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Safety-Key to the Machine Solution




  Dave Collins
  Schneider Electric
  Industry NOW Express


2011 Schneider Electric. All Rights Reserved.
Confused about safety?

                                                                                     ● You   are not alone
                                                                                     ● Almost60% are not aware of
                                                                                      Safety Categories
                                                                                     ● 68% not familiar with
                                                                                      Performance Levels
                                                                                     ● Most have difficulty in applying
                                                                                      safety products




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                        2
Standards

● Safety            is driven by standards
● Standards  determine devices to use, how to use them, and sometimes
   how safety products are constructed
● Some             US standards are similar to IEC standards




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   3
US Standards

A few of the most important US Standards are:
●   OSHA 29 CFR1910
●   NFPA 79, 2007 Edition, Electrical Standard for Industrial Machinery
●   ANSI B11.19, Performance Criteria for Safeguarding
●   ANSI/RIA R15.06, Industrial Robots and Robot Systems, Safety
    Requirements
Locally
●   UL and CSA (in Canada)
       ●    UL is mandatory in most US cities in their codes and requirements.
       ●    Customers and users demand these approvals even if local codes do
            not require it.
Canada
●   CSA is mandatory in Canada
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   4
European / International Standards

●   Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since
    December 31, 2011
●   Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety
    categories on January 1, 2012
●   SIL (Safety Integrity Levels) are designed for use primarily for more complex
    systems or microprocessor and software based systems
●   SIL can be determined by either IEC 61508 or IEC 62061




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   5
EN/ISO 13849-1                                                                                   Required     Low contribution
     Risk graph and parameters                                                                      performance    to risk reduction
                                                                                                     level (PLr)



      Uses the same criteria as EN 954-1                                                  F1
                                                                                               P1       a
                                                                                               P2
                                                                                     S1
                                                                                          F2
                                                                                               P1       b
                                                    Starting point                             P2
                                                       for the
                                                    evaluation of
                                                       the risk                           F1
                                                                                               P1       c
                                                                                               P2
                                                                                     S2
      S Severity of injury                                                                F2
                                                                                               P1       d
           S1 Slight (normally reversible injury)                                              P2
           S2 Serious (normally irreversible) injury including death

      F Frequency and/or exposure time to the hazard
                                                                                                        e
           F1 Seldom to less often and/or the exposure time is short
                                                                                                                   High contribution
           F2 Frequent to continuous and/or the exposure time is long                                              to risk reduction

      P Possibility of avoiding the hazard or limiting the harm
           P1 Possible under specific conditions
           P2 Virtually impossible


Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                     6
EN/ISO 13849-1
 ● EN/ISO 13849-1 adds new parameters to the requirements of the categories of
   EN 954-1 in order to determine the Performance Level (PL):


         ●    MTTFd = mean time to dangerous failure
              Three levels of MTTFd are defined in this standard in order to classify the
              requirements of the categories and the performance levels (PL):
             Denotation of mean time to dangerous failure
                                                                                           Range of MTTFd

                                          low                                         3 years <= MTTFd < 10 years
                                       medium                                        10 years <= MTTFd < 30 years
                                         high                                        30 years <= MTTFd < 100 years




         ●    DC                  = diagnostic coverage                                 DC = dd / d total
                     Denotation of diagnostic coverage                                      Range of DC
                                    none                                                      DC < 60%
                                     low                                                  60% <= DC < 90%
                                  medium                                                  90% <= DC < 99%
                                    high                                                     99% <= DC


                ldd / ld total                                           dd  Dangerousfailuresdetected
                                                                         d total  Dangerousfailurestotal
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                   7
EN/ISO 13849-1
     Relationship between categories, DC, MTTFd and PL

                              a                                                                                                    *




                                                                                                                                       Safety Integrity Level
                              b                                                                                                 1
          Performance level




                                                          *
                              c                                                                                                 1


                              d                                                                                                 2


                              e                                                                                                 3

                                    Cat. B        Cat. 1        Cat. 2        Cat. 2        Cat. 3       Cat. 3       Cat. 4
                                   DC avg =      DC avg =      DC avg =      DC avg =      DC avg =     DC avg =     DC avg =
                                      0             0            low         medium          low        medium         high

