X X X
belt guide rollers
5.3.5.2 Safeguarding of inrunning nips between pressure and X X
support rollers and reel
5.3.5.3 Hold-to-run control for inserting chucking cones X X X

5.3.5.4 Safety measures with reel in lifted position X X X

5.3.5.5 Machine start-up with chucking cones inserted X X

5.3.5.6 Safeguarding against ejection of unwound reels X X

5.3.5.7 Safeguarding of danger points between lifting arms and X X X

machine frame
5.3.5.8 Safeguarding of inrunning nip between the end of surface X X X
of reel and lifting arm
5.3.5.9 Protection of crushing point on reel stand, reel splicer and X X X
turrets
5.3.5.10 Semi-automatic reel transport systems X X X

5.3.5.11 Automatic reel loading systems X X X

NOTE 1 Inspection is a visual means of checking whether the characteristics and properties of the equipment and components supplied
are appropriate for the specific application.
NOTE2 The functional test will show whether the parts in question function in such a way as to satisfy the specific requirements.
NOTE 3 Verification by means of measuring instruments is used to check whether the requirements are fulfilled within the specified
limits.
NOTE4 Drawings and calculations are used to check whether the design characteristics of the components used satisfy the specific
requirements.

A The safety distance between the guard and the inrunning nip according to EN 294:1992 is measured at that point where the distance
between the roller surfaces is 10 mm (see Figure 12).
B Force measurement: measuring the maximum value with a measuring instrument with a spring constant of 25 N/mm.
C Functional test by triggering a trip device by means of a test finger with low compressibility. After triggering the trip

36
 EN 1010-1 :2004 (E)

Table 2 (concluded)

device, the test finger should not be drawn in by the hazardous movement nor be crushed. The diameter of the test
finger should be 15 mm.
D Compliance with the safety requirements and measures should be verified as follows: the noise emission values such
as the emission sound pressure level at the workstation and the sound power level are to be determined according to
EN 13023:2003 and declared as dual-number values according to EN ISO 4871:1996.

E
+ E
0
�

Figure 12 - Measuring of safety distance at inrunning nips

7 Information for use

7.1 Minimum requirements for machine markings

7.1.1 Machinery shall be provided with the markings, signs and warnings listed and described in 5.4 of
EN ISO 12100-1:2003:

name and address of manufacturer;

year of manufacture;

designation of series or type, if any;

serial number, if any;

rating information (voltage, frequency, power etc.).

7.1.2 On machinery fitted with laser equipment, the classification of the equipment shall be indicated
together with any warnings according to EN 60825-1:1994, where required.

7.1.3 On machinery where UV radiation of at least category 1 according to EN 12198-1:2000 is expected,

the category number according to EN 12198-1:2000 and the type of radiation shall be indicated.

37
EN 1010-1 :2004 (E)

7.1.4 Extra warnings need to be provided on machines with hot machine parts if the surface temperature is
above 65 °C and if they are not protected against contact by insulation or additional guards.

7.2 Instruction handbook

7.2.1 Instruction handbooks shall be devised in accordance with 5.5 of EN ISO 12100-2:2003.

7.2.2 Each machine shall be accompanied by an instruction handbook containing the minimum according to
7.1 and basic specifications according to 5.5.1 of EN ISO 12100-2:2003

NOTE See Annex D (informative) for examples of instruction handbook layout.

7.2.3 Requirements for noise shall comply with 1.7.4 f) of Annex A of EN ISO 12100-2:2003. The instruction
handbook shall give the declared noise emission values of the machine and the reference to the noise test
code EN 13023:2004 and to the basic noise emission standards on which the determination of these values is
based.

7.2.4 In addition to the above requirements, the instruction handbook shall - where required:

a) describe the protective measures to prevent accidental contact with hot machine parts with a surface
temperature of more than 65 °C;

b) specify those areas on the machine suitable for fitting suction devices in order to avoid the emission of
hazardous gases, vapours and dusts, also specifying the required suction capacity;

c) describe any residual risks which cannot be excluded despite the safety measures provided. It shall also
identify where special training is required and which personal protective measures (for example,
protective gloves, clothing, hearing protectors) are to be taken;

d) give all information and instructions required where use in potentially explosive atmospheres can be
foreseen;

e) the instruction handbook for machines using flammable liquids with a flash point below 55 °c shall contain
the instruction that the flooring in an area extending 1,0 m beyond the zone 1 hazardous area shall be
conductive (according to CLC R 044-001 :1999);

f) give instructions for the proper handling and adjusting of adjustable guards;

g) for machines working with web material, give instructions for safe threading of the web;

h) describe the safe handling of hazardous dusts, substances used and cleaning agents.

