The guide to safe use of power-operated paper cutting ... use of guillotines.… · The guide to safe use of power-operated paper-cutting guillotines Page 4 of 74 Health and Safety

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Health and Safety Executive

The guide to safe use of power-operated paper-cutting guillotines

This is a free-to-download, web-friendly version of The guide to safe use of power-operated paper-cuting guillotines (Second edition edition, published 1999). This version has been adapted for online use from HSE’s current printed version.

Youcanbuythebookatwww.hsebooks.co.ukandmostgoodbookshops.

ISBN 978 0 7176 1707 4 Price £7.50

ThispublicationisproducedbythePrintingIndustryAdvisoryCommitteeandisaimedathelpingallthosewhoworkintheprintingindustry,includingemployers,employeesandsuppliers,toidentifythemaincausesofaccidentsandhazardsassociatedwithpower-operatedpapercuttingguillotinesandhowtoeliminatethehazardsandcontroltherisks.

Theguidancealsoexplainsthelevelofknowledgeandexperiencetheengineersneedandalsothetechnicalstandardsrelevanttobothexistingmachinesandsecond-handones.Italsogivesadvicetomanufacturersandsuppliersofnewmachines.

HSE Books

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© Crown copyright 1999

Firstpublished1988

ISBN9780717617074

Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans(electronic,mechanical,photocopying,recordingorotherwise)withoutthepriorwrittenpermissionofthecopyrightowner.

Applicationsforreproductionshouldbemadeinwritingto:TheOfficeofPublicSectorInformation,InformationPolicyTeam,Kew,Richmond,SurreyTW94DUore-mail:[email protected]

ThisguidanceisissuedbytheHealthandSafetyExecutive.Followingtheguidanceisnotcompulsoryandyouarefreetotakeotheraction.Butifyoudofollowtheguidanceyouwillnormallybedoingenoughtocomplywiththelaw.Healthandsafetyinspectorsseektosecurecompliancewiththelawandmayrefertothisguidanceasillustratinggoodpractice.

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Members of the Printing Industry Advisory Committee (PIAC)

Nominated by the CBIMr D E Barker NewspaperSocietyMr G Cooper NewspaperSocietyMr J Fuller BritishPrintingIndustriesFederationMr G McNab ScottishPrintEmployersFederationMr B Purkis NewspaperPublishersAssociationMr W Stothard BritishPrintingIndustriesFederationMrs S Whittaker NewspaperPublishersAssociationMr I Wilcock BritishPrintingIndustriesFederation

Nominated by the TUCMr D Barker GraphicalPaperandMediaUnionMr T Gopsil NationalUnionofJournalistsMr M Griffiths GraphicalPaperandMediaUnionMr R A Hudspith GraphicalPaperandMediaUnionMr A Metcalf GraphicalPaperandMediaUnionMr D Spencer GraphicalPaperandMediaUnionMr P Taylor GraphicalPaperandMediaUnion

HSEMr A D Porter Chairman,HealthandSafetyExecutiveMr M D Wilcock Secretary,HealthandSafetyExecutive

Members of PIAC Guillotines Working Group

Mr N Bayley PiconLtdMr P Borsos EBGallon/PhaselecLtdMr M Brown OscarFreidheimLtdMr B Clarke HealthandSafetyExecutiveMr J Fairbrass Secretary,HealthandSafetyExecutiveMr J Fuller JetStationaryCompanyLtdMr R A Hudspith GraphicalPaperandMediaUnionMr G T Law SafetyAssessmentFederation(SAFed)/ZurichEngineeringMr R Lee HealthandSafetyLaboratoriesMr S B Longbottom HealthandSafetyExecutiveMr B Preston KalamazooGroupMr S Rickman HeidelbergGraphicEquipmentLtdMr M Ward PershkePriceServiceOrganisationLtdMr I Wilcock BritishPrintingIndustriesFederationMr M D Wilcock Chairman,HealthandSafetyExecutive


Theguidetosafeuseofpower-operatedpaper-cuttingguillotines Page4of74


ContentsPreface 7What is PIAC? 7Why does PIAC exist? 7

Introduction 8How to use this book 8

Section 1 - Machinery description: hazards and safeguards 10Hazards 10Knife 10Clamp 11Machinetable 11Backgauge 12Drivemachinery 12Operation 12Controls 12Two-handcontroldevices 12Backgaugehandwheel 13Types of safeguard 13Frontguards 13Activeopto-electronicprotectivedevices(AOPD)(photoelectricguards) 13Interlockingguards 17Fallingfingerguards 17Automaticsweepawayguards 17Body-pushguards 21Rearguards 21Safeguarding of ancillary handling equipment 22Pilelift/hoist 23Scissorlifts 23Joggersandauto-stackingtables 23De-stackers,re-stackersandturningunits 23

Section 2 - User requirements 24Introduction to section 24Maintenance and inspection records - logs 25Buying a guillotine 25Upgrading guillotines 26Locating and siting machines 26Commissioning inspections and tests 27Instruction manuals 27Training and safe working practices 28Startupprocedure 28Gauging 28Knifecleaning 28Knifechanging 29Routine maintenance, inspection and testing 30In-house daily/shift/after-knife-change maintenance checks 31Allmachineswithtwo-handcontrol 31ESPEs 32Interlockingguards 32Monthly/after-knife-change maintenance checks 32Sweepawayguards 32Interlockingguards 32Six-monthly inspection and check 33Engineer’s competency guide 33



When not to wait six months 33Ancillary handling equipment 34Modificationsandservicing 34Safeworkingpractice 34

Section 3 - Engineer’s responsibilities and competence 35Legal requirements 35Competence 35Accreditation of inspecting engineers 35Assessment of competence 36Inspection and testing of guillotines 36Allmachines 36ESPEs 37Interlockingguards 37Sweepawayguards 37

Section 4 - Technical standards for existing machinery and the supply of second-hand machinery 39Introduction 39Guillotine instruction manual and log 40Technical standards 40Electricalsafetyandcontrols 40Gaugingpedal 40Two-handcontroldevices 40Programmableelectronicsystems 41Front guards 41ESPE 41Performancestandardsforpre-1985guillotines 41Performancestandardsforpost-1985guillotines 42Machineprimarycontrolelements 44Stoppingperformancemonitoring 45Overrundetection 45PositioningoftheAOPDrelativetothecuttingstick 46Interlocking guards 46Automatic sweepaway guards 46Brake and clutch design 46Hydraulic design 47Control valves 47Gravity fall 48

Section 5 - Additional information for suppliers of new machines 49Suppliers’ responsibilities 49Manufacturers’ responsibilities 50Conformity assessment 50New machines - harmonised standards 50

Appendices1 Contents of instruction manual 522 Sample logs 533 Guillotine safety checklists 584 Glossary 625 Extract from BPIF booklet Guarding of guillotines and trimmers 646 Extract from the HSE booklet Electro-sensitive safety devices for friction- clutch press brakes 67 7 Method for determining the position of the AOPD relative to the cutting stick 69



References 71

Further information 74



PrefaceWhat is PIAC?

ThePrintingIndustryAdvisoryCommittee(PIAC)wasformedinJuly1979toadvisetheHealthandSafetyCommission(HSC)onmattersconcerningtheprintingindustry.ThemembersofPIACarenominatedbytheCBIandtheTUCandappointedbyHSCtoworktogetherwithHSEtoadvisetheindustryonhealthandsafety.

Why does PIAC exist?

Everyyearpeopleareseriouslyinjuredworkingintheprintingindustry.Manyotherssufferillhealthwhichpreventsthemfromdoingtheirnormalwork.Almostallthesecasescouldbeprevented.

PIACisdeterminedtotakeactiontoimprovehealthandsafetyperformanceintheprintingindustry.AspartofthisprocessPIAChasdevelopedthisguidancebooktohelpthoseresponsibleforhealthandsafetyintheindustryunderstandtheirresponsibilitiesandtakethenecessaryaction.

Thisbookisinaseriesofnewhealthandsafetyguidanceforprinting.Theserieswillbedevelopedoverthenextfewyears.Theaimoftheseriesistohelpallthoseinprinting,includingemployers,employeesandsuppliers,toidentifythemaincausesofaccidentsandillhealthandtoexplainhowtoeliminatethehazardsandcontroltherisks.Everybookintheserieswillbeidentifiedbythelogoonthefrontcover.



Introduction1 Power-operatedpaper-cuttingguillotinesarewidelyusedthroughoutthepapermanufacturing,conversion,printingandprint-finishingindustries.Seriousaccidentshavebeencausedbyknivesandclampsincludingamputation,bruisingandcrushing.Theseinjuriescontinuetooccurinsituationswheretheycouldeasilyhavebeenprevented.

2 Thisbookcontainspracticaladviceonthesafeguardingoftheseguillotines.Itwillhelpifyouuseguillotinesorhavearoleinthedesign,manufacture,supply,testing,examinationandinstallationofguillotinesandtheirsafeguards.Itgivesguidanceonlegaldutiesandprovidestechnicaladviceondifferentsafeguardingmethods,relevantstandards,maintenance,testing,andtraining.

How to use this book

3 Theadviceinthisbookisdividedintofivesections:

n Section1-givesinformationonmachineandsafeguardtypes,hazardsandaccidents;

n Section2-givesadvicefortheuser;n Section3-givesguidanceoncompetencies(ieacombinationoftechnical

knowledge,awarenessandexperience)thatshouldbeacquiredbyguillotineengineerssothattheycaneffectivelyfulfilltheirresponsibilities;

n Section4-givesinformationontechnicalstandardsforexistingmachinesandthosesuppliedsecondhand;

n Section5-givesinformationandadviceforthemanufacturersandsuppliersofnewmachines.

4 UsersshouldseeSection1foradviceon:

n thehazardouspartsofyourguillotineandassociatedhandlingequipment;n typesofsafeguardscommonlyused;n thechecksyoushouldmaketoensurethattheequipmentisadequately

safeguarded.

UsersshouldreadSection2foradviceon:

n theirlegalresponsibilities;n buyingaguillotine-whattolookforinsupplier’sliteraturetomakesurethe

intendedpurchaseissafetouseandcomplieswithlegalrequirements;n trainingemployees;n safesystemsofworkforknifechangingandcleaning;n maintainingtheguillotineandcarryingoutthenecessaryregularsafetychecks

onguardperformance;n selectingacompetentengineertocarryoutsix-monthlyinspectionsand

testing;n maintaininganup-to-datelogforeachguillotine.

5 Guillotine engineers/engineer surveyorswhocarryoutinspectionsandtesting,servicingorrefurbishmentofguillotines,shouldreadSection3foradviceon:

n theirlegalresponsibilities;n theirnecessarylevelofcompetence;n thecontentofthesix-monthlyinspectionandtestatpaper-cuttingguillotines.



TheyshouldalsoreadSection4foradviceon:

n thetechnicalperformancestandardstowhichguillotinesshould complywheninspectedandtested.

6 Used guillotine supplierswhorunabusinesswhichrefurbishesmachinesforresaleorsimplysellonusedguillotinesintheUK,shouldreadSection4foradviceon:

n theirlegalresponsibilities;n thetechnicalperformancestandardsforsecond-handmachinesandthe

upgradingworknecessary;n thetechnicalstandardsneededtoworktowhenupgradingguillotines;n providinganup-to-datemaintenancelog.

7 Manufacturers and suppliersofnewguillotineswillfindadviceinSection4on:

n performancestandardsforexistingguillotines.

TheywillalsofindadviceinSection5on:

n theirlegalresponsibilities;n therelevantcurrentEuropeanStandards.

8 ThebookdoesnotrepeatguidancealreadypublishedseparatelybyHSE.RelevantpublicationsarelistedintheReferencesection.Youcanobtainup-to-dateinformationonHSEpublicationsfromHSE’sInfoLine.

9 ThisbookreplacestheguidancepreviouslycontainedinthePIACbookletSafety at power operated paper cutting guillotinespublishedin1988,ISBN0118854607andreprintedin1992.HSEwillcontinue,periodically,toreviewandrevisethisguidance.



Section 1 Machinery description - hazards and safeguards10Guillotinesconsistofaknife,clamp,machinetableandbackgauge.Theknifeisdriventhroughthepaperstackontoasoftstrip,thecuttingstick,whichissetintothebedofthemachinetable.Powercanbeappliedtotheclamp,backgaugeandknifeinanumberofways.

Figure 1 Atypicalguillotinewithsafeguardingbymeansofanactiveopto-electronicprotective

device(AOPD)

Hazards

Knife11Knivesarenormallydrivenatareducingangleby:

n directhydraulicpower-theknifeisdrivendownbytheactionofahydrauliccylinder(s)andreturnshydraulicallyorbysprings.Controlisbyahydraulicvalve(s);

n directhydromechanicalpower-acrankisdrivenbyahydraulicmotorcontrolledbyvalvessupplyingoiltothehydraulicmotor;

n clutch-operatedmechanicalpower-theknifeispoweredfromacontinuouslyrunningflywheelviaacrankshaftfittedwithafrictionclutchandbrake.Knifecontrolisbyengagement/disengagementoftheclutchandbrakeinturn;

n directelectromechanicalpower-theknifeeccentricarmisdrivendirectlybyanelectricmotorandrotatesoncebeforeactuatingaswitchtocutoffpowerandapplyingthebrake.Knifecontrolisnormallyachievedbybrakingofthemotor.

12Contactwiththeknifeedgewhenitismovingandwhenitisstationarycanresultinseriousinjury,includingamputation.Thiscanbecaused,forexample,



byinadequateguardingorfailureoftheknifetostopattheendofastroke.Accidentalcontactwiththeknifeedgeisgenerallypreventedbythepositionoftheclampwhichmovesinadvanceoftheknife,althoughpartoftheknifeedgecanbeexposedateithersideofthepaperstackifthestrokeisinterrupted.However,injurycanbecausedbyknivesexposedduringcleaning,changingandhandling.

An operator suffered amputation of part of his thumb when the paper-cutting guillotine he was using overran. He was retrieving a cut stack and was injured when the blade failed to halt on the upstroke and descended part way. This was caused by a failure to maintain the brake, and a fault which occurred on the overrun detection switch. The solenoid-operated safety bolt for the knife carrier was also defective. The brake defect, overrun switch fault, and safety bolt were all rectified when the machine was subsequently serviced.

Clamp13 Theclampholdstheworkintwostages:

(a) gauging-alignmentoftheintendedcuttinglinewiththefrontedgeofthe clamp,normallyachievedusingagaugingpedalwithdirectmechanical linkageoralowpressurebalancedhydraulicsystem; (b) cutting-thisrequiresgreaterclampingforceswhichareachievedby variablehydraulicpressure,directdriveusingatorquemotor,orbymanual operationoftheclamp.

14Most injuries at paper-cutting guillotines are caused by clamp descent during gauging.Atthisstagemovementisoftennotsafeguardedandthemanualnatureoftheworkmayrequiretheoperatortohandlework,suchasbusinesscards,neartheclamp.Topreventcrushinjuries,thegaugingforceshouldbelimitedandmaintainedatvaluesgiveninparagraph108.Descentoftheclampunderfullpowershouldbeguarded.

A paper-cutting guillotine operator suffered a crushed finger when it was trapped between the clamp and table. The operator was gauging and placed a block of paper on the table. The backgauge was too far back, he leaned forward to pull work out, intending to adjust the backgauge, and accidentally depressed the foot pedal, operating the clamp. The gauging force was excessive and as a result the operator was off work for four weeks.

15Lipson,orholesin,theclampfaceshouldbeavoidedtopreventanysheartrapsbetweentheascendingclampandknifeedgeonthereturnstroke.Holesshouldbecoveredbyplasticplugs,tapeorsimilarmeans.

While cleaning the clamp face of a guillotine, an operator’s foot slipped from the clamp pedal. The clamp returned upwards but his fingers were caught in the screw-adjustment holes. This caused amputation of part of the left index finger. Caps were subsequently provided over the screw-adjustment holes.

Machine table16Mostmachineshaveasolid,flattablealthoughincreasinglyairtablesareprovidedwhichreduceoperatorfatigueandcanhelptopreventmanual-handlinginjuriesbyreducingfrictionaldrag.Machineswithopeningtables,forexampleforwasteremoval,maypresentacrushingandentrapmenthazardasthetablecloses.Theseshouldbeeffectivelysafeguardedby,forexample,electrosensitiveprotectiveequipment(ESPE).



17Handlingsystemssuchaspilehoistsandjoggingtablesmayalsocauseriskofinjuryifnotsafeguardedtopreventcontactwheninmotion,seeparagraphs42-47forfurtherdetails.

Backgauge18Thebackgaugecanbemovedeithermanuallyorunderpoweredoperationtothecorrectpositionforpapercutting.Manymachinesmaybeprogrammedsothatthebackgaugeautomaticallymovestothecorrectpositionforasequenceofcuts.Theinclusionofa‘pushout’orprogrammableejectionsettingavoidstheneedforoperatorstoreachbeneaththecuttingareaandhelpstoreducefatigueandupper-limbdisorders.