                                            MTTFd of each channel = low                 DC = Diagnostic Coverage
                                            MTTFd of each channel = medium              MTTFd = Mean Time To Failure - Dangerous
                                            MTTFd of each channel = high                PL = Performance Level


          *                   In many applications the realization of performance level c by category 1 may not be
                              sufficient. In this case a higher category e.g. 2 or 3 should be chosen.
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                                              8
100 % of flexibility and optimization with
Flexible Machine Control

         1 software environment
         Simplify machine programming &
         commissioning with SoMachine suite
                                                                                            Safety is
                                                                                            at the
                                                                                            center of
                                                                                            it all
         Multiple hardware Control
         Platforms
         Embedded Intelligence
         where it is needed



           HMI         Drive       Logic       Motion
           controllers controllers controllers controllers                           I/Os

Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012               9
Ready-to-use architectures: TVDA

● Predetermined equipment lists

● Tested
       ● our experts tested each application
         to ensure that they work in all
         possible configurations.

● Validated
       ● Full functional compatibility of
         devices.

● Documented
       ● a full user manual contains all the
        required information for installation
        and assembly, including CAD and
        wiring diagrams
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   11
The ‘Safety Chain’ approach
● One provider for the complete safety chain:
          ● Reduce cost on the machine safety application through a single
            automation and complete safety chain provider



            Acquire the information                     Monitor and processing       Stop the machine




                                                  Safe signal transmission




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                      12
Safety Chain Solution
● Fully aligned with our TVDA approach:
        ● Answers the machine customer’s needs, complementary with our
          automation architectures


                       TVD Architecture
                                                                                     Safe Stop 1 - servo




                                                                                     Safety Chain Solution




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                           13
Safety Chain Solutions
                                                                                     Safe Stop 0, High performance

● Optimized implementation for increased levels
  of protection
      ● A cost optimized solution that reaches a very low
        probability of dangerous failure (PFHd), which
        corresponds to PL e and SIL 3




● Typical applications:
      ● Assembling, machining centers or similar
        machines tools




Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012                                   14
Safety Chain Solutions
                                                                                     Safe Stop 1, Drive - high performance

● Safety integrated devices for an easier safety
  chain configuration
      ● The drive (ATV32) features an integrated safety
        torque off function (STO), which meets the
        requirements of PL e and SIL 3




● Typical applications:
      ● Textile, wood-working or simple packaging
        machines




Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012                                    15
Safety Chain Solutions

● Improved accuracy through safety integrated                                        Safe Stop 2, Servo - enhanced safety

  devices
      ● Stopping the machine with the Safe Stop 2
        (SS2) function by using the enhanced safety
        module (eSM) integrated on the servo-drive;
        it meets the requirements of PL e and SIL 3




● Typical applications:
      ● Packaging, printing, conversion, or similar
        machines with long freewheel stopping times
        (high inertia or low resistive torque)




Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012                                    16
What can we do for our customers?

                                   Schneider Electric provides a wide variety of scalable and
                                   cost effective solutions from simple electromechanical to
                                   programmable systems with safety communications, to
                                   meet Performance Level “e”, and SIL 3 as well as local and
                                   international safety requirements, to help maximize
                                   productivity.




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012         17
Monitor and processing
   Type                   Safety                        Safety                        Safety PLC               AS-I           Safety Card
                          Relay                        Controller
  Family                     XPS                         XPSMC                           XPSMF              ASISAFE            Lexium 32




  Function           Solution for                      Solution for                       Solution for    Solutions using a   Solutions using
                    monitoring one                monitoring several                  monitoring many      safety related        a motion
                       function                       functions                          functions        communications         controller
                                                   simultaneously                     simultaneously             bus
                                                                                            and
                                                                                      communication
                                                                                     over Safe Ethernet
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                          18
Lexium eSM and Adapter
Hardware


  • Optional eSM Terminal Adaptor
  • for LXM32 M
  • Accessories:
    - eSM Terminal adapter
       (Connection of up to 5 Lxm)
      - eSM Cable

                                                                             AC




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   19
Acquire the Information
            Type              Safety Interlock                          Safety Interlock      Safety Interlock
          Family                         XCSA                                        XCSB          XCSC




