T99 - ISO 14119:2013 - Rockwell Automation 14119, 7.2.c & Table 3 OR if detachable fixing used, then it might be mandatory to do one of the following: 1) Mount out of reach ISO 14119,

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900F

PUBLIC INFORMATION

T99 - ISO 14119:2013Interlocking Devices Associated With Guards: A Small Standard With a Lot of Requirements

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 2

Agenda

Who does this affect and how?

ISO 14119:2013 – Major Shifts

Scope, What, Where, When and Why…

Key Impacts

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

Scope: What is ISO 14119:2013?

ISO 14119:2013 is a B2 standard

Guard Interlocking

Design – interlocking device manufactures

Selection – machine builders and integrators

Replaces ISO 14119:1998 as a harmonized standard (BS EN ISO)

Supersedes EN 1088:1995

C: Detailed Safety Requirements for Particular MachinesB2: Standards on SafeguardsB1: Particular Safety Aspects

A: Basic Concepts & Principles - Applies to all Machinery

3


Where Does ISO 14119:2013 apply?

4

Europe as EN ISO 14119

Any country that uses ISO standards

ISO 14119 is THE global safety interlock device standard

Anyone who follows ANSI standards

ANSI/ISO 12100 - references ISO 14119 (x10)

No equivalent standard in the USA or Canada.

ANSI B11.19, CSA Z432, ANSI RIA R15.06 and CSA Z434

Discuss safeguarding and interlocking

No standards for certifying interlocking devices used for safeguarding.


When Does ISO 14119:2013 apply?

April 2015 - conflicting standards must be withdrawn

18 months from October 2013 allows time to meet the standard

Testing

Design

Documentation

5


Why ISO 14119:2013 was developed?

6

Times and needs change. Historically…

Safeguarding electrical integration was not total integration

Tongue actuated switches – viewed as a dual channel redundancy

Reality – single mechanical device with dual electrical circuit

Mechanical life was not well understood

Unsafe component failure

Interlock hardware design behind functional safety standards

Interlock switches viewed simplistically – design discretion

Fault masking

Minimum safe distances

Loss of power

Guard locking performance level


Major Shifts: ISO 14119:2013

References ISO standards

Four types of interlocking devices defined and described

Minimizing interlock defeat is a requirement

Interlock technology affects functional safety

Guard locking has added descriptions and requirements Power to lock vs. power to unlock

Supplementary release

Mechanical requirements

Multiple safety functions

Product certification requirements

Mechanical and integration requirements

7

Expect that the next revision will clean-up some things and address functional safety issues


ISO 14119 references many standards

8

Normative References: ”Indispensable for its application”

ISO 12100 Risk assessment and risk reduction

ISO 13849-1&2 Safety-related parts of control systems

IEC 60204-1 Electrical equipment of machines

IEC 60947-5-3 Control circuit devices and switching elements

IEC 62061 Functional Safety

Other standards referenced in ISO 14119

ISO 11161 Integrated Manufacturing Systems

ISO 13855 Safeguard safe distance and approach speeds

ISO 13857 Safe distance to prevent reaching hazards by limbs

ISO 14120 Guards, fixed and moveable

ISO TR 24119 Fault masking of series guard interlocking


Interlocking Device TypesDefined by actuation principle and actuator type

Actuation Principle Actuator Coding & ExamplesType Interlockper ISO 14119

Example Rockwell

Automation®

Product Line*

MechanicalPhysical

contact

force

uncoded

Rotary cam

Type 1

Safety Limit Switch

Linear cam Safety Limit Switch

HingeRotocam™ &

Safety Limit Switch

coded

Tongue low coding

(shaped actuator) Type 2Trojan™ / TLS GD2

ProSafe®Trapped-key med or high

Non-

contact

Inductive

uncoded

Suitable ferric metal

Type 3(see 7.1a)

– – –

Magnetic Magnet, solenoid Ferrogard™

Capacitive Any suitable object – – –

Ultrasonic Any suitable object – – –

Optic Any suitable object – – –

Magnetic

coded

Coded magnet

Type 4

Sipha™ & MC1/MC2

SensaGuard™,

TLSZ & LZRFID Coded RFID tag

– – –Optic Optically coded tag

Reference: ISO 14119 – Table 1

* Pending Approval

Types are NOT

in hierarchal order

https://rockwell.acrolinx-iq.com/termhelp/?termDatabaseId=44791&locale=en


Interlocking devices & actuation directionNote direction of travel of the actuator to the switch