19Trappinghazardscanarisebetweenthetravellingbackgaugeandthefixedrearsidelaysorretractablesidelaysusedforrearloading.Theseshouldbesafeguarded.Thebackgaugemaymoveassoonaspowertothemachineisswitchedon.Thisshouldalsobesafeguardedby,forexample,interlockingorpositivecommandcontrolsystems.Atrappinghazardbetweenthebackgaugeandrearoftheclampcanoccurwhentheclampplateisremoved.Alwaysensurethatthebackgaugedriveisdisengagedbeforeremovingtheclampplate.

Drive machinery20Beawareoftheriskofinjurywherethereisexposeddriveandtransmissionmachinery,suchasvee-beltsandpulleys,chainandsprocketdrivesandintermeshinggearwheels,whichmaybeaccessedduringmaintenanceandrepairwork.

Operation21Guillotinescanoperateinoneofthreeways:

n singlestrokeormanualoperationwherethecontrolshavetobedepressedtoinitiateeachcutcycle;

n semi-automaticoperationwherethebackgaugeautomaticallymovestothenextprogrammedpositionbutthecontrolshavetobeoperatedbeforetheclampandknifemovementcanbeinitiated;

n fullyautomaticoperationwhereprogrammedrepeatstrokesofthebackgauge,clampandknifeareinitiatedbyaninitialsingleoperationofthecutcommandcontrols.

Controls22Controlsareprovidedonguillotineswhich:

n selecttheoperatingmode;n setthebackgaugeposition;n operatetheclampforgauging;n ‘strikeon’theclampandknife;n selectknifechange.

23Allcontrolsshouldbewithineasyreachoftheoperatorandtheirfunctionshouldbeclearlylabelledbyshapeandcolour,orbyreadilyunderstoodsymbols.

24Guillotine-mountedcontroldevicesshouldbeinaccordancewithEuropeanStandardEN60204:Part11998.Foot-operatedcontrolsareonlyappropriateforgauging.

Two-hand control devices25Atallmachinesitshouldonlybepossibletoinitiateacutcycle,ie‘strikeon’,byoperatingatwo-handcontrolwhichcomplieswithEN574:1997andEN60204:Part11998.Thismeansthat:



n twoseparatehandcontrolsshouldbepositionedandrecessedsothatitisnotpossibletospanbothwithonehandonlyortooperatethemwithonehandandanotherpartofthebody;

n bothcontrolsshouldbeoperatedwithin0.5secondsofeachotherbeforethemachinewilloperate(exceptionally,onoldermachines,thismaybeupto1second).Wherethistimelimitisexceededbothcontroldevicesshouldhavetobereleasedbeforeoperationcanbere-initiated;

n ifonecontrolisreleased,bothcontrolsshouldhavetobereleasedandre-operatedbeforethemachinewilloperate;

n ifoneorbothcontrolsarereleasedbeforecompletionofthestroke,thebladeshouldeitherstopwithoutdelayorreturntotopdeadcentre.

26Two-handcontroldevicesalonearenotanacceptablesafeguardandmustbesupplementedbyfrontandrearguardingasdescribedinparagraphs29-41.

27Inexceptionalcircumstancesguillotinesmaybeusedwithasinglecontroldeviceifhigh-integrityallenclosinginterlockingguardsareprovidedwhicharearrangedwithcross-monitoreddual-channelcontrolusingtwoguard-positionswitchesoperatinginoppositemodes.Acompetentguillotineengineershouldbeabletoadvisewhetherthisisthecase.

Backgauge handwheel28Ifthebackgaugecanbemovedmanuallybyahandwheelandautomaticallyunderpower,makesurethatthehandwheeleitherdoesnotrotateduringpowerdriveorisofthesolidtypewithoutspokesorprojections.Agapof25mmshouldbemaintainedbetweentherearofthehandwheelandthemachinetable.

Types of safeguard

Front guard29Because in the majority of circumstances operators have to place their hands beneath the knife when positioning the work, a combination of a high-integrity method of safeguarding and a two-hand control device is needed. The various options are described in paragraphs 30-47.

Active opto-electronic protective devices (AOPD) (photoelectric guards)30Thisequipmentcommonlyprojectsacurtainofvisibleorinfraredlightacrossthefrontoftheguillotinewhichifinterrupted,forexamplebytheoperator’sarm,willsendasignalwhichstopsorreversestheknifeandclampdescentduringthecuttingcycle.

31 TheAOPDmachinecontrolcomponentssuchassolenoidvalvesandcontactors,clutchandbrakeconstitutetheoverallsafeguardingsystem(electrosensitiveprotectiondevice(ESPD)),seeFigure1,page10.OperatorsrelynotonlyonthecorrectfunctioningoftheESPD,butalsoontheperformanceofthebrake,clutchandothercontrolcomponentssoitisessentialthattheyareallproperlymaintained.

32Standardsrequiredatexistingmachines:

n theguillotineifsuppliednewbetweenapproximately1974and1987shouldhaveanESPDdesignedandoperatingwithfull-functionmonitoring;seeAppendices5and6.Thisistheloweststandardacceptablefortheseoldermachinesandsomemodificationssuchastheremovalofthefullyautomaticfacilitymaybenecessary.Acompetentguillotineengineerormanufacturer/suppliershouldbeabletoadvise;



n iffirstsuppliedafter1987,thesafeguardingshouldmeetthestandardsnowdetailedinIEC/EN61496:Part21997andthepublicationHSG180,1(butseeparagraph5ofHSG180forguillotinessuppliedbetween1January1995andMarch1999withrespecttotheneedforriskassessmentforupgradingwork);

n iffirstsuppliedafter1January1995,theguillotineshouldbeCEmarkedandmeetthestandardsnowdetailedinIEC/EN61496:Part21997;EN1010:1999andguidancewithinthepublicationHSG180,1(butseeparagraph5ofHSG180forguillotinessuppliedbetween1January1995andMarch1999withrespecttotheneedforriskassessmentforupgradingwork).

33Toprovidesufficientprotectiontotheoperator,thepositionoftheAOPDiscritical.TheminimumcurtainseparationdistancedependsonthestoppingperformanceoftheknifeandthedetectioncapabilityoftheAOPD.MachinesfirstsuppliedbeforethedateofthispublicationshouldmeetthestandarddetailedinAppendix7.Itshouldnotbepossibletoreachoverorunderthecurtaintothecuttingstickfromanydirection,includingthesideofthemachinetable.ThepositionoftheAOPDforseveraltypicalformatsisshowninFigures2-6.NotethatmorerecentguillotinesmanufacturedinaccordancewithprEN1010mayhavereduceddistancesfortheAOPDposition:

n wheretheAOPDextendsdowntothemachinetableandthereisfixedsideguarding,theoutermost(lowest)frontbeamshouldbeatleast460mmfromthecuttingstickandlessthan38mmfromthetable(seeFigure2);

Figure 2 Photoelectroniccurtain(AOPD)extendingtomachinetableincombinationwithfixedguards

n whereclearanceisnotrequiredundertheAOPDhousings,thehousingsshould

eitherextendtothemachinetableorhavefixedguardsfittedbeneaththem.Inthisformat,theoutermostbeamshouldbepositionedatthetableedgeataverticaldistanceofnomorethan175mmandatahorizontaldistanceofatleast635mmfromthecuttingstick(seeFigure3);

Less than38 mm

At least 460 mm

Fixed guards



Figure 3 UseoffixedguardswhereclearanceisnotrequiredbeneaththeAOPDhousings

n whereclearanceisrequiredbeneaththecurtainhousing,theoutermostbeamshouldnormallybelocatedbetween610mmand635mmfromthecuttingstickandnomorethan185mmabovethetable.Thehousingsshouldeitherbepositionedatleast610mmfromthepointwherethecuttingstickmeetsthesidelays(Figure4),orextensionstothemachinetableshouldbeprovidedtoincreasethedistancebetweenthetableedgeandknifeto850mm(seeFigure5);

n exceptionally,somenewerverylargeformatmachineswithauseablepileheightgreaterthan185mmmayhavetheoutermostbeamlocatedbetween610mmand700mmfromthecuttingstickandnomorethan205mmabovethetable.Anadditionalbeammustbeprovidedbetween400mmand550mmfromthecuttingstickandbetween0mmand205mmabovethetable(seeFigure6);

An operator had both hands amputated above the wrist when using a guillotine to cut slips of card for a wallpaper sample book. The guillotine was being used in fully automatic mode. It was found to be possible to reach the cut area beneath the lowest part of the AOPD without interrupting it.

n similarly,guillotineswithanautomaticcuttingsequencemustalsohavebeenprovidedwithanadditionalbeambetween400mmand550mmfromthecuttingstickandbetween0mmand205mmfromthemachinetable(seeFigure6).

An operator was using a guillotine on the automatic setting for cutting labels. The machine had been modified for import into this country and a spacer had been added to bring the AOPD housing further from the blade. This enabled a tall person to approach the blade without breaking the curtain. The operator amputated the tip of the middle left-hand finger when adjusting the position of a timber weight on the paper stack without breaking the curtain.

Fixed guard

Fixed guard

Outmost beam and edge of machine tableat least 635 mm from cutting stick

This distance maybe less than 635 mm

Not more than 175 mm



Figure 4 PositionofAOPDhousingsandoutermostbeamwhereclearanceisrequiredbeneaththe

housings

Figure 5 UseofextensionstothemachinetablewhereclearanceisrequiredbeneathAOPDhousings

Figure 6Positionofadditionalbeamforlargeformatmachines

At least 610 mmNot less than 610 mm

Housing to be aslow as practicable

Not more than185 mm abovemachine table

At least 800 mm

At least850 mm

At least635 mm

Not morethan 150 mmExtension

table

Area admissiblefor additional

ESPD

Front of tableCuttingplane

400 mm

550 mm

205

mm



Interlocking guards34 Interlockingguardspreventaccesstotheclampandbladeareawhenclosed.Correctlyfunctioninginterlockingguardsshouldoperatesothat:

n whenintheclosedposition,itisnotpossibletoreachunder,overoraroundthesidesoftheguard;

n strikingonisonlypossiblebyoperationofsynchronoustwo-handcontrolswiththeguardclosed(seeparagraphs25-27);

n whenopened,theinterlockpreventspoweredoperationoftheknifeandclamp.Thisisnormallybymeansoftwoseparatecam-operatedsafetypositionswitchessettooperateinopposingmodes.Inotherwords,ifoneswitchfails,theguillotinewillnotoperate;

n ifanattemptismadetoopentheguardduringastroke,theclampandknifeshouldeitherretractorstop,ortheguardshouldbelockedintheclosedpositionuntilthestrokeiscompleted,seeFigure7.

Figure 7 Guillotinewithaninterlockingguard

Falling finger guards35Veryoldmachinesweresometimesprovidedwithasystemofinterlockedfallingfingerguards.Eachfingerwasmountedonaninterlockedsteelbarandindividuallyhingedoutwardssothattheywouldtakeuptheprofileofthework.Thisarrangementdoesnotprovidesufficientprotectionandshouldbereplacedbyanenclosinginterlockedguardorequallyeffectivemeans. From the date of this publication it is no longer acceptable for machinery to be guarded in this way.

Automatic sweepaway guards36Automaticsweepawayguardsfoundoncertainoldermachinesaredesignedtopushtheoperator’shandawayfromthedangerareaastheclampandknifedescend,seeFigure8.Theyarenotacceptableonnewmachinesunderanycircumstances.From the date of publication of this book, guillotines with automatic sweepaway guards new or second hand should not be supplied or sold on in the UK.

Interlocking guards



Figure 8 Guillotinewithsweepawayguardinextendedposition.

Note: side guards omitted for clarity

The operator of a 32 inch (813 mm) paper-cutting guillotine fitted with a sweepaway guard and two-handed control was seriously injured when the blade repeat cycled and amputated eight fingers and one thumb. The bolt releasing mechanism was not properly adjusted and the bolt was not interlocked.

An operator was removing paper after completing a cut when the knife descended and amputated the tip of his left-hand middle finger. The machine was fitted with a sweepaway guard which extended to 15 inches (381 mm) and two-hand controls. It was concluded that the knife descended under gravity due to brake failure. The hydraulic clamp actuated the sweepaway device but there was no direct interlocking between the knife and the sweepaway device.

An operator lost the tips of two fingers when using a 1970 guillotine fitted with a sweepaway guard. The brake attached to the motor driving the movement of the blade did not operate due to a loose retaining bolt which had become loose and jammed the brake open, allowing continued downward movement of the blade from top-dead-centre. There had been no preventative maintenance for the machine which had been consistently overrunning top-dead-centre.

37 Whereexistingmachinesarestillinuse,itisessentialthatthecorrectextensionofthedevice,clutchandbrakeperformancearemaintained,seeFigure9.Machinesshouldbeupgradedinaccordancewiththefollowingchecklistsothat:

n themainguardbarmovesforwardatleast500mmfromthefrontoftheclamp;

n theguardisinitsfullyextendedpositionbythetimetheclamphasdescended50mmfromitstopposition,unlesstheguardoperatesonknifemovementinwhichcaseeithertheguardisfullyextendedwhentheknifehasdescended50mmandtheclampprecedestheknifebylessthan14mm,orthegaugingpedalisinterlockedsothatithastobefullydepressedbeforetheknifecanmove;

n themovementoftheguardbarisasnearhorizontalaspossible;



n themaximumheightoftheguardbarabovethetableisnotgreaterthan 180mmatthelowestpointofsweep;n theguardbarisatleastaslongastheclamp;n additionalguardbarsatcentresnotgreaterthan100mm(seeFigure9)have

beenprovidedtopreventaccessover/throughtheguardusingrobustmaterialwhichhasnotweakenedthemainbarbythemeansoffixing(egwelding);

n sideaccesstothedangerzoneispreventedwhentheguardisextendedbymeansofsidetablesorfixedguardsmanufacturedtothedimensionsshowninFigure9;

n wheremeanshavebeenprovidedtodisconnectthesweepawayguardlinkageduringknifechange,unguardedoperationoftheknifeandclampispreventedbyinterlockingtheguardwiththetwo-handcontrolandclutch,forexamplebymonitoringtherotationalmovementoftheguardcrankshaft;

n theintegrityoftheelectricalcontrolsystemmeetsIEC/EN61496:1997.Thismaynecessitatecompleterenewaloftheelectricalcontrolsystem;

n thecontrolcamsandassociatedswitchesarearrangedtopreventsinglecomponentfailuregivingrisetodanger.Thiscanbeachievedwithadual-channelsystemwithonepositivelyandonenegativelyoperatinglimitswitch;

n two-handcontrolsarefittedwhichmeetthestandardsdetailedinEN574:1997.

38Ifasauseryouhaveanydoubtsaboutthesepoints,contactthecompetentguillotineengineerwhocarriesoutyoursix-monthlyinspectionsandtests.



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85 m

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85 m

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100

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180

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580

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700 mm 920 mm

785

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700 mm330 mm

300 mm

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1050 mm

100

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Body-push guards39These devices are no longer an acceptable means to safeguard guillotines and machines provided with them should already have been withdrawn from service. Prosecution may result from the operation of guillotines with this type of device.

Figure 10 Guillotineprovidedwithabodypushdeviceinextendedposition.Thesemachinesshouldno

longerbeinuse

Rear guards40Safeguardingshouldbeprovidedtopreventaccesstotherearoftheclamp,backgaugeandknife.Thisisnormallyachievedbyasystemoffixedbarrierswithaninterlockedaccessgateorfixedorinterlockedtunnelguardsattachedtotherearofthemachinetable.BSEN294:1992providesguidanceonreachdistances.Accesstotherearoftheknifeandclampcannotbesafeguardedsimplybyposition,ieagainstthewall.

41Rearsafeguardingshouldbeinstalledsothat:

n fixedguardsdonothinderknifechangingandlubrication;n wheninterlockedrearguardsorgatesareopened,poweredoperationofthe

knifeandclampisprevented;n wheretherearetrapsbetweenthemovingbackgaugeandotherfixedparts,

includingtheopenguard,theguardisinterlockedwithpowertothebackgaugemotor;

n wherebackfeedingisnecessaryinthecaseofverylargeworkorautomatedpaperhandling,fixed,interlockedguardsorESPEsareprovided.Theseshouldalsopreventaccesstoanyautomaticclampingarrangementsandbepositionedsothattrapsarenotformedbythemovementofthebackgaugeorpoweredsidelays;

n whereESPEsarefitted,theyareofthesameintegrityasthoseforfrontguardsandthelowestandoutermostbeamsarenotmorethan38mmabovetherearsidelays,andareatleast635mmfromthenearesttrappingpoint.