         Enclosure                         Metal                                     Metal          Metal
          Function                   Non-Locking                     Locking by Push Button     Locking by Key




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                               20
Acquire the Information
  Type               Safety Interlock                        Safety Interlock        Safety Interlock    Safety Interlock
Family                         XCSE                                     XCSL         XCSLE & XCSLF           XCSTE




Enclosure                        Metal                                   Metal          Metal - XCSLF         Plastic
                                                                                       Plastic - XCSLE
Function                Solenoid Locking                        Solenoid Locking      Solenoid Locking    Solenoid Locking




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                           21
Acquire the Information
           Type              Safety Interlock                     Safety Interlock     Safety Interlock   Safety Interlock
          Family                      XCSPA                                XCSPL           XCSPR              XCSMP




         Enclosure                      Plastic                              Plastic        Plastic            Plastic
          Function                 Non-Locking                           Non-Locking      Non-Locking        Non-Locking




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                         22
Acquire the Information
            Type                Non-Contact                          Non-Contact             Non-Contact            Non-Contact
          Family                    XCSDMC                               XCSDMP                XCSDMR                 XCSDM3/4




         Operating            Sao: 0.20 in (5 mm)                  Sao: 0.31 in (8 mm)      Sao: 0.31 in (8 mm)    Sao: 0.39 in (10 mm)
           Zone               Sar: 0.59 in (15 mm)                 Sar: 0.79 in (20 mm)     Sar: 0.79 in (20 mm)   Sar: 0.79 in (20 mm)
            Wiring             Cable or connector                Cable or connector        Cable or connector      Cable or connector

              Size            2.01 x 0.63 x 0.28 in                3.56 x 0.98 x 0.51 in    30 mm dia. 1.51 in     3.94 x 1.34 x 1.26 in


Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                      23
Acquire the Information
           Type                    Compact                               Compact                 Compact                  Compact
         Family                      XUSLB                                 XUSLD                 XUSLPZ                   XUSLPB




            MOS               14 mm and 30 mm                       14 mm and 30 mm         300, 400,500,600 mm         500 and 600 mm
                              0.55 in and 1.18 in                   0.55 in and 1.18 in    11.8, 15.7, 19.7, 23.6 in.   19.7 and 23.6 in
         Sensing                1 to 22.9 ft, or                       1 to 22.9 ft, or        2.6 to 65.5 ft or          2.6 to 26.3 ft
         Distance           1 to 65.6 ft with PDM                  1 to 65.6 ft with PDM        2.6 to 229.7 ft
            SN


Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                         24
Acquire the Information
              Type                    Cable Pull Switch                               Cable Pull Switch          Emergency Stop
            Family                                  XY2                                        XY2                   XB4 – XB5




             Feature                 Adjustable tripping force                       Viewing windows to aid in   Conforms to ISO 13850
                                                                                      adjusting cable tension
        Cable Length                           165 ft (50 m)                                50 ft (15 m)




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012                                                       25
Other Products for the Safety Chain
                                   In addition to all of the previous products, we offer
                                   complete lines of other devices for use in safety
                                   related applications:
                                   ● E-Stop buttons, EMO
                                   ● Indicating banks
                                   ● Control Relays and Contactors
                                   ● Drives
                                   ● Motion




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012         26
Thank You!




Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012   27

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Safety — Key to the Machine Solution