Type 1Type 3 & 4

3 Actuator (cam)

Direction of Opening

1 Guard

5 Actuating

System

6 Output

System

4

Position

Switch

2

Interlocking

Device

1 Guard1 Guard

1 Guard

2 22

55 5

6 6 6

44

Type 2

Type 2: CODED

Tongue (actuator) Operated

Guard Not Closed

Type 1: UNCODED

Cam Operated

Guard Closed

Type 3: UNCODED or Type 4: CODED

(Type 4 can be low, med, high CODED)

Non-Contact Actuated – Guard Closed

333

Actuation Actuator Coding & Example Type

Mec

han

ical

Physical

contact

force

uncodedRotary cam

Type 1Linear cam

Hinge

codedTongue

Type 2Trapped-key

No

n-

con

tact

Inductive

uncoded


Type 3Magnetic Magnet, solenoid

CapacitiveAny suitable objectUltrasonic

Optic

Magnetic

codedCoded magnet

Type 4RFID Coded RFID tag

Optic Optically coded tag


ISO 14119 Coded actuator definition

11

Coded actuator (3.13)

actuator which is specially designed (e.g. by shape) to actuate a certain position switch <manufacturer must specify the coding>

low level coded actuator (3.13.1)coded actuator for which 1 to 9 variations in code are available

Example: most coded magnetic actuators and standard coded safety RFID actuators

medium level coded actuator (3.13.2)coded actuator for which 10 to 1,000 variations in code are available

high level <unique> coded actuator (3.13.3)coded actuator for which more than 1,000 variations are available

Example: Unique coding for most RFID safety switches

with high coded safety switches, there are fewer installation requirements & defeat analysis

Actuation Actuator Coding & Example ISO 14119

Mec

han

ical

Physical

contact

force

Un-coded

Rotary cam

Type 1Linear cam

Hinge

CodedTongue low coding

Type 2Trapped-key med or high coding

No

n-

con

tact

Inductive

Un-coded


Type 3

Magnetic Magnet, solenoid

Capacitive

ANY suitable objectUltrasonic

Optic

Magnetic

Coded

Coded magnet




ISO 14119 “Defeat” definitions

12

Defeat (3.7): action that makes interlocking devices inoperative or bypasses

them with the result that a machine is used in a manner not intended by the

designer or without the necessary safety measures.

Defeat in a reasonably foreseeable manner (3.8): defeat of an interlocking

device either manually or by using readily available objects (see Note 2)

Note 1: This definition includes the removal of switches or actuators using tools that are

needed for the intended use of the machine or that are readily available (screwdrivers,

wrenches, hexagon keys, pliers).

Note 2: Readily available objects for substitute actuation include screws, needles and

sheet-metal pieces, objects in daily use such as keys, coins, adhesive tape, string and

wire, spare keys for the trapped-key interlocking devices, and spare actuators (hence

emphasis on UNIQUE/ HIGH coding).

Emphasis on HIGH coding


7. Design to minimize defeat possibilities

Implement interlock & guard locking devices to minimize

motivation to defeat (hide limit switches & cams, hide low

coded actuators, OR use HIGH coded actuators …)

Modify the machine(add modes with risk reduction features) to minimize the motivation to defeat

Annex H is a lot of work for the integrator

Figure 9 – Methodology for determining the possible incentive and the required measures by the manufacturer <integrator>


Basic Measures: Fasteners, Location, Interlock Selection

Change Design

Add Modes:- Auto- Manual- Setup

Minimize the “Motivation to Defeat”- Requirements

Annex H - evaluation

Interlock – Type and Coding

14


Minimizing Defeat: Achieved by Selection, Installation, Integration

15

ISO 14119, Clause 7.1 a): Design to minimize defeat possibilities of interlocking devices

a) Implement the basic measures described in 5.2 Arrangement and fastening of switches, 5.3 Arrangement

and fastening of actuators, 5.4 Actuation modes of interlocking devices, 5.7.3.3 Basic measures for minimizing

defeat possibilities and 6.2.2 Specific requirements for selection of guard locking devices.

Type 3 interlocking devices shall not be used unless it is shown by risk assessment that in the application the

device cannot be defeated in a reasonably foreseeable manner.

b) Check whether the motivation to defeat the interlocking devices in reasonably foreseeable manner exists.

c) Check whether the motivation can be minimized or minimized by:

— design measures and/or

— alternative modes.

Implement those measures if possible.

NOTE 3: The implementation of alternative modes of operation can avoid the motivation to defeat. Alternative

modes of operation can be, for example, special modes for setting, tool changing, fault finding, maintenance or

process observation. They depend highly on the type of machine and its application and cannot be dealt with

comprehensively in this standard.

d) If foreseeable motivation for defeat continues to exist, additional measures are required (see 7.2).

Type 3 (non-contact UNCODED) shall NOT be used unless risk assessment shows the device cannot be

defeated in a reasonably foreseeable manner.