Figure 11 Fixedguardingatrearofguillotine

Safeguarding of ancillary handling equipment42 Alargenumberofmanualhandlinginjuriesoccurtooperatorsofpoweredguillotineseveryyear.AsuitableandsufficientmanualhandlingassessmentmadeinaccordancewiththeManualHandlingRegulations19922willidentifyanyneedformechanicalhandlingaidssuchaspilelift/hoists,scissorlifts,joggers,stackersandturningunits.TheuseofthisequipmentisencouragedbyPIAC.

43Suchequipmentwillalsoneedtobeproperlysafeguardedandmaintained.Liftingequipment,whichwillincludepilehoistsandscissorlifts,shouldbesubjecttothoroughexaminationaspartofanexaminationschemeinaccordancewiththeLiftingOperationsandLiftingEquipmentRegulations1998.3

Figure 12 Varioushandlingequipmentincludingpilehoist,joggerandde-stacker/re-stacker



Pile/lift/hoist44Wherefitted,thisequipmentshouldbeinstalledsothat:

n additionalpileliftsandhoistssitedatthesideofaguillotineareprovidedwithhandprotectionbetweenthelift/hoistandtheguillotine,normallyintheformofafixedplatetothefrontorside;

n safeworkingloadsareclearlymarked;n thehazardouszoneismarkedonthefloorbymeansofyellowandblack

hatchingtoextendatleast300mmbeyondthedangerarea.

Scissor lifts45ScissorliftsshouldhavebeendesignedandmanufacturedinaccordancewithBS5323:1980andinstalledsothat:

n thesafeworkingloadhasbeenmarked;n trapsbetweenscissorarmshadbeenpreventedbysuitableflexibleguards;n sensitiveedgesortripflapshadbeenfittedtotheundersideoftheplatform

wheresheartrapsarecreated.Checktheseregularly;n asuitablemechanicalscotchisprovidedwhereaccessbeneaththeraised

platformisrequired.

Joggers and auto-stacking tables46 Thisequipmentshouldhavebeeninstalledsothat:

n handplateshavebeenprovidedwhensitednexttothesideoftheguillotine;n whereairpresserrollersarefitted,anAOPD(type2)isfittedtothefrontofthe

tabletogetherwithsensorsontherollermechanismtohaltforwardmovementoninterruption;

n accesstotherearoftheequipmentisprevented,forexamplebyfixedorinterlockingguarding;

n joggersarefirmlyfixedtothefloorwithsuitablefoundationfixingsorwheremobilebydesign,meansareprovidedtomaintainaminimumseparationdistancebetweentheguillotineandadjacentequipment.

De-stackers and re-stackers and turning units47 Thisequipmentshouldbeinstalledsothat:

n thereare‘allenclosing’1800mmhighfixedbarrierswhichifaccessisrequiredareprovidedwithaccessgatesthatareelectricallyinterlockedwiththeoperatingcircuitsofboththeguillotineandthehandlingequipment;

n exposedstackingpoints,whereaccessispossible,haveAOPD(type2)protection;

n ascendinganddescendingtableshaveprotectionatthebasebymeansoftripdevicesorpressure-sensitivestripswherethereisariskofentrapment;

n stackliftunloadingandloadingsystemshavethehazardouszoneonthefloorbelowthelifting/loweringareamarkedwithyellowandblackhatchingtoextendatleast300mmbeyondtheloading/unloadingpalletarea;

n thepalletguideplateisfirmlyfixedtothefloor.



Section 2 User requirementsIntroduction to section

48Asauserofaguillotine,youneedtomakesurethatyoucomplywithanumberoflegalrequirements.Thesearesummarisedintheboxinsert.Theinformationwithinthissectionwillprovideyouwiththepracticalguidanceneededtoensurecomplianceisachieved.

TheSupply of Machinery (Safety) Regulations 1992imposedutiesonmanufacturers,suppliersandimportersofnewandsubstantiallyrefurbishedmachineryandareintendedtoprovideprotectionforusers.Theybecamecompulsoryasfrom1January1995.SeeBuying new machinery4forfurtheradvice.

TheManagement of Health and Safety at Work Regulations 19925includedutiestoensurethat:

n ariskassessmentismadewhichidentifiesallhazardsandtheriskofharmassociatedwiththeuseofaguillotineandancillaryequipment,includingdangerouspartsandtaskssuchasknifechanging;

n controlmeasures,suchasESPEsandsafeworkingprocedures,areputintoplacetomakesurepersonnelarenotharmed;

n employeesaregiventrainingandinstructionintheuseofguillotinesandancillaryequipment;

n controlmeasureswhichincludesafeguardingandtrainingareproperlyimplementedandmaintained.

TherequirementsoftheProvision and Use of Work Equipment Regulations 1998 (PUWER 98)6includedutiestoensurethat:

n dangerouspartsofguillotinesandhandlingequipmentaresafeguarded;n controlsandcontrolsystemsareunambiguous,reliableandperformallthe

tasksnecessaryforsafeoperation,n egprovisionofemergencystopandothercontrols;n guillotinesaremaintained.Thismeansperformingthedailychecksdescribed

inthissection(andrecordingtheresultsinamaintenancerecordorlog,whereprovided);

n guillotinesareinspectedbyacompetentpersonatsuitableintervals(detailedlaterinthissection);

n maintenanceandinspectioncanbecarriedoutsafely,n egadequateworkingspaceatelectricalcabinets;

n equipmentcanbeisolatedfromtheelectricalsupply.n Aproperlyearthedelectricalsupplyisolatorshouldbeprovidedbyusers

adjacenttothemachine;n recordsofinspectionsarekept.SeeAppendix2fordetailsofasample

maintenancerecord/log;n equipmentsoldonisaccompaniedbythemaintenancerecord/log;n newequipment(includingsecond-handequipmentfromoutsidethe

EuropeanEconomicArea(EEA))conformswithproductsafetylegislation,egSupplyofMachinery(Safety)Regulations1992;

n fullinstructionandtrainingisgiventooperators.



Maintenance and inspection records - Logs

49TohelpyoucomplywiththerequirementsofPUWER98,sampleformsforrecordingtheresultsofin-housedailyandmonthlychecksandasampleloghavebeenincludedinAppendices2and3.Thelogcontainssectionsforrecording:

n nameandaddressofmanufacturer/agent;n machinemodelandtypeincludingserialno;n nameandaddressofuser;n resultsofcommissioningexaminationsandtestsn (seeparagraph61);n technicaldetailsofallmechanicalandelectricalmodifications,n thedateundertakenandbywho;n allreportsbycompetentengineers/surveyors;n detailsofservicingundertaken;n datesoldandtowho;n namesandaddressesofsubsequentsuppliersandusers;n technicaldetailsofsafety-relatedpartsofthecontrolsystemintheformof

diagrams,schematicdrawings,etc;n allavailabledetailsofprogrammableelectronic-baseditemssuchassoftware

listings/versions.

50 Itisstronglyrecommendedthatyoukeepsuchalogforexistingmachines.Theguillotinelogprovidesyou,theenforcingauthority,yourinsurancecompany,inspectingorganisations,engineersandprospectivepurchaserswithevidencethattheguillotinehasbeenproperlymaintained.Bymakingsureyoukeepituptodatewiththeaboveinformation,itwilldemonstratethatdaily,monthlyandsix-monthlyinspectionsandtestshavebeencarriedoutandthatanymanufacturer’ssafetymodificationshavebeenimplemented.Remember, you are legally required to keep records of inspection.

51 Theinformationwithinalogcanbeessentialforcontinuedsafeoperationoftheguillotine.Thisinformationshouldcomewiththemachineregardlessofwhetherneworsecondhand.Queryanymachinethatcomeswithoutthispaperwork.

Buying a guillotine

52Beforeyoumakeapurchase,tellthesupplierwherethemachinewillbeused.

53Askthesupplierthefollowingquestions:

n Towhatstandardsistheguillotinemanufactured?n Whatsafeguardingsystemisprovided?n Whathasbeendonetoeliminatetheriskofelectricshockparticularlyduring

maintenanceworkwhencoversorcontrolpaneldoorsmaybeopen?n Aretherepossiblerisksfromothersourcesofenergy,suchashydraulicor

pneumatic?n Willyousupplymewithacurrentlog(ortheinformationtocompleteone)and

machineinstructionmanualincludinginformationoninstallation,maintenance,cleaning,andbreakdownprocedures?

n Willyouprovideorarrangeforthefirstsix-monthlyinspection?

54 Itisgoodpracticeforthesupplierormanufacturertohaveserviceback-uporahelpline.Youmightcheckwhatisinplacebeforeyoubuy.



55Onbuyingtheguillotinemakesurethat:

n anup-to-date,completemachinelogandinstructionmanualisprovided;n unlessitisasecond-handmachinewhichwasfirstsuppliedbefore1January

1995,ithasaCEmarkaffixedandacopyoftheECDeclarationofConformityhasbeenprovided;

n thesupplierhasexplainedwhatthemachineryisdesignedtobeusedforandwhatitcannotbeusedfor;

n aninstructionmanualhasbeensuppliedwhichincludesinstructionsforcleaning,knifechanging,assembly,installation,commissioning,adjustmentandmaintenance;

n theinstructionmanualisclearlyunderstandableandlegible;n informationhasbeenprovidedaboutanyremainingrisksfromthemachine,

andtheprecautionsyouneedtotaketodealwiththem,egrecommendedsafesystemsofwork.Thesemayincludeelectrical,hydraulic,pneumaticorthermalhazards;

n anywarningsignsarevisibleandeasytounderstand;n duringcommissioningcomprehensivetrainingisgiven;n youthinkthemachineissafe;n anyearlyconcernsaboutthesafetyofthemachinearereportedtothe

supplier.

56NeverassumethatmachineryissafejustbecauseithasCEmarking.YouneedtocarryoutariskassessmentinaccordancewiththeManagementofHealthandSafetyatWorkRegulations1992andcheckthatthemachineissafeguardedproperlyasrequiredbytheSupplyofMachinery(Safety)Regulations1992andPUWER98.Theleaflet5 steps to risk assessmentprovidesgeneraladvice.7

Upgrading guillotines

57Guillotinescurrentlyinusemayrequireupgradingtomeetthestandardsdetailedinthisbookandacompetentengineermayadviseyouofthisatthetimeofthesix-monthlyinspectionreferredtoinparagraph94.Itisessentialthatthesemodificationsareonlyundertakenbycompetentguillotineengineers.Guillotinecontrolsystemsandprotectivedevicesaresophisticatedsystemsandaccidentscanresultiftheyaretamperedwithbypeoplewithinsufficientknowledgeorunderstandingofthemachine.GuidanceoncompetenceisgiveninSection3ofthispublication.

58 Guillotineusershavearesponsibilitytoensurethatthemanufacturer’s/supplier’sinstructionmanualandlog(whereprovided)arekeptavailable,bothfortheuseofoperatorsandforthoseundertakingroutinemaintenance.Suchmanualsandlogsshouldaccompanythemachinethroughoutitsworkinglife.

Locating and siting machines

59Carefulconsiderationshouldbegiventothepositionchosentositeaguillotine.Operatorsneedsufficientworkingspacetoallowsafeoperationanduseoftheguillotinecontrolsandassociatedequipmentsuchaspilehoistsandjoggingtables.Congestedworkareascancreateadditionaltrappingandslip/triphazards.Makesureyou:

n allowsufficientspacetoensureefficientthroughputofwork;n planfortheexpectedquantityofworkinprogressanddefinesuchareasby

crosshatchedlinesmarkedonthefloor;n positionmachinesawayfrommainthoroughfares.



60Rememberthataccesswillberequiredformaintenanceandcleaningattherearandsidesofthemachine.Wherepracticablethedistancearoundthemachineshouldbeatleast0.5m.Forexample,whereaccesstoelectricalsystemsisrequiredandliveconductorsarewithinreach,theworkingspacedimensionsshouldbeadequatetoallowpeopletopullbackawayfromconductorswithoutrisk,andifpeopleneedtopassoneanother,todosowitheaseandwithoutrisk.Asaguide,thedistancebetweenlivepartsandafixedobstructionsuchasawallshouldnotbelessthan1m.

61Whenamachineismovedtoanewlocation,whetherinthesamebuildingorelsewhere,itshouldbeinspectedandtestedbyacompetentguillotineengineerafterre-installationasperthesix-monthlyinspection.

Commissioning inspections and tests

62Followingtheinstallationofaneworsecond-handmachine,aninspectionandanynecessarytestsshouldbecarriedoutbyacompetentguillotineengineerwhohasaccesstoallthemanufacturer’s/supplier’sinformationrelatingtothemachine.Asktheengineerifhehasincludedthefollowingitemswhencarryingouttheinspection:

n thefrontandreartableguardscomplywiththeguidanceinthisbook;n anybrakesandclutchesareadjustedtothemanufacturer’sspecification;n thestoppingperformanceiscorrectandtheoverrundetectionsystemsare

correctlyset.

63Inaddition,wheretheguillotinehasESPE,askthefollowing:

n Whatisthemeanoverallstoppingperformanceoftenreadings?n WhatistheminimumobjectdetectioncapabilityoftheAOPD?n WhatisthedistancefromthecuttingsticktothenearestpartoftheAOPD?

64Ensurethatthesemeasurementsarecheckedforcompliancewiththoseprovidedbythemanufacturerandthatadjustmentsaremadeasnecessary.

65 Whenamachineisre-installedatanewlocationwithinyourpremises,aninspectionandtestshouldbecarriedoutasforthesix-monthlyinspection.Itisstronglyrecommendedthatyoudonotacceptamachineunlesstheresultsofthesetestshavebeenrecordedinamachinelogandthatthesehaveinturnbeensignedbythesupplier/engineer.

66Beawarethatmanufacturersandsuppliersofbothnewandsecond-handmachinesshouldensurethatappropriatetestingiscarriedoutontheirproductssothatthestandardsdescribedinSections1,4and5ofthispublicationaremet.Makesureyouaregivenrelevantinformationaboutsuchtestssothattheguillotinecanbeproperlyusedandmaintained.

Instruction manuals

67Thefollowinginformationshouldbeprovidedintheformofaclearlywritteninstructionmanual:

n theinstallationprocedures;n thepurposeandoperationofthecontrols;



n thecorrectmethodsofoperationandmaintenance;n restrictionsonuseincertainenvironments,egpotentiallyflammable

atmospheres.

68FulldetailsofthecontentsofthesemanualsisgiveninAppenidx1.

Training and safe working practices

69Makesureallguillotineoperatorsarecompetent.Theyshouldhavebeentrainedtounderstand:

n risksarisingfromtheuseofthemachineincludingspecificoperationssuchasknifechangingandknifecleaning,etc;

n theoperationofcontrolsandsafeguards;n theimportanceofsafeworkingpractices;n howtocarryoutdailychecksonthemachine.

70Forgeneraladviceontrainingstaff,seethePIACopenlearningpackage.8Printingcolleges,safetytrainingorganisationsandguillotinesupplierscanoftenprovideformalshortcourses.Guillotineoperatorsshouldreceivetrainingontheaspectsdetailedinparagraphs71-93and101.RememberthattheEmploymentofYoungPersons(Safety)Regulations19799requiresspecificriskassessmenttotakeaccountoftheadditionalriskarisingfromtheinexperienceandimmaturityofayoungperson.

Startup procedure71Oncompletionofthedailychecksdetailedinparagraphs85-90,ifthemachineisingoodworkingorderoperatorsshouldsignthelog.Operatorsshouldreportanymachinethatfailstomeettheperformancestandardtothemanagementwhoshouldthenlockoffandlabelthemachineuntilthefaulthasbeeninvestigatedandremedied.

72 Operatorsshouldnotoperateamachinewithasignificantdefect.Detailsofanydefectorabnormaleventshouldberecordedinthelog,forexamplefailureoftheoperationoftheAOPDorunprovokedlockout.

73 Operatorsshouldalsocheckthattheknifedoesnotprotrudebelowthebottomoftheclampwhenitreturnstotop-dead-centreoncompletionofatrialstroke.

Gauging74Operatorsshouldbetrainedtousethefollowingprocedureswhengauging:

n alwayscheckthatthumbsandfingersareclearbeforebringingtheclampdown;

n wherefitted,usetheopticalcuttinglineindicatortocheckthatitissafetodepressthegaugingpedal;

n expelairfromthepileonlybyasingleoperationoftheclamp,notbyrepeateduseoftheclamp,hands,orblocksofwood.Toremoveair,providejoggingtablesoraprogrammedclamp/no-cutfacility.

Knife cleaning75Certainoperationswillleadtotheregularneedtocleantheknifewithsolvent,forexamplewherecuttingoflabelsleadstoabuildupofadhesive.