  • 1. Safety-Key to the Machine Solution Dave Collins Schneider Electric Industry NOW Express 2011 Schneider Electric. All Rights Reserved.
  • 2. Confused about safety? ● You are not alone ● Almost60% are not aware of Safety Categories ● 68% not familiar with Performance Levels ● Most have difficulty in applying safety products Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 2
  • 3. Standards ● Safety is driven by standards ● Standards determine devices to use, how to use them, and sometimes how safety products are constructed ● Some US standards are similar to IEC standards Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 3
  • 4. US Standards A few of the most important US Standards are: ● OSHA 29 CFR1910 ● NFPA 79, 2007 Edition, Electrical Standard for Industrial Machinery ● ANSI B11.19, Performance Criteria for Safeguarding ● ANSI/RIA R15.06, Industrial Robots and Robot Systems, Safety Requirements Locally ● UL and CSA (in Canada) ● UL is mandatory in most US cities in their codes and requirements. ● Customers and users demand these approvals even if local codes do not require it. Canada ● CSA is mandatory in Canada Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 4
  • 5. European / International Standards ● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since December 31, 2011 ● Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety categories on January 1, 2012 ● SIL (Safety Integrity Levels) are designed for use primarily for more complex systems or microprocessor and software based systems ● SIL can be determined by either IEC 61508 or IEC 62061 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 5
  • 6. EN/ISO 13849-1 Required Low contribution Risk graph and parameters performance to risk reduction level (PLr) Uses the same criteria as EN 954-1 F1 P1 a P2 S1 F2 P1 b Starting point P2 for the evaluation of the risk F1 P1 c P2 S2 S Severity of injury F2 P1 d S1 Slight (normally reversible injury) P2 S2 Serious (normally irreversible) injury including death F Frequency and/or exposure time to the hazard e F1 Seldom to less often and/or the exposure time is short High contribution F2 Frequent to continuous and/or the exposure time is long to risk reduction P Possibility of avoiding the hazard or limiting the harm P1 Possible under specific conditions P2 Virtually impossible Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 6
  • 7. EN/ISO 13849-1 ● EN/ISO 13849-1 adds new parameters to the requirements of the categories of EN 954-1 in order to determine the Performance Level (PL): ● MTTFd = mean time to dangerous failure Three levels of MTTFd are defined in this standard in order to classify the requirements of the categories and the performance levels (PL): Denotation of mean time to dangerous failure Range of MTTFd low 3 years <= MTTFd < 10 years medium 10 years <= MTTFd < 30 years high 30 years <= MTTFd < 100 years ● DC = diagnostic coverage DC = dd / d total Denotation of diagnostic coverage Range of DC none DC < 60% low 60% <= DC < 90% medium 90% <= DC < 99% high 99% <= DC ldd / ld total dd  Dangerousfailuresdetected d total  Dangerousfailurestotal Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 7
  • 8. EN/ISO 13849-1 Relationship between categories, DC, MTTFd and PL a * Safety Integrity Level b 1 Performance level * c 1 d 2 e 3 Cat. B Cat. 1 Cat. 2 Cat. 2 Cat. 3 Cat. 3 Cat. 4 DC avg = DC avg = DC avg = DC avg = DC avg = DC avg = DC avg = 0 0 low medium low medium high MTTFd of each channel = low DC = Diagnostic Coverage MTTFd of each channel = medium MTTFd = Mean Time To Failure - Dangerous MTTFd of each channel = high PL = Performance Level * In many applications the realization of performance level c by category 1 may not be sufficient. In this case a higher category e.g. 2 or 3 should be chosen. Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 8
  • 9. 100 % of flexibility and optimization with Flexible Machine Control 1 software environment Simplify machine programming & commissioning with SoMachine suite Safety is at the center of it all Multiple hardware Control Platforms Embedded Intelligence where it is needed HMI Drive Logic Motion controllers controllers controllers controllers I/Os Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 9
  • 10. Ready-to-use architectures: TVDA ● Predetermined equipment lists ● Tested ● our experts tested each application to ensure that they work in all possible configurations. ● Validated ● Full functional compatibility of devices. ● Documented ● a full user manual contains all the required information for installation and assembly, including CAD and wiring diagrams Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 11
  • 11. The ‘Safety Chain’ approach ● One provider for the complete safety chain: ● Reduce cost on the machine safety application through a single automation and complete safety chain provider Acquire the information Monitor and processing Stop the machine Safe signal transmission Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 12