7.2.5 The instruction handbook for pile lifting and lowering devices shall contain the following information:

a) permissible operating pressure on pneumatically-driven pile lifting and lowering devices;

b) permissible operating pressure on hydraulically-driven pile lifting and lowering devices as long as the
pressure generator is not a component part of the pile lifting and lowering device;

c) maximum carrying capacity;

d) for format sizes above 2,5 m2 , a sign indicating that travelling on the device is forbidden.

38
 EN 1010-1 :2004 (E)

Annex A
(informative)

Classification of zones for printing presses and finishing machines

(relating to 5.2.4)

EN 1127-1 specifies methods for the identification of hazardous situations that may lead to an explosion. It
details the design and construction measures to achieve the required safety.

It includes the relationship between categories and zones and the applicable equipment in the different zones.

Information on the control and classification of hazardous places for gases and vapours by the use of
ventilation is given in EN 60079-10:2001.

Information on classification of hazardous places for dust is given in EN 50281-1-3:2002.

The following are examples of zoning for the different machines which may vary according to ventilation and
location of machine:

A.1 Rotary web gravure printing machines

Zone 1: the area of the printing unit between the printing unit side frames.

The service walkway between the printing units up to a height of 2,0 m including the area between the side
frames.

The area of the ink fountain, the area of the printing unit ink container, connected to the machine and the area
of the storage tank and the area surrounding it up to a distance of 500 mm on all sides.

The area of the web material and the area surrounding it up to a distance of 250 mm on all sides, based on
the maximum possible printing width, up to the point of entrance into the dryer, however up to a maximum
length of 2,0 m of the freshly printed web-type material.

A.2 Sheet-fed rotary gravure printing machines

Zone 1: the area within the machine frame in which the printing unit, for example with ink fountain, forme
cylinder, intermediate roller and the freshly printed material are located.

The area of the ink fountain, extending at right angles to the axis of the fountain roller within a radius of 1,0 m
and to the sides a radius of 500 mm. The area of the ink container connected to the machine and the area of
the storage tank within a radius of 500 mm on all sides.

A.3 Rotary web flexographic printing machines, wallpaper printing machines

Zone 1: the area of the ink fountain defined by a radius corresponding to the length of the rollers, however, not
more than 500 mm.

The space below the printing units down to floor level in an area which results from the vertical projection of
the danger area of the printing units.

39
EN 1010-1 :2004 (E)

The area of the ink container of the printing units which is connected to the machine and the area of the
storage tank within a 500 mm radius on all sides.

The area of the web material within a 250 mm radius on all sides, based on the maximum printing width, from
the entry of the web material into the first print unit to the entry of the web material into the dryer tunnel,
including exhaust and ventilation ducts or up to 500 mm behind the point where the web material leaves the
last printing unit, respectively.

A.4 Screen printing machines for printing on sheets, web or three-dimensional

objects

Zone 1: the area around the silk screen printing frame or cylinder within a 500 mm radius on all sides and the
vertical projection of this area down to floor level.

The area of the storage containers within a 500 mm radius on all sides.

The area of the freshly printed sheet or web material within a 250 mm radius on all sides, based on the
maximum printing format, including an area beginning at the exit and extending for 2,0 m from there or up to
the entry of the dryer tunnel respectively.

A.5 Rotary and flatbed film printing machines

Zone 1: the area of the printing table within a 500 mm radius on all sides and the vertical projection of this
area down to floor level.

The area of the storage containers within a 500 mm radius on all sides.

The area of the freshly printed web material within a 250 mm radius on all sides, based on the maximum
printing width, extended from the exit of the printing machine up to the entry of the dryer tunnel.