76Operatorsshoulduseasafesystemofworkasrecommendedbythemanufacturer.Ifnorecommendedsystemisavailableyoushould:



n eithermanually(withthepowersupplyisolated)orinknifechangemode,movetheknifetobottom-dead-centresothatitisincontactwiththecuttingstick;

n usingaholdercontainingthesolventsoakedcloth,wipetheknife.Donotholdthecleaningclothdirectlyinyourhand;

n cleaneachsideoftheknifefromtherespectivesideofthemachine-avoidreachingbeneaththebladeandupwards.

Knife changing77 Knifechangingisaparticularlyhazardousoperationandspecialprecautionsarerequiredtopreventinjury.Alwaysstressthedangerstothoseperformingthework.Only trained competent and authorised personnel should undertake this task.

An operator suffered a severe cut when a new guillotine blade he was installing fell onto his foot. He had removed the new blade from its case and placed it onto a table to insert the carrying handles. As he did this the blade slipped and fell. The operator had failed to clear the table of other material or to allow sufficient working space for this task to be undertaken safely.

78Whereprovidedyoushouldfollowthemanufacturer’sinstructions.Ifnoinstructionsareavailableyoushoulddevelop,inconjunctionwithacompetentengineer,asafesystemofwork.Thiswilldependonthemakeofmachinebutshouldincludethefollowingprinciples.Makesure:

n theproceduretakesaccountofthefactthattheAOPDmaynotbeactiveonolderguillotinesduringtheknife-changeoperation;

n theareaisclearofpalletsandstoredmaterials;n everyknifehasitsowncase/box(ieoneforboththenewandoldknives);n thatboththeknifecases/boxesandholderaremaintainedingoodconditionso

thatthebladeedgeisproperlyprotectedandtheknifecanbeheldsecurely;n thereisasecure,clearsurfacetoputtheknifecase/boxon-normallythe

machinetable;n youremovethesidelayswherethiswillassistinkniferemoval;n thattheknifedoesnotoverhangtheedgeofthetable;n youhaveallthecorrecttoolsincludingtheknifeholder;n otherpersonsareexcludedfromtheknife-changeareabysignsand

barriers(unlessthelargesizeofthekniferequirestwotocarryit.Inthesecircumstances,itmaybepossibletoslidetheknifeontoanadjacenttableatthesameheightwithouthavingtoliftit);

n theknifeisexposedfortheleastpossibletime;n knifesarenotrestedorplacedonpaperstacks;n themovementoftheknifeislimitedtotheshortestdistancepossible;n thecuttingstickisreplacedwhentheknifeisout;n a‘dailycheck’takesplaceafteraknifechange.



Figure 13 Twotypesofknifeholder

79Therearetwotypesofknifeforcuttingpaperforprintwork:steelortungstencarbide.Thelattermaygivealifeincreasebetween10and25times-withlessneedforsharpeningandchanging.Alwaysuseagoodqualityknife.Donotuseabluntknifeforprolongedperiodsasthiscancausetheknifetoshatter,damagethemachineandproducepoorqualitywork.Areputablesupplierforregrindingknivesshouldbeusedwhowillgiveyouadvancewarningshouldtherebeaproblemwiththeknife,egbowing,wearorover-grinding/end-of-knifelife.

Routine maintenance, inspection and testing

80Varioussafeguardingequipmentmaybeusedtoprotectguillotineoperatorsfromriskofinjury,anditisessentialthatthesearemaintainedinworkingorderandcheckedtoensureproperfunctioning.

81Allguillotinesshouldbesubjecttodailyandmonthlychecksandsix-monthlyinspectionsassummarisedinTable1.Thesamechecksshouldalsotakeplaceafterknifechanging.

BladeBlade

Full blade protection

Side view ofknife holder

Side view ofknife holder

Knife holder handle

Tip protection

Knife holder handle



Table 1 Summaryofwhoshouldcarryoutthechecksandinspectionsappropriatefordifferent

safeguardarrangementsandatwhatfrequency

82YoucanrecordtheresultsofeverycheckandinspectionusingthesampleformsgiveninAppendix2.Carryoutdailyormonthlychecksusingtrained,competentoperatorsandensurethatmanagersmonitorthatthecheckstakeplace.Thechecklisthasaplaceformanagerstosigntoconfirmthis.Iftheguillotinefailsanypartofthecheckortest,reportthistomanagementwhoshouldimmediatelytakeitoutofserviceandhaveitinspectedbyacompetentguillotineengineer.

83Six-monthlyinspectionsofguillotines,includingallsafetycomponents(egbrakes,clutches,interlocks,switchesandcams),stoppingperformanceandgaugingpressureneedtobecarriedoutbyacompetentguillotineengineer/engineersurveyor.Routineservicingandmaintenanceworkmaybecarriedoutatthesametime.

In-house daily/shift/after-knife-change maintenance checks

84 Thefollowingseriesofmaintenancechecksshouldbecarriedoutbyacompetentoperator:

All machines with two-hand control85Theguillotineshouldstrikeonwhenyouoperatebothcontrolsindependentlywithin0.5seconds.

86Theguillotineshouldnotstrikeonwhenyou:

n operateeachcontrolandresetitinturn;n operateonecontrolfollowedbytheotherafterashortdelayof2-3seconds;n repeatthelasttestwithoperationofcontrolsinreverseorder;n operatebothcontrolswithin0.5secondsbutreleaseonemid-waythroughthe

strokeandthenre-operateit;n repeatthelasttestbutreleasetheothercontrol.

Guillotine

safety

device

Daily

shift

check

After

knife

change

Monthly

maintenance

check

Six-monthly

inspections

Interlocking Operator Operator Operator Guillotine

engineer/

engineer

surveyor

Photoelectric Operator Operator Notapplicable Guillotine

engineer/

engineer

surveyor

Sweepaway Operator Operator Operator Guillotine

engineer/

engineer

surveyor



ESPEs87Withthepoweronbuttheguillotineatrest:

n checkAOPDstatuslights;n insertthemanufacturer’srecommendedtestpieceintothecurtainandpassit

slowlydownthecurtainwiththetestpiecedirectedtowardsthecuttingstickatthreepositions-ateithersideadjacenttoeachhousingandinthecentre.Thetestlightshouldilluminatewheneverthecurtainisinterrupted;

n whereAOPDstatuslightsarenotfitted,performtheabovetestwhileasecondpersonmakesrepeatedattemptstostrikeon.Nomovementoftheknifeorclampshouldoccurwhilethetestpieceisinterruptingthecurtain;

n initiateastrokeandmovebodyforwardtointerruptthecurtainwhilekeepingyourhandsonthetwo-handcontrol.Theknifeandclampshouldcometorestorreversewithoutanydelay.Do not attempt to thrust arm through the AOPD guard towards the blade;

n checktheoperationofthetwo-handcontrolinaccordancewithparagraphs85and86.

Interlocking guards88Wherethereisanautomaticlockingarrangement:

n strikeonandapplyalightupwardforcetocheckthattheguarddoesnotopen.

89Wherethereisnolockingarrangement:

n checkthestoppingefficiencyoftheknifebyopeningtheguardatmid-strokeoftheknifefirst,andthentheclamp.Eachshouldcometorestwithoutanyapparentdelay.

90Wherethereisasingle-controldeviceandtheinterlockingguardhastobeheldclosedagainstspringpressuretoinitiateastroke:

n operatecontrolandthencloseguard.Theguillotineshouldnotstrikeon;n releasethecontrolandre-operatewiththeguardclosed.Theguillotineshould

strikeon;n withtheguardstillclosed,operatethecontrolbutreleasetheguardbeforethe

knifereachesbottom-dead-centre.Theknifemotionshouldceaseorreverse.

Monthly/after-knife-change maintenance checks

Sweepaway guards91Checkthat:

n themainguardbarextendsatleast500mmbythetimetheknifeorclamphasdescended50mmandthattheguardbarisnomorethan180mmfromthetableatthelowestpointofsweep;

n theoperationofthetwo-handcontrolisinaccordancewithparagraphs85and86.

92Inspecttheguardlinkagesforwearatpivotpoints,pinsandmountings.

Interlocking guards93Checkthat:

n interlockingdevicessuchasvalvesandelectricalswitchesaresecurelyattached;



n actuatorssuchascams,leversandlinkagesarecorrectlyalignedandattached.Theseshouldbenon-adjustable,forexamplebyusingpinsanddowels,insteadofgrubscrews;

n thereisnolateralmovementoftheguardwhichwouldcausetheinterlockingdevicestobecomemis-aligned;

n anywearintheinterlockandactuatordoesnotallowknifeorclampoperationwhentheguardispartlyopen;

n checktheoperationofthetwo-handcontrolinaccordancewithparagraphs85and86.

Six-monthly inspection and check

94Everysixmonthsacompetentguillotineengineerorindependentengineer/engineersurveyorshouldperformathoroughinspectionofthemachinewhichshouldcompriseaseriesofperformancechecksandtestsin additiontothevariouschecksandtestscarriedoutateachshift,afterknifechangesandeverymonth.ThesearedetailedinSection3ofthispublication.Awrittenreportshouldbeissuedandkeptinyourlog(seeAppendix2).

Engineer’s competence guide

95Beforeemployingaservicecompanyorengineer,satisfyyourselfoftheircompetence.Youcandothisbyaskingthefollowingquestions.Thislistisnotexhaustiveandyouneedtoassesstheresponsesastotheirrelevancetotheworkyouexpectthemtoundertake.

n Whatqualificationsdoestheengineerhave?n Whattrainingandrelevantexperiencehastheengineerhad(includingsafety

training)?n Istheengineerfamiliarwiththispublication?n Whatequipmentistheengineerusingtomeasurestoppingperformance?n Whenwasthatequipmentlastcalibrated?n Cantheengineerprovideacopyofthecalibrationcertificate?n Howdoestheengineercheckthatthemaximumgaugingforceisnotbeing

exceeded?n Cantheengineerprovideaspecimenservicereport?

96Engineersshouldhavereceivedproductspecifictrainingandtrainingonthehealthandsafetyaspectsofguillotines.Theyshouldbefamiliarwithandunderstandthecontentofthisbookandcarrystoppingperformancetestequipmentwhichshouldberecalibratedeverytwelvemonthsasaminimum.

When not to wait six months

97Inspectionsandtestsshouldbecarriedouteverysixmonthseveniftheguillotinecontinuestofunctionandoperatecorrectly.However,wheretheguillotineshowsanysignsofabnormalbehaviourduringtheinterveningsixmonths,additionalinspectionandtestsshouldbecarriedout.Examplesofabnormalbehaviourincludelockouts,overrunsandthemalfunctioningofanysafetycomponent.Continualuseofamachineonathree-shiftcyclemayrequireinspectionmorefrequentlythaneverysixmonths.



Ancillary handling equipment

98Whenconnectingautomaticorsemi-automaticpaperhandlingequipmenttoaguillotinecontrolsystem,ensurethattheintegrityofthesafetysystemsonbothmachinesismaintained,particularlyifinterconnectingsystemshavebeensuppliedbydifferentmanufacturers.Asauser,youshouldensurethatretrospectivelyfittedadditionalhandlingequipmentisofthesamesafetystandardandintegrityastheguillotine.TheneedforhandlingequipmentwilloftenbeidentifiedbyassessmentsmadeundertheManualHandlingRegulations1992.2

99Whenchoosingsuchequipment,makesureyoudesignthejobtoreducetheriskofupper-limbdisorders(ULDs)byapplyingergonomicprinciplestothemachinery,workstationsandworkmethodssothatthejobfitstheperson.AdviceonthesemattersincludingtrainingrequirementsiscontainedinanumberofHSEpublications.2,8,10-12

Modifications and servicing100 Asauser,thekeypointstorememberare:

n nevermakemodifications,additionsorconversionswhichmightaffectsafetywithoutreferencetoacompetentguillotineengineer.Thisalsoappliestotheinstallationandadjustmentofsafetydevices,valvesandguarding,aswellastoweldingworkcarriedouttotheloadbearingelementsoftheequipment;

n neverattempttomodifythesoftwareofprogrammablecontrolsystems;n ensurethatmodificationstothecontrolsandsafetysystemsatthemachine

arerecordedinthelogandrevisedcircuitdiagramsaresuppliedbythemanufacturer/supplier;

n reviewandwherenecessaryreviseexistingriskassessmentsfollowingmodification;

n donotexceedthemanufacturer’smaximumloadcarryingcapacity;n rememberthatsomeequipmentsuchasscissorliftsandpilehoistswillbe

subjecttothethoroughexaminationrequirementsoftheLiftingOperationsandLiftingEquipmentRegulations19983andthePressureSystemsandTransportableGasContainersRegulations1989.13Alwayshavelifting/loweringequipment’spneumatic,mechanical,hydraulicandelectricalsystemsregularlyexamined,especiallysuchitemsaschains,airreceivers,hydrauliccylindersandhoses.

Safe working practice101 Observethefollowinggoodpractice:

n Beforeinitiatingmachinemotion,makesurethatnobodyisatrisk.n Neverswitchofforremovepressure,suctionorventilationdeviceswhenthe

machineisoperation.n Ensurethatguillotineswithancillaryhandlingequipmentareonlyoperatedby

competentstaffwhoarefamiliarwithboth.n Definetheoperator’sresponsibilitiesandgivetheoperatortheauthorityto

refuseinstructionsbyothersthatareunsafe.n Makesureanypersonundergoingtrainingorinstructionisbeingsupervisedby

anexperiencedoperator.n Intheeventofanychangesinbehaviourofthemachineduringoperation,stop

themachineimmediately,lockoffandseekadvicefromacompetentengineer.



Section 3 Engineer’s responsibilities and competenceLegal requirements

102 Asaguillotineengineer/engineersurveyor,youneedtomakesurethatyoucomplywithanumberoflegalrequirements.Thesearesummarisedintheboxinsert.TheinformationwithinthissectionandSection4willprovideyouwithpracticalandtechnicalguidancetohelpyoutocomply.Ifyouinspect/serviceaguillotinewhichfailsperformancetestsordoesnotcomplywiththetechnicalstandardswithinthisbook,youshouldadvisetheuseraccordinglyinwriting.Do not issue an inspection/test certificate without recording the defects.

Relevant legislation

The Health and Safety at Work etc Act 197414placesadutyonthoseconductinganundertaking,suchastheprovisionofaguillotineinspectionandmaintenanceservice,todosoinawaywhichdoesnotendangerthehealthorsafetyofthosewhoarenotintheiremployment,includingtheguillotineoperator.

The Provision and Use of Work Equipment Regulations 19986(PUWER 98)applytothosewhocontroltoanyextenttheuseofworkequipmentsuchasaguillotine.EngineerstakingresponsibilityforinspectionandservicingworkaretoanextentexercisingcontrolovertheuseofguillotinesandwillhavedutiesunderthefollowingaspectsoftheRegulations:

n equipmentismaintainedandinspectedinaccordancewiththeguidanceinthisbook;

n dangerouspartsofmachineryareguarded;n controlsandcontrolsystemsareunambiguous,reliableandperformallthe

tasksnecessaryforsafeoperation,includingminimisedfailuretodanger,egprovisionofemergencystopandothercontrols;

n recordsofinspectionareprovided.

Competence

103 Guillotineengineersshouldbecompetent.Theywillnormallybeaqualifiedmechanicalorelectrical/electronicengineer,withatleastaCityandGuilds,ONCorHNDqualification,orequivalenttraining/experience.Engineersshouldnormallyhavesuitableandsufficientexperienceofguillotineswithatleastoneyears’experienceofthemakeofmachinetobesuppliedorserviced,togetherwithproductspecifictrainingandtrainingonthehealthandsafetyaspectsofguillotines.Engineersshouldbefamiliarwithandunderstandthecontentofthisbook.Engineersshouldbefullyawareofthelimitationsoftheirownknowledgeandexpertiseand,wherenecessary,havetheabilitytocallupontheservicesofspecialiststoensuresafetyattheguillotine.

Accreditation of inspecting engineers

104 Atthedateofpublication,thereisnospecificschemeforaccreditationofguillotineengineerswhocarryoutinspectionalthoughtheUnitedKingdom



AccreditationService(UKAS)haspublishedguidance(RG1)15which,togetherwithEuropeanStandardEN45004:1995providesguidanceonappropriatequalificationsforcompetentengineersinspectingpowerpressesandtheirassociatedguardsandprotectiondevices.Similarqualificationscanbeconsideredforthoseinspectingguillotinesandtheirsafeguardarrangements.Thereisnorequirementunderhealthandsafetylegislationthatinspectingengineersmustbeaccredited,butaccreditationcanbetakenasoneindicationofcompetence.

