This presentation covers international and local safety standards. In addition, it explains how Schneider Electric tested, validated, and documented approach helps machine building OEMs design safe, more energy efficient machines.
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
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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
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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
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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● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since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
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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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)
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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.
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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