  • 12. Safety Chain Solution ● Fully aligned with our TVDA approach: ● Answers the machine customer’s needs, complementary with our automation architectures TVD Architecture Safe Stop 1 - servo Safety Chain Solution Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 13
  • 13. Safety Chain Solutions Safe Stop 0, High performance ● Optimized implementation for increased levels of protection ● A cost optimized solution that reaches a very low probability of dangerous failure (PFHd), which corresponds to PL e and SIL 3 ● Typical applications: ● Assembling, machining centers or similar machines tools Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012 14
  • 14. Safety Chain Solutions Safe Stop 1, Drive - high performance ● Safety integrated devices for an easier safety chain configuration ● The drive (ATV32) features an integrated safety torque off function (STO), which meets the requirements of PL e and SIL 3 ● Typical applications: ● Textile, wood-working or simple packaging machines Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012 15
  • 15. Safety Chain Solutions ● Improved accuracy through safety integrated Safe Stop 2, Servo - enhanced safety devices ● Stopping the machine with the Safe Stop 2 (SS2) function by using the enhanced safety module (eSM) integrated on the servo-drive; it meets the requirements of PL e and SIL 3 ● Typical applications: ● Packaging, printing, conversion, or similar machines with long freewheel stopping times (high inertia or low resistive torque) Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012 16
  • 16. What can we do for our customers? Schneider Electric provides a wide variety of scalable and cost effective solutions from simple electromechanical to programmable systems with safety communications, to meet Performance Level “e”, and SIL 3 as well as local and international safety requirements, to help maximize productivity. Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 17
  • 17. Monitor and processing Type Safety Safety Safety PLC AS-I Safety Card Relay Controller Family XPS XPSMC XPSMF ASISAFE Lexium 32 Function Solution for Solution for Solution for Solutions using a Solutions using monitoring one monitoring several monitoring many safety related a motion function functions functions communications controller simultaneously simultaneously bus and communication over Safe Ethernet Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 18
  • 18. Lexium eSM and Adapter Hardware • Optional eSM Terminal Adaptor • for LXM32 M • Accessories: - eSM Terminal adapter (Connection of up to 5 Lxm) - eSM Cable AC Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 19
  • 19. Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Family XCSA XCSB XCSC Enclosure Metal Metal Metal Function Non-Locking Locking by Push Button Locking by Key Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 20
  • 20. Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock Family XCSE XCSL XCSLE & XCSLF XCSTE Enclosure Metal Metal Metal - XCSLF Plastic Plastic - XCSLE Function Solenoid Locking Solenoid Locking Solenoid Locking Solenoid Locking Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 21
  • 21. Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock Family XCSPA XCSPL XCSPR XCSMP Enclosure Plastic Plastic Plastic Plastic Function Non-Locking Non-Locking Non-Locking Non-Locking Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 22
  • 22. Acquire the Information Type Non-Contact Non-Contact Non-Contact Non-Contact Family XCSDMC XCSDMP XCSDMR XCSDM3/4 Operating Sao: 0.20 in (5 mm) Sao: 0.31 in (8 mm) Sao: 0.31 in (8 mm) Sao: 0.39 in (10 mm) Zone Sar: 0.59 in (15 mm) Sar: 0.79 in (20 mm) Sar: 0.79 in (20 mm) Sar: 0.79 in (20 mm) Wiring Cable or connector Cable or connector Cable or connector Cable or connector Size 2.01 x 0.63 x 0.28 in 3.56 x 0.98 x 0.51 in 30 mm dia. 1.51 in 3.94 x 1.34 x 1.26 in Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 23
  • 23. Acquire the Information Type Compact Compact Compact Compact Family XUSLB XUSLD XUSLPZ XUSLPB MOS 14 mm and 30 mm 14 mm and 30 mm 300, 400,500,600 mm 500 and 600 mm 0.55 in and 1.18 in 0.55 in and 1.18 in 11.8, 15.7, 19.7, 23.6 in. 19.7 and 23.6 in Sensing 1 to 22.9 ft, or 1 to 22.9 ft, or 2.6 to 65.5 ft or 2.6 to 26.3 ft Distance 1 to 65.6 ft with PDM 1 to 65.6 ft with PDM 2.6 to 229.7 ft SN Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 24
  • 24. Acquire the Information Type Cable Pull Switch Cable Pull Switch Emergency Stop Family XY2 XY2 XB4 – XB5 Feature Adjustable tripping force Viewing windows to aid in Conforms to ISO 13850 adjusting cable tension Cable Length 165 ft (50 m) 50 ft (15 m) Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 25
  • 25. Other Products for the Safety Chain In addition to all of the previous products, we offer complete lines of other devices for use in safety related applications: ● E-Stop buttons, EMO ● Indicating banks ● Control Relays and Contactors ● Drives ● Motion Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 26
  • 26. Thank You! Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 27