Assessment of competence

105 Engineersshouldbepreparedtoanswerthefollowingquestionsfromguillotineusersbeforebeingemployed:

n Whatrelevantqualificationsdoyouhave?n Whatexperiencedoyouhaveonthemachineinquestion?n Whattraininghaveyouhad?n Areyoufamiliarwiththeguidanceinthispublication?n Canyouprovidethenamesofotheruserswhosemachinesyouhaveserviced?n Whatequipmentareyouusingtomeasurestoppingperformance?n Whenwasthatequipmentlastcalibrated?n Canyouprovideacopyofthecalibrationcertificate?n Howdoyoucheckthattherecommendedmaximumgaugingforceisnot

beingexceeded?n Canyouprovideaspecimenservicereport?An operator’s left hand was amputated on a 32 inch (813 mm) guillotine. The blade and clamp operated when all six light beams of the AOPD were broken simultaneously. This occurred as a replacement solenoid valve had been incorrectly wired by the supplier engineer.

Inspection and testing of guillotines

106 Asacompetentguillotineengineer,youhaveapivotalroleinensuringthecontinuedsafeoperationofthemachineryyouinspect.Itiscrucialthatinspectionandtestworkisperformedrigorouslysothatanydeteriorationinthemachineorsafeguardperformanceisdetectedandrectifiedattheearliestopportunity.

107 Makesureyouperformallofthefollowingcheckswhererelevanttothemachinebeinginspectedinadditiontotherecommendeddailyandmonthlychecksnormallycarriedoutbytheuser(seeparagraphs85-93):

All machines108 Onallmachineswhichhavetherelevantequipment,carryoutteststoensurethat:

n onmachinesmanufacturedafter1995,thedynamicgaugingforcedoesnotexceed500Nandthestaticgaugingforcedoesnotexceed300N;

n onmachinesmanufacturedbefore1995,ingeneralthedynamicgaugingforceshouldnotexceed500Nandthestaticgaugingforceshouldnotexceed300N,butexceptionallythestaticgaugingforcemayreachamaximumof500Nat60%pileheight;

n onmachineswithamechanicalclamp,thestaticgaugingforceislimitedtoamaximumof300Nbyatensatorspring.Thesearenotavailablefromtheguillotinemanufacturers,butarereadilyobtainablefromothersources.Thelinkageshouldbesmoothinoperationandarrangedsothatclampandpedalmovementareproportionate;



n onmachineswithelectricallyoperatedclamps,movementoftheclampisonlypossiblebytwo-hand-controloperationwiththefrontguardinposition.

ESPEs109 Checkthat:

n therelevantuser-checksdetailedinparagraph87ofSection2canbesatisfied;n thepositionoftheAOPDisthecorrectdistancefromthedangerouspartsas

specifiedontheinformationplate;n theoverallstoppingperformancedoesnotexceedthatstatedonthe

informationplate;n thedetectioncapabilityofthesystemaccordswiththemanufacturer’s

instructions;n thestoppingperformancemonitorandoverrundetectionsystemwherefitted

arecorrectlypositionedandfittedandareworkingtothemanufacturer’srecommendations;

n clampgaugingforcesdonotexceedthemaximumfiguresgiveninparagraph108;

n thebrakeandclutchwherefittedareworkingtothemanufacturer’srecommendationsandareuncontaminatedbyoilorgreasetotheextentthatthiswouldaffectstoppingperformance.Internalexaminationshouldnormallytakeplaceatapproximatelytwo-yearintervals,subjecttomanufacturer’srecommendationsand/orwear;

n themachineprimarycontrolelement(s)arefunctioningcorrectlyandareuncontaminatedbyoilorgrease;

n nolockoutshaveoccurredbyverifyingwiththeoperator;n therearenoothermechanicalorstructuralaspectsthatwouldpreventtheknife

stoppingorreversingwhenrequired;n theguillotinecontrolsandconnectionstotheAOPDhavenotbeenadversely

modifiedandthatanymodificationshavebeenrecordedinthelog;n theconditionofthecontrolgear,programmableelectronic-basedcontrol

systemenclosures,cams,camswitches,andtheirfixingsarefreeofweardamageorcontaminationbyoilanddirt;

n camsarepinned.

110 AreportproformatoattachtothemachineslogisprovidedinAppendix4.

Interlocking guards111 Checkthat:


n therelevantuserchecksdetailedinparagraphs88-90and93ofSection2canbesatisfied;

n thebrakeandclutchareperformingtothemanufacturer’srecommendationsandareuncontaminatedbyoilorgreasetotheextentthatthiswouldaffectstoppingperformance.


Sweepaway guards113 Checkthat:

n sweepawayguardshavebeenupgradedtomeetthestandardsdetailedinparagraph37ofSection1;




n therelevantuserchecksdetailedinparagraphs91-92ofSection2canbesatisfied;

n theguardoperatesbothduringanormalstrokeandinasimulatedoverrunsituation;

n guardmovementiscausedbypartofthemachineunaffectedbytheheightoftheknifecarrier(unlesstheheightofthecarrierdoesnothavetobealteredtoaccommodatedifferentknives);

n theforcedrivingtheguardissufficienttoremovetheoperatorfromthearea;n wheretheguardretractsunderpowerordirectmechanicallinkage,trapping

betweenguardarmsandthemachineframeisprevented;n thebrakeandclutchareperformingtothemanufacturer’srecommendations

andareuncontaminatedbyoilorgreasetotheextentthatthiswouldaffectstoppingperformance.




Section 4 Technical standards for existing machinery and the supply of second-hand machinery

Introduction

115 Asasupplierofusedguillotinesoraguillotineengineer,youneedtomakesurethatallmachinesyousupplyorworkonaresafe.Thepracticaleffectofthelegalrequirementswithwhichyouneedtocomply,isthatanymachineofanyagemustmeetthestandardssetoutinthissection.Rememberthat:

n Beforeyousupplyausedguillotine,youhavealegaldutytocarryoutallthemodificationsandupgradingworknecessarytomeetthestandardsdetailedinthissection.

n Ifyouprovideaninspectionandtestserviceforguillotinesinuse,youhaveadutytoadvisetheuserofanynecessarymodificationsorupgradingwork.

Relevant legislation

The Supply of Machinery (Safety) Regulations 1992 (SMR)16applytothefirstsupplyofmachineryintotheEuropeanEconomicArea(EEA),andonlywherethishashappenedafter1January1993.Ifyousupplysecond-handmachinerywhichwasfirstusedbefore1993insidetheEEA,withoutsubstantiallyrefurbishingit,themachinerydoesnotneedtocomplywiththeseRegulations.Similarly,ifyouaresimplyre-supplyingusedCEmarkedmachinery,theseRegulationsdonotapply.IneithercaseyouwillstillhavedutiesunderSection6oftheHealthandSafetyatWorketcAct1974(HSWAct).

Ifthemachinehasbeenrefurbishedtotheextentthatalmostallthereplaceablepartsarenew,itwouldbeconsideredtobenewmachinerytowhichSMRwouldapply.Theadditionofnewguardsorcontroldeviceswouldnotmakethemachine‘new’,butcompleteredesignofthehydraulicsystemandreplacementofdrivemotorsandcontrolcircuitswould.WhereSMRdoesapply,theguillotinewillneedtocomplywiththecurrentEuropeanstandardsdetailedinSection5ofthisbook.

NotwithstandingdutiescoveredunderSMR,Section6oftheHSWAct14appliestotheresaleofallusedworkplacemachinery,andrequiresthattheguillotineisdesignedandconstructedsothatitissafeandwithoutrisktohealthwhenitisusedatwork.Italsorequiresthatadequateinformationissupplied.Theserequirementswillnotbesatisfiedunlessupgradingtothestandardsdetailedwithinthissectioniscompleted.

116 Tomakesureyoucomplywiththeserequirements,whenyoupreparemachinerypriortoresalealways:



n lookforobviousdefects,suchasmissingordefectiveguardsorothersafetydevices,orinadequatelyprotectedelectricalwiring;

n checkthatknownriskswillbeproperlycontrolledorthatthereisinformationabouthowtheycanbecontrolled;

n makesureyouhaveprovided,fromaninformedsource,instructionsonsafeinstallation,use,adjustmentandmaintenance-seeparagraph117,‘Guillotineinstructionmanualandlog’;

n ensurewarningsignsarevisibleandeasytounderstand.

Guillotine instruction manual and log

117 TheinformationyouneedtosupplyunderSection6oftheHSWActincludes;

n acompleteoperatingmanual-seeAppendix1forfulldetails;n acopyoftheECDeclarationofConformityiffirstsuppliedafter1January

1995;n detailsofservicingwork(maintenance,inspectionandtesting)and

modificationsundertaken;n ownershiphistory.

118 Thelasttwobulletpointscomprisetheguillotinelog,forwhichasampleformatisgiveninAppendix2.Ifnologwasacquiredwiththeguillotine,makesureyouprovideanewoneandincludeallavailableinformation.

Technical standards

Electrical safety and controls119 Whereupgradingiscarriedout,electricalequipmentandcontrolgearshouldbeinaccordancewithEuropeanStandardEN60204:Part11998.Inaddition,EN61310:Parts1&21995willapplytotheindication,markingandactuationofelectricalcontrolgearattheguillotine.Workmaybenecessarytoensurethatexistingearthingandisolationarrangementsmeettherequirementsofthe16theditionoftheIEERegulations.17

Gauging pedal120 Foot-operatedcontrolsshouldbeprovidedforgaugingonly.

121 Forsafegaugingensurethat:

n theouter,upperedgeofthegaugingpedalatrestisbetweenn 50mmand125mmabovefloorlevel;n theouteredgeofthepedalisatleast150mminfromtheedgen ofthemachinetableattheoperatingposition;n thewidthofthegaugingpedaldoesnotexceed225mm;n ifitispossibletoinadvertentlyoperatethegaugingpedal,itisshrouded.

Two-hand control devices122 Onallmachines,engineersshouldensurethatitisonlypossibletostartacutbyoperatingatwo-handcontrolunlessprovidedwithfullyenclosingguardswithdual-channelcontrolcross-monitoredinterlockingorequivalent.

123 Two-handelectricalcontrolsshouldcomplywithEN574:1997.Inparticular:



n type111Cforelectrical/electricdrivenknives,andn type111Bforhydraulic/pneumaticdrivenknives.

Programmable electronic systems124 Programmableelectronicsystemsarefrequentlyusedtocontrolclamp,knifeandbackgaugeoperation,normallyinmachinesprovidedwithaphotoelectricsystem.Guidanceforprogrammableelectronic-basedtechnologiesusedinsafety-relatedapplicationsisgiveninIEC61508:Part11998andHSEpublications.18-19

125 Makesurethattheprogrammableelectronicsystemhasbeenarrangedsothat:

n stopsignalsfromtheESPEoranyotheremergencystop,interlockingguardortripdeviceareapplieddirectlytotheprimarycontrolelements.Noothercontrolsignalshouldbeabletorestartthemachineuntilthestopdevicehasbeenreset;

n thereisfullcompatibilitybetweentheguillotinecontrolsystemandthesafetysystem;

n thedesigntakesaccountoftheactionoftheESPEand/orothersystemsontheguillotineprimaryandsecondarycontrolelements;

n informationontheconditionofthemachinesafetysystem,egcurtaininterrupted,isfedintotheprogrammableelectronic-basedcontrolsystemtoupdateit;

n correctoperationofthemachinesafetysystemcannotbeoverriddenbyincorrectoperationoftheprogrammableelectronic-basedcontrolsystem;

n theprogrammableelectronic-basedcontrolsystemallowstheknifeandclamptoberaisedandloweredmanually.

126 Beforeupgradingguillotinesthatincorporateprogrammableelectronic-basedsafety-relatedcontrolsystems,obtainandkeepproperdocumentationrelatingtothehardwareandsoftwareelementsandensurethatallmodificationsareassessed,recordedanddated.Itisessentialthatmodificationstoprogrammableelectronic-basedcontrolsystemsanddevicesconsidertheextenttowhichanyalterationsmayaffectthefunctionalsafetyperformance(orsafetyintegritylevel)ofthesesafety-relatedsystems.

Front guards

127 Thissectiondescribesthestandardsforsafeguardsthatneedtobeprovidedatthefrontofanyreconditionedguillotinetopreventoperatorcontactwiththedescendingknifeandclamp.

ESPE

128 ESPEshouldcausetheguillotinecontrolmechanismtostoporretracttheknifeandclampbeforetheoperatorcanreachthem.Atpresent,theonlytypeofESPEappliedtopaper-cuttingguillotinesistheESPEusingAOPDs,normallyeitheralightcurtainoranarrangementoflight-beamdevices(seeSections3.206and3.205ofBSIEC61496:Part21997).

Performance standards for pre-1985 guillotines129 Machinesoriginallysuppliedbefore1985whichdonotmeettherequirementsofBSIEC61496:Part21997(suchasfrictionclutchmachineswithfull-functionmonitoring)designedinaccordanceandcomplyingwiththestandardsdetailedinthe1976editionoftheBPIFbookGuarding of guillotines and trimmers



(seeAppendix5),requirethefollowingmodificationstoachieveaminimumacceptablestandard:

n supplytothemachineprimarycontrolelement(s)tobeinterruptedwhentheguillotinelocksout;andeither,

n twomachinesecondarycontrolelementsarrangedsothatfailureofonewouldbedetectedandpowerpreventedfromreachingtheprimemover;or,

n asinglemachinesecondarycontrolelementwhichifitfailstothepermanentlyenergisedstatewillpreventtheguillotinestartingafterthepowersupplyhasbeenswitchedon.

Inaddition:n theguillotineisprovidedwithtwo-handcontrolasdescribedinparagraph

25exceptthatadelayofupto1secondbetweenoperatingeachcontrolisacceptable;

n ifonlyonefinalswitchingdeviceisprovided,thatifthefinalswitchingdevicefails,thefailureisdetectedandtheknifewillstopimmediatelyorattop-dead-centre,andtheguillotinewilllockout;

n wheretheguillotineiscapableoffullyautomaticoperation,thereareinadditiontotheaboverequirementstwofinalswitchingdevices.

Performance standards for post-1985 guillotines130 EN61496:Part11998andBSIEC61496:Part21999givetherelevantstandardforESPEssuppliedfromapproximately1985.Atype4ESPEshouldbeusedwhichshouldnotrespondtoanysourceotherthanthattransmittedbythesystem(seeFigure14).

131 Mutingfacilitiescanbeautomaticallyappliedontheupstroke,manualselectionbeingunnecessary.Themeansofactuatingthemuteshouldbekeyedorpinned.ForguillotinesthathavebeenprovidedwitharetrofittedESPE,itisnecessarytoensurethatthecontrolsystemoftheguillotineisdesignedtoanequivalentstandard,toassuretheoverallperformanceintegrity.Anyoriginalcontrolequipmentnottoanequivalentintegrityofthesafetysystemyouarefittingshouldbereplaced.



Figure 14 Schematicexamplefortheinterfacingofatype4ESPEtotheguillotine

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132 Theoverallsafeguardingsystemshouldcomplywiththefollowing:

(a) itshouldnotbepossiblefortheclamptodescendunderfullpowerand cuttingtocommencewhiletheESPEismuted; (b) itshouldnotbepossibleto‘strikeon’whileanypartofaperson interruptstheAOPD; (c) interruptionoftheAOPDduringadangerouspartofthecuttingcycle shouldcausetheknifeandclamptostoporbegintoretractwithout apparentdelay.Itmustnotbepossiblefortheknifeandclamptobesetin motionagainuntilthetwo-handcontrolhasbeenre-initiated. (d) duringdangerousmotionthereshouldbenomeansofrenderingtheESPE ineffective;. (e) lossofanypowersourceoftheguillotine,internalorexternal,willnotresult inafailurethatwillcompromisethesafetyintegrityofanypartofthe machine; (f) thecontrolsystemasawhole,includingguillotineandsafetysystems, shouldbedesignedsothatintheeventofasinglecomponentfailure,the overallsafeguardingsystemwillnotfailtodanger; (g) itshouldbesoconstructedthatitisnotadverselyaffectedbythe environmentalconditionsnormallyfoundintheprintingandpaper industries.Usersandguillotineengineersshouldexchangeinformation ifconditionsareoutsidethenorm.(SeealsoEN60204:Part11998and IEC/EN61496:1997.)Aspectstobearinmindare:

(i) mechanicalvibrationandshockfromthemachineorfrom anyothersource; (ii) dust,oil,moistureandcorrosion; (iii) variationsofambienttemperatures; (iv) variationsofsupplyvoltageandfrequency; (v) potentiallyexplosiveatmospheres(equipmentusedshould besuitableforthatenvironment); (vi) electromagneticdisturbances;

(h) thepositioningandinstallationofthephotoelectriccurtainshouldensure thattheobjectdetectioncapabilityisnotadverselyaffectedbyanylight reflectivesurfacesontheguillotineorthemateriallikelytobecut; (i) mostguillotinesshouldhaveavisualindicatorwhichthepersoncarrying outthedailyinspectionandtestofthecurtaincansee.Thiswouldindicate wheninsertionoftheappropriatelysizedtestpiecehasgivenrisetothe correctAOPD.(ThisisarequirementinEN61496:Part11997); (j) thataccesstothedangerzonefromanydirectionnotprotectedbyan AOPDshouldbepreventedbyeffectivefixedorinterlockingguardsor screens,orotherphysicalbarrierssuchassidetables.