Minimizing Defeat by Install / IntegrationType 1 Hinged – Requirements

16

Mandatory

Non-detachablefixing of switch & actuator

ISO 14119, 7.2.c & Table 3

OR if detachable fixing used, then it might be mandatory to do one of the following:

1) Mount out of reach ISO 14119, 7.2.a) 1) & Table 3OR

2) Additional interlocking device and plausibility checking ISO 14119, 7.2.d) 2) & Table 3

Recommended

Additional interlocking device

and plausibility checking ISO 14119, 7.2.d) 2) & Table 3

Non-detachable fixing (for example, welding, gluing, one-way screws, riveting)

Actuator examples ISO 14119 Product *

Mechanical

uncodedHinge Type 1 Rotocam™

* Pending Approval


Define Design RequirementsAvoid the defeat of interlock devices

17

Type 1 - Hinged

Mandatory: Non-detachable

fixing of switch and actuator

Type 1 (Not Hinged) and Type 3

Mandatory to do 1 of the following:

1) Mount out of Reach

2) Physically Obstruct / Shield

3) Hide the switch

4) Status Monitoring or Cyclic Testing

5) Non-detachable switch and actuator

Recommended: Additional interlocking device and plausibility checking

Non-detachable fixing (e.g. welding, gluing, one-way screws, riveting)

Actuation Principle Actuator ExampleISO

14119

Example

Product *

Mechanical

UNCODED

Physical

contact

force

Rotary cam

Type

1

Safety Limit

SwitchLinear cam

Hinge Rotocam™

Non-

contact

UNCODED

InductiveSuitable ferric

metal

Type

3

– – –

Magnetic Magnet, solenoid Ferrogard™

CapacitiveAny suitable

object

– – –

Ultrasonic – – –

Optic – – –


Minimizing Defeat by Install / Integration

18

Type 1 HINGED:

Mandatory: non-detachablefixing of switch and actuator

ISO 14119, 7.2.c & Table 3

Type 1 NOT Hinge, Type 2 & Type 3

Mandatory: choose at least 1 (risk assessment determines if more than 1 of the following is needed):

1) Mount out of reach ISO 14119, 7.2.a) 1) & Table 3

2) Physical obstruction / shielding ISO 14119, 7.2.a) 2) & Table 3

3) Mounting in a hidden position ISO 14119, 7.2.a) 3) & Table 3

4) Status monitoring or cyclic testing ISO 14119, 7.2.d) 1) i) and ii) & Table 3

For Type 1 (not hinge) and Type 3, this is also a choice in addition to 1 through 4

5) Non-detachable switch and actuator ISO 14119, 7.2.c) & Table 3

Recommended: Additional interlocking device and plausibility checking ISO 14119, 7.2.d) 2) & Table 3

Non-detachable fixing (For example, welding, gluing, one-way screws, riveting)

Actuator examples Interlock Product Line*

Mechanical

uncoded

Rotary or Linear cam

Type 1Safety Limit Switch

HingeRotocam™ &

Safety Limit Switch

Mechanical

codedTongue low coding

(shaped actuator)Type 2

Trojan™ / TLS GD2

Prosafe™

Non-

Contact

uncoded


Type 3

– – –

Ferrogard™Magnet, solenoid

Any suitable object – – –

* Pending Approval


Minimizing Defeat by Install / IntegrationType 1 (not Hinged) Type 2, Type 3 & low/med coded Type 4

19

Mandatory: choose at least 1 (risk assessment determines

if more than 1 is needed):





5) Non-detachable fixing of

* switch and actuator (Type 1 & Type 2) ISO 14119, 7.2.c) & Table 3

* actuator only (Type 3 & low/med Type 4) ISO 14119, 7.2.c) & Table 3

Recommended: Additional interlocking device

and plausibility checking ISO 14119, 7.2.d) 2) & Table 3


Actuator examplesMechanical

uncodedRotary or Linear

Mechanical


(shaped actuator)

Non-

Contact

uncoded


Magnet, solenoid

Any suitable object

* Pending Approval


Minimizing Defeat by Install / IntegrationType 1 (not Hinged) – Requirements

20

Type 1 NOT Hinge, Type 2 & Type 3 (not high)

Mandatory: choose at least 1 (risk assessment determines if more than 1 is needed):





For Type 1 (not hinge) and Type 3, this is also a choice in addition to 1 through 4

5) Non-detachable switch and actuator ISO 14119, 7.2.c) & Table 3

Recommended: Additional interlocking device and plausibility checking ISO 14119, 7.2.d) 2) & Table 3


