Safety — Key to the Machine Solution
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The document outlines the importance of safety standards in industrial machinery and highlights key US and international standards such as OSHA and EN/ISO 13849-1. It discusses the transition from safety categories to performance levels and introduces key parameters like mean time to dangerous failure and diagnostic coverage for assessing safety performance. Schneider Electric offers a comprehensive range of safety solutions that comply with these standards to enhance productivity and ensure machine safety.
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 European / International Standards ● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since December 31, 2011 ● Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety categories on January 1, 2012 ● SIL (Safety Integrity Levels)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