Machine primary control elements133 AnESPEactuatestheguillotineprimarycontrolelementstostoptheknifeandclampbeforetheoperatorcanreachthem.Theseelementsaredirectlyresponsibleforbringingtheknifeandclamptorestandpreventinganyfurtherdangerousmovementwhilethephotoelectriccurtain(AOPD)isinterrupted.

134 Toensure:

(a) assuredstoppingcapability; (b) preventionofunexpectedstartup(uncovenantedstroke); (c) thatalevelofsafetyperformancecommensuratewiththatoftheESPEis maintained;and (d) adequatefacilitiesforsafetymonitoringmeansareavailable,



engineersshouldcheckthatboththeknifeandclampeachhavetwomachineprimarycontrolelements.However,if,intheguillotinedesign,powertoboththeknifeandtheclampcouldbecontrolledbyasinglemachineprimarycontrolelementandtheeffectofitsoperationinbothclampandknifecircuitscanbemonitored,thenonlytworatherthanfourguillotineprimarycontrolelementsneedbeprovided.MachinessuppliedbeforeOctober1990donotneedtohavetwomachineprimarycontrolelementsforeachoftheknifeandclamp,butthesameintegrityasdetailedinparagraphs130-132shouldbeachieved.Inexceptionalcircumstances,asinglemachineprimarycontrolelementcanbeprovidedwhere:

(a) thereisanelectromagneticclutch(thecoilisthemachineprimarycontrol element);and, (b) thereisanelectricmotorfittedwithafail-safebrake(thewindingofthe motoristhemachineprimarycontrolelement).Standardsofdesignfor theelectromagneticclutchshouldbeasperparagraphs146-147.

The operator of a guillotine that did not have full-function monitoring, had three fingers of one hand amputated. The operator had reached in to remove a stack of paper thinking that the knife would stop at the top of its stroke. An undetected failure of a cam switch caused the guillotine to overrun, and then continue to cycle unguarded.

Stopping performance monitoring135 Engineersshouldcheckthat:

n clutch-operatedmechanicalguillotinesareequippedwithstoppingperformancemonitoring;

n thestoppingperformancemonitorisascloseaspossibletotop-dead-centreandsetsothattheESPEwilllockoutiftheoverallsystemstoppingperformanceexceedsthatusedforthecalculationofminimumcurtainseparationdistance;

n stoppingperformancemonitoringiscarriedoutatleastoncepercycle(providedthisisrepresentativeofthebrakingconditionswhichwouldoccuriftheAOPDwasinterruptedduringdangerousmotionoftheknifeorclamp).

136 Stoppingperformancemonitoringsystemsinclude:

(a) fully comprehensive system,asdescribedinA3ofEN61496: Part11997; (b) single cycle system,egoverrundetection.

137 Full-functionmonitoringshouldincludeoverrundetectionfordirecthydromechanical,clutch-operatedandelectromechanicalguillotines,eitherbyhardwiredorprogrammableelectronic-basedcontrolsystems.

138 Checkthatthesensorsaresecurelyfixedinposition,andtheirproperpositionshouldbepermanentlymarkedandcontainedwithinasecureenclosure.

Overrun direction139 Certaintypesofknifemechanism(iedirecthydromechanical,clutch-operatedmechanicalanddirectelectromechanical)whicharereciprocatinginaction,arefittedwithmachinepositionsensors(egcam-operatedswitches).Ensurethatlockoutoccursifthecrankshaftoverrunstop-dead-centrebymorethan10°.Themeansofoverrundetectionshouldbeinasecureenclosure.Wheresafetybolts/pawlsarefittedtoactasamechanicalscotch,ensurethattheyarefullyfunctional.



Positioning of the AOPD relative to the cutting stick140 WhenfittinganewESPEensurethattheAOPDispositionedaccordingtoSections5.2.2and5.2.3ofEN1010:Part31999;EN999:1999andHSG180.1Guidanceforexistingguillotinesfirstsuppliedbeforethedateofthispublicationisprovidedinparagraph33andAppendix7.

Interlocking guards

141 EnsurethatinterlockingguardsarefittedaccordingtoSection5.2.3ofEN1010:Part31999.

142 Allmachineswithinterlockingguardsshouldhaveadual-channelcontrolsystemwhichiscrossmonitored,iedual-channelcontrolinterlockingwithtwoguardpositionswitchesoperatinginoppositemodes(oneperchannel)whichshouldbecrossmonitored.Operationoftheclampandknifeisnormallybymeansofatwo-handcontroldevicebutinthiscasemaybebymeansofasinglecontroldevice.

Automatic sweepaway guards

143 Machines fitted with automatic sweepaway guards should not be resold after the date of publication of this book.

144 NeverreplaceasweepawayguardwithanESPEwherethemachineisfittedwithabrakewhichmayfailandcausedanger.

145 Ifyouprovideaninspectionandtestserviceforexistingguillotineswithsweepawayguards,refertoSection1paragraph37fortherelevantstandards.

Brake and clutch design

146 Ensurethatanybrakeorclutchusedcomplieswiththefollowing:

(a) electricpowersupplyfailure,orlossofpneumaticorhydraulicpressure, shouldimmediatelyactivatethebrake,andwhereappropriate,disengage theclutch; (b) theyshouldbecapableofperformingsatisfactorilyduringmaximum sustaineduse; (c) overheatingshouldbepreventedbydissipation; (d) failureofanyonecomponentshouldnotcauserapidconsequentialfailure ofothercomponents; (e) thepotentialforcorrosionoftheworkingpartswhichmightaffectthe efficiencyoftheclutchandbrakeshouldbeminimised; (f) thedesignandpositioningofbrakesshouldensurethatlubricantsdonot reachthefrictionsurfaces; (g) anynecessaryworkingclearancesforclutchesshouldbesufficientto ensurethatfrictiondragleadingtounintendedmovementoftheknife orclampcannotdevelopevenunderthemostsevereoperatingconditions; (h) anyfrictionliningstobereplacedshouldbetothemanufacturers specificationandfastenedsothattheyareunlikelytobecomedetached duringuse; (i) accumulationofdustordebrisproducedfromfrictionalsurfacesshouldbe minimisedinareaswhereitmightcausedragorseizure;inaddition,the designshouldensurethatfragmentsfrombrokenclutchorbrake componentsareunlikelytocausefailure;



(j) wheretheclutchandbrakearecombined,theconnectionbetweenclutch andbrakeshouldberobustandasshortanddirectaspossibletoensure correctsynchronisationoftheclutchandbrake; (k) wherediaphragmclutchesareused,theyshouldbedesignedand installedtominimisethepossibilityoffailure,due,forexample,toover stressingorfatigue;sharpedgesshouldbeavoided.

147 Ensurethatanyspringsusedforapplyingthebrakeordisengagingtheclutchareadequatelyratedforsafetyandstrongenoughtoensurepromptandeffectivebrakeapplication.Compressionspringsshouldbeusedfordisengagingtheclutchandtheyshouldnotbeoverstressed.Asinglespringshouldnotbereliedonforthesedutiesunlessequivalentsafetyisassuredbyothermeans.Anysetofspringsshouldbeuniformindimension,qualityandrating,andthefailureofonespringshouldnotpreventthebrakefromoperatingeffectivelynoraffecttheabilityoftheclutchtodisengageuponreleaseoftheengagingforce.Thespringsshouldbesoloadedthat,whencorrectlyadjusted,thesprings’anchoragecanbelockedtopreventriskofslackeningback.Thearrangementsforspringhousingandguidingandofguidepins,shouldminimiseanyriskofbinding.

Hydraulic design

148 Theclampiscommonlydrivenhydraulicallyandmanyguillotinesalsohavehydraulicknifeoperation.Checkthatallhydrauliccomponentsareofadequatestrengthandsuitableforthepurposeforwhichtheyaretobeused.

149 Neitherlossofelectricalpowertoanysolenoidnorlossofhydraulicpressureshouldcausedanger.Thehydraulicsystemshouldbedesignedsothattheknifeand/orclampcanbestoppedorreversedatanypointonthedescendingstroke.

150 Hydraulicsystemsshouldbedesignedandconstructedtowithstandthemaximumsystemdesignpressure,andbearrangedtoavoidgenerationofharmfultransientpressures.Systemprotectionshouldbeprovidedwhereinjuryordamagemayresultfromeitherexcessiveorinadequatehydraulicpressure.

151 Reliefvalvesshouldbeprovidedtopreventover-pressurisationandshouldbesuchthattheycanbeadjustedonlybyqualifiedmaintenancestaff.

152 Theprovisionofgaugesorgaugeconnectionpointsfordiagnostictestsofbothprimaryandsecondary(pilot)pressureisrecommended.

Control valves

153 Whereupgradingofcontrolvalvesisundertaken,ensurethatwherethereisasingle-controlvalve,meansareprovidedtodetectanyfailureofthisdevicewithinonestrokeofthemachineandthatthisresultsinlockout.

154 Monitoredsolenoid-operatedvalvesshouldbedesignedtoensurethatthemonitordevicealwaysregisterseachoftheactualpiston/spoolpositions.Solenoid-operatedvalvescanhavemeansofmanualoperationandshouldnotbypassthesafetydevice(s).However,manuallyoperateddevicesshouldbedesignedtoprevent,asfaraspracticable,inadvertentorcarelessoperation.



Gravity fall

155 Protectionagainstgravityfalloftheknifeandclampshouldbeprovidedby:

(a) externalreturnsprings(withtwo-yearlyreplacement);or (b) aspringreturnsingleactingcylinder;or (c) apilot-operatedcheckvalveinassociationwithacounterbalancevalve.

156 Check-valveswhichprotectagainstgravityfallshouldbemounteddirectlyontothehold-upcylinder(s).Onlyseatedvalvesshouldbeusedascheck-valvestosupporttheknifeandclampbecausetheyarelesslikelytobeaffectedbydirtinthehydraulicsystemthanspoolvalves.

157 Oilfromthereturnareaofacylindershouldbepassedthroughthemaincontrolvalvesor,ifthisisnotpossible,throughauxiliaryvalves,theoperationofwhichdependstotallyonthesupplyofpilotoilfromthemaincontrolvalves.Thisisnecessaryevenwhentheguillotineisfittedwithseated‘hold-up’valvessinceitprovidesback-upsecurity.

158 AdviceiscontainedinBSEN982:1996.



Section 5 Additional information for suppliers of new machinesLegal requirements

Relevantlegislationincludes:

n theSupplyofMachinery(Safety)Regulations1992;16

n Section6oftheHealthandSafetyatWork(etc)Act1974;14

n theElectricalEquipment(Safety)Regulations1994.20

TheSupply of Machinery (Safety) Regulations 1992applytothesupplyofallnewmachinerymanufacturedorsuppliedintheUK,whereveritistobeusedintheEEA.

Theterm‘supply’appliestoallthoseengagedinthesupplyprocessandincludesagentswhosolelymakethearrangementsforasaleonbehalfofthemanufactureranduser.

TheyrequireallUKsuppliersandmanufacturerstomakesurethat:

n themachinerysuppliedmeetstherelevantessentialhealthandsafetyrequirementswhicharelistedintheScheduletotheRegulations,includingtheprovisionofsufficientinstructions;

n atechnicalfilehasbeenassembled;n thereisa‘declarationofconformity’forthemachinewhichshouldbeissued

withit;n thereisa‘CE’markingattachedtothemachine.

DetailedguidanceontheseRegulationsisgiveninthepublicationDTI product standards - machinery: Guidance notes on UK Regulations.21

Suppliers’ responsibilities

159 TheMachineryDirectivehasbeenimplementedinallEEAcountriesbutasanimporterofmachineryintotheUKyoustillneedtomakesurethatthemachineryissafebeforesupplyingit.UsethefollowingchecklistifimportingfromtheEEA:

n lookforobviousdefects,suchasmissingguardsorothersafetydevices,orinadequatelyprotectedwiring;

n checkthatknownrisksfromthemachinerywhenitisinusewillbeproperlycontrolledorthatthereisinformationonhowtheycanbecontrolled;

n makesurethemanufacturerhasprovidedinstructionsforsafeinstallation,use,assembly,commissioning,safehandling,adjustmentandmaintenance.AdetailedlistofthecontentsofoperatingandservicingmanualsisgiveninAppendix1;

n makesuretheinstructionmanualiswritteninEnglishifthemachineryisforuseintheUK.Themaintenanceinstructionsmayhoweverbewritteninanotherlanguageifspecialisedstafffromthemanufacturerorsupplierwillcarryoutmaintenance;



n provideasuitablelogfortheusertorecordownershiphistory,detailsofservicingandmodifications,andtestcertificates. AsampleformatisprovidedinAppendix2.

n ensurepowerrequirements,weightsandfloorloadingandheatoutput,whereappropriate,havebeenchecked;

n ensurethatanywarningsignsarevisibleandeasytounderstand;n checkthatithasaCEmarking;n checkwiththemanufacturerifyouhaveanyconcernsaboutanyoftheabove

matters;n neverassumethatmachineryissafejustbecauseithasCEmarking;n checkthatthemachinecompliestoBSEN1010:Part31999andisnota

machinethatwasdestinedforanon-EEAcountry

160 IfyouimportfromoutsidetheEEA,youwilltakeonthelegaldutiesofthemanufacturer.

Manufacturers’ responsibilities

161 Manufacturersneedtodesignandconstructmachinerysothatitcanbeusedsafely.Thisincludesactionto:

n identifyhealthandsafetyhazards,suchastrapping,crushingandelectricalshock,whicharelikelytobepresentwhentheguillotineandanyassociatedhandlingequipmentareinuse;

n assessthelikelyrisks;n eliminatetheidentifiedrisksorprovidesafeguardsandinformationaboutany

residualrisk.

Conformity assessment

162 Beforeissuingadeclarationofconformity,manufacturersshoulddrawupatechnicalfile.Thisshouldcomprise:

n anoveralldrawingofthemachinewithdrawingsanddiagramsofthecontrolcircuits;

n drawings,calculationsandtestresultsdemonstratingconformitywiththeessentialhealthandsafetyrequirements;

n alistofrelevantessentialhealthandsafetyrequirements,standardsandothertechnicalspecifications;

n adescriptionofthemethodsusedtoeliminatehazards;n whereappropriate,technicalreportsofcertificatesfromcompetentbodiesor

laboratories;n whererelevant,anytechnicalreportcontainingtestresultsofcompliancewith

harmonisedstandards;n acopyoftheinstructionsforthemachine.

New machines - harmonised standards

163 Manufacturersneedtoensurethattheirproductssatisfytheessentialhealthandsafetyrequirements.ThereareanincreasingnumberofharmonisedEuropeanStandardsthatwillhelpyoutodothis.ThedetailedharmonisedstandardsforguillotinesarespecifiedinEN1010:Part31999.



164 Otherrelevantstandardsinclude:

n EN292:1991n EN294:1992n BSEN574:1997n BSEN954:Part11997n BSEN982:1996n BSEN983:1996n EN999:1999n EN1037:1996n EN1050:1997n EN1088:1996n EN60204:Part11998n BSEN60947:Parts4(1)1992n BSEN61496:Part11997n BSEN61496:Part21997n IEC61508:Part11998(NOTE:Thisaseven-partstandardwhichdealswith

allaspectsofthefunctionalsafetyofsafety-relatedsystems.Parts1,3,4and5areavailableasIECstandardswhileParts2,6and7arecurrentlyfinaldraftinternationalstandards(FDIS).ItisanticipatedthatthesePartswillbeavailableasIECstandardsbytheendof1999.)

HSEpublications

n HSG1801n HSG4322

Forfurtherdetails,seetheReferencesection.



Appendix 1 Contents of instruction manualsForallmachines:

1 Nameandaddressofmanufacturer/supplier.2 Machinemodelandtype.3 Themethodandactuationoftheknifeandclamp.4 Themodesofoperation.5 Anypotentialsystemhazardandrecommendedsafesystemsofwork,egknife changingandcleaning.6 Adescription,includingcircuitdiagrams,ofthecontrolandsafetysystem.7 Ageneraldescription,includinghydraulic/mechanical/pneumaticdiagrams,of knifeandclampoperation.8 Supplyvoltageandfrequency.9 Dynamicandstaticgaugingforces.10Adescriptionofcorrectguardoperation.11Detailsofsix-monthlyexaminationsandadjustmentsincludingoverallstopping performanceoftheknifeinmilliseconds.12Actionrequirediftheknifesticksinapileortheshearbolts/pinsfail.13Instructionsforperiodiclubrication,adjustmentandmaintenance.