Actuator examples Interlock Product Line*Mechanical

uncodedRotary or Linear cam Type 1 Safety Limit Switch

Mechanical


(shaped actuator)Type 2

Trojan™ / TLS GD2

Prosafe™

Non-

Contact

uncoded


Type 3

– – –

Ferrogard™Magnet, solenoid

Any suitable object – – –

* Pending Approval


Define Design RequirementsAvoid the defeat of interlock devices

21

Type 2 and Type 4

ALL coding Mandatory:

Non-detachable actuator

Low or Medium Coding

Mandatory: at least 1 of the following:

1) Mount out of Reach

2) Physically Obstruct / Shield

3) Hide

4) Status Monitoring or Cyclic Testing

Recommended: Additional interlocking device and plausibility checking

Non-detachable fixing, e.g. welding, gluing, one-way screws, riveting

Measures Against Defeat: Simplified with high coded safety switches

Actuation PrincipleActuator

Example

ISO

14119

Example

Product*

Mechanical

CODED

Physical

contact

force

Tongue

low coding Type

2

Trojan™

TLS GD2

ProSafe®Trapped-key

med or high

Non-

contact

CODED

MagneticCoded

magnet

Type

4

Sipha™ &

MC1/MC2

SensaGuard™

TLSZ & LZRFIDCoded RFID

tag

– – –OpticOptically

coded tag

https://rockwell.acrolinx-iq.com/termhelp/?termDatabaseId=44791&locale=en


Measures Against Defeat: documentation

required unless using high coded safety switches

There are new requirements of the design process, design decisions, and proof of due diligence.

Part of Clause 7.2: Additional measures to minimize defeat possibilities



Annex HEvaluation of Motivation to Defeat

24


Minimizing Defeat by Coding Selection

25

Coded Actuator (3.13)

actuator which is specially designed to actuate a certain position switch

low level coded actuator (3.13.1)

coded actuator for which 1 to 9 variations in code are available

Ex: tongue interlocks, coded magnetic, and standard-code RFID

medium level coded actuator (3.13.2)

coded actuator for which 10 to 1,000 variations in code are available

high level <unique> coded actuator (3.13.3)

coded actuator for which more than 1,000 variations are available

Ex: Unique coded RFID

High coded safety switches have fewer installation and defeat analysis requirements


Series Connection

26

Restrictions for series connected contacts (electromechanical)

8.6 Logical series connection of interlocking devices

When interlocking devices with redundant contacts are connected in series the detection of a single fault can be

masked by the actuation of any interlocking device connected between the fault and the safety related control system.

Maximum of 5 dry contact switches in series for PLd - for 1 frequently used guard

Detailed in: ISO/TR 24119

>1/hr <1/hr <1/hr <1/hr <1/hr


Motivation to Defeat

27

Defeat

Action that makes interlocking devices inoperative or bypasses them with the result that a

machine is used in a manner not intended by the designer or without the necessary safety

measures

Defeat in a reasonably foreseeable manner

Defeat of an interlocking device either manually or by using readily available objects

Note 1: This definition includes the removal of switches or actuators using tools that are needed for

the intended use of the machine or that are readily available (screw drivers, wrenches, hexagon

keys, pliers)

Note 2: Readily available objects for substitute actuation include screws, needles and sheet-metal

pieces, objects in daily use such as keys, coins, adhesive tape, string and wire, spare keys for the

trapped-key interlocking devices, and spare actuators

Emphasis on HIGH coding


Interlocking – guard location and guard openings

28

While the guards are closed and equipment can operate, the guard openings and its distance to the hazards

is required to meet ISO 13857.

Example Body PartGraphic

(upper limbs shown, but table is

applicable to both upper & lower)

Opening (e)

(Smallest Dimension) in mm

Minimum (Safe) Distance Sr

Slotted Square Round

Finger tip

0 < e ≤ 4 ≥ 2 ≥ 2 ≥ 2

4 < e ≤ 6 ≥ 10 ≥ 5 ≥ 5

6 < e ≤ 8 ≥ 20 ≥ 15 ≥ 5

Finger to knuckle joint

6 < e ≤ 8 ≥ 20 ≥ 15 ≥ 5

8 < e ≤ 10 ≥ 80 ≥ 25 ≥ 20

Hand

10 < e ≤ 12 ≥ 100 ≥ 80 ≥ 80

12 < e ≤ 20 ≥ 120 ≥ 120 ≥ 120

20 < e ≤ 30 ≥ 850 ≥ 120 ≥ 120

Arm up to junction with

shoulder

30 < e ≤ 40 ≥ 850 ≥ 200 ≥ 120

40 < e ≤ 120 ≥ 850 ≥ 850 ≥ 850

Over

(reach over the guard)UPPER Limb ONLY 120 < e See Reaching Over

Under

(reach under the guard)Upper or Lower Limbs 180 < e See Reaching Under

Source: ISO 13857:2008, 4.2.4.1, Table 4, with addition of “Over” and “Under” rows]


6.2 Selection of an interlocking device6.2.1 Overall system stopping performance & access time

Machine system stopping

performance is critical.