A.6 Machines for printing imitation leather and film

Zone 1: the area of the printing unit between the printing unit side frames.

The area of the ink fountain, the area of the ink container of the printing unit connected to the machine and the
area of the storage tank within a 500 mm radius on all sides.

The area of the web itself within a 250 mm radius on all sides, based on the maximum printing width, up to the
entry of the web-type material into the dryer tunnel, up to a maximum length, however, of 2,0 m of the freshly
printed material.

A.7 Wash-out machines and washing machines in which flammable liquids with
flash points below 55 °C are used

Zone 0: the inside of the machine.

Zone 1: the area of the machine within a 5,0 m radius on all sides and the vertical projection of this area down
to floor level and up to a height of 1,5 m above the machine.

A.8 Roller coating units with closed side frames reaching down to floor level

Zone 1: the area of the roller coater between the side frames of the roller coating unit.

40
 EN 1010-1 :2004 (E)

The service walkway between the roller coating units up to a width of 2,0 m and up to a height of 2,0 m
including the area between the side frames.

The area of the fountain for coating, impregnating and gluing materials, the area of the container which is
connected to the roller coater unit and the area of the storage tank within a 500 mm radius on all sides.

The area of the web-type material within a 250 mm radius on all sides, based on the maximum coating width,
extending up to the entry of the web-type material into the dryer tunnel up to a maximum length, however, of
2,0 m of the freshly coated web-type material.

A.9 Roller coaters with side frames with cut-outs or with side frames that do not
reach to floor level

Zone 1: the area of the fountain for coating, impregnating and gluing materials within a radius equal to the
length of the rollers, on all sides, however, not exceeding 500 mm.

The space underneath the roller coaters down to floor level in an area resulting from the vertical projection of
the danger areas of the roller coater units.

The area of the container connected to the machine and the area of the storage tank within a 500 mm radius
on all sides.

The area of the web-type material itself within a 250 mm radius on all sides, based on the maximum coating
width, from the entry of the web material into the first roller coating unit up to the entry of the web material into
the dryer tunnel or 500 mm after leaving the last roller coating unit.

41
EN 1010-1 :2004 (E)

Annex B
(normative)

Audible prestart warning devices

Audible prestart warning devices shall satisfy the following requirements:

B.1 Application

The prestart warning device shall deliver a clearly audible signal before the start-up of the machine.

B.2 Control arrangement

Control circuits shall be designed such that, before starting the machine, an audible signal of a duration of 1 s
to 3 s is given (signal time). From the moment of actuation of the signal, at least 3 s shall elapse (waiting time)
before the machine can be started by repeated actuation of the same or a different control element. After
elapse of the waiting time or after termination of a preceding operation in the inch mode (no continuous run
mode), starting of the machine is permissible within O s to 12 s without a preceding signal (release time).
Release time starts with the termination of the waiting time or if the operation of the machine in the inch mode
is interrupted and should not exceed 6 s.

After elapse of the release time or actuation of the stop control element or the emergency stop control device,
it shall only be possible to operate the machine after the audible prestart warning signal has been given.

A non-central warning system (signalling device for each working place) shall be preferred.

B.3 Timing chart

See Figure B.1.

Starting the machine after standstill or continuous run

42
 EN 1010-1 :2004 (E)

3 4
2
5

9
8 7

t/s
3 9 15

Starting the machine after hold-to-run control mode

6 2

9
7

0 6 12 t/s
Key

1 Signal time 6 Machine running in hold-to-run control mode

2 Release time 7 Machine can be started (release time)
3 Minimum 8 Machine cannot be started
4 Maximum 9 Machine can neither be started nor operate in hold-to-run
5 Waiting time control without previous signalling

Figure B.1 -Timing: starting the machine

43
EN 1010-1 :2004 (E)

Annex C
(informative)

Risk analysis relating to the pitch angle of access stairs

Access stairs for raised workplaces should preferably be stairs with a maximum pitch angle of 45 °. If, due to
lack of space, no stairs can be installed, the following exceptions are permissible:

with an evaluation value of E � 6:

fixed stepladders secured against slipping away with a maximum pitch angle of 46 ° to 60 ° and with
handrails on both sides;

with an evaluation value of E � 3:

- fixed stepladders secured against slipping away with a maximum pitch angle of 46 ° to 74 °;

with an evaluation value of E � 2 and E2 = 0:

- fixed ladders secured against slipping away with a pitch angle of 75 ° to 90 °.