Additionalinformationforguillotineswithahydraulicallyoperatedknife/clamp:

1 Maximumandminimumworkingpressuresforbothclampingandgauging operationsandhowtocheckthem.2 Settingsforadjustablepressurerelieforreducingvalvesandhowtocheck them.3 Adescriptionofactuatorandvalvefunction.4 Accumulatorcapacityandinitialpressuresetting.5 Typesoffilterrequiredanddegreeoffiltrationinmicrons.6 Thetypeofhydraulicfluidthatshouldbeused.7 Forclutch-operatedmechanicalguillotines,thecorrectmethodofmaintaining thebrakeandclutchsettingsshouldbedetailed.8 Formachineswithelectrosensitivesafetysystems,aplateshouldbeaffixedto themachineinaccordancewithEN999:1998whichgivesthefollowing information:n overallsystemresponsetime(inmilliseconds);n objectdetectionsensitivityinmillimetres;n minimumAOPDseparationdistanceinmillimetres.



Appendix 2 Sample logsMachine Log

Part 1 of 4 - Ownership history

Machinemodel/type:.................................Serialno:..........................

Note: Upon installation/commissioning, inspection checks should be carried out.

Nameandaddressofmanufacturer/agent Nameandaddressoffirstuser:firstsupplying: ..................................................... .................................................... ..................................................... .................................................... ..................................................... .................................................... ..................................................... ....................................................

Datesold:......................................... Dateofsafetycheck:..................

Nameandaddressofnewagent: Nameandaddressofnewuser:.................................................... ........................................................................................................ ........................................................................................................ ........................................................................................................ ....................................................

Datesold:................................... Dateofsafetycheck:...................

Nameandaddressofnewagent: Nameandaddressofnewuser:.............................................. .................................................................................................. .................................................................................................. .................................................................................................. ....................................................

Datesold:............................. Dateofsafetycheck:...................

Nameandaddressofnewagent: Nameandaddressofnewuser: ............................................. .................................................... ............................................. .................................................... ............................................. .................................................... ............................................. ....................................................

Datesold:................................... Dateofsafetycheck:...................



Guillotine log

Part 2 of 4 - Commissioning, servicing and modifications

Results of commissioning inspections and tests:Toberecordedoneachoccasionthemachineismovedtoanewlocation(includingwithinthesamepremises).

Newlocation:..........................................................................................................Engineer’sname:.............................Signature:..................................Date:.........Engineer’scompany:...............................................................................................

Details of servicing: To be next serviced on:.......................Recordofalldetailsofservicingworkcarriedoutincludingrepairs.

Engineer’sname:.............................Signature:...............................Date:............Engineer’scompany:................................................................................................

Details of servicing: To be next serviced on:.......................Recordofalldetailsofservicingworkcarriedoutincludingrepairs.

Engineer’sname:..............................Signature:............................Date:..............Engineer’scompany:................................................................................................



Guillotine log

Part 2 of 4 - Commissioning, servicing and modifications (continued)

Technical details of any modifications made:Recordalldetailsofanymodificationsmadetoupgradethemachinetocurrentstandards.

Engineer’sname:......................................................Date:...................................Engineer’scompany:...............................................................................................

Technical details of any modifications made:Recordalldetailsofanymodificationsmadetoupgradethemachinetocurrentstandards.

Engineer’sname:.................................................Date:........................................Engineer’scompany:...............................................................................................

Details of failure to pass any in-house daily shift or monthly check:Recordalldetailsandcircumstancesofanyfailuretopassroutinechecksorabnormalbehaviour.

Operator:..................................... Date:.................................Supervisor:..................................

Details of failure to pass any in-house daily shift or monthly check:Recordalldetailsandcircumstancesofanyfailuretopassroutinechecksorabnormalbehaviour.

Operator:..................................... Date:.................................Supervisor:..................................



Guillotine log

Part 3 of 4 - Test certificates

Attachcopiesofeitherallphotoelectricguardsix-monthlytestcertificateswithdetailsofstoppingperformanceandgaugingforceorinterlocking/sweepawayguardmonthly/six-monthlytestcertificates.



Guillotine log

Part 4 of 4 - Records of daily shift and knife-change checks

Attachcopiesofchecksheets.



Appendix 3 Guillotine safety checklistsDaily or shift/knife-change checks (see paragraphs 85-90)

Machinemake/model:..............................Serialno:........................Weekcommencing:......................

Test/check: state pass or fail Mon Tue Wed Thu Fri Sat Sun

All machines with two-hand control (including sweepaway guards)

Guillotineshouldstrikeonwhenbothcontrolsaredepressedwithin0.5second.

n eachcontrolisoperatedindependentlyandresetinturn.

n onecontrolisoperatedfollowedbyotherafter2-3secondsdelay

n bothcontrolsareoperatedwithin0.5secondbutoneisreleasedmid-way

throughthestrokeandthenre-operated

Machines with ESPDs

Istheguardindicatorworking(wherefitted)?

Isrecommendedtestpiecedetected(threepositions)?

Doesknifeandclampstopwhencurtainisinterruptedduringstroke?

Isfixedreartableguardingfittedandsecuredordoesinterlockedaccessgate

preventpoweredknifeandclampmovement?

Machines with interlocking guards

Checkguardcannotopenduringstrokeiflockingarrangementfitted

Checkthatstoppingefficiencyisadequatebyopeningtheguardatmid-stokeof

firsttheknifeandthentheclamp(nolockingarrangement)

Formachineswithasinglecutbuttonwheretheguardhastobehelddown

againstspringpressure,check:

n machinedoesnotstrikeonifbuttonisoperatedbeforeguardclosed

n theguillotinestrikesonwhenthecontrolisreleasedandre-operatedwith

theguardclosed

n theknifestopsiftheguardisheldclosedbutthecontrolisreleasedbefore

theknifereachesbottomdead-centre

Isaccesstorearofknifeandclampguarded?

Checkedby(operator’sname):

Confirmedby(supervisor’sname):



Monthly checks of machines with sweepaway or interlocking guards (see paragraphs 91-93)

Machinemake/model:..............................Serialno:........................Weekcommencing:......................

Test/check: state pass or fail Jan / Jul Feb / Aug Mar / Sep Apr / Oct May / Nov Jun / Dec

Machines fitted with sweepaway guards

Doesthemainguardbarextendatleast500mmbythe

timetheknifeorclamphasdescended50mm?

Istheguardbaramaximumof180mmfromthetableat

thelowestpointofsweep?

Arelinkagesfreefromwearandsecurelyattached?

Aretheguardbars/screensfirmlyfixedtopreventaccess

throughtheguard?

Issideaccesstotheknifepreventedbysideguardsortable

extensions?

Machines fitted with interlocked guards

Arevalvesandelectricalswitchessecurelyattached?

Areactuatorssuchascams,leversandlinkagescorrectly

alignedandattached?

Istheguardfreefromlateralmovementwhichwouldcause

theinterlockswitchestobecomemis-alignedandfailto

engage?

Aretheinterlockswitchesandactuatorsfreefromwearthat

wouldallowknifeoperationwhentheguardispartlyopen?

Checkedby(operator’sname):

Confirmedby(supervisor’sname):



Six-monthly inspection and test of machines with ESPDs (see paragraph 109)

Machinemake:.....................................Model:............................... Serialno:...............................

Inspection/test (to be performed in addition to daily shift

checks)

Comments/result Details of remedial work

undertaken/advised

Machines with ESPDs

CheckthatthepositionoftheAOPDisthecorrectdistance

fromthedangerousparts.Recordminimumseparation

distance

TestobjectdetectioncapabilityofAOPDagainst

manufacturer’srecommendation(statetestpiecesize)

Examinestoppingperformancemonitor(andindicator)

andoverrundetectionsystemagainstmanufacturer’s

recommendationstoensurecorrectpositioningandinstallation

Examineanybrakeandclutchtomanufacturer’s

recommendations.Stateairgap

Testoverallstoppingperformanceagainstmanufacturer’s

recommendationandrecordresultinmilliseconds

Checkthatdynamicandstaticgaugingforcesdonotexceed

500Nand300Nrespectively

Examineandtestthemachineprimarycontrolelementsto

ensurecorrectoperation

Inspecttheguillotinetoensuretherearenomechanicalor

structuralaspectsthatwouldpreventtheknifeandclampfrom

stoppingorreversingwhencalledupon

Examineandinspectthecontrolsandconnectionstothe

photoelectricsafetysystemtoensurenomodificationshave

beenmadewhichadverselyaffectthesystem

Checktheconditionofcontrolgear,programmableelectronic

systemenclosures,fixings,camswitchesandcamwearand

thattheyarefreefromdirtandoilcontamination

Havedailyorshift/knifechangechecksbeencompleted?

Statepassorfailandprovidedetails

Signatureofengineer: Date:



Six-monthly inspection and test of interlocking and sweepaway guards (see paragraphs 111 and 113)

Machinemake:................................. Model:.......................... Serialno:...............................

Inspection/test (to be performed in addition to daily shift checks) Comments/result Details of remedial work

undertaken/recommended

Machines fitted with interlocking guards

Arevalvesandelectricalswitchessecurelyattached?

Areactuatorssuchascams,leversandlinkagescorrectlyalignedandattached?

Istheguardfreefromlateralmovementwhichwouldcausetheinterlockswitchesto

becomemis-alignedandfailtoengage?

Aretheinterlockswitchesandactuatorsfreefromwearthatwouldallowknife

operationwhentheguardispartlyopen?

Examinethebrakeandclutchtoensurethattheyareperformingtothe

manufacturer’srecommendations.Adjustasnecessaryandstateairgap

Statewhetherdynamicandstaticgaugingforcesexceed500Nand300N

respectively

Havedailyorshift/knife-changechecksbeencompleted?Statepassorfailand

providedetails

Machines fitted with sweepaway guards

Doesthemainguardbarextendatleast500mmbythetimetheknifeorclamphas

descended50mm?

Istheguardbaramaximumof180mmfromthetableatthelowestpointof

sweep?

Arelinkagesfreefromwearandsecurelyattached?

Aretheguardbars/screensfirmlyfixedtopreventaccessthroughtheguard?

Issideaccesstotheknifepreventedbysideguardsortableextensions?

Examinethebrakeandclutchtoensurethattheyareperformingtothe

manufacturer’srecommendations

Statewhetherdynamicandstaticgaugingforcesexceed500Nand300N

respectively

Havedailyorshift/knife-changechecksbeencompleted?Statepassorfailand

providedetails

Signatureofengineer: Date:

Signatureofcompanymanager: Date:



Appendix 4 GlossaryActive opto-electronic protection devices (AOPD)-alightcurtainand/orlightbeamdevicecomprisingemittingandreceivingelementswhichformadetectionzone.

Assured stopping capability -theuseoftwoindependentcontrolmechanismseachofwhichiscapableofstoppingthedangerouspart.

Backgauge-amoveablestop,behindandparalleltothecuttingstick.

Curtain separation distance-thedistancebetweentheareaofdetectionoftheAOPDandthecuttingstick.

Cutting stick -aflexiblestripofmaterialinsertedintothemachinetableinlinewiththeknife.

Detection zone-thezonewithinwhichaspecifiedtestpiecewillbedetectedbytheelectrosensitiveprotectiveequipment(ESPE).

Dual-channel control interlocking-interlockingwithtwoseparatepowerinterruptingdevices,arrangedinseriessothattheoperationofeitherwillresultintheinterruptionofthepowermedium.

Electrosensitive protection equipment/device (ESPE/D)-Anassemblyofdevicesand/orcomponentsworkingtogetherforprotectivetrippingorpresencesensingandcomprisingasaminimum:

n asensingdevice;n control/monitoringdevices;n outputsignalswitchingdevices.

Final switching device-thecomponentofthemachinessafety-relatedcontrolsystemthatinterruptsthecircuittothemachineprimarycontrolelementwhentheoutputsignalswitchingdevicegoestotheOFF-state.

Full-function monitoring -seeAppendices5and6fordetailedexplanation.

Gauging-useofthegaugingpedaltolowertheclampdownontothematerialtobecuttoallowthematerialtobeaccuratelypositioned.

Interface -thesumofallthepointsofelectricalinteractionbetweenthemachineandsafetysystem.

Knife holder/carrier-adeviceattachedtotheknifeduringchangingwhichcoversthecuttingedgeofthebladeandprovidesasecurehandleatthepointatwhichtheknifeisboltedintothemachine.

Light curtain-anactiveopto-electronicprotectivedevice(AOPD)comprisinganintegratedassemblyofoneormoreemittingelement(s)formingadetectionzonewithadetectioncapability,bothspecifiedbythesupplier.

Lockout condition-acondition,initiatedbyafault,preventingnormaloperationoftheelectrosensitiveprotectiveequipment(ESPE)whichisautomaticallyattainedwhenalloutputsignalswitchingdevicesand,whereapplicable,allfinalswitchingdevicesandsecondaryswitchingdevicesaresignalledtogototheOFF-state.



Machine primary control element-theelectricallypoweredelementthatdirectlycontrolsthenormaloperationofamachineinsuchawaythatitisthelastelement(intime)tofunctionwhenmachineoperationistobeinitiatedorarrested.Thiselementcanbe,forexample,amainscontactor,amagneticclutch,oranelectricallyoperatedhydraulicvalve.

Machine secondary control element-amachinecontrolelement,independentofthemachineprimarycontrolelement,thatiscapableofremovingthesourceofpowerfromtheprimemoveroftherelevanthazardousparts.Themachinesecondarycontrolelementisnormallycontrolledbythesecondaryswitchingdevice.Thiselementcanbe,forexample,amainscontactor,amagneticclutchoranelectrically-operatedhydraulicvalve.

Muting-atemporaryautomaticsuspensionofasafetyfunctionorfunctionsbysafetyrelatedpartsofthecontrolsystem.

Object detection capability-theminimumsizeoftestpiecewhichwhenplacedatrightanglestotheAOPDwillbedetected.

OEM -originalequipmentmanufacturer.

Overall safeguarding system-thecombinationoftheESPEandmachineprimarycontrolelementswiththesecondarycontrolelementandclutchorbrakingsystemwhichtogethercausetheclampandknifetohaltorretractwhentheAOPDisinterrupted.

Overall system response time-thetimeintervalresultingfromthesumoftheelectro-sensitiveprotectiveequipment(ESPE)responsetimeandthetimetocessationofhazardousmachineoperation.

Overall stopping performance-seeoverallsystemresponsetime.

Overrun -thecontinuedmovementoftheknifeorclampbeyondtop-dead-centrefollowingacuttingcycle.

Programmable guillotine -aguillotinecapableofcompletingapredeterminedseriesofbackgaugemovementsand/orcapableofco-ordinatingcuttingcycleswithbackgaugemovements.

Secondary switching device (SSD)-Adevicewhich,inalockoutcondition,performsaback-upsafetyfunctionbygoingtotheOFF-stateandinitiatinganappropriatemachinecontrolaction,egde-energisingthemachinesecondarycontrolelement.

Side lays-fixedverticalguidesateithersideofthereartableextendingfromthethroatofthemachine.

Striking-on-initiationoffullpressuredescentoftheclampandknifebyoperationofthecontrols.

Test piece-anopaquecylindricalobjectoflowreflectivityusedtotesttheAOPDdetectioncapability.

Throat -theareaboundedbythecuttingstick,sidelaysandundersideoftheclamp.



Appendix 5 Extract from British Printing Industries Federation booklet Guarding of guillotines and trimmers, December 1976 editionThe following extract details a standard which is applicable only to guillotines manufactured and in use before 1985 - see paragraph 129.

Photoelectric devices

1 Thelightcurtainofthesedevicesisdesignedtostopthemotionoftheknifeorclampbeforeaperson’shandscanreachthedangerzone.Eachoperatorshouldreceiveinstructionsonthefunctioningofthedevicetoenablerecognitionofanydefectsinitsoperation.Themechanical,electricalandelectronicpartsoftheequipmentshouldbeperiodicallyinspectedandefficientlymaintainedbyacompetentperson,andrecordsshouldbekept.