If the machine’s stopping time is

more than the time for a person to

access a hazard, EITHER– move back the guard to the

required MINIMUM <safe> distance

(more floor space)

OR– guard locking is

REQUIRED which must meet

the required PL & Cat

(functional safety) for

protection of personnel

(Power to Release).Figure 7 – Determination of the need for guard locking devices


Interlocking – minimum “safe” distanceInterlocks & Power to lock guard locking devices

30

Open Interlock Generates Stop Command:

Access Time SHALL be longer than the overall system stopping performance

ISO 13855 Safeguard safe distance and approach speeds


Minimum Safe Distance FormulaRequired for Interlocks

31

ISO 13855:2010 is required by ISO 14119

S = (K x T) + C

S = Minimum (safe) distance between the safeguarding device and the hazard, in mm

K = Speed constant, based on approach speeds of the body or parts of the body (either ≥ 1,600 or 2,000 mm/sec)

T = Overall system stopping time, in seconds (ISO 10218: anticipated worst case)

C = Intrusion distance (Depth penetration factor), in mm

For info: ANSI B11.19-2010, CSA Z432, CSA Z434

Ds = [K x (Ts + Tc + Tr)] + Dpf

Ds = Minimum (safe) distance between the safeguarding device and the hazard, in mm

K = Speed constant, based on approach speeds of the body or parts of the body (≥ 1600 mm/sec)

Ts = Worst anticipated stopping time of the machine or equipment, in seconds

Tc = Worst anticipated response time of the control system, in seconds

Tr = Response time of the protective device, including its interface, in seconds

Dpf = Depth penetration factor (intrusion distance), in millimeters

S


Interlocking with Guard Locking

32

Guard Locking Devices:

Protection of People: Shall be A or C – unless not appropriate by Risk Assessment


InterlockingWith Guard Locking – Releases

33

Foreseeable Access – as defined by Risk Assessment

Release

Type

Guard

Locking

Safety

Actuated Operating

Release Result Reset Notes

Wh

ere

Aid

sUnlocking

Escape People Inside No

Directly on

Locking

Mechanism

Stop Command

-Emergency and Escape release can be

SAME, if Escape Release Requirements

met (mounted inside)

Emergency People Outside No

Directly on

Locking

Mechanism

Stop Command and

Lock Blocking

Tool,Replacement,

Control System

-Marked for Emergency Only

-Shielded from accidental use

-Emergency and Escape release can be

SAME, if Escape Release Requirements

met (mounted inside)

Auxiliary Process Outside

Tool

or

Key

Stop Command

Tool,Replacement,

Control System

-For Exceptional Use

-Shielded from accidental use


Interlocking – Performance Level

34

Control System Requirements:

Interlocks are safety related parts of a control system (ISO 13849-1)

Fault Exclusion of Broken Tongue Actuator

PLd requires full written justification

PLe not justifiable

When Manual Functional Test required to detect accumulation of faults:

PLd = 12 months

PLe = monthly

Guard Door Locking must meet PLr

PLr of unlocking often less than PLr interlock

Lock engaged

Includes release conditions: speed, position, time delay


Series Connection

35

Restrictions for series connected contacts (electromechanical)

8.6 Logical series connection of interlocking devices

When interlocking devices with redundant contacts are connected in series the detection of a single fault can be masked by the actuation of any interlocking device connected between the fault and the safety related control system. It could also lead to the unexpected reset from a detected fault condition.

Maximum of 5 dry contact switches in series for PLd - for 1 frequently used guard (ref: ISO TR 24119)

>1/hr <1/hr <1/hr <1/hr <1/hr

Number of frequently used movable guards1

Number of additional movable guards

Masking probability Diagnostic CoverageMaximum

Achievable PL

0

2 to 4 Low > 60 % PL d

5 to 30 Medium > 60 % PL d

> 30 High < 60 % (none) PL c

1

1 Low > 60 % PL d

2 to 4 Medium > 60 % PL d

> 5 High < 60 % (none) PL c

> 1 - High < 60 % (none) PL c1switching frequency greater than once per hour


Fault Masking

36

ISO TR 24119 is expected to state…

PLe not be allowed for devices with simple dry contacts connected

in series (the maximum PL will be PLd ).

As it is, one simple switch with dry contacts cannot achieve PLe because fault

exclusion is used for breakage of the tongue actuator/ key.

In systems where fault masking is foreseeable for series connection

of dry (zero voltage) contacts, DC is reduced to NONE and the

system is limited to a maximum of PLc

Monitoring

Safety

Relay

Door 1 Door 2


ISO 14119: How are Products Affected?

