Press Machine Safety Guide(For employers and employees)

This safety guide is an English translation of Japanese safety guide based onJapanese laws and regulations.
Please comply with your country's laws and regulations if you are outside of Japan.

Eighth edition
April 2020

Preface
This safety guide provides employers and employees with important safety information theyshould know when they purchase AMADA press machines.
Safety information for using press machines is also available in the operator’s manuals of pressmachines and the warning labels affixed to the press machines. Before you use the machine,
fully understand all of these pieces of safety information.
The safety guide contains information on residual risks of the machine. Fully recognize hazards
associated with machine installation, workpiece and die setup, machine operation, inspection,cleaning and maintenance, and other tasks. On your own responsibility as employer, takesafeguarding measures to suit the environment of your shop and the method of using yourmachine. Also conduct safety and health education for your operators.
The Industrial Safety and Health Act states that employers must take machine safeguarding
measures.
(See “Responsibilities of employer” on the next page.)
Several examples of preventive measures are introduced here. Safeguarding devices
recommended by AMADA are offered as options. Please study and adopt them.

For machine safeguarding procedures, etc., refer to “Guidelines for the Comprehensive
Safety Standards of Machinery” published by the Ministry of Health, Labour and Welfare(LSB Notification No. 0731001, revised on July 31, 2007).
To see the guidelines, go to the website of the Japan Advanced Information Center ofSafety and Health (https://www.jaish.gr.jp), click the “Laws, Regulations and Notifications”
button, enter “No. 0731001”, and find the LSB Notification No. 0731001.

When you retrofit safeguarding devices to your already installed machine, you may have tomodify the machine and its controls. When you study what safeguarding devices to adopt,please contact AMADA.

1Responsibilities of employer
The Industrial Safety and Health Act (hereinafter referred to as Act) and Ordinance on Industrial
Safety and Health (hereinafter referred to as Ordinance) mainly impose the following duties onemployers who have their workers use machines, in order to reduce industrial accidents.

(1) Notifying of plans- Notify the Labour Standards Office of plans.
Notify the Labour Standards Office of plans to install, relocate or alter machines, etc.
(Article 88 of Act and Article 85 of Ordinance)
Notify the Labour Standards Office of such plans, have the plans checked for safety, andreceive guidance about the plans.
- Notify the competent government office of a specified facility and apply to the competent
government office for permission to use the specified facility.
If the specified facility falls under the provisions of the Noise Control Act, the Vibration
Control Act and the environmental conservation ordinance of the competent localgovernment, notify the competent environmental conservation contact office of thespecified facility.
Since the notification duties, control values, etc., vary from region to region, check thedetails at the competent environmental conservation contact office.
(2) Investigating hazardousness and harmfulness
Investigate the hazardousness and harmfulness of tasks and duties (or assess the risks oftasks and duties). Also, make efforts to take necessary measures to prevent hazards toworkers and prevent their physical disorders. (Article 28-2 of Act)For data concerning residual risks peculiar to specific machines and required to perform
risk assessment, contact AMADA.
(3) Preventing hazards
Take appropriate safeguarding measures to ensure the safety of press operators. (Article20 of Act and Article 131 of Ordinance)
Protect workers from hazards from machines, hazardous materials, and electricity andother energy sources.
Take measures to prevent the body parts of workers from entering the hazardous area.
(4) Appointing chief operator
Appoint a qualified chief operator. (Article 14 of Act and Article 16 of Ordinance)
In a workplace with five or more power presses, appoint a chief operator from among
workers given technical training.

2(5) Conducting safety and health education
Conduct safety and health education to workers who operate the machine for the first time.
(Article 35 of Ordinance)
Provide special education to workers who change or adjust dies. (Article 36 of Ordinanceand Article 3 of Rules on Special Safety and Health Education)(6) Inspecting before start of day’s workInspect the machine before the start of the day’s work. (Article 136 of Ordinance)
Try to find equipment failures and faults as soon as possible. If a problem is found, repair
it or take any other necessary measure to prevent an accident.
(7) Conducting special voluntary inspection
Conduct legal inspection by qualified personnel once or more per year. (Article 135 ofOrdinance)
Repair any problems found by the inspection, and file the inspection results and repair
records.

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1. Operating environment and installation space of press machine
1-1. Operating environment
Use the press machine in the following environment.
If used outside the operating environment in the table below, the machine and safety devices will
not function properly, causing a fire, failure, malfunction, or damage, which may lead to personal
injury.
Operating environment
Input power supply

Voltage:Frequency:
Grounding:3-phase 200 V/ 220 V±10%50 Hz/60 Hz±1 Hz● TP, TPW, TPWL, PDL series
Class D (Class 3)
Inverter supporting item when an earth leakage
circuit breaker is used for inverter specification
machine● SDE, SDEW, SWE Series
Independent grounding Class C (Special Class 3)
Inverter supporting item when an earth leakage
circuit breaker is used for inverter specification
machine (Recommended sensitivity current: 100 mAor more)
Air supply:Supply pressure 0.5 MPa or more
(dry and clean compressed air without dust and drain)
Operating ambient temperature:+5 to +40ºC (no freezing)
Operating ambient humidity:
20 to 90% (no dew condensation)
Atmosphere:
No salt and conductive dust
No corrosive gas or flammable gas
No splash of water, oil, chemicals, etc.
No affect by electrical noise
No direct sunlight and wind from air conditioner
Installation base:Tolerance:
70 kN/m2 or more
The base dimensions differ depending on the model andspecifications of the machine. For details, refer to the separatematerials.
Caution when connecting external devices:
When connecting an external device, incorporate a protective circuit
such as a surge absorber or the like.