2 Thestandardofperformanceofphotoelectricdevicesshouldbeasfollows:

(a) ifanypartofapersonisundertheknifeorclampitmustnotbepossible fortheknifeorclamptobesetinmotionbythereleaseofthebrakeand/ orengagementoftheclutch; (b) intheeventofaninterruptionofanyofthelightbeamswhiletheknifeor clampisdescending,theknifeorclampmustbebroughttorestbefore theobjectwhichhascausedtheinterruptioncanreachthespacebeneath theknifeorclamp.Itmustnotbepossiblefortheknifeorclamptobeset inmotionagainuntilthesafetydevicehasbeencompletelyrestoredtothe clutchdisengagedposition; (c) thedeviceshouldbesoinstalledandconnectedastoensurethattheknife andclampcannotbebroughtintomotionunlessthedeviceisinafully operativecondition; (d) thesafetydevicemustnotberenderedineffectivebystraylightwhether artificially,naturallyordeliberatelyapplied; (e) accesstotheknifeorclampatthefrontofthemachinefromanydirection notprotectedbythelightcurtainorscreenshouldbeeffectivelyprevented byfixedguards,screenorextendedsidetables; (f) arrangementsshouldbemadebytheprovisionofeffectiveguardsorby additionalelectrosensitivedevices,suitablypositionedtopreventthe machinebeingusedifapersonisstandingbetweenthelightcurtainand trappingarea; (g) thedevicemustfailtosafetyinrespectoffailureofelectricalorother powersuppliesandsofarasitisreasonablypracticableinallother respectsitmustnotmalfunctionasaresultofelectricalinterference anditmustnotberenderedineffectivebynormalfluctuationsinvoltage andfrequency; (h) thedevicemustbesoconstructedandmountedasnottobeadversely affectedbyvibrationorshockfromthemachineorfromanyothersource;



(i) thedeviceandtheassociatedelectricalapparatusmustbesoenclosedas topreventfailureresultingfromdust,oil,moistureorcorrosion.Particular attentionshouldbegiventopreventingdustandotherforeignmatter enteringsuchenclosureswhentheyareopenedformaintenanceorother purposes; (j) theequipmentmustnotberenderedineffectivebyvariationinambient temperaturewithintherange0°Cto55°C.Thesensitivityasdefinedin(n) and(o)mustbemaintainedthroughoutthistemperaturerangeandinan atmosphereofupto95%relativehumidity; (k) thedeviceshouldbelockedandthekeyaccessibleonlytoanauthorised person(iethefactoryoccupierorsuchotherpersonasmaybeappointed byhimtoberesponsiblefortheproperoperationoftheapparatus); (l) thedeviceshouldincorporateasystemoffullfunctionmonitoringinwhich anautomaticcheckisprovidedtoproveateachcycleofthemachinethat theguardandvariouspartsoftheguillotineareoperatingcorrectly.The checkismadeduringtheupstrokeandifallpartsofthesafetysystemare operational,theknifewillcometorestattopdeadcentre.Ifanyfault causestheclamporknifetooverruntopdeadcentre,anoverrunswitchis broughtintooperation,whichstopsthemachineinsuchamannerthat operationcanonlyberestoredbyanauthorisedperson.Onafullfunction monitoredguillotinethefollowingarechecked:

(i) theoperationofthelightcurtainitself.Wherethesensing devicecomprisesanumberofdiscreteunits(suchas individuallightbeams)theautomaticcheckmustoperate toprovethateachunitisoperatingeffectively; (ii) therelaysandcontactorsinthesafetycircuits,allbeing crossmonitoredsothatanyfailure,forinstanceinthetop deadcentreoverrunswitch,resultsinlockout; (iii) themachineelectricsthemselvessuchasthemain contactors,whichcouldconceivablyweldoracomponent whichcouldbecomefaulty. (iv) theclutchandbrake.Iftheclutchdragsorthebrake wearssothattheknifedoesnotstopatthetop,thetop deadcentreoverrunswitchisactivated.

Requirementsforfull-functionmonitoringaregivenintheeighthreportoftheJointStandingCommitteeonsafetyintheuseofpowerpressesentitledElectrosensitive safety devices for friction-clutch press brakes;[seeAppendix6]

(m) whereaguillotinemaybeoperatedinflammableorexplosiveatmospheres, additionalprecautionsmaybenecessarytomeettherequirementsof Regulation27oftheElectricity(FactoriesAct)SpecialRegulations1944; (n) thesensitivityofthedeviceshouldbesuchthatitcandetecttheinsertion ofastandardtestgaugeofadiameterdeterminedinaccordancewiththe followingtable:

Distanceofplanoflight 450mm(18inches) curtainfromthefaceof 610mm(24inches) theclamp

Diameteroftestgauge 40mm(1.5inches) 50mm(2inches)

Thesensitivityshouldnotbecapableofsuchadjustmentastorenderthe apparatusineffectiveasasafetydeviceandthefollowingtestshouldbe madeatthecommencementofeachshift,oncethereafterduringeach



shiftandalsobeforeeachproductionrunafterknifechanging.Atest gauge(seeabovetable),preferablyalongcardboardtube,shouldbe thrustquicklythroughthelightcurtaininthedirectionoftheknifeand clampwhiletheyaredescending.Ifthespeedoftheresponseofthe deviceandthesensitivityofthelightcurtainareadequateitshouldnotbe possiblefortheknifetodamagetheendofthetube.

Whereitisnecessarytoallowforoverhangofmaterial,themaximum verticaldistancebetweentheouterlightbeamandthemachinetable shouldbeassmallaspracticableandinnocasegreaterthan175mm (7inches).Inbothcasestheouterlightbeamshouldbeaminimum horizontaldistanceof635mm(25inches)fromthefaceoftheclamp. (o) inanalternativemethodoffittingtheguardtheouterlightbeammustnot belessthan1050mm(41inches)fromthefaceoftheclampmeasured horizontallyataminimumheightof765mm(30inches)abovewhere theoperatorstands.Inadditionthedistancebetweentheinnerlightbeam andthefrontedgeofthetableorbetweenanypairoflightbeamsmust notbemorethan150mm(6inches).



Appendix 6 Extract from the Health and Safety publication Electro-sensitive safety devices for friction-clutch press brakes eighth report of the joint standing committtee on safety in the use of power pressesThe following extract describes a full-function monitoring system applied to a press brake. The equipment used on a guillotine will differ, but the general principle of overrun protection is the same. Full-function monitoring is applicable only to guillotines manufactured and in use before 1985 - see paragraph 129.

Full-function monitoring

Theillustration(Figure1)isdrawndiagrammaticallytoshowtheprinciplesoffull-functionmonitoring.Thedeviceismutedbymeansofswitch‘A’justbeforebendingbegins,ieatminimumgap.Thedeviceremains‘off’untilthepressbrakereachesapre-setpointinthereturnstroke,whenswitch‘B’simulatestheconditionofbreakingthelightbeamssimultaneouslyforabriefinstantandasignalisgiventostopthemachine.Thisisarrangedsoastobringthepresstorestattop-dead-centre,(orbottom-dead-centreonanupstrokingmachine)andifitdoesnotstopwithinapre-setdistance,itoperateslimitswitch‘C’andallincomingelectricalsupplytothepressisimmediatelyisolatedbyamastercircuitbreakerorcontractor.Thepresscanonlyberestartedbyusingare-setkey.

Apracticalrealisationofthesystemisnecessarilymorecomplexthanthesimplifieddiagram.Switch‘C’mustbetakenmomentarilyoutofcircuitatthebeginningofeachnormalworkingstroke.Itisalsonecessaryforthephoto-cellstobeswitchedfromaseriestoaparallelarrangement(byswitch‘A’orbyaseparateswitch)beforetheoperationofswitch‘B’.Failuretorestoreswitch‘C’wouldresultinlossofmonitoringandfailuretorestorethecellstotheseriesmodewouldresultinlossofguarding.Itisessentialtherefore,thatprovisionbemadeinapracticalsystemtoensurethatboththesetypesoffailurewouldthemselvesbedetectedandwouldresultinlockoutoftheincomingmainssupplytothemachine.



Figure 1 Diagramshowinglocationofpositionswitchesforfullfunctionmonitoring



Appendix 7 Method for determining the position of the AOPD relative to the cutting stickThe following extract details a standard which is applicable only to guillotines manufactured and in use before the date of this publication - see paragraphs 33 and 140.

1 Themanufacturershouldusereliablemeasurementtechniquestoascertainthemaximumoverallsystemstoppingperformance(SP)inmilliseconds,withinwhichallguillotinesbuilttothesamespecificationshouldbeabletoperform.Teststoestablishthisshouldnormallybecarriedoutduringthedevelopmentofeverymodelandbemadeatdifferentpointsinthestrokeandatdifferentpointsalongtheknifeandclamp.

2 TothisfigureofSPshouldbeadded:

a) anamountinmillisecondswhichtakesintoaccountthetolerance(t)ofthe instrumentandmethodusedfortakingthemeasurements;and b) afurtheramountinmillisecondswhichrepresentsthemaximumpotential deterioration(e)inthestoppingperformancethatislikelytohaveoccurred aftersixmonthsuse.Thisshouldbedeterminedempiricallybytests designedtorepresentaperiodequivalenttosixmonthsuse.

3 Theoverallsystemresponsetime(RT)afteristhesumofSP,tande:RT=SP+t+e

4 ThevalueofRTshouldbemarkedonaclearlyvisibleandpermanentinformationplateheaded‘Standardtowhichguillotineisconstructed’.Itshouldbeusedforsettingthestoppingperformancemonitor,iffitted.

5 Inaddition,theguillotinemanufacturerwillneedtoknowtheobjectdetectioncapabilityorsensitivity(S)ofthephotoelectriccurtainnamelythediameterofthesmallesttestpiece(inmillimetres)whichwillbedetectedatanypositioninthecurtainwheninsertedatarightangletotheplaneofthecurtain.Smaynotbesimplythespacingofthecentresofadjacentbeams.ThevalueofSshouldbeobtainedfromthecurtainmanufacturer(asdescribedinBS6491:Parts1&21984&1987)andrecordedontheinformationplatementionedabove.

6 Thepotentialdistance(P)thatahandcanpenetratethecurtainbeforeitisdetectedshouldthenbedeterminedfromtheequation:P=3.4(S-7)mm

7 Thecurtainshouldthenbepositionedsothatnopartofthephotoelectriccurtainisnearerthecuttingstickthantheminimumseparationdistance(D)where:D=P+(RTx1.8)or255mm,whicheveristhegreater

1.8m/sisthederivedhandspeedforCategory1machines.ThevalueofDshouldalsoberecordedonthesupplier’sinformationplate.

8 Asexamples,theminimumseparationdistance(D)against(RT)isshowngraphicallyatFigure1forvaluesofS=38mmandS=50mm.



9 Thevaluesspecifiedinparagraphs5to7arebasedoncurrentlyavailableknowledgeandmaybesubjecttoamendmentasaresultoffuturedevelopment

Figure 1 Graphofminimumseparationdistanceagainstoverallstoppingperformance

0

100

200

300

400

500

600

700

100 2000 300Overall stopping performance (RT) in ms

Min

imum

cur

tain

sep

erat

ion

dist

ance

(D) i

n m

m when S = 50 mm

when S = 38 mm



References1 The application of electro-sensitive protective equipment using light curtains and light beam devices to machinery.HSG180HSEBooks1999 ISBN0717615502

2 Manual handling. Manual Handling Operations Regulations 1992. Guidance on Regulations.L23HSEBooks1998ISBN0717624153

3 Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations 1998. Approved Code of Practice and Guidance on Regulations. L113HSEBooks1998ISBN0717616282

4 Buying new machinery.INDG271HSEBooks(singlecopiesfree; ISBN0717615596forpricedpacks)

5 Management of health and safety at work. Management of Health and Safety at Work Regulations 1992. Approved Code of Practice.L21HSEBooks1998 ISBN0717604128

6 Safe use of work equipment. Provision and Use of Work Equipment Regulations 1998. Approved Code of Practice and Guidance.L22HSEBooks1992 ISBN0717616266

7 5 steps to risk assessment.INDG163(rev)HSEBooks1998(singlecopiesfree; ISBN0717615650forpricedpacks)

8 Printing industry: health and safety open learning training package.HSEBooks 1998ISBN0717614816

9 Young people at work: a guide for employers.HSG165HSEBooks1997 ISBN0717612856

10 Work-related upper limb disorders: a guide to prevention.HSG60HSEBooks 1990ISBN0717604756

11 Manual handling: solutions you can handle.HSG115HSEBooks1994 ISBN0717606937

12 A pain in your workplace: ergonomic problems and solutions.HSG121HSE Books1994ISBN0717606686

13 Pressure systems - safety and you.INDG261HSEBooks1997

14 A guide to the Health and Safety at Work etc Act 1974 - Guidance on the Act. L1HSEBooks1992ISBN0717604411

15 Accreditation for in-service inspection of power presses and other specified machines and their safeguarding systems.RG1UnitedKingdomAccreditation ServiceTeddington1999

16 The Supply of Machinery (Safety) Regulations 1992.SI1992No3073HMSO ISBN0110257197

17 The Institution of Electrical Engineers Regulations for Electrical Installations 16th Edition. (The IEE Wiring Regulations)(obtainablefromtheIEE,POBox26, Hitchin,Herts,SG51SA)



18 Programmable electronic systems in safety-related applications: An introductory guide.HSEBooks1987ISBN0717612783

19 Programmable electronic systems in safety-related applications: General technical guidelines.HSEBooks1987ISBN0717605450

20 The Electrical Equipment (Safety) Regulations1994SI1994No3260HMSO ISBN0110439171

21 Product standards. Machinery Guidance notes on UK Regulations.Department ofTradeandIndustry1996.CopiesavailablefromDTIBusinessinEurope Hotline01179444888

22 Industrial robot safety.HSG43HSEBooks1988ISBN0717612376

British/European Standards

BSEN292:1991Safety of machinery - Basic concepts, general principles fordesign. Part 1 1991 Basic terminology, methodology. Part 2 1991 Technical principles and specifications

EN294:1992Safety of machinery - Safety distances to prevent danger zonesbeing reached by the upper limbs

BSEN574:1997Safety of machinery. Two-hand control devices. Functionalaspects. Principles for design

BSEN954:1997Safety of machinery - safety related parts of control systems. Part 1 1997 General principles for design

BSEN982:1996Safety of machinery - safety requirements for fluid power systems and their components - hydraulics

BSEN983:1996Safety of machinery - safety requirements for fluid power systems and their components - pneumatics

EN999:1999Safety of machinery - the positioning of protective equipment in respect of approach speeds of parts of the human body

prEN1010:1999Safety of machinery - safety requirements for the design and construction of printing and paper converting machines. Part 3 Cutting machines

EN1037:1996Safety of machinery - prevention of unexpected startup

EN1050:1997Safety of machinery - principles for risk assessment

EN1088:1996Safety of machinery - interlocking devices associated withguards. Principles for design and selection

BS5323:1980Code of Practice for scissor lifts. Recommended design and safety requirements for fixed scissor lifts with a working height not exceeding 1.98 m ground or floor level and mobile vehicle and self propelled scissor lifts of any working height

BS6491: Electrosensitive safety systems for industrial machines. Part 1 1984 Specification for general requirements. Part 2 1987 Specification for particular requirements for incorporating photoelectric sensing units



EN45004:1995General criteria for the operation of various types of inspectionbodies performing inspection

EN60204:1998Safety of machinery - electrical equipment of machines. Part 1 Specification for general requirements

BSEN60947:1992Specification for low voltage switch gear and control gear. Part 4-1 1992 Contactors and motor starters

EN61310:1995Safety of machinery - indicative marking and actuation. Part 1- Requirements for visual, auditory and tactile signals. Part 2 - Requirements for marking

IEC/EN61496:Safety of machinery - electro-sensitive protective equipment. Part 1 1997 General requirements and tests. Part 2 1997 Particular requirements for equipment using active opto-electronic protective devices (AOPDs)IEC61508:1998Functional safety of electrical/ electronic/ programmable electronic (E/E/PE) safety related systems.(NOTE:Thisaseven-partstandardwhichdealswithallaspectsofthefunctionalsafetyofsafety-relatedsystems.Parts1,3,4and5areavailableasIECstandardswhileParts2,6and7arecurrentlyfinaldraftinternationalstandards(FDIS).ItisanticipatedthatthesePartswillbeavailableasIECstandardsbytheendof1999.)

IEC61508:1998Functional safety of electrical/ electronic/ programmableelectronic (E/E/PE) safety related systems.(NOTE:Thisaseven-partstandardwhichdealswithallaspectsofthefunctionalsafetyofsafety-relatedsystems.Parts1,3,4and5areavailableasIECstandardswhileParts2,6and7arecurrentlyfinaldraftinternationalstandards(FDIS).ItisanticipatedthatthesePartswillbeavailableasIECstandardsbytheendof1999.)

Further informationForinformationabouthealthandsafetyringHSE’sInfolineTel:08453450055Fax:08454089566Textphone:08454089577e-mail:[email protected],CaerphillyBusinessPark,CaerphillyCF833GG.

HSEpricedandfreepublicationscanbeviewedonlineororderedfromwww.hse.gov.ukorcontactHSEBooks,POBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995.HSEpricedpublicationsarealsoavailablefrombookshops.

BritishStandardscanbeobtainedinPDForhardcopyformatsfromtheBSIonlineshop:www.bsigroup.com/ShoporbycontactingBSICustomerServicesforhardcopiesonlyTel:02089969001e-mail:[email protected].

TheStationeryOfficepublicationsareavailablefromTheStationeryOffice,POBox29,NorwichNR31GNTel:08706005522Fax:08706005533e-mail:[email protected]:www.tso.co.uk(Theyarealsoavailablefrombookshops.)StatutoryInstrumentscanbeviewedfreeofchargeatwww.opsi.gov.uk.

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