2011 Schneider Electric. All Rights Reserved. Safety-Key to the Machine Solution Dave Collins Schneider Electric Industry NOW Express
2011 Schneider Electric. All Rights Reserved.
Safety-Key to the Machine Solution
Dave Collins Schneider Electric Industry NOW Express
2 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Confused about safety?
● You are not alone
● Almost 60% are not aware of Safety Categories
● 68% not familiar with Performance Levels
● Most have difficulty in applying safety products
3 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
4 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
5 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since December 31, 2011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
6 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Starting point for the
evaluation of the risk
a
b
c
d
e
P1
P2 P1
P2
P2
P2
P1
P1
F2
F1
F1
F2
S1
S2
Required performance
level (PLr)
Low contribution to risk reduction
High contribution to risk reduction
S Severity of injury S1 Slight (normally reversible injury) S2 Serious (normally irreversible) injury including death F Frequency and/or exposure time to the hazard F1 Seldom to less often and/or the exposure time is short F2 Frequent to continuous and/or the exposure time is long P Possibility of avoiding the hazard or limiting the harm P1 Possible under specific conditions P2 Virtually impossible
EN/ISO 13849-1 Risk graph and parameters
Uses the same criteria as EN 954-1
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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):
● DC = diagnostic coverage
DC = λdd / λd total
Denotation of mean time to dangerous failure Range of MTTFd
low 3 years <= MTTFd < 10 yearsmedium 10 years <= MTTFd < 30 years
high 30 years <= MTTFd < 100 years
Denotation of diagnostic coverage Range of DCnone DC < 60%low 60% <= DC < 90%
medium 90% <= DC < 99%high 99% <= DC
ldd / ld total total failures Dangerous
detected failures Dangerous
total d
dd
==
λλ
8 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
EN/ISO 13849-1 Relationship between categories, DC, MTTFd and PL
MTTFd of each channel = low MTTFd of each channel = medium MTTFd of each channel = high
* In many applications the realization of performance level c by category 1 may not be suf f icient. In this case a higher category e.g. 2 or 3 should be chosen.
a *
b 1
c 1
d 2
e 3
Cat. BDC avg =
0
Cat. 1DC avg =
0
Cat. 2DC avg =
low
Cat. 2DC avg =medium
Cat. 3DC avg =
low
Cat. 3DC avg =medium
Cat. 4DC avg =
high
Perf
orm
ance
leve
l
Saf
ety
Inte
grity
Lev
el
*
DC = Diagnostic Coverage MTTFd = Mean Time To Failure - Dangerous PL = Performance Level
9 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
100 % of flexibility and optimization with Flexible Machine Control
1 software environment Simplify machine programming & commissioning with SoMachine suite
Multiple hardware Control Platforms Embedded Intelligence where it is needed
Logic controllers
Motion controllers
HMI controllers
Drive controllers I/Os
Safety is at the center of it all
11 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
12 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
The ‘Safety Chain’ approach
Acquire the information Monitor and processing Stop the machine
Safe signal transmission
● One provider for the complete safety chain: ● Reduce cost on the machine safety application through a single
automation and complete safety chain provider
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● Fully aligned with our TVDA approach: ● Answers the machine customer’s needs, complementary with our
automation architectures
Safety Chain Solution
Safe Stop 1 - servo TVD Architecture
Safety Chain Solution
14 Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
●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
Safe Stop 0, High performance
Safety Chain Solutions
15 Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
Safety Chain Solutions
●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
Safe Stop 1, Drive - high performance
16 Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
● Improved accuracy through safety integrated 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)
Safety Chain Solutions
Safe Stop 2, Servo - enhanced safety
17 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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.
18 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Monitor and processing Type Safety
Relay Safety
Controller Safety PLC AS-I
Safety Card
Family XPS XPSMC XPSMF ASISAFE
Lexium 32
Function Solution for monitoring one
function
Solution for monitoring several
functions simultaneously
Solution for monitoring many
functions simultaneously
and communication
over Safe Ethernet
Solutions using a safety related
communications bus
Solutions using a motion controller
19 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
20 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
21 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Acquire the Information Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock
Family XCSE XCSL XCSLE & XCSLF XCSTE
Enclosure Metal Metal Metal - XCSLF Plastic - XCSLE
Plastic
Function Solenoid Locking Solenoid Locking Solenoid Locking Solenoid Locking
22 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
23 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Acquire the Information Type Non-Contact Non-Contact Non-Contact Non-Contact
Family XCSDMC XCSDMP XCSDMR XCSDM3/4
Operating Zone
Sao: 0.20 in (5 mm) Sar: 0.59 in (15 mm)
Sao: 0.31 in (8 mm) Sar: 0.79 in (20 mm)
Sao: 0.31 in (8 mm) Sar: 0.79 in (20 mm)
Sao: 0.39 in (10 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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Acquire the Information Type Compact Compact Compact Compact
Family XUSLB XUSLD XUSLPZ XUSLPB
MOS 14 mm and 30 mm 0.55 in and 1.18 in
14 mm and 30 mm 0.55 in and 1.18 in
300, 400,500,600 mm 11.8, 15.7, 19.7, 23.6 in.
500 and 600 mm 19.7 and 23.6 in
Sensing Distance
SN
1 to 22.9 ft, or 1 to 65.6 ft with PDM
1 to 22.9 ft, or 1 to 65.6 ft with PDM
2.6 to 65.5 ft or 2.6 to 229.7 ft
2.6 to 26.3 ft
25 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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 adjusting cable tension
Conforms to ISO 13850
Cable Length 165 ft (50 m) 50 ft (15 m)
26 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
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
Other Products for the Safety Chain
27 Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Thank You!