Safety Switches

Update documentation stating compliance to ISO 14119 by 4/15/2015

Refer to ISO 14119 for interlocking installation and use issues

Type 2: Tongue interlocks & guard locking (except TLSZ & 440G-LZ)

Max PLd when used for guard interlocking (requires fault exclusion)

Limitation of # of switches in series wiring & achieving the required PL

Type 2: Guard locking (except TLSZ & 440G-LZ)

Tested and certified to the new holding force requirements

Type 4: Non-contact interlocks

List actuator coding: low, medium, and high

Only LOW (standard RFID & others) and HIGH (unique RFID)

Type 4: Non-contact sensing for Guard locking (TLSZ, 440G-LZ)

State compliance, holding forces

State PL for both guard position monitoring (interlocking) and lock monitoring

37


Guard Locking Holding Force

38

Holding Force

The guard locking device manufacturer shall

state the holding force (Fh) & test to 1.3

times the stated Fh (holding force).

Electromagnetic products:- 500 to 1000 N holding force typical

- Lock releases on power loss

- Minimum safe distance is required

- Lock function cannot be used for

personnel safety

- Listed by manufacturers

as “Process Protection”

Power to Lock Guard Locking Devices - Lock releases on power loss

- Minimum safe distance is required

- Lock function NOT for personnel safety

- Listed by as “Process Protection”


Summary: Mechanical Design Requirements

39

Minimize motivation to defeat interlock devices:

Installation and Location

Protected from foreseeable damage

Sufficiently rigid to maintain operation

Withstand expected forces: vibration, door slamming

Not used as a door stop, unless impact rating declared by manufacturer

Fastening shall be designed to withstand the locking device holding force


ISO 14119 – Key Impacts

40

European machines moving toward PLe solutions

Less documentation and analysis required when using PLe interlocking devices with

high coded actuators

Existing versus New Application

Existing systems - no requirement to change or update

Applies to new equipment

Safe distance requirements apply to ALL interlocking devices

Machine builders and integrators need time to understand their requirements for risk

assessment, analysis, and documentation (motivation to defeat, fault exclusion)

Diagnostic Coverage (DC) and functional safety link ISO 14119 to ISO 13849

Fault masking limits DC and achievable PL

Interlock Selection: type, coding, holding force, power-to-unlock


Four (4) types of interlocking devices

41

Actuation Principle Actuator examplesAbbreviation

(NOT Functional Safety)

MechanicalPhysical

contact

force

uncoded

Rotary cam

Type 1Linear cam

Hinge

coded

Tongue

(shaped actuator) Type 2Trapped-key

Non-

contact

Inductive

uncoded


Type 3For restrictions, see 7.1a

Magnetic Magnet, solenoid

Capacitive Any suitable object

Ultrasonic Any suitable object

Optic Any suitable object

Magnetic Coded(low,

medium,

high)

Coded magnet




Interlocking devices & actuation directionNote direction of travel of the actuator to the switch

Type 1 Type 3 & 4

3 Actuator (cam)

Direction of Opening

1 Guard

5 Actuating

System

6 Output

System

4

Position

Switch

2

Interlocking

Device

1 Guard 1 Guard1 Guard

2 2 255 5

6 66

44

Type 2

CODED

Tongue (actuator) Operated

Guard Not Closed

UNCODED

Cam Operated

Guard Closed

UNCODED or CODED

(low, med, high CODED)

Non-Contact Actuated

Guard Closed

333


TYPE 1 - Mechanical - Uncoded

43

Examples

Rotary Cam Annex A.1

Linear Cam Annex A.2, A.4

Hinge Annex A.3

4.1 Overview of interlocking Devices Table 1

Type 1

AbbreviationActuation Principles

Uncoded

Actuator Examples

Mechanical Physical contact / force

Annex A.1

Product?

Mode of operation?

Annex A.2 Annex A.4 Annex A.3


TYPE 2 - Mechanical - Coded

44

Annex B.1

Product?

Annex B.2

Examples

Tongue ( shaped Actuator Annex B.1

Trapped key Annex B.2


Type 2

AbbreviationActuation Principles

Coded

Actuator Examples

Mechanical Physical contact/force

The standard does not provide all the specificrequirements for trapped key systems


Examples

Inductive Suitable ferric metal

Magnetic Magnetic Solenoid

Capacitive any suitable object

Ultrasonic any suitable object

Optic any suitable object


Type 3 Annex CNon Contact Uncoded

AbbreviationActuation Principles Actuator Examples

TYPE 3 - Non Contact - Uncoded

45

Annex C

Product?