The evaluation figure E is the sum of evaluation figure E1 according to Table C.1, E2 according to Table C.2
and the additional factors A1 and A2 according to Table C.3: E = E1 + E2 + A1 + A2.

Table C.1 - Evaluation figure E1 for the frequency of use

Frequency of use Evaluation figure E1

Less than once per week 1

Not more than once per week 2

Not more than once per day 3

More than once per day 4

Table C.2 - Evaluation figure E2 for carrying objects

Carrying objects Evaluation figure E2•

No objects to be carried in the hands 0

Light objects(� 5 kg) 1

Objects of moderate weight(� 10 kg) 2

Heavy objects(> 10 kg) 3

a Where the height covered is less than 1,6 m, the value may be deemed to
be E2 = 0.

44
 EN 1010-1 :2004 (E)

Table C.3 - Additional factors A1 and A2

Additions Additional factors A1, A2

Addition if bulky objects have to be
A1 = 1
carried
Addition if the height to be covered
A2 = 1
is more than 3 m

45
EN 1010-1 :2004 (E)

Annex D
(informative)

Example of layout of an instruction handbook

D.1 Information relating to the machine

name and address of the manufacturer or supplier;

designation of series or type;

performance data, data on noise emission;

description of application of machinery (intended use);

specification of workplaces on the machine;

etc.

D.2 Information relating to safety

diagrams or cross sections of machine showing safety devices and measures;

risks caused by neglecting safety measures;

safe working practices;

safety information for the operator;

unintended use;

etc.

D.3 Information relating to transport, handling and storage of the machine

safety measures;

dimensions and weight of the machine;

etc.

D.4 Installation, commissioning, removal

assembly and mounting of machine;

decommissioning;

fixing and anchoring conditions;

46
 EN 1010-1 :2004 (E)

space needed for operation, preventive maintenance and maintenance;

permissible environmental conditions;

instructions for connecting the machine to power supply;

etc.

D.5 Information relating to the use of the machine

description of manual controls;

instructions for setting-up and adjustment, handling of guards;

information about residual risks;

information about prohibited applications and errors of operation;

instructions for fault detection and repair;

instructions relating to the use of personal protective equipment.

D.6 Information relating to maintenance of the machine

nature and frequency of inspections;

preventive measures (parts with defined life, lubrication);

spare parts;

trouble-shooting;

etc.

47
EN 1010-1 :2004 (E)

AnnexZA
(informative)
Relationship between this European Standard and the Essential Requirements of
EU Directive 98/37/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide one means of conforming to Essential Requirements of
the New Approach Directive Machinery 98/37/EC, amended by 98/79/EC.

Once this standard is cited in the Official Journal of the European Communities under that Directive and has
been implemented as a national standard in at least one Member State, compliance with the normative
clauses of this standard confers, within the limits of the scope of this standard, a presumption of conformity
with the relevant Essential Requirements of that Directive and associated EFTA regulations.

WARNING: Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard.

48
 EN 1010-1 :2004 (E)

AnnexZB
(informative)

Relationship between this European Standard and the Essential Requirements of

EU Directive 94/9/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide a means of conforming to Essential Requirements of the
New Approach Directive ATEX 94/9/EC.

Once this standard is cited in the Official Journal of the European Communities under that Directive and has
been implemented as a national standard in at least one Member State, compliance with the clauses of this
standard given in table ZB confers, within the limits of the scope of this standard, a presumption of conformity
with the corresponding Essential Requirements of that Directive and associated EFTA regulations.

WARNING: Other requirements and other EU Directives may be applicable to the product(s) falling within the
scope of this standard.