41-2. Installation space

Necessary
maintenancespace

1.5 m or more

When installing a machine, secure adequate maintenance space around the machine.
If the press machine cannot be inspected and maintained adequately, the machine and safety
devices will not function properly, which will impair safety.
The figure below is the minimum maintenance space required in the front, rear, left and right ofthe press machine.

1.5 m or more

1.5 m or more

1.5 m or more

(Refer to the catalog for details since the machine dimensions differ according to the model andspecifications of the machine.)52. Protection examples
2-1. Basic protection method
In order to prevent the danger of being caught in the die, firstly prevent entry into thehazardous area, and if it is impossible, adopt a light curtain or the like to stop the pressmachine.
If insertion of workpieces or removal of processed parts cannot be automated, it is the basic
protection that you do not need to put a part of your body into a hazardous area by using
manual tools.
Movable front guardLight curtain

Protection
examples2-2. Measures against entry from outside (beyond upper limit) of protection range
Before installing a guard or safety device, you need to sufficiently consider the physique andworking posture of workers.
You must determine the protection height so that a part of body does not reach thehazardous area beyond the upper limit of the protection range of guards or light curtain.
Movable front guard

Protectionexamples

6Light curtain(with extended protection height)

2-3. Measures against entry from outside (under lower limit ) of protection range
Before installing a guard or safety device, sufficiently consider the physique and working
posture of workers. If it is assumed that a part of body enters the hazardous area by going
through under the lower limit of the guard range or the protection range of a light curtain, takemeasures such as completely shielding the working surface or furnishing a light curtain
combined with a baffle plate.
Automatic movable front guardLight curtain + Baffle plate

Protection
examples2-4. Measures against entry from outside (left or right side) of protection range
Even if the operation side is protected with a guard or a safety device, workers may enterfrom a position other than the front side for unsteady work such as adjustment or inspection.
Also, you need to consider protection for assistant workers and third persons.
Protect with a fixed guard or a light curtain even against the entry from the side of themachine.
Light curtain + Side guard

Protection
examples7

Light curtain (three-sided protection)

2-5. Measures against entry from outside (rear side) of protection range
You also have to assume that a third person may activate the machine when you areworking inside the machine for adjustment or cleaning.
You also need to consider protection for assistant workers and third persons.
Protect with a fixed rear guard or a light curtain against the entry from the rear side and theinadvertent activation by a third person.
Fixed rear guardLight curtain

Protection
examples2-6. Measures against entry of part of body between bolster and light curtain
In order to prevent any gap between the light beam of the light curtain and the front end of
the bolster that a part of body may enter, protect from such a gap with a baffle plate or a lightcurtain.
Such a gap must be less than 75 mm.
Light curtain + Baffle plate

Protection
examples38

Light curtain + Auxiliary
light beam

2-7. Protection from flying objects
Be sure to adopt a guard-type protection when flying of fragments due to breakage of the die
is foreseeable. Flying of fragments is not limited toward the front. Be sure to consider
protection of persons other than workers.
With automatic machines, an accident is likely to occur at setup more than in normalproduction.
It is recommended to adopt interlock which disables even jogging function when the guard isopen.
Automatic movable
front guardInterlocking front guard

Protection
examples2-8. Measures against pinch hazard with knockout device
Other than the hazardous area created with the die, there are places where a part of yourbody is possibly pinched.
When using a mechanical knockout device, you need to consider the risk where a third
person erroneously activates the machine during adjustment or a third person accidentally
touches the machine while it operates.
If entry to the vicinity of the knockout device cannot be restricted, you need to increase theprotection height of the side guard and the side light curtain.
Side guard(with extendedprotection height)
Protection
examples9Light curtain(with extendedprotection height)

3. Other devices/functions
In order to use the press machine more safely, the following equipment and devices arefurnished as standard features or available as options. Choose them according to the contentsof your work.

3-1. Electrical enclosure main circuit breaker [Standard feature]
Opening the door of the electrical enclosure with the power on willlead to fatal accidents due to electric shock because of a highvoltage.
The electrical enclosure main circuit breaker permits to open thedoor only after the power is turned off.

3-2. Simultaneous operation for jogging [Standard feature]
Since the slide operates only when the two-hand controls arepressed simultaneously within 0.5 seconds, dangerous work by
one-hand operation is prevented.

3-3. Clutch brake solenoid valve with monitoring function [Standard feature]
Abnormality of the clutch brake solenoid valve is electricallysensed and notified.

3-4. Light curtain (2-light beam obstruction specification) [Option]
A normal light curtain stops the press when one light beam isobstructed, but a light curtain of the 2-light beam obstruction
specification stops the press;● when two consecutive light beams are obstructed, or● when only the uppermost or lowermost light beam is obstructed.
The press does not stop even if one light beam is obstructed by theworkpiece.
* This option is suitable for the work where a workpiece is passed
from the light beam plane.

3-5. Flywheel brake [Option]
Stops the rotation of the flywheel within a short time.

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AMADA hopes that this safety guide book will help you to provide a safe workplace for your pressmachine operators.
If you have something to know about the safeguarding of press machines or need more informationor proposals, contact AMADA.

AMADA PRESS SYSTEM CO., LTD.
200, Ishida, Isehara-shi, Kanagawa, Japan+81-463-96-3321
https://www.amp.amada.co.jp/en/