Annex C

5.4 - Type 3 & 4 devices to meet the requirements of 60947-5-3 proximity deviceswith defined behaviour under fault condition


TYPE 4 - Non Contact - Coded

46

Annex D.1

Product?

Examples

Magnetic coded magnet Annex D1

RFID coded RFID tag Annex D2

Optic optically coded tag -


Type 4Non Contact Coded

AbbreviationActuation Principles Actuator Examples

Annex D.2


Distance to the closest hazard when reaching through or around a guard

47

Example Body

Part

Graphic (upper limbs shown because of

their smaller dimensions, but

table is applicable to both upper

and lower limbs)

Opening (e)

(Smallest Dimension)

Minimum (Safe) Distance Srdoes NOT replace C or Dpf in safety distance formula

Slotted mm

inSquare mm

inRound mm

in

Finger tip

mm

in.

0 < e ≤ 4

0 < e ≤ 0.16

≥ 2

0.08

≥ 2

0.08

≥ 2

0.08

mm

in.

4 < e ≤ 6

0.16 < e ≤ 0.24

≥ 10

0.39

≥ 5

0.20

≥ 5

0.20

mm

in.

6 < e ≤ 8

0.24 < e ≤ 0.31

≥ 20

0.79

≥ 15

0.59

≥ 5

0.20

Finger to knuckle

joint

mm

in.

6 < e ≤ 8

0.24 < e ≤ 0.31

≥ 20

0.79

≥ 15

0.59

≥ 5

0.20

mm

in.

8 < e ≤ 10

0.31 < e ≤ 0.39

≥ 80

3.1

≥ 25

0.98

≥ 20

0.20

Hand

mm

in.

10 < e ≤ 12

0.39 < e ≤ 0.47

≥ 100 ≥ 80 ≥ 80

mm

in.

12 < e ≤ 20

0.47 < e ≤ 0.79

≥ 120 ≥ 120 ≥ 120

mm

in.

20 < e ≤ 30

0.79 < e ≤ 1.2

≥ 850* ≥ 120 ≥ 120

Arm up to junction

with shoulder

mm

in.

30 < e ≤ 40

1.2 < e ≤ 1.6

≥ 850* ≥ 200 ≥ 120

mm

in.

40 < e ≤ 120

1.6 < e ≤ 4.7

≥ 850* ≥ 850* ≥ 850*

OVER (reach over)UPPER

Limb ONLYmm

in.

120 < e

4.7 < eSee Reaching OVER

Requirements

UNDER

(reach under the

guard)

Upper or

Lower Limbsmm

in.

180 < e

7 < e

Use SLOTTED column above. Additional safeguarding required if opening

greater than 180mm

Source: ISO 13857:2008, 4.2.4.1, Table 4, with RIA R15.406 addition of “Over” and “Under” rows

The

dim

ensi

on o

f the

ope

ning

, e, c

orre

spon

ds to

the

side

of a

squ

are

open

ing,

the

diam

eter

of a

rou

nd o

peni

ng a

nd th

e na

rrow

est d

imen

sion

of a

slo

t ope

ning

* P

er A

NS

IB

11.1

9, C

SA

Z43

4 &

CS

A

Z43

2: a

rm r

each

is 9

15 m

m (

36 in

.)


Reaching OVER a guard…

48

High Risk:For hazard zones above 2,500 mm (98 in.) (reaching upwards), H shall be at least 2,700 mm (106 in.)

Low Risk: For hazard zones above 2,500 mm (98 in.) (reaching upwards), H shall be at least 2,500 mm (98 in.)

[ISO 13857:2008]


Reach OVER – HIGH RISK situations

49

Height of

Hazard area

Height of Protective Structure (b) Dimensions in mm

1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,500 2,700

(a) Horizontal minimum (safety) distance to hazard zone (c) in HIGH RISK situations

2,700 0 0 0 0 0 0 0 0 0 0

2,600 900 800 700 600 600 500 400 300 100 0

2,400 1,100 1,000 900 800 700 600 400 300 100 0

2,200 1,300 1,200 1,000 900 800 600 400 300 0 0

2,000 1,400 1,300 1,100 900 800 600 400 0 0 0

1,800 1,500 1,400 1,100 900 800 600 0 0 0 0

1,600 1,500 1,400 1,100 900 800 500 0 0 0 0

1,400 1,500 1,400 1,100 900 800 0 0 0 0 0

1,200 1,500 1,400 1,100 900 700 0 0 0 0 0

1,000 1,500 1,400 1,000 800 0 0 0 0 0 0

800 1,500 1,300 900 600 0 0 0 0 0 0

600 1,400 1,300 800 0 0 0 0 0 0 0

400 1,400 1,200 400 0 0 0 0 0 0 0

200 1,200 900 0 0 0 0 0 0 0 0

0 1,100 500 0 0 0 0 0 0 0 0

[ISO 13857:2008, Table 2]NOTE – Do not interpolate numbers. Use the figures that will result in a more conservative outcome.