Table ZB - Correspondence between this European Standard and Directive 94/9/EC

Clause(s)/sub-clause(s) of this EN Essential Requirements (ERs) of Directive 94/9/EC

5.2.4 1.0 General requirements
5.2.4, Annex A (informative) 1.0.1 Principles of integrated explosion safety

5.2.4, Annex A (informative) 1.0.2 Design considerations

5.2.4.9, 7.2.4 1.0.6 Instructions
5.2.4.1 1.1 Selection of materials
5.2.4 1.1.1 Explosion avoidance
5.2.4.9, 5.2.4.10 1.1.3 Effects on predictable changes in materials characteristics
5.2.4 1.2 Design and construction
5.2.4.6 1.2.4 Dust deposits
5.2.5.1 1.2.7 Protection against other hazards
a) Injury
5.2.4.4, 5.2.4.5, 5.2.4.6 b) Surface temperatures
5.2.4.4, 5.2.4.5, 5.2.4.6, 5.2.4.7, 5.2.4.8, c) Elimination of non-electrical dangers
5.2.4.11
5.2.4.3.1 1.2.8 Overloading of equipment
5.2.4.3.1 1.2.9 Flameproof enclosure systems
5.2.4 1.3 Potential ignition sources
5.2.4 1.3.1 Hazards arising from different ignition sources
5.2.4.8, 5.2.4.9, 5.2.4.10 1.3.2 Hazards arising from static electricity
1.4 Hazards arising from external effects
5.2.6 1.4.1 Safe functioning

49
EN 1010-1 :2004 (E)

Table ZB (continued)
Clause(s)/sub-clause(s) of this EN Essential Requirements (ERs) of Directive 94/9/EC
1.5 Requirements in respect of safety related devices

5.2.6.1.1 1.5.1 Independent function of safety devices of measurement and

control. Fail safe principles for electric circuits. Safety related switches
independent of software and command
5.2.6.1.1 1.5.2 Safety device failure
5.2.5.3 1.5.3 Emergency stop controls
5.2.6.1.1 1.5.8 Risks arising from software
5.2.4 2.1 Requirements applicable to equipment in category 1 of equipment
group II
5.2.4.3, 5.2.4.4.1, 5.2.4.4.2 2.1.1 Explosive atmospheres causes by gases, vapours or hazes
5.2.4.7, 5.2.4.9, 5.2.4.10 2.1.1.1 Design and protection of equipment to prevent sources of
ignition becoming active
5.2.4.4.1, 5.2.4.5 2.1.1.2 Stated maximum surface temperatures not to be exceeded
5.2.4.5, 5.2.4.9 2.1.2 Explosive atmospheres caused by air/dust mixtures
5.2.4.5 2.1.2.3 Surface temperatures to be kept below ignition temperatures of
suspended dust
5.2.4 2.2 Requirements applicable to equipment in category 2 of equipment
group II
5.2.4.3, 5.2.4.4.1, 5.2.4.4.3, 5.2.4.5, 2.2.1 Explosive atmospheres caused by gases, vapours or mists
5.2.4.10
5.2.4.7, 5.2.4.11 2.2.1.1 Design and construction of equipment to prevent ignition
sources arising
5.2.4.5, 5.2.4.9 2.2.2 Explosive atmospheres caused by air/dust mixtures
5.2.4.5, 5.2.4.6 2.2.2.1 Design and construction of equipment to prevent ignition of
air/dust mixtures
2.2.2.2
2.1.2.3 applies
see 2.2.- Requirements 2.3 Requirements applicable to equipment in category 3 of equipment
group II
see 2.2.- Requirements 2.3.1 Explosive atmospheres caused by gases, vapours or mists
see 2.2.- Requirements 2.3.1.1 Design and construction of equipment to prevent foreseeable
ignition during normal operation
see 2.2.- Requirements 2.3.1.2 Surface temperatures not to exceed stated figures
see 2.2.- Requirements 2.3.2 Explosive atmospheres caused by air/dust mixtures
see 2.2.- Requirements 2.3.2.1 Design and construction of equipment to prevent ignition of
air/dust mixtures during normal operation
see 2.2.- Requirements 2.3.2.2
2.1.2.3 applies
see 2.2.- Requirements 2.3.2.3 Prevention of dust particles mixing with air in equipment to
cause ignition

50
 EN 1010-1 :2004 (E)

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51
EN 1010-1 :2004 (E)

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52
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BSEN
1010-1:2004
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