Understanding HSG 180 and Guidance for Testing Light Curtains

HSG 180

HSG 180 is a guidance document issued by the Health and Safety Executive. It covers a broad range of advice for the application of light curtains and light beams as safeguarding measures. One of the primary subjects addressed in the guidelines is the proper inspection and testing of light curtains to ensure they function as intended. Light curtains are one of the most widely used safety devices in industries ranging from automotive and aerospace to food and beverage.

Light Curtains

Light curtains consist of a linear array of light beams that form a protective barrier to prevent workers from entering dangerous zones of machinery. They belong to the ESPE category known as AOPDs (Active Opto-electronic Protection Devices), which use sending and receiving elements to detect interruptions in optical beams. Light curtains are composed of two main components: an emitter, which projects the light beams, and a receiver, which detects interruptions. When a person or object breaks the light beam, the machine’s control system either brings the machine to a safe stop or prevents it from starting.

Light curtains can be either:

Type 2 Safety Light Curtains: For general safety protection where the risks are moderate.

Type 4 Safety Light Curtains: Typically used for high-risk applications, offering greater reliability, and the option of finger level detection.

Guidance for Testing Light Curtains as Per HSG 180

In line with PUWER Regulation 6, HSG 180 advises that an initial inspection and test, and periodic inspection and testing should be completed on all equipment where there is significant risk to personnel from incorrect installation/reinstallation or degradation.

Inspections should be conducted by competent personnel equipped with the necessary knowledge, information, and equipment. They are designed to ensure that machines and their AOPD operate safely and correctly. Primarily, testing includes verification that:

• it is not possible for dangerous parts of the machine to operate whilst the light curtain is broken.
• when the light curtain is broken the dangerous parts of the machine are brought to a stop or otherwise safe condition before they can be reached.
• hazardous parts of the machine cannot become operational until the light curtain has been fully restored to its normal state and the machine controls have been properly reactivated.

Additional checks include verifying that any additionally required safeguards to prevent access are present and correctly installed. It should also be ensured that it is not possible to stand between the light curtain and the hazard, and that the machine cannot be unintentionally or accidentally restarted.

Initial inspections should be carried out when the machine is first commissioned, as well as after any repairs or modifications that could compromise the safe operation of the light curtain. Periodic inspections and testing should be based on the overall risk to safety, however HSG 180 advises the following intervals:

??? Type 4 light curtains: At least every six months.

??? Type 2 light curtains: At least every twelve months.

Adhering to these schedules ensures your equipment remains properly set up and minimises the risk of injury. Results from all inspection and testing must be documented and retained by the end user.

Benefits of Working with HSG 180

HSG 180 provides a framework to ensure that light curtains are not only installed, but also actively maintained and regularly tested to maximise their effectiveness. This guidance emphasises the importance of consistent, systematic testing to ensure that light curtains remain reliable in safeguarding workers and maintaining operational safety standards.

Adhering to HSG 180, provides several key benefits. Regular testing of light curtains significantly reduces the risk of injury by ensuring these devices function correctly to prevent unauthorised access to hazardous zones. This is particularly vital in environments where ineffective functioning of safety devices could lead to serious accidents. Well-maintained light curtains also contribute to improved operational efficiency. Ensuring that safety devices are in proper working order minimises downtime caused by unexpected failures, thereby reducing costly disruptions. Furthermore, implementing the principles of HSG 180 reinforces a company’s commitment to worker safety. By prioritising proactive maintenance and testing, organisations can promote a strong safety culture where employees feel valued and protected.

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