For example, if the height of the hazard area (a) is 1,300 mm (51 in.), then use 1,400 mm (55 in.).

If the protective structure height (b) is 1,900 mm (75 in.), use the 1,800 mm (72 in.) column for the protective height structure.


Reach OVER – LOW RISK situations

50

Height of

Hazard area

Height of Protective Structure (b) Dimensions in mm

1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,500 2,700

(a) Horizontal minimum (safety) distance to hazard zone (c) in LOW RISK situations

2,500 0 0 0 0 0 0 0 0 0 0

2,400 100 100 100 100 100 100 100 100 0 0

2,200 600 600 500 500 800 400 350 250 0 0

2,000 1,100 900 700 600 500 350 0 0 0 0

1,800 1,100 1,000 900 900 600 0 0 0 0 0

1,600 1,300 1,000 900 900 500 0 0 0 0 0

1,400 1,300 1,000 900 800 100 0 0 0 0 0

1,200 1,400 1,000 900 500 0 0 0 0 0 0

1,000 1,400 1,400 900 300 0 0 0 0 0 0

800 1,300 900 600 0 0 0 0 0 0 0

600 1,200 500 0 0 0 0 0 0 0 0

400 1,200 300 0 0 0 0 0 0 0 0

200 1,100 200 0 0 0 0 0 0 0 0

0 1,100 200 0 0 0 0 0 0 0 0

[ISO 13857:2008, Table 1]NOTE – Do not interpolate numbers.

Use the figures that will result in a more conservative outcome.

For example, if the height of the hazard area (a) is 1,300 mm (51 in.) , then use 1,400 mm (55 in.).

If the protective structure height (b) is 1,900 mm (75 in.), use the 1,800 mm (72 in.) column for the protective height structure.


Perimeter Guard (reach over, reach under)

EXAMPLE R15.06-1999ISO 10218

R15.06-2012CSA Z434

Lower Dimension, max 300mm (12”) 180mm ( 7”) 150mm (6”)

Upper Dimension, min 1500mm (60”) 1400mm (55”) 1800mm (72”)

Lower Dimension Upper Dimension

Presumes no hazard can be reached over the guard or under the guard (by arm or leg). This means no hazard within 1100mm for High Risk (over and under). See ISO 13857.

If hazard can be reached, the dimensions change.


Minimum (Safe) Distance Formularequired for the “interlocked portion of the guard”

52

ISO 13855:2010 is required by ISO 14119

S = (K x T) + C Where:

S = Minimum (safe) distance between the safeguarding device and the hazard, in mm

K = Speed constant, based on approach speeds of the body or parts of the body (either ≥ 1,600 or 2,000 mm/sec)

T = Overall system stopping time, in seconds (anticipated worst case – see standard for details)

C = Intrusion distance (Depth penetration factor), in mm

For info: ANSI B11.19-2010, RIA R15.06-1999, CSA Z432 & CSA Z434

Ds = [K x (Ts + Tc + Tr)] + Dpf Where:

Ds = Minimum (safe) distance between the safeguarding device and the hazard, in mm

K = Speed constant, based on approach speeds of the body or parts of the body (≥ 1600 mm/sec)

Ts = Worst anticipated stopping time of the machine or equipment, in seconds

Tc = Worst anticipated response time of the control system, in seconds

Tr = Response time of the protective device, including its interface, in seconds

Dpf = Depth penetration factor (intrusion distance), in millimeters

S

not all guarding shown


Various guard locking requirements…

53

Definitions

3.4 Guard Locking Device: a device intended to lock a guard in the

closed position and linked to the control system

3.5 Interlocking Guard with Guard Locking

3.24 Prevention of inadvertent locking position (G3.3.)

3.25 Emergency release of guard locking (from outside) (5.7.2, 5.7.5.3)

3.26 Auxiliary release of guard locking (from outside) (5.7.5.4)

3.27 Escape release of guard locking (from inside) (5.7.5.2)

3.28 Guard locking for protection of a person

3.29 Guard locking for protection of the process (or production)

5.7 Additional requirements on guard locking devices: manufacturer of

device, machine builder, integrator of device See 5.7.6: requirement that fastening must also withstand holding force rating.

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

www.rockwellautomation.com

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PUBLIC INFORMATION

Questions?

T99 - ISO 14119:2013 - Rockwell Automation 14119, 7.2.c & Table 3 OR if detachable fixing used, then it might be mandatory to do one of the following: 1) Mount out of reach ISO 14119,

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